NISSAN NAVARA 2005 Repair Workshop Manual

RFD-38
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
PREPARATION
Drift
a: 67 mm (2.63 in) dia.Installing drive pinion front bearing outer
race
Installer
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.Installing drive pinion rear bearing inner
race Tool nameDescription
PDIA0893E
NT065

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
RFD-39
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS003AM
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
´: ApplicableReference page
RFD-90, "
INSPECTION AFTER DISASSEMBLY
"
RFD-83, "
Tooth Contact
"
RFD-90, "
INSPECTION AFTER DISASSEMBLY
"
RFD-84, "
Backlash
"
RFD-85, "
Companion Flange Runout
"
RFD-40, "
Checking Differential Gear Oil
"
PR-2, "
NVH Troubleshooting Chart
"
RAX-5, "
NVH Troubleshooting Chart
",RSU-3, "
NVH Troubleshooting Chart
"
WT-2, "
NVH Troubleshooting Chart
"
RAX-5, "
NVH Troubleshooting Chart
"
BR-5, "
NVH Troubleshooting Chart
"
PS-5, "
NVH Troubleshooting Chart
"
Possible cause and SUSPECTED PARTS
Gear tooth rough
Gear contact improper
Tooth surfaces worn
Backlash incorrect
Companion flange excessive runout
Gear oil improper
PROPELLER SHAFT
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
AXLE SHAFT
BRAKES
STEERING
Symptom Noise´´´´´´´´´´´´´

RFD-40
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
DIFFERENTIAL GEAR OIL
DIFFERENTIAL GEAR OIL
PFP:KLD30
Changing Differential Gear OilEDS003AN
DRAINING
1. Stop engine.
2. Remove drain plug and drain gear oil.
3. Apply sealant to drain plug. Install drain plug to final drive
assembly and tighten to the specified torque. Refer toRFD-82,
"COMPONENTS".
FILLING
1. Remove filler plug. Fill with new gear oil until oil level reaches
the specified limit near filler plug hole.
2. After refilling oil, check oil level. Apply sealant to filler plug.
Install filler plug to final drive assembly and tighten to the speci-
fied torque. Refer toRFD-82, "
COMPONENTS".
Checking Differential Gear OilEDS003AO
OIL LEAKAGE AND OIL LEVEL
1. Make sure that gear oil is not leaking from final drive assembly or around it.
2. Check oil level from filler plug hole as shown.
CAUTION:
Do not start engine while checking oil level.
3. Apply sealant to filler plug. Install filler plug to final drive assem-
bly and tighten to the specified torque. Refer toRFD-82, "
COM-
PONENTS".
PDIA1038E
Oil grade and Viscosity:
Refer toMA-14, "
Fluids and Lubricants".
Oil capacity:
Approx. 2.01 (3-1/2pt)
PDIA1039E
PDIA1039E

DIFFERENTIAL LOCK SYSTEM
RFD-41
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
DIFFERENTIAL LOCK SYSTEMPFP:28496
Cross-sectional ViewEDS003AP
1. Companion flange 2. Drive pinion 3. Drive gear
4. Differential case 5. Pinion mate gear 6. Axle shaft
7. Side gear 8. Spring 9. Differential lock solenoid
10. Pinion mate shaft 11. Pressure plate 12. Differential lock position switch
13. Cam ring
PDIA1062E

