differential NISSAN NAVARA 2005 Repair Owner's Manual

FRONT FINAL DRIVE ASSEMBLY
FFD-27
C
E
F
G
H
I
J
K
L
MA
B
FFD
ADJUSTMENT AND SELECTION ADJUSTING WASHERS
Differential Side Gear Clearance
lAssemble the differential parts if they are disassembled. Refer toFFD-32, "Differential Assembly".
1. Place differential case straight up so that side gear to be mea-
sured comes upward.
2. Using feeler gauge, measure the clearance between side gear
back and differential case at 3 different points, while rotating
side gear. Average the 3 readings, and then measure the clear-
ance. (Measure the clearance of the other side as well.)
CAUTION:
To prevent side gear from tilting, insert feeler gauges with
thesamethicknessfrombothsides.
3. If the back clearance is outside the specification, use a thicker/
thinner side gear thrust washer to adjust. Refer toFFD-37, "
Side
Gear Thrust Washer".
CAUTION:
Select a side gear thrust washer for right and left individu-
ally.
PDIA0460E
Side gear back clearance specification:
0.1 mm (0.004 in) or less.
(Each gear should rotate smoothly without excessive
resistance during differential motion.)
When the back clearance is greater than specification:
Use a thicker thrust washer.
When the back clearance is less than specification:
Use a thinner thrust washer.
PDIA0576E

FFD-30
FRONT FINAL DRIVE ASSEMBLY
e. Temporarily tighten removed drive pinon nut to drive pinion.
NOTE:
Use removed drive pinon nut only for the preload measurement.
f. Adjust the drive pinion lock nut tightening torque and pinion
bearing preload torque using Tool.
CAUTION:
Drive pinon nut is tightened with no collapsible spacer. Be
careful not to overtighten it. While measuring the preload,
tighten it by 5°to 10°.
g. Apply gear oil to side bearings, and install new side bearing
adjusting washer with the same thickness or re-install the old
ones to the same mounting position they were in prior to disas-
sembly. Install differential case assembly to gear carrier.
h. Align matching mark on bearing cap with that on gear carrier.
i. Check and adjust the tooth contact. Refer toFFD-19, "
To o t h
Contact".
j. Check and adjust the backlash. Refer toFFD-20, "
Backlash".
k. Remove bearing caps.
l. Lift differential case assembly out using suitable tool.
CAUTION:
lKeep side bearing outer races together with inner race.
Do not mix them up.
lKeep side bearing adjusting washers together with bear-
ings.
m. Remove companion flange.
n. Press drive pinion assembly out of gear carrier. (Together with
collapsible spacer.)
CAUTION:
Do not drop drive pinion assembly.
o. Remove pinion front bearing inner race.Tool number A: ST3127S000
Drive pinion bearing preload:
1.08 - 1.66 N·m (0.11 - 0.16 kg-m, 10 - 14 in-lb)
PDIA1005E
PDIA0700E
PDIA0704E

FFD-32
FRONT FINAL DRIVE ASSEMBLY
11. Apply anti-corrosive oil to the thread and seat of drive pinion
lock nut, and temporarily tighten drive pinion lock nut to drive
pinion.
CAUTION:
Do not reuse drive pinion lock nut.
12. Adjust the drive pinion lock nut tightening torque and pinion
bearing preload torque using Tool.
CAUTION:
lAdjust the lower limit of the drive pinion lock nut tighten-
ing torque first.
lIf the preload torque exceeds the specified value, replace
collapsible spacer and tighten it again to adjust. Do not
loosen drive pinion lock nut to adjust the preload torque.
lAfter adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
13. Install differential case assembly. Refer toFFD-32, "
Differential Assembly".
CAUTION:
Do not install rear cover yet.
14. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion
flange runout. Refer toFFD-18, "
Drive Gear Runout",FFD-19, "To o t h C o n t a c t",FFD-20, "Backlash",
FFD-21, "
Companion Flange Runout".
Recheck above items. Readjust the above description, if necessary.
15. Check total preload torque. Refer toFFD-18, "
Total Preload Torque".
16. Install rear cover. Refer toFFD-32, "
Differential Assembly".
17. Install side shaft assembly. Refer toFFD-35, "
Side Shaft".
Differential Assembly
1. Install side gear thrust washers with the same thickness as the
ones installed prior to disassembly or reinstall the old ones on
the side gears.Tool number A: ST3127S000
Drive pinion lock nut tightening torque:
186 - 294 N·m (19 - 29 kg-m, 138 - 216 ft-lb)
Drive pinion bearing preload:
1.08 - 1.66 N·m (0.11 - 0.16 kg-m, 10 - 14 in-lb)
PDIA1005E
SDIA0193J

