service NISSAN NAVARA 2005 Repair Workshop Manual

MA-42
SERVICE DATA AND SPECIFICATIONS (SDS)

MT-1
MANUAL TRANSMISSION
C TRANSMISSION/TRANSAXLE
CONTENTS
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MANUAL TRANSMISSION
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
DOUBLE-CONE SYNCHRONIZER ...................... 8
TRIPLE-CONE SYNCHRONIZER ........................ 8
M/T OIL ....................................................................... 9
Changing M/T Oil ..................................................... 9
DRAINING ............................................................. 9
FILLING ................................................................. 9
Checking M/T Oil ...................................................... 9
OIL LEAKAGE AND OIL LEVEL ........................... 9
REAR OIL SEAL ...................................................... 10
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION .................................................... 11
POSITION SWITCH .................................................. 12
Checking ................................................................ 12
BACK-UP LAMP SWITCH .................................. 12
PARK/NEUTRAL POSITION (PNP) SWITCH ..... 12SHIFT CONTROL ..................................................... 13
Removal and Installation ........................................ 13
COMPONENTS ................................................... 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
INSPECTION AFTER INSTALLATION ................ 14
AIR BREATHER HOSE ............................................ 15
Removal and Installation ........................................ 15
TRANSMISSION ASSEMBLY .................................. 16
Removal and Installation from Vehicle ................... 16
COMPONENTS ................................................... 16
REMOVAL ........................................................... 17
INSTALLATION ................................................... 18
Disassembly and Assembly .................................... 19
COMPONENTS ................................................... 19
DISASSEMBLY ................................................... 25
INSPECTION AFTER DISASSEMBLY ................ 40
ASSEMBLY ......................................................... 44
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 67
General Specifications ............................................ 67
Gear End Play ........................................................ 68
Snap Rings ............................................................. 68
Baulk Ring Clearance ............................................. 69

MT-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
ServiceNoticeorPrecautionsECS00ICY
lDo not reuse transmission oil, once it has been drained.
lCheck oil level or replace oil with vehicle on level surface.
lDuring removal or installation, keep inside of transmission clear of dust or dirt.
lCheck for the correct installation status prior to removal or disassembly. If matching mark are required, be
certain they do not interfere with the function of the parts they are applied.
lIn principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it.
lBe careful not to damage sliding surfaces and mating surfaces.

PREPARATION
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PREPARATIONPFP:00002
Special Service ToolsECS00ICZ
Tool number
Tool nameDescription
ST30911000
Inserter
a: 98 mm (3.86 in) dia.
b: 40 mm (1.57 in) dia.
lInstalling mainshaft bearing
lInstalling 5th-6th synchronizer hub
assembly
lInstalling reverse main gear bushing
lInstalling 3rd gear bushing
lInstalling 3rd-4th synchronizer hub
assembly
ST30022000
Inserter
a: 110 mm (4.33 in) dia.
b: 46 mm (1.81 in) dia.
lInstalling 3rd main gear
lInstalling 4th main gear
ST27861000
Support ring
a: 62 mm (2.44 in) dia.
b: 52 mm (2.05 in) dia.
lInstalling 1st-2nd synchronizer hub
assembly
lInstalling 1st gear bushing
ST30032000
Inserter
a: 80 mm (3.15 in) dia.
b: 31 mm (1.22 in) dia.Installing counter rear bearing inner race
KV32102700
Drift
a: 48 mm (1.89 in) dia.
b: 41 mm (1.61 in) dia.Installing main drive gear bearing
ST23860000
Drift
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.Installing reverse counter gear
ST01530000
Drift
a: 50 mm (1.97 in) dia.
b: 41 mm (1.61 in) dia.Installing reverse synchronizer hub assembly
ZZA0920D
ZZA0920D
ZZA0832D
ZZA0920D
ZZA0534D
ZZA0534D
ZZA0534D

PREPARATION
MT-5
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Commercial Service ToolsECS00ID0
ST30031000
PullerMeasuring wear of inner baulk ring
ST22490000
Adapter setting plateHolding a adapter plate Tool number
Tool nameDescription
ZZC0499D
ZZC0465D
Tool nameDescription
PullerRemoving each bearing, gear and bushing
Pin punch
Tipdiameter:6.0mm(0.236in)dia.Removing and installing each retaining pin
Puller
lRemoving reverse synchronizer hub
assembly
lRemoving reverse main gear
lRemoving reverse counter gear
Drift
a: 32 mm (1.26 in) dia.Installing counter end bearing
PullerRemoving counter end bearing
ZZB0823D
ZZA0815D
NT077
LCIA0362E
S-NT134

