service NISSAN NAVARA 2005 Repair Workshop Manual

SERVICE DATA AND SPECIFICATIONS (SDS)
EM-145
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AVAILABLE MAIN BEARING
Main bearing
Unit: mm (in)
Undersize
Unit: mm (in)
AVAILABLE CONNECTING ROD BEARING
Connecting Rod Bearing
Unit: mm (in)
Undersize
Unit: mm (in)
MISCELLANEOUS COMPONENTS
Flywheel
Unit: mm (in)
*: Total indicator readingGrade number Thickness “T” Width “W” Identification color
STD 0 1.816 - 1.820 (0.0715 - 0.0717)
19.9 - 20.1 (0.783 - 0.791)Black
STD 1 1.820 - 1.824 (0.0717 - 0.0718) Brown
STD 2 1.824 - 1.828 (0.0718 - 0.0720) Green
STD 3 1.828 - 1.832 (0.0720 - 0.0721) Yellow
STD 4 1.832 - 1.836 (0.0721 - 0.0723) Blue
SEM255G
Size Thickness Main journal diameter “Dm”
0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)Grind so that bearing clearance is the
specified value.
Grade number Thickness “T” Width “W” Identification color (mark)
STD 0 1.492 - 1.496 (0.0587 - 0.0589)
22.9 - 23.1
(0.902 - 0.909)Black
STD 1 1.496 - 1.500 (0.0589 - 0.0591) Brown
STD 2 1.500 - 1.504 (0.0591 - 0.0592) Green
Size Thickness Crank pin journal diameter “Dp”
0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
Grind so that bearing clearance is the
specified value. 0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
Flywheel deflection [TIR]* Standard 0.45 (0.0177) or less

EM-146
SERVICE DATA AND SPECIFICATIONS (SDS)
Bearing Clearance
Unit: mm (in)
Main bearing oil clearance Standard 0.047 - 0.077 (0.0019 - 0.0030)
Connecting rod bearing oil
clearanceStandard 0.039 - 0.070 (0.0015 - 0.0028)

FAX-1
FRONT AXLE
D DRIVELINE/AXLE
CONTENTS
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SECTIONFA X
A
B
FA X
FRONT AXLE
PRECAUTIONS .......................................................... 2
Precautions .............................................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 4
NVH Troubleshooting Chart ..................................... 4
WHEEL HUB .............................................................. 5
On-Vehicle Inspection and Service .......................... 5
WHEEL BEARING INSPECTION ......................... 5
Removal and Installation .......................................... 5
REMOVAL ............................................................. 5
INSPECTION AFTER REMOVAL ......................... 6
INSTALLATION ..................................................... 6DRIVE SHAFT ............................................................. 7
Removal and Installation .......................................... 7
REMOVAL ............................................................. 7
INSPECTION AFTER REMOVAL ......................... 7
INSTALLATION ..................................................... 8
Disassembly and Assembly ...................................... 8
DISASSEMBLY ..................................................... 8
INSPECTION AFTER DISASSEMBLY .................. 9
ASSEMBLY ......................................................... 10
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 14
Wheel Bearing ........................................................ 14
Drive Shaft .............................................................. 14

PREPARATION
FAX-3
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FA X
PREPARATIONPFP:00002
Special Service ToolsEDS003I4
Commercial Service ToolsEDS003I5
Tool number
Tool nameDescription
ST29020001
Gear arm pullerRemoving ball joint for steering knuckle
a: 34 mm (1.34 in)
b: 6.5 mm (0.256 in)
c: 61.5 mm (2.421 in)
KV38105500
ProtectorInstalling drive shaft
a: 40 mm (1.57 in) dia
KV40107300
BootbandcrimpingtoolInstalling boot bands
NT694
ZZA0835D
ZZA1229D
Tool nameDescription
PullerRemoving drive shaft
NT077

WHEEL HUB
FAX-5
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FA X
WHEEL HUBPFP:43202
On-Vehicle Inspection and ServiceEDS003I7
Make sure the mounting conditions (looseness, backlash) of each component and component status (wear,
damage) are normal.
WHEEL BEARING INSPECTION
lMove wheel hub in the axial direction by hand. Make sure there
is no looseness of wheel bearing.
lRotate wheel hub and make sure there is no unusual noise or
other irregular conditions. If there are any irregular conditions,
replace wheel hub and bearing assembly.
Removal and InstallationEDS003I8
REMOVAL
1. Remove wheel.
2. Without disassembling the hydraulic lines, remove caliper torque member bolts. Then reposition brake
caliper aside with wire. Refer toBR-26, "
Removal and Installation of Brake Caliper Assembly".
CAUTION:
Do not press brake pedal while brake caliper is removed.Axial end play limit : 0.05 mm (0.002 in) or less
SMA571A
1. Disc rotor 2. Wheel hub and bearing assembly* 3. Wheel stud
4. Splash guard 5. Steering knuckle 6. Wheel sensor bracket
*: Do not disassemble
MDIB9011E

