4WD NISSAN NAVARA 2005 Repair Workshop Manual

PRECAUTIONS
TF-5
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B
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METHODFORADJUSTMENTWITH4WDSHIFTSWITCHAT“2WD”
Select Adjustment Pattern
1. Start engine. Run engine for at least 10 seconds.
2. Check 4WD shift indicator lamp and 4LO indicator lamp.
Pattern A
1. Stay in the below for at least 2 seconds.
lFor A/T models, stop the vehicle and move A/T selector lever to “N” position with the brake pedal
depressed.
lFor M/T models, stop the vehicle and move M/T shift lever to the neutral position with the brake and
clutch pedal depressed.
2. Turn 4WD shift switch to “4LO” position. Stay in "4LO" for at least 2 seconds.
3. Turn ignition switch “OFF”.
4. Start engine.
5. Erase self-diagnosis. Refer toTF-46, "
How to Erase Self-diagnostic Results"(with CONSULT-II) orTF-
51, "ERASE SELF-DIAGNOSIS"(without CONSULT-II).
6. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer toTF-4, "
CHECK 4WD SHIFT INDI-
CATOR PATTERN".
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.
Pattern B
1. Stay in the below for at least 2 seconds.
lFor A/T models, stop the vehicle and move A/T selector lever to “N” position with the brake pedal
depressed.
lFor M/T models, stop the vehicle and move M/T shift lever to the neutral position with the brake and
clutch pedal depressed.
2. Turn ignition switch “OFF”.
3. Start engine.
4. Erase self-diagnosis. Refer toTF-46, "
How to Erase Self-diagnostic Results"(with CONSULT-II) orTF-
51, "ERASE SELF-DIAGNOSIS"(without CONSULT-II).
5. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer toTF-4, "
CHECK 4WD SHIFT INDI-
CATOR PATTERN".
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.
METHODFORADJUSTMENTWITH4WDSHIFTSWITCHAT“4H”OR“4LO”
1. Start engine. Run the engine for at least 10 seconds.
2. Stay in the below for at least 2 seconds.
lFor A/T models, stop the vehicle and move A/T selector lever to “N” position with the brake pedal
depressed.
lFor M/T models, stop the vehicle and move M/T shift lever to the neutral position with the brake and
clutch pedal depressed.
3. Turn 4WD shift switch to “2WD” position. Stay in "2WD" for at least 2 seconds.
4. Turn ignition switch “OFF”.
5. Start engine.
6. Erase self-diagnosis. Refer toTF-46, "
How to Erase Self-diagnostic Results"(with CONSULT-II) orTF-
51, "ERASE SELF-DIAGNOSIS"(without CONSULT-II).
7. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer toTF-4, "
CHECK 4WD SHIFT INDI-
CATOR PATTERN".
Indicator lamp condition Refer procedure
When 4WD shift indicator lamp or 4LO indicator lamp is flashing.TF-5, "
Pattern A"
Except for above.TF-5, "Pattern B"

TF-6
PRECAUTIONS
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.
PrecautionsEDS0031B
lBefore connecting or disconnecting the transfer control unit harness connector, turn ignition
switch “OFF” and disconnect the battery cables. Battery voltage is applied to transfer control unit
even if ignition switch is turned “OFF”.
lWhen connecting or disconnecting pin connectors into or
from transfer control unit, take care not to damage pin ter-
minals (bend or break).
When connecting pin connectors make sure that there are
not any bends or breaks on transfer control unit pin termi-
nals.
lBefore replacing transfer control unit, perform transfer con-
trol unit input/output signal inspection and make sure
whether transfer control unit functions properly or not.
Refer toTF-38, "
Transfer Control Unit Input/Output Signal
Reference Values".
Service NoticeEDS0031C
lAfter overhaul refill the transfer with new transfer fluid.
lCheck the fluid level or replace the fluid only with the vehicle parked on level ground.
lDuring removal or installation, keep inside of transfer clear of dust or dirt.
lDisassemblyshouldbedoneinacleanworkarea.
lBefore proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal
parts from becoming contaminated by dirt or other foreign matter.
lCheck for the correct installation status prior to removal or disassembly. If matchmarks are required, be
certain they do not interfere with the function of the parts when applied.
lAll parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
lCheck appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary.
lGaskets, seals and O-rings should replaced any time the transfer is disassembled.
lIn principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it.
lObserve the specified torque when assembling.
lClean and flush the parts sufficiently and blow-dry them.
lBe careful not to damage sliding surfaces and mating surfaces.
lUse lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere
with the operation of the transfer.
SEF291H
MEF040DB

