light NISSAN TERRANO 2002 Service Repair Manual

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

Diagnosis by CONSULT-II
NOTICE
1. The CONSULT-II electrically displays shift timing and lock-up timing (that is, operation timing of each
solenoid).
Check for time difference between actual shift timing and the CONSULT-II display. If the difference is
noticeable, mechanical parts (except solenoids, sensors, etc.) may be malfunctioning. Check mechanical
parts using applicable diagnostic procedures.
2. Shift schedule (which implies gear position) displayed on CONSULT-II and that indicated in Service Manual
may differ slightly. This occurs because of the following reasons:
IActual shift schedule has more or less tolerance or allowance,
IShift schedule indicated in Service Manual refers to the point where shifts start. Gear position displayed
on CONSULT-II indicates the point where shifts are completed.
3. Shift solenoid valve ªAº or ªBº is displayed on CONSULT-II at the start of shifting. Gear position is displayed
upon completion of shifting (which is computed by TCM).
4. Additional CONSULT-II information can be found in the Operation Manual supplied with the CONSULT-II
unit.
SELF-DIAGNOSTIC RESULT TEST MODE
Refer to AT-14.
DATA MONITOR DIAGNOSTIC TEST MODE
Item DisplayMonitor item
Description Remarks ECU
input
signalsMain
signals
Vehicle speed sensor 1
(A/T)
(Revolution sensor)VHCL/S SE×A/T
[km/h] or [mph]
XÐIVehicle speed computed from signal
of revolution sensor is displayed.When racing engine in ªNº or ªPº posi-
tion with vehicle stationary, CON-
SULT-II data may not indicate
0 km/h (0 MPH).
Vehicle speed sensor 2
(Meter)VHCL/S SE×MTR
[km/h] or [mph]
XÐIVehicle speed computed from signal
of vehicle speed sensor is dis-
played.Vehicle speed display may not be
accurate under approx. 10 km/h
(6 MPH). It may not indicate 0 km/h (0
MPH) when vehicle is stationary.
Throttle (accelerator)
position sensorTHRTL POS SEN
[V]XÐIThrottle (accelerator) position sen-
sor signal voltage is displayed.
A/T fluid temperature
sensorFLUID TEMP SE
[V]
XÐIA/T fluid temperature sensor signal
voltage is displayed.
ISignal voltage lowers as fluid tem-
perature rises.
Battery voltage BATTERY VOLT
[V]XÐISource voltage of TCM is displayed.
Engine speed ENGINE SPEED
[rpm]
XXIEngine speed, computed from
engine speed signal, is displayed.Engine speed display may not be
accurate under approx. 800 rpm. It
may not indicate 0 rpm even when
engine is not running.
Overdrive control switch OVERDRIVE SW
[ON/OFF]XÐION/OFF state computed from signal
of overdrive control SW is displayed.
P/N position switch P/N POSI SW
[ON/OFF]XÐION/OFF state computed from signal
of P/N position SW is displayed.
R position switch R POSITION SW
[ON/OFF]XÐION/OFF state computed from signal
of R position SW is displayed.
D position switch D POSITION SW
[ON/OFF]XÐION/OFF state computed from signal
of D position SW is displayed.
2 position switch 2 POSITION SW
[ON/OFF]XÐION/OFF status, computed from sig-
nal of 2 position SW, is displayed.
1 position switch 1 POSITION SW
[ON/OFF]XÐION/OFF status, computed from sig-
nal of 1 position SW, is displayed.
ASCD-cruise signal ASCD×CRUISE
[ON/OFF]
XÐIStatus of ASCD cruise signal is dis-
played.
ON ... Cruising state
OFF ... Normal running stateIThis is displayed even when no
ASCD is mounted.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
AT-20

