NISSAN NAVARA 2005 Repair User Guide

AT-3
D
E
F
G
H
I
J
K
L
MA
B
AT CONSULT-II Reference Value .............................. 144
On Board Diagnosis Logic ................................... 144
Possible Cause .................................................... 144
DTC Confirmation Procedure ............................... 144
Diagnostic Procedure ........................................... 145
DTC P1767 HIGH AND LOW REVERSE CLUTCH
SOLENOID VALVE ................................................. 147
Description ........................................................... 147
CONSULT-II Reference Value .............................. 147
On Board Diagnosis Logic ................................... 147
Possible Cause .................................................... 147
DTC Confirmation Procedure ............................... 147
Diagnostic Procedure ........................................... 148
DTC P1769 HIGH AND LOW REVERSE CLUTCH
SOLENOID VALVE FUNCTION ............................. 149
Description ........................................................... 149
CONSULT-II Reference Value .............................. 149
On Board Diagnosis Logic ................................... 149
Possible Cause .................................................... 149
DTC Confirmation Procedure ............................... 149
Diagnostic Procedure ........................................... 150
DTC P1772 LOW COAST BRAKE SOLENOID
VALVE ..................................................................... 152
Description ........................................................... 152
CONSULT-II Reference Value .............................. 152
On Board Diagnosis Logic ................................... 152
Possible Cause .................................................... 152
DTC Confirmation Procedure ............................... 152
Diagnostic Procedure ........................................... 153
DTC P1774 LOW COAST BRAKE SOLENOID
VALVE FUNCTION ................................................. 154
Description ........................................................... 154
CONSULT-II Reference Value .............................. 154
On Board Diagnosis Logic ................................... 154
Possible Cause .................................................... 154
DTC Confirmation Procedure ............................... 154
Diagnostic Procedure ........................................... 155
DTC P1841 ATF PRESSURE SWITCH 1 ............... 156
Description ........................................................... 156
CONSULT-II Reference Value .............................. 156
On Board Diagnosis Logic ................................... 156
Possible Cause .................................................... 156
DTC Confirmation Procedure ............................... 156
Diagnostic Procedure ........................................... 157
DTC P1843 ATF PRESSURE SWITCH 3 ............... 158
Description ........................................................... 158
CONSULT-II Reference Value .............................. 158
On Board Diagnosis Logic ................................... 158
Possible Cause .................................................... 158
DTC Confirmation Procedure ............................... 158
Diagnostic Procedure ........................................... 159
DTC P1845 ATF PRESSURE SWITCH 5 ............... 160
Description ........................................................... 160
CONSULT-II Reference Value .............................. 160
On Board Diagnosis Logic ................................... 160
Possible Cause .................................................... 160
DTC Confirmation Procedure ............................... 160
Diagnostic Procedure ........................................... 161
DTC P1846 ATF PRESSURE SWITCH 6 ............... 162Description ............................................................162
CONSULT-II Reference Value ..............................162
On Board Diagnosis Logic ....................................162
Possible Cause .....................................................162
DTC Confirmation Procedure ...............................162
Diagnostic Procedure ...........................................163
MAIN POWER SUPPLY AND GROUND CIRCUIT. 164
Wiring Diagram — AT — MAIN ............................164
Diagnostic Procedure ...........................................165
CLOSED THROTTLE POSITION AND WIDE OPEN
THROTTLE POSITION CIRCUIT ............................168
CONSULT-II Reference Value ..............................168
Diagnostic Procedure ...........................................168
BRAKE SIGNAL CIRCUIT ......................................169
CONSULT-II Reference Value ..............................169
Diagnostic Procedure ...........................................169
1ST POSITION SWITCH .........................................170
CONSULT-II Reference Value ..............................170
Diagnostic Procedure ...........................................170
OVERDRIVE CONTROL SWITCH .........................172
CONSULT-II Reference Value ..............................172
Diagnostic Procedure ...........................................172
TROUBLE DIAGNOSIS FOR SYMPTOMS ............174
Wiring Diagram — AT — NONDTC ......................174
OD OFF Indicator Lamp Does Not Come On .......177
Engine Cannot Be Started in “P” or “N” Position ..177
In “P” Position, Vehicle Moves When Pushed ......178
In “N” Position, Vehicle Moves ..............................179
Large Shock (“N” to “D” Position) .........................180
Vehicle Does Not Creep Backward in “R” Position. 182
Vehicle Does Not Creep Forward in “D” Position . 184
Vehicle Cannot Be Started from D
1......................186
A/T Does Not Shift: D
1®D2................................188
A/T Does Not Shift: D
2®D3................................190
A/T Does Not Shift: D
3®D4................................192
A/T Does Not Shift: D
4®D5................................194
A/T Does Not Perform Lock-up ............................196
A/T Does Not Hold Lock-up Condition ..................197
Lock-up Is Not Released ......................................199
Engine Speed Does Not Return to Idle ................199
A/T Does Not Shift: 5th Gear®4th Gear ............200
A/T Does Not Shift: 4th Gear®3rd Gear ............202
A/T Does Not Shift: 3rd Gear®2nd Gear ...........203
A/T Does Not Shift: 2nd Gear®1st Gear ...........204
Vehicle Does Not Decelerate by Engine Brake ....206
SHIFT CONTROL SYSTEM ....................................208
Control Device Removal and Installation ..............208
Control Cable Removal and Installation ...............210
Adjustment of A/T Position ...................................211
Checking of A/T Position ......................................211
A/T SHIFT LOCK SYSTEM ....................................212
Description ............................................................212
Shift Lock System Electrical Parts Location .........212
Wiring Diagram — A/T — SHIFT ..........................213
Diagnostic Procedure ...........................................214
KEY INTERLOCK CABLE ......................................216
Removal and Installation ......................................216
ON-VEHICLE SERVICE ..........................................218
Control Valve With TCM and A/T Fluid Temperature

