4WD NISSAN NAVARA 2005 Repair Workshop Manual

RFD-60
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
TROUBLE DIAGNOSIS FOR SYSTEM
Differential Lock Position Switch
EDS003B4
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE
Data are reference value.
DIFFERENTIAL CONTROL UNIT TERMINALS AND REFERENCE VALUE
Data are reference value and are measured between each terminal and ground.
CAUTION:
When using a circuit tester to measure voltage for inspection, be sure not to extend forcibly any connector terminals.Monitor item [Unit] Content Condition Display value
D-LOCK POS SW [ON/
OFF]Condition of differential
lock position switch
lVehicle stopped
lEngine running
l4WD shift switch: 4LODifferential lock mode
switch: ON
(DIFF LOCK indicator
lamp: ON)ON
Differential lock mode
switch: OFF
(DIFF LOCK indicator
lamp: OFF)OFF
Te r m i n a lWire
colorItem Condition Data (Approx.)
20 BRDifferential lock position
switch
lVehicle stopped
lEngine running
l4WD shift switch: 4LODifferential lock mode switch: ON
(DIFF LOCK indicator lamp: ON)0V
Differential lock mode switch: OFF
(DIFF LOCK indicator lamp: OFF)Battery voltage

TROUBLE DIAGNOSIS FOR SYSTEM
RFD-61
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
DIAGNOSTIC PROCEDURE
1.CHECK DIFFERENTIAL LOCK POSITION SWITCH SIGNAL
With CONSULT-II
1. Start engine.
2. Select “DATA MONITOR” mode for “DIFF LOCK” with CONSULT-II.
3. Read out ON/OFF switching action of “D-LOCK POS SW SIG”.
Without CONSULT-II
1. Start engine.
2. Check voltage between differential lock control unit harness
connector terminal and ground.
OK or NG
OK >> GO TO 5.
NG >> GO TO 2.
2.CHECK GROUND CIRCUIT
1. Turn ignition switch “OFF”.
2. Disconnect differential lock position switch harness connector.
3. Check continuity between differential lock position switch har-
ness connector C22 terminal 2 and ground.
Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 3.
NG >> Repair open circuit or short to ground or short to power
in harness or connectors.
Monitor item ConditionDisplay
value
D-LOCK POS
SW SIG
lVehicle stopped
lEngine running
l4WD shift
switch: 4LODifferential lock mode
switch: ON
(DIFF LOCK indicator
lamp: ON)ON
Differential lock mode
switch: OFF
(DIFF LOCK indicator
lamp: OFF)OFF
SDIA2538E
Connector Terminal ConditionVo l ta g e
(Approx.)
M10720 -
Ground
lVehicle stopped
lEngine running
l4WD shift switch:
4LODifferential lock mode
switch: ON
(DIFF LOCK indicator
lamp: ON)0V
Differential lock mode
switch: OFF
(DIFF LOCK indicator
lamp: OFF)Battery
voltage
SDIA2570E
Continuity should exist.
SDIA3428E

TROUBLE DIAGNOSIS FOR SYSTEM
RFD-63
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
COMPONENT INSPECTION
1. Turn ignition switch “OFF”.
2. Disconnect differential lock position switch harness connector.
3. Remove differential lock position switch. Refer toRFD-45, "
Location of Electrical Parts".
4. Pull differential lock position switch and check continuity
between differential lock position switch harness connector ter-
minals.
5. If NG, replace differential lock position switch.
Differential Lock Solenoid RelayEDS003B5
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE
Data are reference value.
DIAGNOSTIC PROCEDURE
1.CHECK DIFFERENTIAL LOCK SOLENOID SYSTEM
Perform self-diagnosis. Refer toRFD-51, "
SELF-DIAG RESULTS MODE".
Is
“RELAY [P1844]”displayed?
YES >> Perform trouble diagnosis for differential lock solenoid. Refer toRFD-64, "Differential Lock Sole-
noid".
NO >> GO TO 2.
2.CHECK DIFFERENTIAL LOCK SOLENOID RELAY SIGNAL
With CONSULT-II
1. Start engine.
2. Select “DATA MONITOR” mode for “DIFF LOCK” with CONSULT-II.
3. Read out ON/OFF switching action of “RELAY ON”.
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.
Terminal Condition Continuity
1-2Pull differential position switch Yes
Release Differential position switch No
SDIA3429E
Monitor item [Unit] Content Condition Display value
RELAY ON [ON/OFF]Operating condition of dif-
ferential lock solenoid
relay (integrated in differ-
ential lock control unit)
lVehicle stopped
lEngine running
l4WD shift switch: 4LODifferential lock mode
switch: ONON
Differential lock mode
switch: OFFOFF
Monitor item ConditionDisplay
value
RELAY ON
lVehicle stopped
lEngine running
l4WD shift
switch: 4LODifferential lock mode
switch: ONON
Differential lock mode
switch: OFFOFF
SDIA2642E