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

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

qA
Does A/T shift from D3to D4at the speci-
fied speed?
Read gear position, throttle posi-
tion and vehicle speed.
Specified speed when shifting from
D
3to D4:
Refer to Shift schedule, AT-196.
Ye s
ENo
Go to ª14. A/T Does Not
Shift: D
3,D4º, AT-105.
Does A/T perform lock-up at the specified
speed?
Read vehicle speed, throttle posi-
tion when lock-up duty becomes
94%.
Specified speed when lock-up
occurs:
Refer to Shift schedule, AT-196.
Ye s
ENo
Go to ª15. A/T Does Not
Perform Lock-upº, AT-106.
Does A/T hold lock-up condition for more
than 30 seconds?
Ye s
ENo
Go to ª16. A/T Does Not
Hold Lock-up Conditionº,
AT-107.
1. Release accelerator pedal.
2. Is lock-up released when accelerator
pedal is released?
Ye s
ENo
Go to ª17. Lock-up Is Not
Releasedº, AT-107.
1. Decelerate vehicle by applying foot
brake lightly.
2. Does engine speed return to idle
smoothly when A/T is shifted from D
4to
D
3?
Read gear position and engine
speed.
Ye s
ENo
Go to ª18. Engine Speed
Does Not Return To Idle
(Light Braking D
4,D3)º,
AT-108.
1. Stop vehicle.
2. Go to ªCruise test Ð Part 2º, AT-41.
SAT402H
SAT403H
H
H
H
H
H
H
TROUBLE DIAGNOSIS Ð Basic Inspection
Road Test (Cont'd)
AT-40

CRUISE TEST Ð Part 3
1. Confirm overdrive control switch is in
ªONº position.
2. Confirm selector lever is in ªDº position.
Accelerate vehicle using half-throttle to D4.
Release accelerator pedal.
Set overdrive control switch to ªOFFº posi-
tion while driving in D
4.
Does A/T shift from D4to D3(O/D OFF)?Read gear position and vehicle
speed.
Ye s
ENo
Go to ª21. A/T Does Not
Shift: D
4,D3, When
Overdrive Control Switch
ªONº,ªOFFºº, AT-111.
Does vehicle decelerate by engine brake?
Ye s
ENo
Go to ª18. Engine Speed
Does Not Return To Idle
(Light Braking D
4,D3)º,
AT-108.
Move selector lever from ªDº to ª2º position
while driving in D
3(O/D OFF).
Does A/T shift from D3(O/D OFF) to 22?Read gear position.
Ye s
ENo
Go to ª22. A/T Does Not
Shift: D
3,22, When
Selector Lever ªDº,ª2º
Positionº, AT-111.
Does vehicle decelerate by engine brake?
Ye s
ENo
Go to ª18. Engine Speed
Does Not Return To Idle
(Light Braking D
4,D3)º,
AT-108.
1. Move selector lever from ª2º to ª1º posi-
tion while driving in 2
2.
2. Does A/T shift from 2
2to 11position?Read gear position.
Ye s
ENo
Go to ª23. A/T Does Not
Shift: 2
2,11, When
Selector Lever ª2º,ª1º
Positionº, AT-112.
Does vehicle decelerate by engine brake?
Ye s
ENo
Go to ª24. Vehicle Does
Not Decelerate By
Engine Brakeº, AT-112.
1. Stop vehicle.
2. Perform self-diagnosis. Refer to SELF-
DIAGNOSTIC PROCEDURE, AT-14.
SAT812A
SAT813A
SAT776BA
SAT791GA
SAT778B
H
H
H
H
H
H
H
H
H
H
H
TROUBLE DIAGNOSIS Ð Basic Inspection
Road Test (Cont'd)
AT-42

Throttle (accelerator) position switch
Closed throttle position switch (idle position)
ICheck continuity between terminalsq
5andq6.
Accelerator pedal condition Continuity
Released Yes
Depressed No
ITo adjust closed throttle (accelerator) position switch, refer to
EC section (ªBasic Inspectionº, ªTROUBLE DIAGNOSIS Ð
Basic Inspectionº).
Wide open throttle position switch
ICheck continuity between terminalsq
4andq5.
Accelerator pedal condition Continuity
Released No
Depressed Yes
A/T fluid temperature switch
1. Make sure the A/T fluid warning lamp lights when the key is
inserted and turned to ªONº.
2. Make sure the A/T fluid warning lamp goes off when turning the
ignition switch to ªONº.
3. For removal, refer to AT-113.
4. Check resistance between terminalq
6and ground while chang-
ing temperature as shown at left.
Temperature ÉC (ÉF) Continuity
140 (284) or more Yes
140 (284) or less No
YAT330
YAT331
YAT335
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Park/neutral Position, Overdrive Control or
Throttle (Accelerator) Position Switches
(Cont'd)
AT-93