SERVICE DATA AND SPECIFICATIONS (SDS)
MT-67
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsECS00IDB
Engine typeYD25DDTi
Transmission modelFS6R31A
Axle type 2WD 4WD
Number of speed6
Synchromesh typeWarner
Shift pattern
Gear ratio1st 4.692
2nd 2.705
3rd 1.747
4th 1.291
5th 1.000
6th 0.827
Reverse 4.260
Main gear
(Number of teeth)Drive 23
1st 37
2nd 32
3rd 31
4th 28
6th 25
Reverse 42
Counter gear
(Number of teeth)Drive 35
1st 12
2nd 18
3rd 27
4th 33
6th 46
Reverse 15
Reverse idler gear (Number of teeth) 26
Oil capacity (Approx.)
(Imp pt)3.99 (7) 4.32 (7-5/8)
RemarksReverse synchronizer Installed
Double cone synchronizer 1st, 3rd and 4th
Triple cone synchronizer 2nd
SCIA0955E

MT-68
SERVICE DATA AND SPECIFICATIONS (SDS)
Gear End Play
ECS00IDC
Unit: mm (in)
Snap RingsECS00IDD
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.Item Standard value
Counter gear0 - 0.10 (0 - 0.004)
Main drive gear0 - 0.10 (0 - 0.004)
Mainshaft (Front side) 0 - 0.10 (0 - 0.004)
Mainshaft (Rear side) 0 - 0.10 (0 - 0.004)
Selective parts Thickness Part number*
Main drive gear1.89 (0.0744)
1.95 (0.0768)
1.99 (0.0783)
2.03 (0.0799)
2.07 (0.0815)
2.11 (0.0831)32204 01G60
32204 01G61
32204 01G62
32204 01G63
32204 01G64
32204 01G65
Counter gear1.96 (0.0772)
2.02 (0.0795)
2.08 (0.0819)
2.14 (0.0843)
2.20 (0.0866)
2.26 (0.0890)
2.32 (0.0913)
2.38 (0.0937)
2.44 (0.0961)
2.50 (0.0984)
2.56 (0.1008)
2.62 (0.1031)32236 CD000
32236 CD001
32236 CD002
32236 CD003
32236 CD004
32236 CD005
32236 CD006
32236 CD007
32236 CD008
32236 CD009
32236 CD010
32236 CD011
MainshaftFront side2.08 (0.0819)
2.14 (0.0843)
2.20 (0.0866)
2.26 (0.0890)32204 CD000
32204 CD001
32204 CD002
32204 CD003
Rear side2.08 (0.0819)
2.14 (0.0843)
2.20 (0.0866)
2.26 (0.0890)
2.32 (0.0913)
2.38 (0.0937)
2.44 (0.0961)
2.50 (0.0984)
2.56 (0.1008)
2.62 (0.1031)
2.68 (0.1055)
2.74 (0.1079)
2.80 (0.1102)
2.86 (0.1126)
2.92 (0.1150)
2.98 (0.1173)32204 CD000
32204 CD001
32204 CD002
32204 CD003
32204 CD004
32204 CD005
32204 CD006
32204 CD007
32204 CD008
32204 CD009
32204 CD010
32204 CD011
32204 CD012
32204 CD013
32204 CD014
32204 CD015

SERVICE DATA AND SPECIFICATIONS (SDS)
MT-69
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Baulk Ring ClearanceECS00IDE
Unit: mm (in)
Measurement point Standard value Limit value
1st, 3rd and 4th
(Double-cone synchronizer)Clearance between synchronizer cone
and inner baulk ring end face “A”0.5 - 0.7 (0.020 - 0.028) 0.3 (0.012)
Clearance between outer baulk ring
pawl and synchronizer cone “B”1st: 1.0 - 1.5 (0.039 - 0.059)
3rd: 0.85 - 1.35 (0.0335 - 0.0531)
4th: 0.85 - 1.35 (0.0335 - 0.0531)0.7 (0.028)
2nd
(Triple-cone synchronizer)Clearance between synchronizer and
clutch gear end face “A”0.6 - 1.3 (0.024 - 0.051) 0.3 (0.012)
Clearance between outer baulk ring
pawl and synchronizer cone “B”0.85 - 1.35 (0.0335 - 0.0531) 0.7 (0.028)
Clearance between inner baulk ring and
clutch gear end face “C”0.7 - 1.25 (0.028 - 0.0492) 0.3 (0.012)
5th and 6th 0.7 - 1.35 (0.028 - 0.0531)
0.5 (0.020)
Reverse 0.75 - 1.2 (0.0295 - 0.047)
PCIB0249E
PCIB0835J