RFD-42
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
DIFFERENTIAL LOCK SYSTEM
Differential Lock Operation
EDS003AQ
1. Differential lock solenoid operates pressure plate.
2. Pressure plate presses cam ring.
3. Engage cam ring and side gear, and then differential is locked.
System DescriptionEDS003AR
DIFFERENTIAL LOCK SOLENOID
It is operated by signal from differential lock control unit, and it operates pressure plate so as to switch lock/
unlock.
DIFFERENTIAL LOCK POSITION SWITCH
It detects that differential is in lock or unlock by pressure plate position, and sends it to differential lock control
unit.
DIFFERENTIAL LOCK CONTROL UNIT
lDifferential lock control unit controls differential lock solenoid by input signals of each sensor and each
switch.
lAs a fail-safe function, differential lock disengages, if malfunction is detected in differential lock system.
lSelf-diagnosis can be done with CONSULT-II.
DIFFERENTIAL LOCK MODE SWITCH
Able to select differential lock and unlock.
DIFF LOCK INDICATOR LAMP
The following is the indications of indicator lamp.
NOTE:
Differential lock standby condition is the condition that differential lock mode switch is ON and differential is unlocked.
SDIA2498E
Condition DIFF LOCK indicator lamp
Differential lock/unlock ON/OFF
Differential lock standby condition Flashing: 1 time/2 seconds
Differential lock system malfunction OFF (Even if differential lock mode switch is turned ON)
Lamp checkTurns ON when ignition switch is turned ON.
Turns OFF after engine start.

DIFFERENTIAL LOCK SYSTEM
RFD-43
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
System DiagramEDS003AS
COMPONENTS FUNCTION DESCRIPTION
CAN CommunicationEDS003AT
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 toDI-65, "
CAN Communication Unit".
SDIA2500E
Component parts Function
Differential lock control unit
lControls differential lock solenoid and switches differential lock/unlock.
lAs a fail-safe function, differential lock disengages, if malfunction is detected in differential lock
system.
Differential lock solenoid Controls pressure plate by current from differential lock control unit.
Differential lock position switch Detects that differential is lock or unlock condition.
Differential lock mode switch Able to select differential lock or unlock.
DIFF LOCK indicator lamp Illuminates that differential is in lock or lock standby condition.
ABS actuator and electric unit
(control unit)Transmits the following signals via CAN communication to differential lock control unit.
lVehicle speed signal
Transfer control unitTransmits the following signal via CAN communication to differential lock control unit.
l4WD shift switch signal

RFD-44
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
PFP:00004
Fail-safe FunctionEDS003AU
If any malfunction occurs in differential lock system, and control unit detects the malfunction, DIFF LOCK indi-
cator lamp on combination meter does not turn ON to indicate system malfunction. Differential lock control unit
turns differential lock solenoid OFF.
How to Perform Trouble DiagnosisEDS003AV
BASIC CONCEPT
lTo perform trouble diagnosis, it is the most important to have understanding about vehicle systems (con-
trol and mechanism) thoroughly.
lIt is also important to clarify customer complaints before inspec-
tion.
First of all, reproduce symptoms, and understand them fully.
Ask customer about his/her complaints carefully. In some cases,
it will be necessary to check symptoms by driving vehicle with
customer.
CAUTION:
Customers are not professional. It is dangerous to make an
easy guess like "maybe the customer means that...," or
"maybe the customer mentions this symptom".
lIt is essential to check symptoms right from the beginning in
order to repair malfunctions completely.
For intermittent malfunctions, reproduce symptoms based on
interview with customer and past examples. Do not perform
inspection on ad hoc basis. Most intermittent malfunctions are
caused by poor contacts. In this case, it will be effective to shake
suspected harness or connector by hand. When repairing with-
out any symptom diagnosis, you cannot judge if malfunctions
have actually been eliminated.
lAfter completing diagnosis, always erase diagnostic memory.
Refer toRFD-52, "
How to Erase Self-diagnostic Results".
lFor intermittent malfunctions, move harness or harness connec-
tor by hand. Then check for poor contact or reproduced open circuit.
SEF233G
SEF234G

TROUBLE DIAGNOSIS
RFD-45
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
Location of Electrical PartsEDS003AW
SDIA3427E

RFD-46
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
TROUBLE DIAGNOSIS
Wiring Diagram — DIFLOC —
EDS003AX
MDWA0065E

TROUBLE DIAGNOSIS
RFD-47
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
MDWA0066E