brake NISSAN TERRANO 2002 Service Repair Manual

Edition: February 2002
Release: February 2002 (01)
Publication No.: SM2E00-1R20E0E
GENERAL INFORMATIONGI
MAINTENANCEMA
ENGINE MECHANICALEM
ENGINE LUBRICATION &
COOLING SYSTEMSLC
ENGINE CONTROL SYSTEMEC
ACCELERATOR CONTROL,
FUEL & EXHAUST SYSTEMFE
CLUTCHCL
MANUAL TRANSMISSIONMT
AUTOMATIC TRANSMISSIONAT
TRANSFERTF
PROPELLER SHAFT &
DIFFERENTIAL CARRIERPD
FRONT AXLE & FRONT SUSPENSIONFA
REAR AXLE & REAR SUSPENSIONRA
BRAKE SYSTEMBR
STEERING SYSTEMST
RESTRAINT SYSTEMRS
BODY & TRIMBT
HEATER & AIR CONDITIONERHA
STARTING & CHARGING SYSTEMSSC
ELECTRICAL SYSTEMEL
ALPHABETICAL INDEXIDX
TERRANO
MODEL R20 SERIES
NISSAN EUROPE N.V.
NISSAN EUROPE N.V.
Produced in The Netherlands

QUICK REFERENCE INDEX

1. SPORT Indicator Lamp Does Not Come On ........94
2. SPORT or SNOW Indicator Lamp Does Not
Come On...................................................................95
3. O/D OFF Indicator Lamp Does Not Come On......95
4. SPORT Indicator Lamp Does Not Come On ........96
5. Engine Cannot Be Started In²P²and²N²
Position......................................................................97
6. In²P²Position, Vehicle Moves Forward Or
Backward When Pushed...........................................97
7. In²N²Position, Vehicle Moves .............................98
8. Large Shock.²N²->²R²Position .........................99
9. Vehicle Does Not Creep Backward In²R²
Position....................................................................100
10. Vehicle Does Not Creep Forward In²D²,²2²
Or²1²Position.........................................................101
11. Vehicle Cannot Be Started From D
1.................102
12. A/T Does Not Shift: D
1-> D2Or Does Not
Kickdown: D
4-> D2..................................................103
13. A/T Does Not Shift: D
2-> D3............................104
14. A/T Does Not Shift: D
3-> D4.............................105
15. A/T Does Not Perform Lock-up .........................106
16. A/T Does Not Hold Lock-up Condition ..............107
17. Lock-up Is Not Released ...................................107
18. Engine Speed Does Not Return To Idle (Light
Braking D
4-> D3) .....................................................108
19. Vehicle Does Not Start From D
1.......................109
20. A/T Does Not Shift: D
2-> D1When
Depressing Accelerator Pedal................................. 110
21. A/T Does Not Shift: D
4-> D3, When
Overdrive Control Switch²ON²->²OFF²............... 111
22. A/T Does Not Shift: D
3-> 22, When Selector
Lever²D²->²2²Position......................................... 111
23. A/T Does Not Shift: 2
2-> 11, When Selector
Lever²2²->²1²Position ......................................... 112
24. Vehicle Does Not Decelerate By Engine
Brake........................................................................ 112
ON-VEHICLE SERVICE.............................................. 113Control Valve Assembly and Accumulators ............. 113
Revolution Sensor Replacement ............................. 114
Rear Oil Seal Replacement ..................................... 114
Parking Components Inspection.............................. 114
Park/neutral Position Switch Adjustment ................. 114
Manual Control Linkage Adjustment........................ 115
REMOVAL AND INSTALLATION................................ 116
Removal ................................................................... 116
Installation ................................................................ 117
MAJOR OVERHAUL................................................... 119
Oil Channel ..............................................................121
Locations of Needle Bearings, Thrust Washers
and Snap Rings .......................................................122
DISASSEMBLY............................................................123
Disassembly.............................................................123
REPAIR FOR COMPONENT PARTS..........................134
Oil Pump ..................................................................134
Control Valve Assembly ...........................................138
Control Valve Upper Body .......................................144
Control Valve Lower Body .......................................149
Reverse Clutch ........................................................151
High Clutch ..............................................................155
Forward and Overrun Clutches ...............................157
Low & Reverse Brake..............................................161
Forward Clutch Drum Assembly ..............................165
Rear Internal Gear and Forward Clutch Hub ..........168
Band Servo Piston Assembly ..................................171
Parking Pawl Components ......................................175
ASSEMBLY..................................................................177
Assembly (1) ............................................................177
Adjustment ...............................................................185
Assembly (2) ............................................................188
A/T FLUID COOLER SYSTEM...................................195
A/T Fluid Cooler.......................................................195
SERVICE DATA AND SPECIFICATIONS (SDS)........196
General Specifications .............................................196
Specifications and Adjustment.................................196
When you read wiring diagrams:
IRead GI section, ªHOW TO READ WIRING DIAGRAMSº.
ISee EL section, ªPOWER SUPPLY ROUTINGº for power distribution circuit.
When you perform trouble diagnoses, read GI section, ªHOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSESº and ªHOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRI-
CAL INCIDENTº.
CONTENTS(Cont'd)
AT- 2