FRONT FINAL DRIVE ASSEMBLY
FFD-33
C
E
F
G
H
I
J
K
L
MA
B
FFD
2. Install side gears and thrust washers into differential case.
3. Align 2 pinion mate gears in diagonally opposite positions, then
rotate and install them into differential case after installing thrust
washer to pinion mate gear.
4. Align the lock pin holes on differential case with shaft, and install
pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate
side gear thrust washers. Refer toFFD-27, "
Differential Side
Gear Clearance".
6. Drive a lock pin into pinion mate shaft, using suitable tool.
Make sure lock pin is flush with differential case.
CAUTION:
Do not reuse lock pin.
7. Align the matching mark of differential case with the mark of
drive gear, then place drive gear.
8. Apply recommended thread locking sealant into the thread hole
of drive gear. Refer toFFD-17, "
COMPONENTS".
CAUTION:
Make sure the drive gear back and threaded holes are
clean.
SDIA2025E
SDIA0195J
WDIA0131E
SDIA2593E
SDIA2594E

FFD-34
FRONT FINAL DRIVE ASSEMBLY
9. Install drive gear on the bolts, and then tighten to the specified
torque. Refer toFFD-17, "
COMPONENTS".
CAUTION:
lTighten bolts in a crisscross pattern.
lAfter tightening the bolts to the specified torque, tighten
the bolts additionally by turning the bolts 34 to 39
degrees.
10. Press side bearing inner races to differential case, using Tools.
CAUTION:
Do not reuse side bearing inner race.
11. Install housing spacer.
12. Apply gear oil to side bearings, and install differential case
assembly with side bearing outer races into gear carrier.
13. Insert left and right original side bearing adjusting washers in
place between side bearings and gear carrier, using Tool.
SDIA0247J
Tool number A: ST33230000
B: ST33061000
SPD353
SPD527
Tool number : KV38100600
PDIA0706E

SERVICE DATA AND SPECIFICATIONS (SDS)
FFD-37
C
E
F
G
H
I
J
K
L
MA
B
FFD
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsEDS00358
*: Option
Inspection and AdjustmentEDS00359
DRIVE GEAR RUNOUT
Unit: mm (in)
DIFFERENTIAL SIDE GEAR CLEARANCE
Unit: mm (in)
PRELOAD TORQUE
Unit: N·m (kg-m, in-lb)
BACKLASH
Unit: mm (in)
COMPANION FLANGE RUNOUT
Unit: mm (in)
SELECTIVE PARTS
Side Gear Thrust Washer
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.Applied modelYD25DDTi
6M/T 5A/T
Grade SE, XE* XE SE
Final drive modelR180A
Gear ratio 3.692 3.538
Number of teeth (Drive gear/Drive pinion) 48/13 46/13
Oil capacity (Approx.)
(lmp pt)0.85 (1-1/2)
Number of pinion gears2
Drive pinion adjustment spacer type Collapsible
Item Runout limit
Drive gear back face 0.08 (0.0031) or less
Item Specification
Side gear backlash (Clearance between side gear and differential
case)0.1 (0.004) or less
(Each gear should rotate smoothly without excessive resistance
during differential motion.)
Item Specification
Pinion bearing (P
1) 1.08 - 1.66 (0.11 - 0.16, 10 - 14)
Side bearing (P
2) 0.59 - 1.08 (0.06 - 0.11, 6 - 9)
Side bearing to pinion bearing (Total preload)
(Total preload = P
1+P2)1.67 - 2.74 (0.17 - 0.27, 15 - 24)
Item Specification
Drive gear to drive pinion gear 0.10 - 0.15 (0.0039 - 0.0059)
Item Runout limit
Companion flange face 0.1 (0.004) or less
Inner side of the companion flange 0.1 (0.004) or less
Thickness Part number* Thickness Part number*
0.75 (0.0295)
0.78 (0.0307)
0.81 (0.0319)
0.84 (0.0331)38424 W2010
38424 W2011
38424 W2012
38424 W20130.87 (0.0343)
0.90 (0.0354)
0.93 (0.0366)
0.96 (0.0378)38424 W2014
38424 W2015
38424 W2016
38424 W2017

