lock NISSAN NAVARA 2005 Repair Workshop Manual

TF-90
TROUBLE DIAGNOSIS FOR SYMPTOMS
2.CHECK TRANSFER CONTROL UNIT GROUND CIRCUIT
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)
2. Disconnect transfer control unit harness connectors.
3. Check continuity between transfer control unit harness connec-
tor M105 terminals 6, 18, M106 terminal 32 and ground.
Also check harness for short to power.
OK or NG
OK >> GO TO 3.
NG >>
lRepair open circuit or short to power in harness or
connectors.
lHarness for short or open between transfer shut off
relay harness connector E85 terminal 2 and transfer
control unit harness connector M106 terminal 40.
3.CHECK COMBINATION METER POWER SUPPLY CIRCUIT
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)
2. Disconnect combination meter harness connector.
3. Check voltage between combination meter harness connector
terminals and ground.
4. Turn ignition switch “ON”. (Do not start engine.)
5. Check voltage between combination meter harness connector
terminals and ground.
OK or NG
OK >> GO TO 4.
NG >> Check the following. If any items are damaged, repair or
replace damaged parts.
l10A fuse [No. 14, located in the fuse block (J/B)] or
ignition switch.
lHarness for short or open between ignition switch and combination meter harness connector
M23 terminal 16. Continuity should exist.
SDIA3362E
Connector Terminal Voltage (Approx.)
M23 16 - Ground 0V
WDIA0178E
Connector Terminal Voltage (Approx.)
M23 16 - Ground Battery voltage
WDIA0179E

TF-92
TROUBLE DIAGNOSIS FOR SYMPTOMS
DIAGNOSTIC PROCEDURE
1.CHECK TRANSFER CONTROL UNIT POWER SUPPLY CIRCUIT
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)
2. Disconnect transfer control unit harness connector.
3. Check voltage between transfer control unit harness connector
terminals and ground.
4. Turn ignition switch “ON”. (Do not start engine.)
5. Check voltage between transfer control unit harness connector
terminals and ground.
OK or NG
OK >> GO TO 2.
NG >> Check the following. If any items are damaged, repair or replace damaged parts.
l40A fusible link (No.J, located in the fuse and fusible link box). Refer toPG-4, "POWER SUP-
PLY ROUTING CIRCUIT".
l10A fuses [No. 18, located in the fuse block (J/B) and No. 63 and 64 located in the fuse and
relay box]. Refer toPG-4, "
POWER SUPPLY ROUTING CIRCUIT".
lHarness for short or open between battery and transfer control unit harness connector M105
terminal 19.
lHarness for short or open between battery and transfer shut off relay 2 harness connector E85
terminals 1 and 3.
lHarness for short or open between battery and transfer shut off relay 1 harness connector E84
terminal 3.
lHarness for short or open between ignition switch and transfer control unit harness connector
M105 terminal 25.
lHarness for short or open between ignition switch and transfer shut off relay 1 harness connec-
tor E84 terminal 1.
lHarness for short or open between transfer shut off relay 2 harness connector E85 terminal 5
and transfer control unit harness connector M106 terminals 44, 45.
lHarness for short or open between transfer shut off relay 1 harness connector E84 terminal 5
and transfer control unit harness connector M106 terminals 44, 45.
lHarness for short or open between transfer shut off relay 2 harness connector E85 terminal 2
and transfer control unit harness connector M106 terminal 40.
lHarness for open between transfer shut off relay 1 harness connector E84 terminal 2 and
ground.
lBattery and ignition switch. Refer toPG-4, "POWER SUPPLY ROUTING CIRCUIT".
lTransfer shut off relay 1, 2. Refer toTF-54, "COMPONENT INSPECTION".
Connector Terminal Voltage (Approx.)
M10519 - Ground Battery voltage
25 - Ground 0V
M10640 - Ground Battery voltage
44 - Ground
0V
45 - Ground
SDIA3360E
Connector Terminal Voltage (Approx.)
M10519 - Ground
Battery voltage
25 - Ground
M10640 - Ground 0V
44 - Ground
Battery voltage
45 - Ground
SDIA3361E

TROUBLE DIAGNOSIS FOR SYMPTOMS
TF-93
C
E
F
G
H
I
J
K
L
MA
B
TF
2.CHECK TRANSFER CONTROL UNIT GROUND CIRCUIT
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)
2. Disconnect transfer control unit harness connectors.
3. Check continuity between transfer control unit harness connec-
tor M105 terminals 6, 18, M106 terminal 32 and ground.
Also check harness for short to power.
OK or NG
OK >> GO TO 3.
NG >>
lRepair open circuit or short to power in harness or
connectors.
lHarness for short or open between transfer shut off
relay harness connector E85 terminal 2 and transfer
control unit harness connector M106 terminal 40.
3.CHECK COMBINATION METER POWER SUPPLY CIRCUIT
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)
2. Disconnect combination meter harness connector.
3. Check voltage between combination meter harness connector
terminals and ground.
4. Turn ignition switch “ON”. (Do not start engine.)
5. Check voltage between combination meter harness connector
terminals and ground.
OK or NG
OK >> GO TO 4.
NG >> Check the following. If any items are damaged, repair or
replace damaged parts.
l10A fuse [No. 14, located in the fuse block (J/B)] or
ignition switch.
lHarness for short or open between ignition switch and combination meter harness connector
M23 terminal 16. Continuity should exist.
SDIA3362E
Connector Terminal Voltage (Approx.)
M23 16 - Ground 0V
WDIA0178E
Connector Terminal Voltage (Approx.)
M23 16 - Ground Battery voltage
WDIA0179E

