rfd- NISSAN X-TRAIL 2005 Service Repair Manual

TROUBLE DIAGNOSIS FOR SYSTEM
TF-39
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4. CHECK 4WD SOLENOID
1. Turn ignition switch “OFF”.
2. Disconnect 4WD solenoid harness connector.
3. Check resistance between 4WD solenoid harness connector
B152 terminals 1 and 2.
OK or NG
OK >> GO TO 5.
NG >> 4WD solenoid is malfunctioning. Replace electric con-
trolled coupling. Refer to RFD-22, "
Disassembly and
Assembly" .
5. CHECK HARNESS BETWEEN 4WD CONTROL UNIT AND 4WD SOLENOID
1. Turn ignition switch “OFF”.
2. Disconnect 4WD control unit harness connector and 4WD solenoid harness connector.
3. Check continuity between the following terminals.
–4WD control unit harness connector M107 terminal 1 (OR) and
4WD solenoid harness connector B152 terminal 2 (LG).
–4WD control unit harness connector M107 terminal 2 (L/W) and
4WD solenoid harness connector B152 terminal 1 (L/W).
Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> Repair or replace damaged parts.
6. CHECK 4WD CONTROL UNIT
Check 4WD control unit input/output signal. Refer to TF-30, "
4WD Control Unit Input/Output Signal Reference
Va l u e s" .
OK or NG
OK >> GO TO 7.
NG >> Check 4WD control unit pin terminals for damage or loose connection with harness connector. If
any items are damaged, repair or replace damaged parts.
7. CHECK DTC
Perform the self-diagnosis, after driving a vehicle for a while.
OK or NG
OK >>INSPECTION END
NG >> Replace 4WD control unit.
COMPONENT INSPECTION
1. Turn ignition switch “OFF”.
2. Disconnect 4WD solenoid harness connector. 1 - 2 : Approx. 2.45Ω
SDIA3278E
1 (OR) - 2 (LG) : Continuity should exist.
2 (L/W) - 1 (L/W) : Continuity should exist.
SDIA3279E

TF-40
TROUBLE DIAGNOSIS FOR SYSTEM

3. Check resistance between 4WD solenoid harness connector
B152 terminals 1 and 2.
4. If NG, replace the electric controlled coupling. Refer to RFD-22,
"Disassembly and Assembly" .
4WD Actuator RelayEDS001VQ
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE
Data are reference value.
DIAGNOSTIC PROCEDURE

Check the following if “4WD ACTUATOR RLY [C1205]” is displayed in self-diagnosis results of CONSULT-
II.
1. CHECK 4WD SOLENOID SYSTEM
Perform self-diagnosis. Refer to TF-32, "
SELF-DIAG RESULT MODE" .
Is the
“4WD SOLENOID [C1204]” displayed?
YES >> Perform trouble diagnosis for 4WD solenoid. Refer to TF-37, "4WD Solenoid" .
NO >> GO TO 2.
2. CHECK 4WD ACTUATOR RELAY SIGNAL
With CONSULT-II
1. Turn ignition switch “ON”. (Do not start engine.)
2. Select “DATA MONITOR” mode for “ALL MODE AWD/4WD” with CONSULT-II.
3. Start engine and read out ON/OFF signaling action of “ETS
ACTUATOR”.
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.
3. CHECK 4WD CONTROL UNIT
Check 4WD control unit input/output signal. Refer to TF-30, "
4WD Control Unit Input/Output Signal Reference
Va l u e s" .
OK or NG
OK >> GO TO 4.
NG >> Check 4WD control unit pin terminals for damage or loose connection with harness connector. If
any items are damaged, repair or replace damaged parts. 1 - 2 : Approx. 2.45Ω
SDIA3278E
Monitor item Condition Display value
ETS ACTUATOR [ON/OFF]Engine stopped (Ignition switch: ON) OFF
Engine running ON
Monitor item Condition Display value
ETS ACTUATOREngine stopped (Ignition switch: ON) OFF
Engine running ON
SDIA1897E