Shift Mechanism
The automatic transmission uses compact, dual planetary gear systems to improve power-transmission
efficiency, simplify construction and reduce weight.
It also employs an optimum shift control and superwide gear ratios. They improve starting performance and
acceleration during medium and high-speed operation.
Two one-way clutches are also employed: one is used for the forward clutch and the other for the low clutch.
These one-way clutches, combined with four accumulators, reduce shifting shock to a minimum.
CONSTRUCTION
q1Torque converter clutch piston
q
2Torque converter
q
3Oil pump
q
4Input shaft
q
5Brake band
q
6Reverse clutch
q
7High clutch
q
8Front pinion gearq
9Front sun gear
q
10Front internal gear
q
11Front planetary carrier
q
12Rear sun gear
q
13Rear pinion gear
q
14Rear internal gear
q
15Rear planetary carrier
q
16Forward clutchq
17Forward one-way clutch
q
18Overrun clutch
q
19Low one-way clutch
q
20Low & reverse brake
q
21Parking pawl
q
22Parking gear
q
23Output shaft
FUNCTION OF CLUTCH AND BRAKE
Control members Abbr. Function
q
6Reverse clutch R/C To transmit input power to front sun gearq9.
q
7High clutch H/C To transmit input power to front planetary carrierq11.
q
16Forward clutch F/C To connect front planetary carrierq11with forward one-way clutchq17.
q
18Overrun clutch O/C To connect front planetary carrierq11with rear internal gearq14.
q
5Brake band B/B To lock front sun gearq9.
q
17Forward one-way clutch F/O.CWhen forward clutch is engaged, to stop rear internal gearq14from rotating in opposite
direction.
q
19Low one-way clutch L/O.C At D1position, to prevent rear internal gearq14from rotating in opposite direction.
q
20Low & reverse brake L & R/BTo lock rear internal gearq14(2, 12and 11), to lock front planetary carrierq11
(R position).
SAT509I
OVERALL SYSTEM
AT-10

CLUTCH AND BAND CHART
Shift positionq6Reverse
clutchq7High
clutchq16Forward
clutchq18Overrun
clutchBand servoq
17Forward
one-
way
clutchq19Low
one-
way
clutchq20Low &
reverse
brakeLock-up Remarks
2nd
apply3rd
release4th
apply
PPARK
POSITION
RqqREVERSE
POSITION
NNEUTRAL
POSITION
D*41stq*1
vv
Automatic shift
1)2)3)4 2ndq*1
qv
3rdqq*1
*2v
4thq
*3qq
21stq
vv
Automatic shift
1)2
2ndq
qv
11stqqvqLocks (held sta-
tionary)
in 1st speed
1+2 2ndqqqv
*1: Operates when overdrive control or A/T mode switch is being set in ªOFFº or ªSPORTº position.
*2: Oil pressure is applied to both 2nd ªapplyº side and 3rd ªreleaseº side of band servo piston. However, brake band does not contract because oil
pressure area on the ªreleaseº side is greater than that on the ªapplyº side.
*3: Oil pressure is applied to 4th ªapplyº side in condition *2 above, and brake band contracts.
*4: A/T will not shift to 4th when overdrive control or A/T mode switch is set in ªOFFº or ªSPORTº position.
q: Operates.
: Operates when throttle opening is less than 3/16, activating engine brake.
v: Operates during ªprogressiveº acceleration.
: Operates but does not affect power transmission.
: Operates when throttle opening is less than 3/16, but does not affect engine brake.
OVERALL SYSTEM
Shift Mechanism (Cont'd)
AT-11

