NISSAN NAVARA 2005 Repair Workshop Manual

TF-104
REAR OIL SEAL
3. Install the dust cover to the rear case, using suitable tool.
CAUTION:
lDo not reuse dust cover.
lApply petroleum jelly to dust cover.
4. Install the rear propeller shaft. Refer toPR-8, "
Removal and
Installation".
5. Refill the transfer with fluid and check fluid level. Refer toTF-12,
"FILLING".
6. Check the transfer for fluid leakage. Refer toTF-12, "
FLUID
LEAKAGE AND FLUID LEVEL".SDIA3257E

TRANSFER CONTROL DEVICE
TF-105
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TRANSFER CONTROL DEVICEPFP:33251
Removal and InstallationEDS0032M
REMOVAL
1. Switchthe4WDshiftswitchto2WDandsetthetransferassemblyto2WD.
2. Disconnect the transfer control device connector.
3. Remove the breather hose from the transfer control device.
4. Remove the bolts and detach the transfer control device.
INSTALLATION
1. Install the O-ring to the transfer control device.
CAUTION:
lDo not reuse O-ring.
lApply petroleum jelly to O-ring.
2. Install the transfer control device.
a. Turn the control shift rod fully counterclockwise using a flat-
bladed screwdriver, and then put a mark on the control shift rod.
b. Align the transfer control device shaft cutout with the mark on
the control shift rod, and install.
NOTE:
Turn the transfer control device when the transfer control device
connection does not match.
LDIA0136E
SDIA3378E
PDIA0119E
PDIA0120E

TF-106
TRANSFER CONTROL DEVICE
c. Tighten the bolts to the specified torque. Refer toTF-112, "COM-
PONENTS".
3. Install the breather hose to the transfer control device.
4. Connect the transfer control device connector.
5. After the installation, check the 4WD shift indicator pattern. If
NG, adjust the position between the transfer assembly and
transfer control unit. Refer toTF-4, "
Precautions for Transfer
Assembly and Transfer Control Unit Replacement".
SDIA2212E

AIR BREATHER HOSE
TF-107
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AIR BREATHER HOSEPFP:31098
Removal and InstallationEDS0032N
A/T MODELS
Refer to the figure for air breather hose removal and installation information.
CAUTION:
lMake sure there are no pinched or restricted areas on each air breather hose caused by bending
or winding when installing it.
lInstall each air breather hose into the breather tube (metal
connector) until the hose end reaches the end of the curved
section. Set each air breather hose with paint mark facing
upward.
lInstall transfer control device air breather hose and transfer
air breather hose on clip A and clip B with the paint mark
facing upward.
1. Breather tube 2. Clip A 3. Clip B
4. Clip C 5. Clip D 6. Breather tube (transfer)
7. Air breather hose clamp 8. Transfer control device
SDIA3351E
SDIA3299E
SDIA3353E

TF-108
AIR BREATHER HOSE
lInstall clip C on transfer control device air breather hose
and transfer air breather hose with the paint mark matched.
lInstall transfer control device air breather hose and transfer
air breather hose on clip D with the paint mark facing
upward.
lInstall transfer air breather hose into the breather tube
(transfer, metal connector) until the hose end reaches the
base of the tube. Set transfer air breather hose with paint
mark facing upward.
lInstall transfer control device air breather hose into transfer
control device (case connector) until the hose end reaches
the base of the tube. Set transfer control device air breather
hose with paint mark facing forward.
SDIA3354E
SDIA3355E
SDIA3196E
SDIA3300E

AIR BREATHER HOSE
TF-109
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M/T MODELS
Refer to the figure for air breather hose removal and installation information.
CAUTION:
lMake sure there are no pinched or restricted areas on each air breather hose caused by bending
or winding when installing it.
lInstall each air breather hose into the breather tube (metal
connector) until the hose end reaches the end of the curved
section. Set each air breather hose with paint mark facing
upward.
lInstall transfer control device air breather hose and transfer
air breather hose on clip A and clip B with the paint mark
facing upward.
1. Breather tube 2. Clip A 3. Clip B
4. Clip C 5. Breather tube (transfer) 6. Air breather hose clamp
7. Transfer control device
SDIA3352E
SDIA3302E
SDIA3356E

TF-110
AIR BREATHER HOSE
lInstall transfer control device air breather hose and transfer
air breather hose on clip C with the paint mark facing
upward.
lInstall transfer air breather hose into the breather tube
(transfer, metal connector) until the hose end reaches the
base of the tube. Set transfer air breather hose with paint
mark facing upward.
lInstall transfer control device air breather hose into transfer
control device (case connector) until the hose end reaches
the base of the tube. Set transfer control device air breather
hose with paint mark facing forward.
SDIA3357E
SDIA3196E
SDIA3300E

