ABS NISSAN NAVARA 2005 Repair Workshop Manual

REAR FINAL DRIVE ASSEMBLY
RFD-81
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
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RFD
REAR FINAL DRIVE ASSEMBLYPFP:38300
Removal and InstallationEDS003BF
REMOVAL
1. Remove the rear propeller shaft. Refer toPR-8, "Removal and Installation".
lPlug rear end of transmission or transfer.
2. Remove the axle shafts and back plate and torque members. Refer toRAX-7, "
Removal and Installation".
3. Disconnect the following components from the rear final drive.
lABS sensor wire harness
lRear cable (LH) and rear cable (RH)
lBrake hoses and brake tube
lDifferential lock position switch harness connector
lDifferential lock solenoid harness connector
CAUTION:
Position the wire harness, cable and hoses away from the final drive assembly. Failure to do so
may result in components being damaged during rear axle assembly removal.
4. Support the rear final drive using a suitable jack.
5. Remove rear shock absorber lower bolts. Refer toRSU-6, "
Removal and Installation".
6. Remove leaf spring U-bolt nuts. Refer toRSU-7, "
Removal and Installation".
WARNING:
Support the rear final drive assembly using suitable jack before removing leaf spring U-bolt nuts.
7. Remove rear final drive assembly using suitable jack.
INSTALLATION
Installation is the reverse order of removal.
lWhen oil leaks while removing rear final drive assembly, check oil level after the installation. Refer to
RFD-40, "
Checking Differential Gear Oil".
lRefill brake fluid and bleed the air from the brake system. Refer toBR-11, "Bleeding Brake System".
lAfter the installation, check DIFF LOCK indicator lamp. Refer toRFD-33, "Precautions for Differential
Case Assembly and Differential Lock Control Unit Replacement".

RSU-1
REAR SUSPENSION
E SUSPENSION
CONTENTS
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SECTIONRSU
A
B
RSU
REAR SUSPENSION
PRECAUTIONS .......................................................... 2
Precautions .............................................................. 2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 3
NVH Troubleshooting Chart ..................................... 3
REAR SUSPENSION ASSEMBLY ............................. 4
Components ............................................................. 4
On-Vehicle Inspection and Service .......................... 5
SHOCK ABSORBER .................................................. 6
Removal and Installation .......................................... 6
REMOVAL ............................................................. 6
INSPECTION AFTER REMOVAL ......................... 6
INSTALLATION ..................................................... 6LEAF SPRING ............................................................ 7
Removal and Installation .......................................... 7
REMOVAL ............................................................. 8
INSPECTION AFTER REMOVAL ......................... 9
INSTALLATION ..................................................... 9
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 11
General Specifications (Rear) ................................ 11
Wheelarch Height (Unladen*
1) .............................. 11

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
RSU-3
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RSU
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:54000
NVH Troubleshooting ChartEES002JF
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace the parts.
´: Applicable Reference page
RSU-4RSU-6RSU-4RSU-4RSU-9RSU-4
PR-2, "
NVH Troubleshooting Chart
"
RFD-7
(with LSD),RFD-39
(with LD)
RAX-5, "
NVH Troubleshooting Chart
"
WT-2, "
NVH Troubleshooting Chart
"
WT-2, "
NVH Troubleshooting Chart
"
BR-5, "
NVH Troubleshooting Chart
"
PS-5, "
NVH Troubleshooting Chart
"
Possible cause and SUSPECTED PARTS
Improper installation, looseness
Shock absorber deformation, damage or deflection
Bushing or mounting deterioration
Parts interference
Spring fatigue
Suspension looseness
PROPELLER SHAFT
REAR FINAL DRIVE
AXLE
TIRES
ROAD WHEEL
BRAKES
STEERING
SymptomsNoise´´´´´´´´ ´ ´´´ ´
Shake´´´´ ´´ ´ ´´´ ´
Vibration´´´´´ ´ ´ ´ ´
Shimmy´´´´ ´ ´´´ ´
Shudder´´´ ´ ´´´ ´
Poor quality ride or handling´´´´´´ ´ ´´

REAR SUSPENSION ASSEMBLY
RSU-5
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RSU
CAUTION:
When installing the components with rubber bushings, the final tightening of the nuts and bolts must
be done with the vehicle in an unladen condition (the fuel, engine coolant, and engine oil full; the
spare tire, jack, hand tools and mats in their designated positions) with the tires on the ground.
On-Vehicle Inspection and ServiceEES002JH
lCheck the rear suspension parts for any excessive play, cracks, wear, and other damage.
lShake each rear wheel to check for any excessive play as
shown.
lTighten all of the nuts and bolts to the specified torque.
CAUTION:
When installing the components with rubber bushings, the
final tightening of the nuts and bolts must be done with the
vehicle in an unladen condition (the fuel, engine coolant,
and engine oil full; the spare tire, jack, hand tools and mats
in their designated positions) with the tires on the ground.
lCheck the shock absorbers for oil leaks, deformation, and other
damage.
lCheck the shock absorber bushings for excessive wear and
other damage.
10. Shock absorber 11. Bumper 12. Shock absorber (left side)
13. Shock absorber (right side) 14. Damper
SMA525A
MEIB9019E
SRA734