18. Engine Speed Does Not Return To Idle
(Light Braking D
4®D3)
SYMPTOM:
IEngine speed does not smoothly return to idle when A/T
shifts from D
4to D3.
IVehicle does not decelerate by engine brake when turning
overdrive control switch OFF.
IVehicle does not decelerate by engine brake when shifting
A/T from ªDº to ª2º position.
Does self-diagnosis show damage to
overrun clutch solenoid valve circuit after
cruise test?
No
EYe s
Check overrun clutch sole-
noid valve. Refer to AT-69.
Check throttle (accelerator) position sen-
sor. Refer to EC section [TROUBLE
DIAGNOSIS FOR ªTHROTTLE (ACCEL)
POSI SENº].
OK
ENG
Repair or replace throttle
(accelerator) position sen-
sor.
1. Remove oil pan.
2. Check A/T fluid condition.
OK
ENG
1. Remove control valve
assembly. Refer to
AT-113.
2. Check the following
items:
IOverrun clutch control
valve
IOverrun clutch reducing
valve
IOverrun clutch solenoid
valve
3. Disassemble A/T.
4. Check the following
items:
IOverrun clutch assembly
IOil pump assembly
1. Remove control valve assembly. Refer
to AT-113.
2. Check the following items:
IOverrun clutch control valve
IOverrun clutch reducing valve
IOverrun clutch solenoid valve
OK
FOK
Check again.
OK
ENG
1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.
INSPECTION END
YAT338
NAT262
SAT171B
H
H
H
H H
H
DIAGNOSTIC PROCEDURES FOR SYMPTOMS
AT-108

23. A/T Does Not Shift: 22®11, When Selector
Lever ª2º®ª1º Position
SYMPTOM:
A/T does not shift from 22to 11when changing selector lever
from ª2º to ª1º position.
Does ªECU INPUT SIGNALSº in
Data Monitor show damage to park/
neutral position switch circuit?
-----------------------------------------------------------------------------------------------------------------------OR -----------------------------------------------------------------------------------------------------------------------
Does self-diagnosis show damage to
park/neutral position switch circuit?
No
EYe s
Check park/neutral position
switch circuit. Refer to
AT-92.
Check again.
OK
ENG
1. Perform TCM input/
output signal inspection.
2. If NG, recheck TCM pin
terminals for damage or
loose connection with
harness connector.
INSPECTION END
24. Vehicle Does Not Decelerate By Engine
Brake
SYMPTOM:
Vehicle does not decelerate by engine brake when shifting
from 2
2(12)to11.
Is 9. Vehicle Does Not Creep Backward In
ªRº Position OK?
Ye s
ENo
Go to 9. Vehicle Does Not
Creep Backward In ªRº
Position, AT-100.
Go to 18. Engine Speed Does Not Return
To Idle (Light Braking D
4,D3), AT-108.
SAT146BA
SAT778B
H
H
H
DIAGNOSTIC PROCEDURES FOR SYMPTOMS
AT-112

ITighten bolts securing transmission.
Bolt No.Tightening torque
N×m (kg-m, ft-lb)Bolt length ªº
mm (in)
q
139 - 49 (4.0 - 5.0, 29 - 36) 58.0 (2.28)
q
229 - 39 (3.0 - 4.0, 22 - 29) 90.0 (3.54)
q
318 - 22 (1.8 - 2.2, 13 - 16) 16.0 (0.63)
q
43 - 4 (0.3 - 0.4, 2.2 - 2.9) 12.0 (0.47)
q
529 - 39 (3.0 - 4.0, 22 - 29) 35.0 (1.38)
IReinstall any part removed.
ICheck fluid level in transmission.
IMove selector lever through all positions to be sure that trans-
mission operates correctly.
With parking brake applied, rotate engine at idling. Move selec-
tor lever through ªNº to ªDº, to ª2º, to ª1º and to ªRº positions.
A slight shock should be felt by hand gripping selector each
time transmission is shifted.
IPerform road test. Refer to ªROAD TESTº, AT-32.NAT287
SAT638A
REMOVAL AND INSTALLATION
Installation (Cont'd)
AT-118