NISSAN NAVARA 2005 Repair Workshop Manual

TF-4
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EDS003ID
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.
Precautions for Transfer Assembly and Transfer Control Unit ReplacementEDS0031A
lWhen replacing transfer assembly or transfer control unit, check the 4WD shift indicator pattern and
adjustment of the position between transfer assembly and transfer control unit if necessary.
CHECK 4WD SHIFT INDICATOR PATTERN
1. Set 4WD shift switch to “2WD”, “4H”, “4LO”, “4H” and “2WD” in order. Stay at each switch position for at
least 2 seconds.
2. Confirm 4WD shift indicator lamp and 4LO indicator lamp are changed properly as follows.
lIf OK, the position between transfer assembly and transfer control unit is correct.
lIf NG, the position is different between transfer assembly and transfer control unit.
Adjust the position between transfer assembly and transfer control unit. Refer to pattern table below.
Transfer position adjustment pattern
NOTE:
Method of adjustment can be chosen voluntarily, according to location of 4WD shift switch.
SDIA3289E
4WD shift switch condition Refer procedure
4WD shift switch is under “2WD” condition when engine is being stopped.TF-5, "
METHOD FOR ADJUSTMENT WITH 4WD
SHIFT SWITCH AT“2WD”"
4WD shift switch is under “4H” or “4LO” condition when engine is being stopped.TF-5, "METHOD FOR ADJUSTMENT WITH 4WD
SHIFT SWITCH AT“4H”OR“4LO”"

PRECAUTIONS
TF-5
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METHODFORADJUSTMENTWITH4WDSHIFTSWITCHAT“2WD”
Select Adjustment Pattern
1. Start engine. Run engine for at least 10 seconds.
2. Check 4WD shift indicator lamp and 4LO indicator lamp.
Pattern A
1. Stay in the below for at least 2 seconds.
lFor A/T models, stop the vehicle and move A/T selector lever to “N” position with the brake pedal
depressed.
lFor M/T models, stop the vehicle and move M/T shift lever to the neutral position with the brake and
clutch pedal depressed.
2. Turn 4WD shift switch to “4LO” position. Stay in "4LO" for at least 2 seconds.
3. Turn ignition switch “OFF”.
4. Start engine.
5. Erase self-diagnosis. Refer toTF-46, "
How to Erase Self-diagnostic Results"(with CONSULT-II) orTF-
51, "ERASE SELF-DIAGNOSIS"(without CONSULT-II).
6. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer toTF-4, "
CHECK 4WD SHIFT INDI-
CATOR PATTERN".
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.
Pattern B
1. Stay in the below for at least 2 seconds.
lFor A/T models, stop the vehicle and move A/T selector lever to “N” position with the brake pedal
depressed.
lFor M/T models, stop the vehicle and move M/T shift lever to the neutral position with the brake and
clutch pedal depressed.
2. Turn ignition switch “OFF”.
3. Start engine.
4. Erase self-diagnosis. Refer toTF-46, "
How to Erase Self-diagnostic Results"(with CONSULT-II) orTF-
51, "ERASE SELF-DIAGNOSIS"(without CONSULT-II).
5. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer toTF-4, "
CHECK 4WD SHIFT INDI-
CATOR PATTERN".
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.
METHODFORADJUSTMENTWITH4WDSHIFTSWITCHAT“4H”OR“4LO”
1. Start engine. Run the engine for at least 10 seconds.
2. Stay in the below for at least 2 seconds.
lFor A/T models, stop the vehicle and move A/T selector lever to “N” position with the brake pedal
depressed.
lFor M/T models, stop the vehicle and move M/T shift lever to the neutral position with the brake and
clutch pedal depressed.
3. Turn 4WD shift switch to “2WD” position. Stay in "2WD" for at least 2 seconds.
4. Turn ignition switch “OFF”.
5. Start engine.
6. Erase self-diagnosis. Refer toTF-46, "
How to Erase Self-diagnostic Results"(with CONSULT-II) orTF-
51, "ERASE SELF-DIAGNOSIS"(without CONSULT-II).
7. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer toTF-4, "
CHECK 4WD SHIFT INDI-
CATOR PATTERN".
Indicator lamp condition Refer procedure
When 4WD shift indicator lamp or 4LO indicator lamp is flashing.TF-5, "
Pattern A"
Except for above.TF-5, "Pattern B"