RSU-6
SHOCK ABSORBER
SHOCK ABSORBER
PFP:56210
Removal and InstallationEES002JI
REMOVAL
1. Support the rear final drive and suspension assembly using a suitable jack.
2. Remove the shock absorber upper and lower nuts and bolts.
3. Remove the shock absorber.
INSPECTION AFTER REMOVAL
lInspect the shock absorber for any oil leaks, cracks, or deformations. Replace the shock absorber as nec-
essary.
lCheck the shock absorber for smooth operation through a full stroke, both compression and extension.
lIf rubber bushings are cracked or deformed, replace rubber bushings.
INSTALLATION
Installation is in the reverse order of removal.
LEIA0115E
Shock absorber upper and lower nuts : Refer toRSU-4, "Components".

RSU-8
LEAF SPRING
CAUTION:
When installing the components with rubber bushings, the final tightening of the nuts and bolts must
be done with the vehicle in an unladen condition (the fuel, engine coolant, and engine oil full; the
spare tire, jack, hand tools and mats in their designated positions) with the tires on the ground.
REMOVAL
1. Support the rear final drive assembly with a suitable jack to relieve the tension from the rear leaf spring.
lThe axle weight should be supported, but there should be no compression in the rear leaf spring.
2. Remove the shock absorber lower nut and bolt.
3. Remove the four rear spring clip U-bolt nuts, then remove the
rear spring pad.
4. Remove the rear spring shackle and bushings.
5. Remove the rear leaf spring front nut and bolt.
6. Remove the rear leaf spring.
10. Shock absorber 11. Bumper 12. Shock absorber (left side)
13. Shock absorber (right side) 14. Damper
LEIA0115E
LEIA0106E
LEIA0116E
LEIA0107E

LEAF SPRING
RSU-9
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RSU
INSPECTION AFTER REMOVAL
lCheck the rear leaf spring for any cracks or damage. Replace the rear leaf spring if necessary.
lCheck the rear spring shackle, rear spring clip U-bolts, bumper, and rear spring pad for excessive wear,
cracks, straightness, and damage. Replace any components if necessary.
lCheck all bushings for deformation and cracks. Replace any bushings if necessary.
INSTALLATION
1. Apply soapsuds to all of the rubber bushings.
2. Install the rear spring shackle and rear leaf spring front nut and bolt. Finger-tighten the nuts.
3. Install the rear spring clip U-bolts and bumper on top of the rear leaf spring.
4. Install the rear spring pad, and nuts under the axle case.
5. Tighten diagonally and in few steps the rear spring clip U-bolt
nuts, until the lengths of all the exposed rear spring clip U-bolt
threads under spring pad are equal in length, within a tolerance
of 3 mm (0.12 in).
Tighten nuts to specification. Refer toRSU-4, "
Components".
6. Install the shock absorber, and finger-tighten the nuts.
7. Remove the jack supporting the rear final drive assembly and
bounce the rear of the vehicle to stabilize the suspension.
MEIB9018E
WEIA0075E
LEIA0115E
SRA703

RSU-10
LEAF SPRING
8. Tighten the rear spring shackle nuts, rear leaf spring front nut,
and shock absorber nuts to specification.
lWhen installing the components with rubber bushings, the
final nut tightening must be carried out under unladen* condi-
tions with the tires on level ground.
* (Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.)
SRA754

SERVICE DATA AND SPECIFICATIONS (SDS)
RSU-11
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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

FRONT SEAT
SE-25
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SE
Assembly
Assemble in the reverse order of disassembly.
SEAT CUSHION (MANUAL SEAT)
Disassembly
1. Hang snap ring(1) on wire(A), and pull it up to remove.Remove
lifter dial(2).
2. Remove the hog rings on the seat cushion frame, and then disconnect the seat harness connectors.
3. Remove the nuts, and then the seat cushion assembly.
4. Pull up tabs of reclining lever from inside.Slide knob forward to
remove.
5. Remove the screw, and remove the outer and inner seat cush-
ion finisher.
6. Remove the retainer on the seat cushion frame, then remove the seat cushion trim&pad.
7. Remove the hog rings to separate the seat cushion trim, pad, and seat cushion heater unit.
Assembly
Assemble in the reverse order of disassembly.
MIIB0741E
MIIB0742E
MIIB0743E
MIIB0739E