TROUBLE DIAGNOSIS FOR SYMPTOMS
TF-51
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4. CHECK SYSTEM FOR 4WD SOLENOID
Perform trouble diagnosis for 4WD solenoid system. Refer to TF-37, "
4WD Solenoid" .
OK or NG
OK >> GO TO 5.
NG >> Repair or replace damaged parts.
5. CHECK ELECTRIC CONTROLLED COUPLING
1. Turn ignition switch “OFF”.
2. Set the selector lever (shift lever) to “N” (neutral) position and disengage the parking brake.
3. Lift up the vehicle.
4. Rotate the propeller shaft by hand.
5. Hold rear wheel of right and left lightly.
Does rear wheel rotate?
YES >> Replace electric controlled coupling for mechanical malfunction (clutch sticking etc.). Refer to
RFD-22, "
Disassembly and Assembly" .
NO >> GO TO 6.
6. SYMPTOM CHECK
Check again.
OK or NG
OK >>INSPECTION END
NG >> GO TO 7.
7. CHECK 4WD CONTROL UNIT
Check 4WD control unit input/output signal. Refer to TF-30, "
4WD Control Unit Input/Output Signal Reference
Va l u e s" .
OK or NG
OK >>INSPECTION END
NG >> Check 4WD control unit pin terminals for damage or loose connection with harness connector. If
any items are damaged, repair or replace damaged parts.
Vehicle Does Not Enter 4WD Mode Even Though 4WD Warning Lamp Turned to
OFF
EDS001VY
CAUTION:
Make sure that parking brake is securely released if the symptom has occurred at vehicle speed of 10
km/h (6 MPH) or more.

TF-52
TROUBLE DIAGNOSIS FOR SYMPTOMS

DIAGNOSTIC PROCEDURE
1. CHECK PARKING BRAKE SWITCH SIGNAL
With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “DATA MONITOR” mode for “ALL MODE AWD/4WD” with CONSULT-II.
3. Operate parking brake and read out monitor “P BRAKE SW”.
OK or NG
OK >> GO TO 2.
NG >> Check the following. If any items are damaged, repair or
replace damaged parts.

Parking brake switch

Brake warning lamp circuit. Refer to DI-36, "Wiring
Diagram — WARN —/LHD Models" or DI-44, "Wiring Diagram — WARN —/RHD Models" .
2. CHECK 4WD SOLENOID
Check 4WD solenoid. Refer to TF-39, "
COMPONENT INSPECTION" .
OK or NG
OK >> GO TO 3.
NG >> Replace electric controlled coupling for malfunction of 4WD solenoid. Refer to RFD-22, "
Disas-
sembly and Assembly" .
3. CHECK 4WD CONTROL UNIT
Check 4WD control unit input/output signal. Refer to TF-30, "
4WD Control Unit Input/Output Signal Reference
Va l u e s" .
OK or NG
OK >> GO TO 4.
NG >> Check 4WD control unit pin terminals for damage or loose connection with harness connector. If
any items are damaged, repair or replace damaged parts.
4. SYMPTOM CHECK
Check again.
OK or NG
OK >>INSPECTION END
NG >> Replace electric controlled coupling for mechanical malfunction (mechanical engagement of
clutch is not possible.). Refer to RFD-22, "
Disassembly and Assembly" .
While Driving, 4WD Warning Lamp Flashes Rapidly (When Flashing in Approx.
1 Minute and Then Turning OFF)
EDS001VZ
NOTE:
Rapid flashing: 2 times/second
This symptom protects drivetrain parts when a heavy load is applied to the electric controlled coupling and
multiple disc clutch temperature increases. It is not a malfunction.
When this symptom occurs, stop vehicle and allow it to idle for some times. Flashing will stop and system will
be restored.
Monitor item Condition Display value
P BRAKE SWParking brake operated ON
Parking brake not operated OFF
SDIA1933E

RFD-1
REAR FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
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SECTION RFD
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B
RFD

REAR FINAL DRIVE
PRECAUTIONS .......................................................... 2
Service Notice or Precautions .................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 6
NVH Troubleshooting Chart ..................................... 6
REAR FINAL DRIVE SYSTEM ................................... 7
Sectional View .......................................................... 7
DIFFERENTIAL GEAR OIL ........................................ 8
Changing Differential Gear Oil ................................. 8
DRAINING ............................................................. 8
FILLING ................................................................. 8
Checking Differential Gear Oil .................................. 8
OIL LEAKAGE AND OIL LEVEL ........................... 8
FRONT OIL SEAL ...................................................... 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9
SIDE OIL SEAL .........................................................11
Removal and Installation ......................................... 11
REMOVAL ............................................................ 11
INSTALLATION .................................................... 11
ELECTRIC CONTROLLED COUPLING .................. 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 13REAR FINAL DRIVE ASSEMBLY ............................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 15
Components ........................................................... 16
Pre-Inspection ........................................................ 17
TOTAL PRELOAD ............................................... 17
DRIVE GEAR TO DRIVE PINION BACKLASH ... 18
DRIVE GEAR RUNOUT ...................................... 19
COMPANION FLANGE RUNOUT ....................... 19
TOOTH CONTACT .............................................. 19
Disassembly and Assembly .................................... 22
DISASSEMBLY ................................................... 22
ASSEMBLY ......................................................... 25
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 32
General Specification ............................................. 32
Drive Gear Vibration ............................................... 32
Total Preload ........................................................... 32
Side Gear Clearance Adjustment ........................... 32
Drive Pinion Gear Preload Adjustment ................... 32
Side Bearing Preload Adjustment ........................... 32
THRUST WASHER FOR ADJUSTMENT OF SIDE
GEAR BACK CLEARANCE .................................... 32
DRIVE PINION GEAR PRELOAD ADJUSTING
SHIM ....................................................................... 32
ADJUSTING SHIM FOR SIDE BEARING PRE-
LOAD ...................................................................... 33