4WD SYSTEM
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4WD SYSTEMPFP:33084
Cross-Section ViewEDS0031J
1. Mainshaft 2. Rear case 3. Oil pump assembly
4. Clutch gear 5. 2-4 shift fork 6. 2-4 sleeve
7. Drive chain 8. Sprocket 9. L-H shift fork
10. L-H sleeve 11. Internal gear 12. Front case
13. Planetary carrier assembly 14. Sun gear assembly 15. L-H shift rod
16. Control shift rod
(A/T models)17. Companion flange 18. Front drive shaft
19. Control shift rod assembly
(M/T models)20. Transfer control device
SDIA3418E

TF-14
4WD SYSTEM
Power Transfer
EDS0031K
POWER TRANSFER DIAGRAM
1. Mainshaft 2. Clutch gear 3. 2-4 sleeve
4. Drive chain 5. Sprocket 6. L-H sleeve
7. Planetary carrier assembly 8. Sun gear assembly 9. Front drive shaft
WDIA0223E

4WD SYSTEM
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POWER TRANSFER FLOW
System DescriptionEDS0031L
TRANSFER CONTROL DEVICE
Actuator motor and actuator position switch are integrated. Transfer control device shifts from 4HÛ4LO and
between 2WDÛ4WD.
Actuator Motor
Actuator motor is operated by signal from transfer control unit and it operates control shift rod so as to shift
from 4HÛ4LO and between 2WDÛ4WD.
Actuator Position Switch
Actuator position switch detects actuator motor position and sends it to transfer control unit.
WAIT DETECTION SWITCH
Wait detection switch detects if transfer gear is in 4WD by 2-4 shift fork position.
NOTE:
If 4WD shift switch is switched to 4H or 4LO, transfer is not in 4WD completely when gear does not engage.
(Wait detection system is operating.)
4LO SWITCH
4LO switch detects if transfer gear is under 4LO condition by L-H shift fork position.
AT P S W I T C H
ATP switch detects if transfer gear is under neutral condition by L-H shift fork position.
NOTE:
Transfer gear may be under neutral condition when shifting between 4HÛ4LO.
TRANSFER CONTROL UNIT
lTransfer control unit controls transfer control device by input signals of each sensor and each switch, and
itdirectsshiftsfrom4HÛ4LO and 2WDÛ4WD.
lSelf-diagnosis can be done.
TRANSFER SHIFT RELAY
Transfer shift high relay and transfer shift low relay apply power supply to transfer control device (actuator
motor).
TRANSFER SHUT OFF RELAY
Transfer shut off relay 1 and transfer shut off relay 2 apply power supply to transfer control unit.
SDIA2213E

TF-16
4WD SYSTEM
4WD SHIFT SWITCH AND INDICATOR LAMP
4WD Shift Switch
4WD shift switch is able to select from 2WD, 4H or 4LO.
4WD Shift Indicator Lamp
lDisplays driving conditions selected by 4WD shift switch with front, rear and center indicators, while
engine is running. (When shifting from 4H to 4LO, 4LO indicator lamp also turns on. And when 4WD warn-
ing lamp is turned on, all 4WD shift indicator lamps are turned off.)
lTurns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately 1 sec-
ondaftertheenginestartsifsystemisnormal.
4LO Indicator Lamp
lDisplays 4LO condition while engine is running. 4LO indicator lamp flashes if transfer gear does not shift
completely under 4HÛ4LO. In this condition, transfer may be under neutral condition and A/T parking
mechanism may not operate.
lTurns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately 1 sec-
ondaftertheenginestartsifsystemisnormal.
SDIA3290E

4WD SYSTEM
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4WD WARNING LAMP
Turns ON or flashes when there is a malfunction in 4WD system.
Also turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately 1 sec-
ond after the engine starts if system is normal.
4WD Warning Lamp Indication
NOTE:
4WD warning lamp is turned on when the following one or more parts are malfunctioning.
lVehicle speed signal
[from ABS actuator and electric unit (control unit)]
lCAN communication line
lAD converter
lEngine speed signal
l4WD shift switch
lWait detection switch
lActuator motor
lTransfer control device
lTransfer shut off relay
lTransfer shift relay
lPNP switch signal
ATP WARNING LAMP (A/T MODELS)
When A/T selector lever is in “P” position, vehicle may move because A/T parking mechanism does not oper-
ate when transfer is under neutral condition. ATP warning lamp is turned on to indicate this condition to the
driver.
Condition 4WD warning lamp
Lamp checkTurns ON when ignition switch is turned ON.
Turns OFF after engine start.
4WD system malfunctionON
(For indicated malfunction items, see the “NOTE”)
During self-diagnosis Flashes at malfunction mode.
Large difference in diameter of front/
rear tiresSlow flashing: 1 time/2 seconds
(Continues to flash until ignition switch is turned OFF)
Other than above (system normal) OFF