RFD-64
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
TROUBLE DIAGNOSIS FOR SYSTEM
3.CHECK DIFFERENTIAL LOCK CONTROL UNIT
Check differential lock control unit input/output signal. Refer toRFD-48, "
Differential Lock Control Unit Input/
Output Signal Reference Values".
OK or NG
OK >> GO TO 4.
NG >> Check differential lock control unit pin terminals for damage or loose connection with harness con-
nector. If any item is damaged, repair or replace damaged parts.
4.CHECK DTC
Perform the self-diagnosis, after driving the vehicle for a while.
OK or NG
OK >>INSPECTION END
NG >> Replace differential lock control unit. Refer toRFD-76, "
Removal and Installation".
Differential Lock SolenoidEDS003B6
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE
Data are reference value.
DIFFERENTIAL LOCK CONTROL UNIT TERMINALS AND REFERENCE VALUE
Data are reference value and are measured between each terminal and ground.
CAUTION:
When using a circuit tester to measure voltage for inspection, be sure not to extend forcibly any connector terminals.Monitor item [Unit] Content Condition Display value
RELAY ON [ON/OFF]Operating condition of dif-
ferential lock solenoid
relay (integrated in differ-
ential lock control unit)
lVehicle stopped
lEngine running
l4WD shift switch: 4LODifferential lock mode
switch: ONON
Differential lock mode
switch: OFFOFF
RELAY MTR [ON/OFF]Control status of differen-
tial lock solenoid relay
(integrated in differential
lock control unit)
lVehicle stopped
lEngine running
l4WD shift switch: 4LODifferential lock mode
switch: ONON
Differential lock mode
switch: OFFOFF
SOL MTR [ON/OFF]Control status of differen-
tial lock solenoid
lVehicle stopped
lEngine running
l4WD shift switch: 4LODifferential lock mode
switch: ONON
Differential lock mode
switch: OFFOFF
Te r m i n a lWire
colorItem Condition Data (Approx.)
11 GR Differential lock solenoid (-)
lVehicle stopped
lEngine running
l4WD shift switch: 4LODifferential lock mode switch: ON 0V
Differential lock mode switch: OFF Battery voltage
12 L Differential lock solenoid (+)
lVehicle stopped
lEngine running
l4WD shift switch: 4LODifferential lock mode switch: ON 0V
Differential lock mode switch: OFF Battery voltage

TROUBLE DIAGNOSIS FOR SYSTEM
RFD-65
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
DIAGNOSTIC PROCEDURE
1.CHECK DIFFERENTIAL SOLENOID SIGNAL
With CONSULT-II
1. Start engine.
2. Select “DATA MONITOR” mode for “DIFF LOCK” with CONSULT-II.
3. Read out ON/OFF switching action of “RELAY ON”, “RELAY
MTR”, “SOL MTR”.
Without CONSULT-II
1. Start engine.
2. Check voltage between differential lock control unit harness
connector terminal and ground.
OK or NG
OK >> GO TO 6.
NG >> GO TO 2.
Monitor item ConditionDisplay
value
RELAY ON
lVehicle stopped
lEngine running
l4WD shift
switch: 4LODifferential lock mode
switch: ONON
Differential lock mode
switch: OFFOFF
RELAY MTRDifferential lock mode
switch: ONON
Differential lock mode
switch: OFFOFF
SOL MTRDifferential lock mode
switch: ONON
Differential lock mode
switch: OFFOFF
Connector Terminal ConditionData
(Approx.)
M10711 -
Ground
lVehicle stopped
lEngine running
l4WD shift switch: 4LODifferential
lock mode
switch: ON0V
Differential
lock mode
switch: OFFBattery
voltage
12 -
GroundDifferential
lock mode
switch: ON0V
Differential
lock mode
switch: OFFBattery
voltage
SDIA2539E
SDIA2565E