MT-70
SERVICE DATA AND SPECIFICATIONS (SDS)

MTC-1
MANUAL AIR CONDITIONER
J AIR CONDITIONER
CONTENTS
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SECTIONMTC
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MTC
MANUAL AIR CONDITIONER
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 4
Precautions for Working with HFC-134a (R-134a)..... 4
Contaminated Refrigerant ........................................ 4
General Refrigerant Precautions .............................. 5
Precautions for Refrigerant Connection ................... 5
ABOUT ONE-TOUCH JOINT ................................ 5
FEATURES OF NEW TYPE REFRIGERANT
CONNECTION ...................................................... 7
O-RING AND REFRIGERANT CONNECTION..... 9
Precautions for Servicing Compressor ................... 12
Precautions for Service Equipment ........................ 12
RECOVERY/RECYCLING EQUIPMENT ............ 12
ELECTRONIC LEAK DETECTOR ...................... 12
VACUUM PUMP ................................................. 13
MANIFOLD GAUGE SET .................................... 13
SERVICE HOSES ............................................... 13
SERVICE COUPLERS ........................................ 14
REFRIGERANT WEIGHT SCALE ...................... 14
CALIBRATING ACR4 WEIGHT SCALE .............. 14
CHARGING CYLINDER ...................................... 14
Precautions for Leak Detection Dye ....................... 14
IDENTIFICATION ................................................ 15
IDENTIFICATION LABEL FOR VEHICLE ........... 15
Wiring Diagrams and Trouble Diagnosis ................ 15
PREPARATION ......................................................... 16
Special Service Tools ............................................. 16
HFC-134a (R-134a) Service Tools and Equipment... 16
Commercial Service Tools ...................................... 19
REFRIGERATION SYSTEM ..................................... 20
Refrigerant Cycle ................................................... 20
REFRIGERANT FLOW ....................................... 20
FREEZE PROTECTION ..................................... 20
Refrigerant System Protection ............................... 20
REFRIGERANT PRESSURE SENSOR ............. 20
PRESSURE RELIEF VALVE ............................... 21
Component Layout ................................................. 22
REFRIGERATION SYSTEM ............................... 22LUBRICANT .............................................................. 24
Maintenance of Lubricant Quantity in Compressor... 24
LUBRICANT ........................................................ 24
CHECKING AND ADJUSTING ............................ 24
AIR CONDITIONER CONTROL ............................... 26
Description .............................................................. 26
Operation ................................................................ 26
AIR MIX DOOR CONTROL ................................. 26
BLOWER SPEED CONTROL ............................. 26
INTAKE DOORS CONTROL ............................... 26
MODE DOOR CONTROL ................................... 26
DEFROSTER DOOR CONTROL ........................ 26
MAGNET CLUTCH CONTROL ........................... 27
SELF-DIAGNOSTIC SYSTEM ............................ 27
Description of Control System ................................ 28
Control Operation ................................................... 28
DISPLAY SCREEN .............................................. 29
TEMPERATURE SWITCH (TEMPERATURE
CONTROL) (FRONT) .......................................... 29
RECIRCULATION () SWITCH ............................. 29
REAR WINDOW DEFOGGER SWITCH ............. 29
OFF SWITCH (BLOWER SPEED SET TO 0) ..... 29
A/C SWITCH ....................................................... 29
MODE SWITCH .................................................. 29
Discharge Air Flow ................................................. 30
FRONT ................................................................ 30
System Description ................................................. 31
SWITCHES AND THEIR CONTROL FUNCTION... 31
CAN Communication System Description .............. 32
TROUBLE DIAGNOSIS ............................................ 33
CONSULT-II ............................................................ 33
CONSULT-II BASIC OPERATION ....................... 33
DATA MONITOR ................................................. 34
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ...................................................... 35
WORK FLOW ...................................................... 35
SYMPTOM TABLE .............................................. 35
Component Parts and Harness Connector Location... 36
ENGINE COMPARTMENT .................................. 36
FRONT PASSENGER COMPARTMENT ............ 37