AT-4
Sensor 2 ...............................................................218
Parking Components (2WD Models Only) ............230
Rear Oil Seal ........................................................237
Revolution Sensor Components (2WD Models
Only) .....................................................................238
AIR BREATHER HOSE ...........................................243
Removal and Installation ......................................243
A/T FLUID COOLER ...............................................244
Removal and Installation ......................................244
TRANSMISSION ASSEMBLY ................................247
Removal and Installation ......................................247
OVERHAUL .............................................................251
Components .........................................................251
Oil Channel ...........................................................259
Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings ..........................261
DISASSEMBLY .......................................................263
Disassembly .........................................................263
REPAIR FOR COMPONENT PARTS ......................281
Oil Pump ...............................................................281
Front Sun Gear, 3rd One-way Clutch ...................284Front Carrier, Input Clutch, Rear Internal Gear .....286
Mid Sun Gear, Rear Sun Gear, High and Low
Reverse Clutch Hub ..............................................291
High and Low Reverse Clutch ..............................296
Direct Clutch .........................................................298
ASSEMBLY .............................................................300
Assembly (1) .........................................................300
Adjustment ............................................................313
Assembly (2) .........................................................316
SERVICE DATA AND SPECIFICATIONS (SDS) ....323
General Specifications ..........................................323
Stall Speed ............................................................323
Line Pressure ........................................................323
Vehicle Speed at Which Gear Shifting Occurs ......324
Vehicle Speed at Which Lock-Up Occurs/Releases.324
A/T Fluid Temperature Sensor ..............................324
Vehicle Speed Sensor A/T (Revolution Sensor) ...325
Turbine Revolution Sensor ....................................325
Reverse Brake ......................................................325
Total End Play .......................................................325