RFD-100
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
General SpecificationsEDS003BH
Inspection and AdjustmentEDS003BI
PRELOAD TORQUE
Unit: N·m (kg-m, in-lb)
BACKLASH
Unit: mm (in)
COMPANION FLANGE RUNOUT
Unit: mm (in) Applied modelYD25DDTi
4WD
5A/T 6M/T
Final drive modelM226
Gear ratio 3.538 3.692
Number of pinion gears 2
Number of teeth (Drive gear / drive pinion) 46/13 48/13
Oil capacity (Approx.)
(lmp pt)2.01 (3-1/2)
Drive pinion adjustment spacer type Collapsible
ItemStandard
Gear ratio: 3.538 type Gear ratio: 3.692 type
Total preload 2.34 - 4.34 (0.24 - 0.44, 21 - 38) 2.32 - 4.34 (0.24 - 0.44, 21 - 38)
Pinion bearing preload 1.7 - 3.1 (0.18 - 0.31, 15 - 27)
Item Standard
Drive gear to drive pinion gear 0.08 - 0.13 (0.0031 - 0.0051)
Item Runout limit
Companion flange face 0.10 (0.0039) or less
Inner side of companion flange 0.13 (0.0051) or less

SERVICE DATA AND SPECIFICATIONS (SDS)
RSU-11
C
D
F
G
H
I
J
K
L
MA
B
RSU
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General Specifications (Rear)EES002JK
Wheelarch Height (Unladen*1)EES002JL
King Cab
Unit: mm (in)
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
Double Cab
Unit: mm (in)
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.Suspension type Rigid axle with semi-elliptic leaf springs
Shock absorber type Double-acting hydraulic
Engine type YD25
Drive type 2WD 4WD
Applied model XE XE XE, SE SE
Tire size 235/70R16 255/70R16 235/70R16 255/70R16 255/65R17
Front wheelarch height (Hf)833 - 863
(32.80 - 33.98)845 - 875
(33.27 - 34.45)846 - 876
(33.31 - 34.49)858 - 888
(33.78 - 34.96)861 - 891
(33.90 - 35.08)
Rear wheelarch height (Hr)874 - 904
(34.41 - 35.59)877 - 907
(34.53 - 35.71)878 - 908
(34.57 - 35.75)891 - 921
(35.08 - 36.26)893 - 923
(35.16 - 36.34)
LEIA0085E
Engine type YD25
Drive type 2WD 4WD
Applied model SE XE XE, SE SE
Tire size 235/70R16 255/70R16 235/70R16 255/70R16 255/65R17
Front wheelarch height (Hf)832 - 862
(32.76 - 33.94)844 - 874
(33.23 - 34.41)846 - 876
(33.31 - 34.49)857 - 887
(33.74 - 34.92)860 - 890
(33.86 - 35.04)
Rear wheelarch height (Hr)872 - 902
(34.33 - 35.51)885 - 915
(34.84 - 36.02)877 - 907
(34.53 - 35.71)889 - 919
(35.00 - 36.18)891 - 921
(35.08 - 36.26)
LEIA0085E