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
FSU-5
C
D
F
G
H
I
J
K
L
MA
B
FSU
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEES002KK
Use the chart below to help you find the cause of the symptom. Repair or replace parts as necessary.
x: ApplicableReference page
FSU-6FSU-10FSU-6FSU-6FSU-21FSU-7FSU-7FSU-7
FAX-4, "
NVH Troubleshooting Chart
"
FFD-6, "
NVH Troubleshooting Chart
"
FAX-4, "
NVH Troubleshooting Chart
"
WT-2, "
NVH Troubleshooting Chart
"
WT-2, "
NVH Troubleshooting Chart
"
BR-5, "
NVH Troubleshooting Chart
"
PS-5, "
NVH Troubleshooting Chart
"
Possible Cause and
SUSPECTED PARTS
Improper installation, looseness
Shock absorber deformation,
damage or deflection
Bushing or mounting deterioration
Parts interference
Spring fatigue
Suspension looseness
Incorrect wheel alignment
Stabilizer bar fatigue
DRIVE SHAFT
DIFFERENTIAL
WHEEL HUB AND BEARING
TIRES
ROAD WHEEL
BRAKES
STEERING
SymptomNoise´ ´ ´´´´ ´ ´ ´ ´ ´ ´´
Shake´´´´ ´ ´ ´´´´´
Vibration´ ´ ´´´ ´ ´ ´ ´
Shimmy´´´´ ´ ´´´´´
Shudder´´´ ´´´´´
Poor quality ride or handling´ ´ ´´´ ´´ ´ ´ ´

GI-62
TERMINOLOGY
Exhaust gas recirculation control-BPT
valveEGRC-BPT valve BPT valve
Exhaust gas recirculation control-solenoid
valveEGRC-solenoid valve EGR control solenoid valve
Exhaust gas recirculation temperature sen-
sor
EGRT sensor Exhaust gas temperature sensor
EGR temperature sensor
Flash electrically erasable programmable
read only memoryFEEPROM ***
Flash erasable programmable read only
memoryFEPROM ***
Flexible fuel sensor FFS ***
Flexible fuel system FF system ***
Fuel pressure regulator *** Pressure regulator
Fuel pressure regulator control solenoid
valve*** PRVR control solenoid valve
Fuel trim FT ***
Heated Oxygen sensor HO2S Exhaust gas sensor
Idle air control system IAC system Idle speed control
Idle air control valve-air regulator IACV-air regulator Air regulator
Idle air control valve-auxiliary air control
valveIACV-AAC valve Auxiliary air control (AAC) valve
Idle air control valve-FICD solenoid valve IACV-FICD solenoid valve FICD solenoid valve
Idle air control valve-idle up control sole-
noid valveIACV-idle up control solenoid valve Idle up control solenoid valve
Idle speed control-FI pot ISC-FI pot FI pot
Idle speed control system ISC system ***
Ignition control IC ***
Ignition control module ICM ***
Indirect fuel injection system IFI system ***
Intake air IA Air
Intake air temperature sensor IAT sensor Air temperature sensor
Knock *** Detonation
Knock sensor KS Detonation sensor
Malfunction indicator lamp MIL Check engine light
Manifold absolute pressure MAP ***
Manifold absolute pressure sensor MAPS ***
Manifold differential pressure MDP ***
Manifold differential pressure sensor MDPS ***
Manifold surface temperature MST ***
Manifold surface temperature sensor MSTS ***
Manifold vacuum zone MVZ ***
Manifold vacuum zone sensor MVZS ***
Mass air flow sensor MAFS Air flow meter
Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve
Multiport fuel injection System MFI system Fuel injection controlNEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM

IDX-3
A
C
D
E
F
G
H
I
J
K
L B
IDX
ALPHABETICAL INDEX
C
Camshaft ...........................................................EM-59
Camshaft inspection ..........................................EM-60
Camshaft position sensor (CMPS) .....EC-82,EC-171,
EC-177
CAN ....................................................................DI-65
CAN - Wiring diagram ...........EC-80,LAN-26,LAN-44,
LAN-56
,LAN-68,LAN-82,LAN-96,LAN-112,LAN-125,
LAN-139
,LAN-152,LAN-166,LAN-181,LAN-198,
LAN-213
,LAN-230,LAN-248,LAN-267,LAN-279
CAN (Controller Area Network) ..BL-25,BL-59,RF-13
CAN communication .....EC-22,EC-79,AT-91,TF-19,
TF-82
,RFD-43,RFD-69,BRC-28,BL-25,BL-59,RF-13,
LT-88
CHARGE - Wiring diagram ................................SC-15
Charging system ................................................SC-14
Chassis and body maintenance ........................MA-28
CHIME - Wiring diagram .....................................DI-53
CIGAR - Wiring diagram ..................................WW-55
Cigarette lighter ...............................................WW-55
Circuit breaker ...................................................PG-74
CKPS - Wiring diagram .....................EC-161,EC-167
Clutch cover .......................................................CL-17
Clutch disc .........................................................CL-17
Clutch master cylinder .........................................CL-9
Clutch operating cylinder ...................................CL-11
Clutch pedal .........................................................CL-6
CMPS - Wiring diagram .....................EC-173,EC-179
Coil spring (front) .............................................FSU-10
Collision diagnosis ...........................................SRS-56
Combination lamp, front, removal and installation ........
LT-30
Combination lamp, rear, removal and installation ........
LT-144
Combination meter ...............................................DI-4
Combination switch ..........................................LT-114
COMBSW - Wiring diagram ..............................LT-114
COMPAS - Wiring diagram .................................DI-68
Compass ............................................................DI-66
Component Location (auto A/C) .......ATC-36,MTC-36
Compression pressure ......................................EM-92
Compressor clutch removal and installation .ATC-143,
MTC-123
Compressor mounting ..................ATC-142,MTC-122
Compressor special service tool .......ATC-16,MTC-16
Condenser ....................................ATC-147,MTC-127
Connecting rod ................................................EM-127
Connecting rod bearing clearance ...................EM-131
Connecting rod bushing clearance ..................EM-127
Console box - See Instrument panel ...................IP-10
CONSULT for all-mode 4WD .............................TF-44
CONSULT-II for engine .....................................EC-59
Control units (terminal arrangement) .................PG-78
Control valve (A/T) .............................................AT-33
Controller Area Network (CAN) ..BL-25,BL-59,RF-13
Converter housing installation .........................AT-250
COOL/F - Wiring diagram ................................EC-135
Cooling circuit (engine) ........................................CO-6
Cooling fan ........................................................CO-19
Cooling fan motor ............................................EC-141
Cooling unit (A/C evaporator) ......ATC-124,ATC-149,
MTC-103
,MTC-129
Counter gear (M/T) ............................................MT-21
Coupling sleeve (M/T) ........................................MT-21
Crankcase ventilation system ............................EC-21
Crankshaft position sensor (TDC) ......EC-82,EC-159,
EC-165
Cylinder block .................................................EM-110
Cylinder block boring ......................................EM-129
Cylinder head ....................................................EM-92
Cylinder head bolt tightening ............................EM-96
Cylinder head gasket selection .........................EM-96
D
Data link connector for Consult ..........................EC-59
Daytime light system ...........................................LT-31
Daytime running light - See Daytime light systemLT-31
Diagnosis sensor unit .....................................SRS-48
Diagnostic trouble code (DTC) ..........................EC-27
Diagnostic trouble code (DTC) for OBD system ..EC-6
Diagnostic trouble code (DTC) inspection priority chart
EC-37
Differential gear oil replacement ...........MA-33,MA-34
DIFLOC - Wiring diagram ...............................RFD-46
Dimensions .........................................................GI-60
Direct clutch solenoid valve ...............AT-142,AT-144
Display and amp.assembly ...............ATC-60,MTC-55
Dome light - See Interior lamp ..........................LT-145
Door glass ...........................................GW-35,GW-38
Door lock ..........................................................BL-126
Door mirror lamp ...............................................LT-145
Door trim .............................................................EI-30
Door, front .............................BL-118,BL-120,GW-35
Door, rear ............................................BL-118,GW-38
Drive belt ...........................................................EM-12
Drive chain (Transfer) .........................TF-114,TF-120
Driver air bag ..................................................SRS-36
DTRL - Wiring diagram .......................................LT-35
Duct and grilles .............................ATC-134,MTC-113
E
ECM input/output signal .....................................EC-52
ECM power supply .............................................EC-71
ECM relay ........................................................EC-232
ECTS - Wiring diagram ....................................EC-105
EGR function ...................................................EC-302
EGR volume control valve ...............................EC-302
EGRC/V - Wiring diagram ................................EC-304
Electric sunroof ..................................................RF-10
Electrical units location ......................................PG-71
Electronic fuel injection pump ...........................EM-49
Engine control circuit diagram ...........................EC-50
Engine control component parts location ...........EC-46
Engine control module (ECM) ...........EC-213,EC-215,
EC-269