INDEX FOR DTC
AT-5
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MA
B
AT
INDEX FOR DTCPFP:00024
Alphabetical IndexECS00FW4
NOTE:
If DTC “U1000 CAN COMM CIRCUIT” is displayed with other DTCs, first perform the trouble diagnosis
for “DTC U1000 CAN COMMUNICATION LINE”. Refer toAT-91
.
Items
(CONSULT- II screen terms)DTC Reference page
A/T 1ST E/BRAKING P1731AT-130
ATF PRES SW 1/CIRC P1841AT-156
ATF PRES SW 3/CIRC P1843AT-158
ATF PRES SW 5/CIRC P1845AT-160
ATF PRES SW 6/CIRC P1846AT-162
A/T INTERLOCK P1730AT-127
A/T TCC S/V FNCTN P0744AT- 11 2
ATF TEMP SEN/CIRC P1710AT- 11 8
CAN COMM CIRCUIT U1000AT- 9 1
D/C SOLENOID/CIRC P1762AT-142
D/C SOLENOID FNCTN P1764AT-144
ENGINE SPEED SIG P0725AT-108
FR/B SOLENOID/CIRC P1757AT-137
FR/B SOLENOID FNCT P1759AT-139
HLR/C SOL/CIRC P1767AT-147
HLR/C SOL FNCTN P1769AT-149
I/C SOLENOID/CIRC P1752AT-132
I/C SOLENOID FNCTN P1754AT-134
L/PRESS SOL/CIRC P0745AT- 11 4
LC/B SOLENOID/CIRC P1772AT-152
LC/B SOLENOID FNCT P1774AT-154
PNP SW/CIRC P0705AT- 9 9
STARTER RELAY/CIRC P0615AT- 9 4
TCC SOLENOID/CIRC P0740AT- 11 0
TCMP0700AT- 9 8
TP SEN/CIRC A/T P1705AT- 11 6
TURBINE REV S/CIRC P1716AT-123
VEH SPD SE/CIR·MTR P1721AT-125
VEH SPD SEN/CIR AT P0720AT-103

AT-6
INDEX FOR DTC
DTC No. Index
ECS00FW5
NOTE:
If DTC “U1000 CAN COMM CIRCUIT” is displayed with other DTCs, first perform the trouble diagnosis
for “DTC U1000 CAN COMMUNICATION LINE”. Refer toAT-91
.
DTCItems
(CONSULT- II screen terms)Reference page
P0615 STARTER RELAY/CIRCAT- 9 4
P0700 TCMAT- 9 8
P0705 PNP SW/CIRCAT- 9 9
P0720 VEH SPD SEN/CIR ATAT- 1 0 3
P0725 ENGINE SPEED SIGAT- 1 0 8
P0740 TCC SOLENOID/CIRCAT- 11 0
P0744 A/T TCC S/V FNCTNAT- 11 2
P0745 L/PRESS SOL/CIRCAT- 11 4
P1705 TP SEN/CIRC A/TAT- 11 6
P1710 ATF TEMP SEN/CIRCAT- 11 8
P1716 TURBINE REV S/CIRCAT- 1 2 3
P1721 VEH SPD SE/CIR·MTRAT- 1 2 5
P1730 A/T INTERLOCKAT- 1 2 7
P1731 A/T 1ST E/BRAKINGAT- 1 3 0
P1752 I/C SOLENOID/CIRCAT- 1 3 2
P1754 I/C SOLENOID FNCTNAT- 1 3 4
P1757 FR/B SOLENOID/CIRCAT- 1 3 7
P1759 FR/B SOLENOID FNCTAT- 1 3 9
P1762 D/C SOLENOID/CIRCAT- 1 4 2
P1764 D/C SOLENOID FNCTNAT- 1 4 4
P1767 HLR/C SOL/CIRCAT- 1 4 7
P1769 HLR/C SOL FNCTNAT- 1 4 9
P1772 LC/B SOLENOID/CIRCAT- 1 5 2
P1774 LC/B SOLENOID FNCTAT- 1 5 4
P1841 ATF PRES SW 1/CIRCAT- 1 5 6
P1843 ATF PRES SW 3/CIRCAT- 1 5 8
P1845 ATF PRES SW 5/CIRCAT- 1 6 0
P1846 ATF PRES SW 6/CIRCAT- 1 6 2
U1000 CAN COMM CIRCUITAT- 9 1