FAX-14
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Wheel BearingEDS003IB
Drive ShaftEDS003IC
Wheel bearing axial end play 0.05 mm (0.002 in) or less
Wheel Side Final Drive Side
Applied modelEngine YD25, VQ40
Transaxle MT AT
Drive shaft joint type Final drive side AAR3300I AAR3300I
Wheel side UF3700I AC3300I
GreaseQuality Nissan genuine grease or equivalent
Capacity g (oz)Final drive side 134 - 144 (4.73 - 5.08) 134 - 144 (4.73 - 5.08)
Wheel side 226 - 246 (7.97 - 8.68) 110 - 130 (3.88 - 4.59)
Boot length “L” mm (in)Final drive side 176 - 178 (6.93 - 7.01) 176 - 178 (6.93 - 7.01)
Wheel side 154 (6.06) 150.4 (5.92)
MDIB9038EMDIB9037E

FFD-1
FRONT FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
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SECTIONFFD
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FFD
FRONT FINAL DRIVE
PRECAUTIONS .......................................................... 2
Service Notice or Precautions .................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 6
NVH Troubleshooting Chart ..................................... 6
DESCRIPTION ............................................................ 7
Cross-Sectional View ............................................... 7
DIFFERENTIAL GEAR OIL ........................................ 8
Changing Differential Gear Oil ................................. 8
DRAINING ............................................................. 8
FILLING ................................................................. 8
Checking Differential Gear Oil .................................. 8
OIL LEAKAGE AND OIL LEVEL ........................... 8
FRONT OIL SEAL ...................................................... 9
Removal and Installation .......................................... 9
IDENTIFICATION STAMP OF REPLACEMENT
FREQUENCY OF FRONT OIL SEAL ................... 9
REMOVAL ............................................................. 9
INSTALLATION .................................................... 11
SIDE OIL SEAL ........................................................ 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13REAR COVER GASKET ........................................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
FRONT FINAL DRIVE ASSEMBLY .......................... 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
Disassembly and Assembly .................................... 17
COMPONENTS ................................................... 17
ASSEMBLY INSPECTION AND ADJUSTMENT... 18
DISASSEMBLY ................................................... 21
INSPECTION AFTER DISASSEMBLY ................ 26
ADJUSTMENT AND SELECTION ADJUSTING
WASHERS .......................................................... 27
ASSEMBLY ......................................................... 28
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 37
General Specifications ............................................ 37
Inspection and Adjustment ..................................... 37
DRIVE GEAR RUNOUT ...................................... 37
DIFFERENTIAL SIDE GEAR CLEARANCE ....... 37
PRELOAD TORQUE ........................................... 37
BACKLASH ......................................................... 37
COMPANION FLANGE RUNOUT ....................... 37
SELECTIVE PARTS ............................................ 37

FFD-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
ServiceNoticeorPrecautionsEDS0034W
lBefore starting diagnosis of the vehicle, understand the symptoms well. Perform correct and systematic
operations.
lCheck for the correct installation status prior to removal or disassembly. When matching marks are
required, be certain they do not interfere with the function of the parts they are applied to.
lOverhaul should be done in a clean work area, a dust proof area is recommended.
lBefore disassembly, completely remove sand and mud from the exterior of the unit, preventing them from
entering into the unit during disassembly or assembly.
lAlways use shop paper for cleaning the inside of components.
lAvoid using cotton gloves or a shop cloth to prevent the entering of lint.
lCheck appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with new ones if necessary.
lGaskets, seals and O-rings should be replaced any time the unit is disassembled.
lClean and flush the parts sufficiently and blow them dry.
lBe careful not to damage sliding surfaces and mating surfaces.
lWhen applying sealant, remove the old sealant from the mating surface; then remove any moisture, oil,
and foreign materials from the application and mating surfaces.
lIn principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If a
tightening sequence is specified, observe it.
lDuring assembly, observe the specified tightening torque.
lAdd new differential gear oil, petroleum jelly, or multi-purpose grease, as specified.

PREPARATION
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FFD
PREPARATIONPFP:00002
Special Service ToolsEDS0034X
Tool number
Tool nameDescription
KV381054S0
PullerRemoving front oil seal
ST30720000
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
lInstalling front oil seal
lInstalling side oil seal
ST27863000
Drift
a: 74.5 mm (2.933 in) dia.
b: 62.5 mm (2.461 in) dia.
lInstalling front oil seal
lInstalling side oil seal
ST29020001
PullerSeparating the upper link ball joint stud
ST3127S000
Preload gauge
1: GG91030000
Torque wrench
2: HT62940000
Socket adapter (1/2²)
3: HT62900000
Socket adapter (3/8²)Measuring pinion bearing preload and total
preload
K V 1 0 1111 0 0
Seal cutterRemoving rear cover
ST3306S001
Differential side bearing puller set
1: ST33051001
Puller
2: ST33061000
Base
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.Removing and installing side bearing inner
race
ZZA0601D
ZZA0811D
ZZA1003D
NT143
NT124
S-NT046
NT072

PREPARATION
FFD-5
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FFD
Commercial Service ToolsEDS0034Y
ST33230000
Drift
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.
c: 28 mm (1.10 in) dia.Installing side bearing inner race
KV38100600
DriftInstalling side bearing adjusting shim Tool number
Tool nameDescription
ZZA1046D
SDIA0429J
Tool nameDescription
Power toolLoosening nuts and bolts
Flange wrenchRemoving and installing drive pinion lock nut
PBIC0190E
NT771