TRANSFER ASSEMBLY
TF-111
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TRANSFER ASSEMBLYPFP:33100
Removal and InstallationEDS0032O
REMOVAL
1. Switch 4WD shift switch to 2WD and set transfer assembly to 2WD.
2. Remove the drain plug and gasket. Drain the fluid. Refer toTF-12, "
Replacement".
3. Remove the transmission undercover.
4. Remove the main muffler. Refer toEX-3, "
Removal and Installation".
5. Remove the front and rear propeller shafts. Refer toPR-4, "
Removal and Installation"(front) andPR-8,
"Removal and Installation"(rear).
CAUTION:
Do not damage spline, sleeve yoke and rear oil seal when removing rear propeller shaft.
NOTE:
Insert a plug into the rear oil seal after removing the rear propeller shaft.
6. Remove transmission bolts. Refer toAT-247, "
Removal and Installation"(A/T models) orMT-16,
"Removal and Installation from Vehicle"(M/T models).
7. Position two suitable jacks under the transmission and transfer assembly.
8. Remove the transmission crossmember. Refer toAT- 2 4 7 , "
Removal and Installation"(A/T models) orMT-
16, "Removal and Installation from Vehicle"(M/T models).
WARNING:
Support transmission and transfer assembly using two suitable jacks while removing transmis-
sion crossmember.
9. Disconnect the electrical connectors from the following:
lAT P s w i t c h
l4LO switch
lWait detection switch
lTransfer control device
10. Disconnect each air breather hose from the following. Refer toTF-107, "
A/T MODELS"(A/T models) or
TF-109, "
M/T MODELS"(M/T models).
lTransfer control device
lBreather tube (transfer)
11. Remove the transfer to transmission and transmission to trans-
fer bolts.
WARNING:
Support transfer assembly with suitable jack while remov-
ing it.
12. Remove the transfer assembly.
CAUTION:
Do not damage transmission rear oil seal.
SDIA3181E

TF-112
TRANSFER ASSEMBLY
INSTALLATION
Note the following, and install in the reverse order of removal.
lTighten the bolts to specification.
lAfter the installation, check the transfer fluid level and fluid leak-
age. Refer toTF-12, "
FLUID LEAKAGE AND FLUID LEVEL".
lAfter filling, start the engine for one minute. Then stop the
engine and recheck the transfer fluid.
lAfter the installation, check the 4WD shift indicator pattern. If
NG, adjust the position between the transfer assembly and
transfer control unit. Refer toTF-4, "
Precautions for Transfer
Assembly and Transfer Control Unit Replacement".
Disassembly and AssemblyEDS0032P
COMPONENTS
Bolt length : 45 mm (1.77 in)
Tightening torque : 36 N·m (3.7kg-m, 27 ft-lb)
SDIA3181E
1. Baffle plate 2. Breather tube 3. Front case
4. Snap ring 5. Input oil seal 6. Self-lock nut
7. Companion flange 8. Front oil seal 9. 4LO switch (gray with green paint)
10. ATP switch (black) 11. Rear case 12. Wait detection switch (gray)
13. Gasket 14. Filler plug 15. Check ball
16. Check spring 17. Check plug 18. Drain plug
19. O-ring 20. Transfer control device 21. Harness bracket
SDIA3419E

TRANSFER ASSEMBLY
TF-113
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22. Dust cover 23. Rear oil seal 24 Retainer bolt
25. Gasket 26. Air breather hose clamp
1. Input bearing 2. Snap ring 3. Internal gear
4. Carrier bearing 5. Sun gear 6. Needle bearing
7. Metal bushing 8. Planetary carrier assembly 9. L-H sleeve
10. Drive chain 11. Mainshaft 12. Sprocket
13. 2-4 sleeve 14. Clutch gear 15. Oil pump assembly
16. Retainer 17. Mainshaft rear bearing 18. Front bearing
19. Front drive shaft 20. Rear bearing 21. Clevis pin
22. Shift collar 23. L-H shift fork 24. L-H shift rod
25. Retaining pin 26. 2-4 shift bracket 27. 2-4 shift fork
28. Fork guide collar 29. 2-4 shift fork spring 30. Retaining ring
31. Snap ring 32. Drum cam 33. Control shift rod
34. Spacer 35. Control shift rod assembly
SDIA3421E