LAN-1
LAN SYSTEM
K ELECTRICAL
CONTENTS
C
D
E
F
G
H
I
J
L
M
SECTIONLAN
A
B
LAN
LAN SYSTEM
CAN
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
Precautions When Using CONSULT-II ..................... 3
CHECK POINTS FOR USING CONSULT-II ......... 3
Precautions For Trouble Diagnosis .......................... 3
CAN SYSTEM ....................................................... 3
Precautions For Harness Repair .............................. 3
CAN SYSTEM ....................................................... 3
TROUBLE DIAGNOSES WORK FLOW .................... 5
When Displaying CAN Communication System
Errors ....................................................................... 5
WHEN A MALFUNCTION IS DETECTED BY
CAN COMMUNICATION SYSTEM ....................... 5
WHEN A MALFUNCTION IS DETECTED
EXCEPT CAN COMMUNICATION SYSTEM ........ 5
TROUBLE DIAGNOSIS FLOW CHART ............... 6
Diagnosis Procedure ................................................ 7
SELECTING CAN SYSTEM TYPE (HOW TO
USE SPECIFICATION TABLE) ............................. 7
ACQUISITION OF DATA BY CONSULT-II ............ 8
HOW TO USE CHECK SHEET TABLE ................ 9
CAN Diagnostic Support Monitor ........................... 15
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR ECM ............................... 15
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR TCM ............................... 16
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR NAVI CONTROL UNIT ... 17
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR DIFFERENTIAL LOCK
CONTROL UNIT ................................................. 18
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR FRONT AIR CONTROL... 19
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR BCM ............................... 20
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR TRANSFER CONTROLUNIT .................................................................... 21
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR ABS ACTUATOR AND
ELECTRIC UNIT (CONTROL UNIT) ................... 21
DESCRIPTION OF “CAN DIAG SUPPORT
MNTR” SCREEN FOR IPDM E/R ....................... 22
CAN COMMUNICATION ........................................... 23
System Description ................................................. 23
Component Parts and Harness Connector Location... 23
LHD MODELS ..................................................... 23
RHD MODELS .................................................... 24
Schematic ............................................................... 25
Wiring Diagram — CAN — ..................................... 26
CAN Communication Unit ....................................... 30
TYPE 1/ TYPE 2/ TYPE 3 ................................... 32
TYPE 4/ TYPE 5 .................................................. 34
TYPE 6/ TYPE 7/ TYPE 8/ TYPE 9/ TYPE 10/
TYPE 11/ TYPE 16/ TYPE 17 .............................. 36
TYPE 12/ TYPE 13/ TYPE 14/ TYPE 15 ............. 40
CAN SYSTEM (TYPE 1) ........................................... 44
Component Parts and Harness Connector Location... 44
Schematic ............................................................... 44
Wiring Diagram — CAN — ..................................... 44
Check Sheet ........................................................... 45
CHECK SHEET RESULTS (EXAMPLE) ............. 47
CAN SYSTEM (TYPE 2) ........................................... 56
Component Parts and Harness Connector Location... 56
Schematic ............................................................... 56
Wiring Diagram — CAN — ..................................... 56
Check Sheet ........................................................... 57
CHECK SHEET RESULTS (EXAMPLE) ............. 59
CAN SYSTEM (TYPE 3) ........................................... 68
Component Parts and Harness Connector Location... 68
Schematic ............................................................... 68
Wiring Diagram — CAN — ..................................... 68
Check Sheet ........................................................... 69
CHECK SHEET RESULTS (EXAMPLE) ............. 71
CAN SYSTEM (TYPE 4) ........................................... 82
Component Parts and Harness Connector Location... 82
Schematic ............................................................... 82