FRONT OIL SEAL
TF-101
C
E
F
G
H
I
J
K
L
MA
B
TF
FRONT OIL SEALPFP:38189
Removal and InstallationEDS0032K
REMOVAL
1. Partially drain the transfer fluid. Refer toTF-12, "DRAINING".
2. Remove the front propeller shaft. Refer toPR-4, "
Removal and Installation".
3. Remove the companion flange self-lock nut, using Tool.
4. Put a matching mark on top of the front drive shaft in line with
the mark on the companion flange.
CAUTION:
Use paint to make the matching mark on the front drive
shaft. Do not damage the front drive shaft.
5. Remove the companion flange, using suitable tool.
6. Remove the front oil seal from the front case, using Tool.
CAUTION:
Do not damage front case.Tool number : KV40104000
LDIA0142E
SDIA2779E
WDIA0193E
Tool number : KV381054S0
LDIA0144E

TF-102
FRONT OIL SEAL
INSTALLATION
1. Install the front oil seal until it is flush with the end face of the
front case, using Tool.
CAUTION:
lDo not reuse oil seal.
lApply petroleum jelly to oil seal.
2. Align the matching mark of the front drive shaft with the match-
ing mark of the companion flange, then install the companion
flange.
3. Install the self-lock nut and tighten to the specified torque, using
Tool. Refer toTF-112, "
COMPONENTS".
CAUTION:
Do not reuse self-lock nut.
4. Install the front propeller shaft. Refer toPR-4, "
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". Tool number : KV38100500
LDIA0145E
SDIA2214E
Tool number : KV40104000
LDIA0147E

TRANSFER CONTROL DEVICE
TF-105
C
E
F
G
H
I
J
K
L
MA
B
TF
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-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

TF-114
TRANSFER ASSEMBLY
DISASSEMBLY
1. Remove the drain plug and filler plug.
2. Remove the transfer control device from the rear case.
3. Remove the O-ring from the transfer control device.
4. Remove the self-lock nut from the companion flange, using Tool.
5. Put a matching mark on top of the front drive shaft in line with
the mark on the companion flange.
CAUTION:
Use paint to make the matching mark on the front drive
shaft. Do not damage the front drive shaft.
6. Remove the companion flange, using suitable tool.
SDIA2212E
Tool number : KV40104000
SDIA2841E
SDIA2779E
WDIA0133E

TF-122
TRANSFER ASSEMBLY
7. Install the planetary carrier assembly and sun gear assembly to
the front case, using Tool.
8. Install the snap ring to the sun gear.
CAUTION:
lDo not reuse snap ring.
lDo not damage sun gear.
9. Set the L-H sleeve together with the L-H shift fork assembly onto
the planetary carrier assembly.
10. Install the control shift rod assembly to the front case.
CAUTION:
Set pin of L-H shift fork assembly into the groove of drum
cam.
11. Turn the control shift rod assembly fully counterclockwise.
12. Install the L-H shift rod assembly through the L-H shift fork
assembly opening to the front case.
CAUTION:
Set pin of L-H shift rod assembly into the groove of drum
cam.
13. Install the mainshaft to the sun gear assembly.Tool number : KV38100200
SDIA2791E
PDIA0099E
SDIA2438E
WDIA0215E
WDIA0216E

TRANSFER ASSEMBLY
TF-127
C
E
F
G
H
I
J
K
L
MA
B
TF
38. Install the front oil seal until it is flush with the end face of the
front case, using Tool.
CAUTION:
lDo not reuse oil seal.
lApply petroleum jelly to oil seal.
39. Align the matching mark on the front drive shaft with the mark on
the companion flange, then install the companion flange.
40. Install the companion flange self-lock nut. Tighten to the speci-
fied torque, using Tool. Refer toTF-112, "
COMPONENTS".
CAUTION:
Do not reuse self-lock nut.
41. Install the O-ring to the transfer control device.
CAUTION:
lDo not reuse O-ring.
lApply petroleum jelly to O-ring.
42. Install the transfer control device to the rear case.
a. Turn the control shift rod fully counterclockwise using a flat-
bladed screwdriver, and then put a mark on the control shift rod.Tool number : KV38100500
PDIA0117E
SDIA2779E
Tool number : KV40104000
WDIA0219E
SDIA3378E
PDIA0119E