TCM FUNCTION
The function of the TCM is to:
IReceive input signals sent from various switches and sensors.
IDetermine required line pressure, shifting point, lock-up operation, and engine brake operation.
ISend required output signals to the respective solenoids.
INPUT/OUTPUT SIGNAL OF TCM
Sensors and solenoid valves Function
InputPark/neutral position switch Detects select lever position and sends a signal to TCM.
Throttle (accelerator) position sensor Detects throttle valve position and sends a signal to TCM.
Closed throttle position switch Detects throttle valve's fully-closed position and sends a signal to TCM.
Wide open throttle position switchDetects a throttle valve position of greater than 1/2 of full throttle and sends a
signal to TCM.
Engine speed signal From ECM.
A/T fluid temperature sensor Detects transmission fluid temperature and sends a signal to TCM.
Revolution sensor Detects output shaft rpm and sends a signal to TCM.
Vehicle speed sensorUsed as an auxiliary vehicle speed sensor. Sends a signal when revolution sen-
sor (installed on transmission) malfunctions.
Overdrive control switch
A/T mode switchSends a signal, which prohibits a shift to ªD
4º (overdrive) position, to the TCM.
OutputShift solenoid valve A/BSelects shifting point suited to driving conditions in relation to a signal sent from
TCM.
Line pressure solenoid valveRegulates (or decreases) line pressure suited to driving conditions in relation to
a signal sent from TCM.
Torque converter clutch solenoid valveRegulates (or decreases) lock-up pressure suited to driving conditions in relation
to a signal sent from TCM.
Overrun clutch solenoid valveControls an ªengine brakeº effect suited to driving conditions in relation to a sig-
nal sent from TCM.
O/D OFF indicator lamp
SPORT indicator lampShows TCM malfunctions, when A/T control components malfunction.
OVERALL SYSTEM
Control System (Cont'd)
AT-13

DIAGNOSTIC WORKSHEET
1.lRead the Fail-safe and listen to customer complaints. AT-5
2.lA/T FLUID CHECK AT-27
lLeakage (Follow specified procedure)
lFluid condition
lFluid level
3.lPerform STALL TEST and LINE PRESSURE TEST. AT-27,
AT-30
lStall test Ð Mark possible damaged components/others.
lTorque converter one-way clutch
lReverse clutch
lForward clutch
lOverrun clutch
lForward one-way clutchlLow & reverse brake
lLow one-way clutch
lEngine
lLine pressure is low
lClutches and brakes except high
clutch and brake band are OK
lLine pressure test Ð Suspected parts:
4.lPerform all ROAD TEST and mark required procedures. AT-32
4-1. Check before engine is started. AT-33
lSELF-DIAGNOSTIC PROCEDURE Ð Mark detected items.
lVehicle speed sensor×A/T (Revolution sensor), AT-50.
lVehicle speed sensor×MTR, AT-54.
lThrottle (accelerator) position sensor, AT-60.
lShift solenoid valve A, AT-63.
lShift solenoid valve B, AT-66.
lOverrun clutch solenoid valve, AT-69.
lTorque converter clutch solenoid valve, AT-88.
lA/T fluid temperature sensor and TCM power source, AT-76.
lEngine speed signal, AT-80.
lLine pressure solenoid valve, AT-84.
lPark/neutral position, overdrive control, A/T check and throttle
(accelerator) position switches, AT-88.
lBattery
lOthers
4-2. Check at idle AT-35
l1. SPORT Indicator Lamp Does Not Come On, AT-92.
l2. SPORT or SNOW Indicator Lamp Does Not Come On, AT-95.
l3. O/D OFF Indicator Lamp Does Not Come On, AT-95.
l4. SPORT Indicator Lamp Does Not Come On, AT-96.
l5. Engine Cannot Be Started In ªPº And ªNº Position, AT-97.
l6. In ªPº Position, Vehicle Moves Forward Or Backward When Pushed, AT-97.
l7. In ªNº Position, Vehicle Moves, AT-98.
l8. Large Shock. ªNº,ªRº Position, AT-99.
l9. Vehicle Does Not Creep Backward In ªRº Position, AT-100.
l10. Vehicle Does Not Creep Forward In ªDº, ª2º Or ª1º Position, AT-101.
4-3. Cruise testAT-36,
AT-39
Part-1
l11. Vehicle Cannot Be Started From D
1, AT-102.
l12. A/T Does Not Shift: D
1,D2Or Does Not Kickdown: D4,D2, AT-103.
l13. A/T Does Not Shift: D
2,D3, AT-104.
l14. A/T Does Not Shift: D
3,D4, AT-105.
l15. A/T Does Not Perform Lock-up, AT-106.
l16. A/T Does Not Hold Lock-up Condition, AT-107.
l17. Lock-up Is Not Released, AT-107.
l18. Engine Speed Does Not Return To Idle (Light Braking D
4,D3), AT-108.
TROUBLE DIAGNOSIS Ð Introduction
Diagnostic Worksheet (Cont'd)
AT-24