RFD-2
PRECAUTIONS

PRECAUTIONSPFP:00001
Service Notice or PrecautionsEDS001YY

Check for the correct installation status prior to removal or disassembly. If matching marks are required,
be certain they do not interfere with the function of the parts when applied.

Overhaul should be done in a clean work area, it is preferable to work in dustproof area.

Before disassembly, using steam or white gasoline, completely remove sand and mud from the exterior of
the unit, preventing them from entering into the unit during disassembly or assembly.

Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary.

Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.

In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.

Clean and flush the parts sufficiently and blow-dry them.

Be careful not to damage sliding surfaces and mating surfaces.

When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.

Always use shop paper for cleaning the inside of components.

Avoid using cotton gloves or shop rags to prevent entering of lint.

During assembly, observe the specified tightening torque, and apply new differential oil, petroleum jelly, or
multi-purpose grease as specified for each vehicle, if necessary.

PREPARATION
RFD-3
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RFD

PREPARATIONPFP:00002
Special Service ToolsEDS002VE
Tool number
Tool nameDescription
ST27861000
Drift
a: 62 mm (2.44 in) dia.
b: 52 mm (2.05 in) dia.Installing final drive front oil seal
KV38100200
Drift
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.

Installing final drive front oil seal

Installing final drive side oil seal
ST3127S000
Preload gaugeMeasuring preload torque
ST33052000
Drift
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.Removing side bearing inner race
ST33230000
Drift
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.
c: 28.5 mm (1.122 in) dia.Installing pinion front bearing outer race
ST23860000
Drift
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.

Installing pinion rear bearing inner race

Installing pinion front bearing inner race
ST35271000
Drift
a: 72 mm (2.83 in) dia.
b: 63 mm (2.48 in) dia.Installing center oil seal
ZZA0832D
ZZA1143D
ZZA0503D
ZZA1023D
ZZA1046D
ZZA0534D
ZZA0814D

RFD-4
PREPARATION

Commercial Service ToolsEDS002VF
ST22360002
Drift
a: 29 mm (1.14 in) dia.
b: 23 mm (0.91 in) dia.
c: 150 mm (5.91 in)Installing coupling front bearing
KV389L0010
Dummy cover set

Checking backlash

Checking drive gear runout

Checking tooth contact
KV38108500
Drive pinion socket

Measuring preload torque

Removing and installing drive pinion nut
KV38108400
Pinion nut wrench

Measuring preload torque

Removing drive pinion nut Tool number
Tool nameDescription
ZZA0546D
PDIA0894E
ZZA1205D
ZZA1206D
Tool nameDescription
Flange wrench Removing and installing companion flange
lock nut
Drift
a: 54.5 mm (2.146 in) dia.Removing and installing carrier case and rear
cover (2 pieces are used)
Pin punch
a: 4.5 mm (0.177 in) dia.Removing and installing lock pin
NT771
PDIA0893E
NT410

PREPARATION
RFD-5
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Drift
a: 62 mm (2.44 in) dia.Installing pinion rear bearing outer race
Sta ndInstalling pinion front bearing inner race
Drift
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.Installing side bearing inner race
Power toolLoosening nuts and bolts Tool nameDescription
NT109
ZZA1050D
ZZA0936D
PBIC0190E

RFD-6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS001Z1
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: ApplicableReference page
Refer to RFD-24, "
INSPECTION
" .
Refer to RFD-19, "
TOOTH CONTACT
" .
Refer to RFD-24, "
INSPECTION
" .
Refer to RFD-18, "
DRIVE GEAR TO DRIVE PINION BACKLASH
" .
Refer to RFD-19, "
COMPANION FLANGE RUNOUT
" .
Refer to RFD-8, "
Checking Differential Gear Oil
" .
NVH in PR section.
NVH in FAX, RAX, FSU and RSU sections.
NVH in WT section.
NVH in WT section.
NVH in FAX and RAX section.
NVH in BR section.
NVH in PS section.
Possible cause and SUSPECTED PARTS
Gear tooth rough
Gear contact improper
Tooth surfaces worn
Backlash incorrect
Companion flange excessive runout
Gear oil improper
PROPELLER SHAFT
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
STEERING
Symptom Noise×××××××××××××