TF-1
TRANSFER
D DRIVELINE/AXLE
CONTENTS
C
E
F
G
H
I
J
K
L
M
SECTIONTF
A
B
TF
TRANSFER
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 4
Precautions for Transfer Assembly and Transfer
Control Unit Replacement ........................................ 4
CHECK 4WD SHIFT INDICATOR PATTERN ....... 4
METHOD FOR ADJUSTMENT WITH 4WD
SHIFT SWITCH AT “2WD” .................................... 5
METHOD FOR ADJUSTMENT WITH 4WD
SHIFT SWITCH AT “4H” OR “4LO” ....................... 5
Precautions .............................................................. 6
Service Notice .......................................................... 6
Wiring Diagrams and Trouble Diagnosis .................. 7
PREPARATION ........................................................... 8
Special Service Tools ............................................... 8
Commercial Service Tools ...................................... 10
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ...............................................11
NVH Troubleshooting Chart .................................... 11
TRANSFER FLUID ................................................... 12
Replacement .......................................................... 12
DRAINING ........................................................... 12
FILLING ............................................................... 12
Inspection ............................................................... 12
FLUID LEAKAGE AND FLUID LEVEL ................ 12
4WD SYSTEM .......................................................... 13
Cross-Section View ................................................ 13
Power Transfer ....................................................... 14
POWER TRANSFER DIAGRAM ........................ 14
POWER TRANSFER FLOW ............................... 15
System Description ................................................ 15
TRANSFER CONTROL DEVICE ........................ 15
WAIT DETECTION SWITCH .............................. 15
4LO SWITCH ...................................................... 15
ATP SWITCH ...................................................... 15
TRANSFER CONTROL UNIT ............................. 15
TRANSFER SHIFT RELAY ................................. 15
TRANSFER SHUT OFF RELAY ......................... 15
4WD SHIFT SWITCH AND INDICATOR LAMP... 164WD WARNING LAMP ....................................... 17
ATP WARNING LAMP (A/T MODELS) ................ 17
System Diagram ..................................................... 18
COMPONENTS FUNCTION ............................... 18
CAN Communication .............................................. 19
SYSTEM DESCRIPTION .................................... 19
TROUBLE DIAGNOSIS ............................................ 20
How to Perform Trouble Diagnosis ......................... 20
BASIC CONCEPT ............................................... 20
Location of Electrical Parts ..................................... 21
A/T MODELS ....................................................... 21
M/T MODELS ...................................................... 22
Circuit Diagram ....................................................... 23
A/T MODELS ....................................................... 23
M/T MODELS ...................................................... 24
Wiring Diagram — T/F — ....................................... 25
A/T MODELS ....................................................... 25
M/T MODELS ...................................................... 31
Trouble Diagnosis Chart for Symptoms .................. 38
Transfer Control Unit Input/Output Signal Refer-
ence Values ............................................................ 38
TRANSFER CONTROL UNIT INSPECTION
TABLE ................................................................. 38
CONSULT-II Function (ALL MODE AWD/4WD) ..... 44
FUNCTION .......................................................... 44
CONSULT-II SETTING PROCEDURE ................ 44
SELF-DIAG RESULT MODE ............................... 45
DATA MONITOR MODE ...................................... 47
Self-Diagnostic Procedure ...................................... 49
SELF-DIAGNOSTIC PROCEDURE (WITH
CONSULT-II) ....................................................... 49
SELF-DIAGNOSTIC PROCEDURE (WITHOUT
CONSULT-II) ....................................................... 49
ERASE SELF-DIAGNOSIS ................................. 51
TROUBLE DIAGNOSIS FOR SYSTEM .................... 52
Power Supply Circuit For Transfer Control Unit ...... 52
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 52
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 52