4. Part-2
l19. Vehicle Does Not Start From D
1, AT-109.
l12. A/T Does Not Shift: D
1,D2Or Does Not Kickdown: D4,D2, AT-103.
l13. A/T Does Not Shift: D
2,D3, AT-104.
l14. A/T Does Not Shift: D
3,D4, AT-105.AT-41
Part-3
l20. A/T Does Not Shift: D
2,D1When Depressing Accelerator Pedal, AT-5.
l21. A/T Does Not Shift: D
4,D3When Overdrive Control Switch ªONº,
ªOFFº, AT-111.
l18. Engine Speed Does Not Return To Idle (Engine Brake In D
3), AT-108.
l22. A/T Does Not Shift: D
3,22, When Selector Lever ªDº,ª2º Position,
AT- 111 .
l18. Engine Speed Does Not Return To Idle (Engine Brake In 2
2), AT-108.
l23. A/T Does Not Shift: 2
2,11, When Selector Lever ª2º,ª1º Position,
AT-5.
l24. Vehicle Does Not Decelerate By Engine Brake, AT-112.
lSELF-DIAGNOSTIC PROCEDURE Ð Mark detected items.AT-42
lVehicle speed sensor×A/T (Revolution sensor), AT-50.
lVehicle speed sensor×MTR, AT-54.
lThrottle (accelerator) position sensor, AT-60.
lShift solenoid valve A, AT-63.
lShift solenoid valve B, AT-66.
lOverrun clutch solenoid valve, AT-69.
lTorque converter clutch solenoid valve, AT-69.
lA/T fluid temperature sensor and TCM power source, AT-76.
lEngine speed signal, AT-80.
lLine pressure solenoid valve, AT-84.
lPark/neutral position, overdrive control, A/T check and throttle
(accelerator) position switches, AT-88.
lBattery
lOthers
5.lFor self-diagnosis NG items, inspect each component. Repair or replace the
damaged parts.AT-14
6.lPerform all ROAD TEST and re-mark required procedures. AT-32
7.lPerform the Diagnostic Procedures for all remaining items marked NG. Repair or
replace the damaged parts.
Refer to the Symptom Chart when you perform the procedures. (The chart also
shows some other possible symptoms and the component inspection orders.)AT-46
AT-43
8.lErase self-diagnosis code from TCM memories. AT-19
TROUBLE DIAGNOSIS Ð Introduction
Diagnostic Worksheet (Cont'd)
AT-25