PRECAUTIONS
AT-7
D
E
F
G
H
I
J
K
L
MA
B
AT
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
ECS00IPT
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.
PrecautionsECS00IPR
lBefore connecting or disconnecting the A/T assembly har-
ness connector, turn ignition switch OFF and disconnect
the battery cable from the negative terminal. Because bat-
tery voltage is applied to TCM even if ignition switch is
turned OFF.
lAfter performing each TROUBLE DIAGNOSIS, perform
“DTC Confirmation Procedure”.
If the repair is completed the DTC should not be displayed
in the “DTC Confirmation Procedure”.
lAlways use the specified brand of ATF. Refer toMA-14, "REC-
OMMENDED FLUIDS AND LUBRICANTS".
lUse lint-free paper not cloth rags during work.
lAfter replacing ATF, dispose of the waste oil using the methods prescribed by law, ordinance, etc.
lBefore proceeding with disassembly, thoroughly clean the outside of the transmission. It is important to
prevent the internal parts from becoming contaminated by dirt or other foreign matter.
lDisassembly should be done in a clean work area.
lUse lint-free paper or towels for wiping parts clean. Common shop rags can leave fibers that could inter-
fere with the operation of the transmission.
lPlace disassembled parts in order for easier and proper assembly.
lAll parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
lGaskets, seals and O-rings should be replaced any time the transmission is disassembled.
lIt is very important to perform functional tests whenever they are indicated.
lThe valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place disassembled valve body parts in order for easier and proper assembly. Care will also prevent
springs and small parts from becoming scattered or lost.
lProperly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
lBefore assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, or hold bearings and washers in place during assembly. Do not use grease.
lExtreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
lAfter overhaul, refill the transmission with new ATF.
lWhen the drain plug is removed, only some of the ATF is drained. Old ATF will remain in torque converter
and A/T fluid cooling system.
Always follow the procedures under “Changing A/T Fluid” in the AT section when changing A/T fluid. Refer
toAT-11, "
Changing A/T Fluid",AT-12, "Checking A/T Fluid".
SEF289H

AT-8
PRECAUTIONS
Wiring Diagrams and Trouble Diagnosis
ECS00IPS
When reading wiring diagrams, refer to the following:
lGI-15, "How to Read Wiring Diagrams".
lPG-4, "POWER SUPPLY ROUTING CIRCUIT"for power distribution circuit.
When performing trouble diagnosis, refer to the following:
lGI-11, "How to Follow Trouble Diagnoses".
lGI-24, "How to Perform Efficient Diagnosis for an Electrical Incident".

PREPARATION
AT-9
D
E
F
G
H
I
J
K
L
MA
B
AT
PREPARATIONPFP:00002
Special Service ToolsECS00FWB
Tool number
Tool nameDescription
ST2505S001
Oil pressure gauge set
1 ST25051001
Oil pressure gauge
2 ST25052000
Hose
3 ST25053000
Joint pipe
4 ST25054000
Adapter
5 ST25055000
AdapterMeasuring line pressure
KV31103600
Joint pipe adapter
(With ST25054000)Measuring line pressure
ST33400001
Drift
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
lInstalling rear oil seal (2WD models)
lInstalling oil pump housing oil seal
KV31102400
Clutch spring compressor
a: 320 mm (12.60 in)
b: 174 mm (6.85 in)Installing reverse brake return spring retainer
ST25850000
Sliding hammer
a: 179 mm (7.05 in)
b: 70 mm (2.76 in)
c: 40 mm (1.57 in)
d: M12X1.75PRemove oil pump assembly
SCIA3695J
ZZA1227D
NT086
NT423
NT422