TF-6
PRECAUTIONS
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.
PrecautionsEDS0031B
lBefore connecting or disconnecting the transfer control unit harness connector, turn ignition
switch “OFF” and disconnect the battery cables. Battery voltage is applied to transfer control unit
even if ignition switch is turned “OFF”.
lWhen connecting or disconnecting pin connectors into or
from transfer control unit, take care not to damage pin ter-
minals (bend or break).
When connecting pin connectors make sure that there are
not any bends or breaks on transfer control unit pin termi-
nals.
lBefore replacing transfer control unit, perform transfer con-
trol unit input/output signal inspection and make sure
whether transfer control unit functions properly or not.
Refer toTF-38, "
Transfer Control Unit Input/Output Signal
Reference Values".
Service NoticeEDS0031C
lAfter overhaul refill the transfer with new transfer fluid.
lCheck the fluid level or replace the fluid only with the vehicle parked on level ground.
lDuring removal or installation, keep inside of transfer clear of dust or dirt.
lDisassemblyshouldbedoneinacleanworkarea.
lBefore proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal
parts from becoming contaminated by dirt or other foreign matter.
lCheck for the correct installation status prior to removal or disassembly. If matchmarks are required, be
certain they do not interfere with the function of the parts when applied.
lAll parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
lCheck appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary.
lGaskets, seals and O-rings should replaced any time the transfer is disassembled.
lIn principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it.
lObserve the specified torque when assembling.
lClean and flush the parts sufficiently and blow-dry them.
lBe careful not to damage sliding surfaces and mating surfaces.
lUse lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere
with the operation of the transfer.
SEF291H
MEF040DB

PRECAUTIONS
TF-7
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Wiring Diagrams and Trouble DiagnosisEDS0031D
When reading wiring diagrams, refer to the following:
lGI-15, "How to Read Wiring Diagrams".
lPG-4, "POWER SUPPLY ROUTING 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".

TF-8
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsEDS0031E
Tool number
Tool nameDescription
KV40104000
Flange wrench
a: 85 mm (3.35 in)
b: 65 mm (2.56 in)
lRemoving self-lock nut
lInstalling self-lock nut
KV381054S0
Puller
lRemoving front oil seal
lRemoving rear oil seal
lRemoving metal bushing
KV38100500
Drift
a: 80 mm (3.15 in) dia.
b: 60 mm (2.36 in) dia.
lInstalling front oil seal
lInstalling rear oil seal
lInstalling rear bearing
lInstalling front bearing
KV38100200
Drift
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.
lRemoving sun gear assembly and
planetary carrier assembly
lRemoving input bearing
lInstalling sun gear assembly and planetary
carrier assembly
ST30720000
Drift
a: 77 mm (3.03 in) dia.
b: 55 mm (2.17 in) dia.
lInstalling input bearing
lInstalling input oil seal
lInstalling carrier bearing
KV32102700
Drift
a: 48 mm (1.89 in) dia.
b: 41 mm (1.61 in) dia.Installing mainshaft rear bearing
KV40104830
Drift
a: 70 mm (2.76 in) dia.
b: 63.5 mm (2.50 in) dia.Installing input oil seal
NT659
ZZA0601D
ZZA0811D
ZZA1143D
ZZA0811D
ZZA0534D
ZZA1003D