A/T Fluid Check
FLUID LEAKAGE CHECK
1. Clean area suspected of leaking. Ð for example, mating sur-
face of converter housing and transmission case.
2. Start engine, apply foot brake, place selector lever in ªDº posi-
tion and wait a few minutes.
3. Stop engine.
4. Check for fresh leakage.
FLUID CONDITION CHECK
Fluid color Suspected problem
Dark or black with burned odor Wear of frictional material
Milky pinkWater contamination Ð Road water enter-
ing through filler tube or breather
Varnished fluid, light to dark
brown and tackyOxidation Ð Over or under filling, Ð Over-
heating
FLUID LEVEL CHECK
Refer to MA section (ªChecking A/T Fluidº, ªCHASSIS AND BODY
MAINTENANCEº).
Stall Test
STALL TEST PROCEDURE
1. Check A/T and engine fluid levels. If necessary, add.
2. Drive vehicle for approx. 10 minutes or until engine oil and ATF
reach operating temperature.
ATF operating temperature:
50 - 80ÉC (122 - 176ÉF)
3. Set parking brake and block wheels.
4. Install a tachometer where it can be seen by driver during test.
IIt is good practice to put a mark on point of specified
engine rpm on indicator.
5. Start engine, apply foot brake, and place selector lever in ªDº
position.
6. Accelerate to wide open throttle gradually while applying foot
brake.
7. Quickly note the engine stall revolution and immediately
release throttle.
IDuring test, never hold throttle wide open for more than 5
seconds.
Stall revolution:
2,450 - 2,700 rpm
SAT801A
SAT638A
SAT647B
SAT513G
SAT514G
TROUBLE DIAGNOSIS Ð Basic Inspection
AT-27

8. Move selector lever to ªNº position.
9. Cool off ATF.
IRun engine at idle for at least one minute.
10. Repeat steps 5 through 9 with selector lever in ª2º, ª1º and ªRº
positions.
JUDGEMENT OF STALL TEST
The test result and possible damaged components relating to each result are shown in the illustration.
In order to pinpoint the possible damaged components, follow the WORK FLOW as shown in AT-26.
Note
Stall revolution is too high in ªDº or ª2º position:
ISlippage occurs in 1st gear but not in 2nd and 3rd gears. ..... Low one-way clutch slippage
ISlippage occurs at the following gears:
1st through 3rd gears in ªDº position and engine brake functions.
1st and 2nd gears in ª2º position and engine brake functions with accelerator pedal released (fully closed
throttle). ..... Forward clutch or forward one-way clutch slippage
Stall revolution is too high in ªRº position:
IEngine brake does not function in ª1º position. ..... Low & reverse brake slippage
IEngine brake functions in ª1º position. ..... Reverse clutch slippage
Stall revolution within specifications:
IVehicle does not achieve speed of more than 80 km/h (50 MPH). ..... One-way clutch seizure in torque
converter housing
CAUTION:
Be careful since automatic fluid temperature increases abnormally.
ISlippage occurs in 3rd and 4th gears in ªDº position. ..... High clutch slippage
ISlippage occurs in 2nd and 4th gears in ªDº position. ..... Brake band slippage
Stall revolution less than specifications:
IPoor acceleration during starts. ..... One-way clutch seizure in torque converter
SAT771B
TROUBLE DIAGNOSIS Ð Basic Inspection
Stall Test (Cont'd)
AT-28

4. Set parking brake and block wheels.
IContinue to depress brake pedal fully while line pressure
test is being performed at stall speed.
5. Start engine and measure line pressure at idle and stall speed.
IWhen measuring line pressure at stall speed, follow the
stall test procedure.
Line pressure:
Refer to SDS, AT-196.
JUDGEMENT OF LINE PRESSURE TEST
Judgement Suspected parts
At idleLine pressure is low in all
positions.IOil pump wear
IControl piston damage
IPressure regulator valve or plug sticking
ISpring for pressure regulator valve damaged
IA/T fluid pressure leakage between oil strainer and pressure regulator valve
IClogged strainer
Line pressure is low in par-
ticular position.IFluid pressure leakage between manual valve and particular clutch
IFor example, line pressure is:
Ð Low in ªRº and ª1º positions,
Ð Normal in ªDº and ª2º positions.
Then, fluid leakage exists at or around low and reverse brake circuit.
Refer to ªCLUTCH AND BAND CHARTº, AT-11.
Line pressure is high.IMal-adjustment of throttle position sensor
IA/T fluid temperature sensor damaged
ILine pressure solenoid valve sticking
IShort circuit of line pressure solenoid valve circuit
IPressure modifier valve sticking
IPressure regulator valve or plug sticking
IOpen in dropping resistor circuit
At stall speedLine pressure is low.IMal-adjustment of throttle position sensor
ILine pressure solenoid valve sticking
IShort circuit of line pressure solenoid valve circuit
IPressure regulator valve or plug sticking
IPressure modifier valve sticking
IPilot valve sticking
SAT513G
SAT493G
TROUBLE DIAGNOSIS Ð Basic Inspection
Line Pressure Test (Cont'd)
AT-31