AT-10
PREPARATION
Commercial Service Tools
ECS00FWC
Tool nameDescription
Drift
a: 22 mm (0.87 in) dia.Installing manual shaft oil seals
Drift
a: 64 mm (2.52 in) dia.Installing rear oil seal (4WD models)
NT083
SCIA5338E

A/T FLUID
AT-11
D
E
F
G
H
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MA
B
AT
A/T FLUIDPFP:KLE40
Changing A/T FluidECS00FWD
1. Warm up ATF.
2. Stop engine.
3. Loosen level gauge bolt.
4. Remove A/T fluid level gauge.
5. Remove drain plug and drain ATF from drain hole.
6. Install drain plug gasket and drain plug to oil pan.
CAUTION:
Do not reuse drain plug gasket.
7. Tighten drain plug to the specified torque. Refer toAT-218,
"COMPONENTS".
8. Refill with new ATF. Always refill same volume with drained ATF.
lTo replace the ATF, pour in new ATF at A/T fluid charging pipe
with the engine idling and at the same time drain the old ATF
from A/T fluid cooler hose return side.
lWhen the color of the ATF coming out is about the same as the color of the new ATF, the replacement
is complete. The amount of new ATF to use should be 30 to 50% increase of the specified amount.
CAUTION:
lUse only Genuine NISSAN ATF Matic Fluid J. Do not mix with other ATF.
lUsing ATF other than Genuine NISSAN ATF Matic Fluid J will cause deterioration in driveability
and A/T durability, and may damage the A/T, which is not covered by the NISSAN new vehicle
warranty.
lWhen filling ATF, take care not to spillover heat generating parts such as exhaust.
9. Run engine at idle speed for 5 minutes.
10. Check A/T fluid level and condition. Refer toAT-12, "
Checking A/T Fluid". If ATF is still dirty, repeat step 2
through 9.
11. Install the removed A/T fluid level gauge into A/T fluid charging pipe.
12. Tighten level gauge bolt to the specified torque. Refer toAT- 2 4 7 , "
COMPONENTS". ATF: Genuine NISSAN ATF Matic Fluid J
Fluid capacity:
10.3 (9-1/8 lmp qt)
SCIA4896E

AT-12
A/T FLUID
Checking A/T Fluid
ECS00FWE
1. Warm up engine.
2. Check for A/T fluid leakage.
3. Loosen level gauge bolt.
4. Before driving, A/T fluid level can be checked at A/T fluid tem-
peratures of 30 to 50°C (86 to 122°F) using “COLD” range on A/
T fluid level gauge as follows.
a. Park vehicle on level surface and set parking brake.
b. Start engine and move selector lever through each gear posi-
tion. Leave selector lever in “P” position.
c. Check A/T fluid level with engine idling.
d. Remove A/T fluid level gauge and wipe clean with lint-free
paper.
CAUTION:
When wiping away A/T fluid level gauge, always use lint-
free paper, not a cloth one.
e. Reinsert A/T fluid level gauge into A/T fluid charging pipe as far as it will go.
CAUTION:
To check A/T fluid level, insert A/T fluid level gauge until the cap contacts the end of A/T fluid
charging pipe, with A/T fluid level gauge reversed from the normal attachment conditions.
f. Remove A/T fluid level gauge and note reading. If reading is at low side of range, add ATF to A/T fluid
charging pipe.
CAUTION:
Do not overfill.
5. Drive vehicle for approximately 5 minutes in urban areas.
6. Make the A/T fluid temperature approximately 65°C(149°F).
NOTE:
A/T fluid level will be greatly affected by temperature as shown in figure. Therefore, be certain to
perform operation while checking data with CONSULT-II.
a. Connect CONSULT-II to data link connector. Refer toAT-79, "
CONSULT-II SETTING PROCEDURE".
b. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II.
c. Readthevalueof“ATFTEMP1”.
7. Recheck A/T fluid level at A/T fluid temperatures of approximately 65°C(149°F)using“HOT”rangeonA/
T fluid level gauge.
SCIA7120E
SLIA0016E