TF-2
DIAGNOSTIC PROCEDURE .............................. 53
COMPONENT INSPECTION .............................. 54
Transfer Control Unit .............................................. 54
DIAGNOSTIC PROCEDURE .............................. 54
Output Shaft Revolution Signal (TCM) ................... 55
DIAGNOSTIC PROCEDURE .............................. 55
Vehicle Speed Sensor (ABS) .................................. 55
DIAGNOSTIC PROCEDURE .............................. 55
4LO Switch ............................................................. 56
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 56
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 56
DIAGNOSTIC PROCEDURE .............................. 57
COMPONENT INSPECTION .............................. 59
4WD Shift Switch .................................................... 59
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 59
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 59
DIAGNOSTIC PROCEDURE .............................. 60
COMPONENT INSPECTION .............................. 62
Wait Detection Switch ............................................. 63
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 63
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 63
DIAGNOSTIC PROCEDURE .............................. 64
COMPONENT INSPECTION .............................. 66
PNP Switch Signal (TCM) ...................................... 66
DIAGNOSTIC PROCEDURE .............................. 66
Actuator Motor ........................................................ 67
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 67
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 67
DIAGNOSTIC PROCEDURE .............................. 68
COMPONENT INSPECTION .............................. 74
Actuator Position Switch ......................................... 75
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 75
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 75
DIAGNOSTIC PROCEDURE .............................. 76
Transfer Control Device .......................................... 78
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 78
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 78
DIAGNOSTIC PROCEDURE .............................. 79
Engine Speed Signal (ECM) ................................... 81
DIAGNOSTIC PROCEDURE .............................. 81
CAN Communication Line ...................................... 82
DIAGNOSTIC PROCEDURE .............................. 82
ATP Switch ............................................................. 82
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 82
TRANSFER CONTROL UNIT TERMINALS ANDREFERENCE VALUE .......................................... 82
DIAGNOSTIC PROCEDURE ............................... 83
COMPONENT INSPECTION ............................... 85
Park/Neutral Position Switch ................................... 85
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 85
DIAGNOSTIC PROCEDURE ............................... 85
COMPONENT INSPECTION ............................... 87
TROUBLE DIAGNOSIS FOR SYMPTOMS .............. 88
4WD Shift Indicator Lamp and 4LO Indicator Lamp
Do Not Turn ON ...................................................... 88
SYMPTOM: .......................................................... 88
DIAGNOSTIC PROCEDURE ............................... 89
4WD Warning Lamp Does Not Turn ON ................. 91
SYMPTOM: .......................................................... 91
DIAGNOSTIC PROCEDURE ............................... 92
4WD Shift Indicator Lamp or 4LO Indicator Lamp
Does Not Change ................................................... 94
SYMPTOM: .......................................................... 94
DIAGNOSTIC PROCEDURE ............................... 95
ATP Warning Lamp Does Not Turn ON .................. 96
SYMPTOM: .......................................................... 96
DIAGNOSTIC PROCEDURE ............................... 96
4WD Shift Indicator Lamp Repeats Flashing .......... 98
SYMPTOM: .......................................................... 98
DIAGNOSTIC PROCEDURE ............................... 98
4WD Warning Lamp Flashes Slowly ....................... 99
SYMPTOM: .......................................................... 99
DIAGNOSTIC PROCEDURE ............................... 99
TRANSFER CONTROL UNIT .................................100
Removal and Installation .......................................100
REMOVAL ..........................................................100
INSTALLATION ..................................................100
FRONT OIL SEAL ...................................................101
Removal and Installation .......................................101
REMOVAL ..........................................................101
INSTALLATION ..................................................102
REAR OIL SEAL .....................................................103
Removal and Installation .......................................103
REMOVAL ..........................................................103
INSTALLATION ..................................................103
TRANSFER CONTROL DEVICE ............................105
Removal and Installation .......................................105
REMOVAL ..........................................................105
INSTALLATION ..................................................105
AIR BREATHER HOSE ...........................................107
Removal and Installation .......................................107
A/T MODELS .....................................................107
M/T MODELS .....................................................109
TRANSFER ASSEMBLY ......................................... 111
Removal and Installation ....................................... 111
REMOVAL .......................................................... 111
INSTALLATION ..................................................112
Disassembly and Assembly ..................................112
COMPONENTS .................................................112
DISASSEMBLY ..................................................114
INSPECTION AFTER DISASSEMBLY ..............119
ASSEMBLY ........................................................120

TF-4
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EDS003ID
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
lTo avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Transfer Assembly and Transfer Control Unit ReplacementEDS0031A
lWhen replacing transfer assembly or transfer control unit, check the 4WD shift indicator pattern and
adjustment of the position between transfer assembly and transfer control unit if necessary.
CHECK 4WD SHIFT INDICATOR PATTERN
1. Set 4WD shift switch to “2WD”, “4H”, “4LO”, “4H” and “2WD” in order. Stay at each switch position for at
least 2 seconds.
2. Confirm 4WD shift indicator lamp and 4LO indicator lamp are changed properly as follows.
lIf OK, the position between transfer assembly and transfer control unit is correct.
lIf NG, the position is different between transfer assembly and transfer control unit.
Adjust the position between transfer assembly and transfer control unit. Refer to pattern table below.
Transfer position adjustment pattern
NOTE:
Method of adjustment can be chosen voluntarily, according to location of 4WD shift switch.
SDIA3289E
4WD shift switch condition Refer procedure
4WD shift switch is under “2WD” condition when engine is being stopped.TF-5, "
METHOD FOR ADJUSTMENT WITH 4WD
SHIFT SWITCH AT“2WD”"
4WD shift switch is under “4H” or “4LO” condition when engine is being stopped.TF-5, "METHOD FOR ADJUSTMENT WITH 4WD
SHIFT SWITCH AT“4H”OR“4LO”"