PREPARATION
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ST35300000
Drift
a: 59 mm (2.32 in) dia.
b: 45 mm (1.77 in) dia.lRemoving carrier bearing
lInstalling metal bushing
lRemoving front bearing
ST30021000
Puller
lRemoving carrier bearing
lRemoving front bearing
lRemoving rear bearing
ST33710000
Drift
a: 89 mm (3.5 in)
b: 30 mm (1.18 in) dia.
c: 24 mm (0.94 in) dia.
lRemoving needle bearing
lRemoving metal bushing
lRemoving rear bearing
ST35325000
Drift bar
a: 215 mm (8.46 in)
b: 25 mm (0.98 in) dia.
c: M12´1.5PRemoving metal bushing
ST33220000
Drift
a: 37 mm (1.46 in) dia.
b: 31 mm (1.22 in) dia.
c: 22 mm (0.87 in) dia.Installing needle bearing
ST27863000
Drift
a: 75 mm (2.95 in) dia.
b: 62 mm (2.44 in) dia.Installing carrier bearing
ST30901000
Drift
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.38 in) dia.
lInstalling rear bearing
lInstalling front bearing Tool number
Tool nameDescription
NT073
ZZA0537D
ZZA1057D
NT663
ZZA1046D
ZZA1003D
ZZA0978D

TF-10
PREPARATION
Commercial Service Tools
EDS0031F
Tool nameDescription
Puller
lRemoving companion flange
lRemoving mainshaft rear bearing
Drift
a: 81 mm (3.19 in) dia.Installing dust cover
PullerRemoving mainshaft rear bearing
Pin punch
a: 6 mm (0.24 in) dia.Removing retaining pin
NT077
ZZA1236D
ZZB0823D
NT410

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
TF-11
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS0031G
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference page
TF-12TF-112TF-136TF-120TF-120
SUSPECTED PARTS
(Possible cause)
TRANSFER FLUID (Level low)
TRANSFER FLUID (Wrong)
TRANSFER FLUID (Level too high)
LIQUID GASKET (Damaged)
O-RING (Worn or damaged)
OIL SEAL (Worn or damaged)
SHIFT FORK (Worn or damaged)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
SymptomNoise 1 2 3 3
Transfer fluid leakage 3 1 2 2 2
Hard to shift or will not shift 1 1 2

TF-12
TRANSFER FLUID
TRANSFER FLUID
PFP:31001
ReplacementEDS0031H
DRAINING
1. Stop engine.
2. Remove the drain plug and gasket. Drain the fluid.
3. Install the drain plug with a new gasket to the transfer. Tighten to
the specified torque. Refer toTF-112, "
COMPONENTS".
CAUTION:
Do not reuse gasket.
FILLING
1. Remove the filler plug and gasket.
2. Fill the transfer with new fluid until the fluid level reaches the
specified limit near the filler plug hole.
CAUTION:
Carefully fill fluid. (Fill up for approx. 3 minutes.)
3. Leave the vehicle for 3 minutes, and check fluid level again.
4. Install the filler plug with a new gasket to the transfer. Tighten to
the specified torque. Refer toTF-112, "
COMPONENTS".
CAUTION:
Do not reuse gasket.
InspectionEDS0031I
FLUID LEAKAGE AND FLUID LEVEL
1. Make sure that fluid is not leaking from the transfer assembly or around it.
2. Check fluid level from the filler plug hole as shown.
CAUTION:
Do not start engine while checking fluid level.
3. Install the filler plug with a new gasket to the transfer. Tighten to
the specified torque. Refer toTF-112, "
COMPONENTS".
CAUTION:
Do not reuse gasket.
SDIA3286E
Fluid grade:
Refer toMA-14, "
Fluids and Lubricants".
Fluid capacity:
Approx. 2.0 (1-3/4 Imp qt)
SDIA3287E
SDIA3287E

4WD SYSTEM
TF-13
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4WD SYSTEMPFP:33084
Cross-Section ViewEDS0031J
1. Mainshaft 2. Rear case 3. Oil pump assembly
4. Clutch gear 5. 2-4 shift fork 6. 2-4 sleeve
7. Drive chain 8. Sprocket 9. L-H shift fork
10. L-H sleeve 11. Internal gear 12. Front case
13. Planetary carrier assembly 14. Sun gear assembly 15. L-H shift rod
16. Control shift rod
(A/T models)17. Companion flange 18. Front drive shaft
19. Control shift rod assembly
(M/T models)20. Transfer control device
SDIA3418E