TF-18
4WD SYSTEM
System Diagram
EDS0031M
COMPONENTS FUNCTION
SDIA3416E
Component parts Function
Transfer control unit Controls transfer control device and switches 4HÛ4LO under 4WD condition and 2WDÛ4WD.
Transfer control device Actuator motor and actuator position switch are integrated so as to switch driving modes.
Actuator motor Controls shift rod by signals from transfer control unit.
Actuator position switch Detects actuator motor position.
Wait detection switch Detects that transfer is under 4WD condition.
4LO switch Detects that transfer is under 4LO condition.
AT P s w i t c h
(A/T models)Detects that transfer is under neutral condition.
4WD shift switch Able to select from 2WD, 4H or 4LO.
4WD warning lamp
lIlluminates if malfunction is detected in electrical system of 4WD system.
lThere is 1 blink in 2 seconds if rotation difference of front wheels and rear wheels is large.
ATP warning lamp
(A/T models)Indicates that A/T parking mechanism does not operate when A/T selector lever is in “P” position
and transfer is under neutral condition.
4WD shift indicator lamp Displays driving condition selected by 4WD shift switch.
4LO indicator lamp Displays 4LO condition.
PNP switch
(M/T models)Detects that manual transmission is under neutral condition.
ABS actuator and electric unit
(control unit)Transmits the following signals via CAN communication to Transfer control unit.
lVehicle speed signal
lStop lamp switch signal (brake signal)

4WD SYSTEM
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CAN CommunicationEDS0031N
SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
For details, refer toLAN-23, "
CAN COMMUNICATION".
TCM
(A/T models)Transmits the following signal via CAN communication to Transfer control unit.lOutput shaft revolution signal
lA/T position indicator signal (PNP switch signal)
ECMTransmits engine speed signal via CAN communication to Transfer control unit.
lEngine speed signal Component parts Function

TF-38
TROUBLE DIAGNOSIS
Trouble Diagnosis Chart for Symptoms
EDS0031U
If 4WD warning lamp turns ON, perform self-diagnosis. Refer toTF-49, "Self-Diagnostic Procedure".
Transfer Control Unit Input/Output Signal Reference ValuesEDS0031V
TRANSFER CONTROL UNIT INSPECTION TABLE
Specifications with CONSULT-II
Symptom Condition Check item Reference page
4WD shift indicator lamp and 4LO indicator
lamp do not turn ON
(4WD shift indicator lamp and 4LO indicator
lamp check)Ignition switch: ONPower supply and ground for transfer
control unit
TF-88
Transfer shut off relay
Combination meter
4WD warning lamp does not turn ON
(4WD warning lamp check)Ignition switch: ONPower supply and ground for transfer
control unit
TF-91
Transfer shut off relay
Combination meter
4WD shift indicator lamp or 4LO indicator
lamp does not changeEngine running4WD shift switch
TF-94
Wait detection switch
4LO switch
AT P s w i t c h
Transfer inner parts
ATP warning lamp does not turn ON Engine runningCAN communication line
TF-96
4WD shift switch
PNP switch signal
AT P s w i t c h
Combination meter
Transfer inner parts
4WD shift indicator lamp repeats flashing Engine runningWait detection switch
TF-98
4LO switch
Transfer inner parts
4WD warning lamp flashes slowly
Slow flashing: 1 time/2 secondsWhile drivingTire size is different between front and
rear of vehicle.TF-99
Monitored item [Unit] Content Condition Display value
VHCL/S SEN·FR [km/h]
or [mph]Wheel speed (Front wheel)Vehicle stopped 0 km/h (0 mph)
Vehicle running
CAUTION:
Check air pressure of tire under standard condi-
tion.Approximately
equal to the indica-
tion on speedome-
ter (Inside of±10%)
VHCL/S SEN·RR [km/h]
or [mph]Wheel speed (Rear wheel)Vehicle stopped 0 km/h (0 mph)
Vehicle running
CAUTION:
Check air pressure of tire under standard condi-
tion.Approximately
equal to the indica-
tion on speedome-
ter (Inside of±10%)
ENGINE SPEED [rpm] Engine speedEngine stopped
(Engine speed: Less than 400 rpm)0rpm
Engine running
(Engine speed: 400 rpm or more)Approximately
equal to the indica-
tion on tachometer
BATTERY VOLT [V]Power supply voltage for
transfer control unitIgnition switch: ON Battery voltage