2004 INFINITI QX56 clutch

TF-1
TRANSFER
D DRIVELINE/AXLE
CONTENTS
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TF
Revision: August 20072004 QX56 PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 7
PRECAUTIONS .......................................................... 8
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 8
Precautions .............................................................. 8
Service Notice .......................................................... 9
Wiring Diagrams and Trouble Diagnosis .................. 9
ALL-MODE 4WD SYSTEM ...................................... 10
Cross-sectional View .............................................. 10
Control System ........................................................11
ALL-MODE 4WD TRANSFER BASIC CONTROL
... 12
HYDRAULIC CONTROL CIRCUITS ................... 12
OUTLINE ............................................................. 12
CONTROL SYSTEM DIAGRAM ......................... 13
INDICATIONS OF 4WD WARNING LAMP ......... 13
CAN Communication .............................................. 13
SYSTEM DESCRIPTION .................................... 13
Location of Electrical Parts ..................................... 14
Description of Electrical Parts ................................ 15
TRANSFER MOTOR .......................................... 15
WAIT DETECTION SWITCH .............................. 15
2-4WD SHIFT SOLENOID VALVE ...................... 15
LINE PRESSURE SWITCH ................................ 16
Circuit Diagram for Quick Pinpoint Check .............. 17
Wiring Diagram — T/F — ....................................... 18
ON BOARD DIAGNOSTIC SYSTEM DESCRIP-
TION .......................................................................... 27
Trouble Diagnosis without CONSULT-II ................. 27
DESCRIPTION .................................................... 27
SELF-DIAGNOSTIC PROCEDURE .................... 28
INDICATIONS OF 4WD WARNING LAMP ......... 28CONSULT-II Function (ALL MODE AWD/4WD) ..... 31
Trouble Diagnosis with CONSULT-II ...................... 31
SELF-DIAGNOSIS .............................................. 31
SELF-DIAGNOSTIC ITEMS ................................ 32
DATA MONITOR ................................................. 34
DATA MONITOR ITEMS ..................................... 35
REFERENCE VALUE IN DATA MONITOR MODE
... 38
WORK SUPPORT ............................................... 41
CLUTCH FORCE RELEASE LIMIT ADJUST-
MENT .................................................................. 42
TROUBLE DIAGNOSIS — INTRODUCTION ........... 44
Introduction ............................................................. 44
DESCRIPTION .................................................... 44
DIAGNOSTIC WORKSHEET .............................. 44
Work Flow ............................................................... 46
HOW TO PERFORM TROUBLE DIAGNOSES
FOR QUICK AND ACCURATE REPAIR ............. 46
TROUBLE DIAGNOSIS — BASIC INSPECTION .... 47
Listen to Customer Complaints .............................. 47
Transfer Fluid Check .............................................. 47
Road Test ............................................................... 47
PREPARATION FOR ROAD TEST ..................... 47
1. CHECK BEFORE ENGINE IS STARTED ....... 48
2. CHECK AT IDLE .............................................. 49
3. CRUISE TEST ................................................. 53
TROUBLE DIAGNOSIS — GENERAL DESCRIP-
TION .......................................................................... 55
Transfer Control Unit Terminals and Reference
Value ....................................................................... 55
TRANSFER CONTROL UNIT HARNESS CON-
NECTOR LAYOUT .............................................. 55
TRANSFER CONTROL UNIT INSPECTION
TABLE ................................................................. 55
DTC U1000, U1001 CAN COMMUNICATION LINE ... 59
CAN Communication System Inspection ................ 59
4WD SOLENOID VALVE .......................................... 60
Diagnostic Procedure ............................................. 60
2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT

TF-2Revision: August 20072004 QX56 SWITCH ..................................................................... 62
Diagnostic Procedure ............................................. 62
TRANSFER MOTOR AND TRANSFER MOTOR
RELAY ....................................................................... 64
Diagnostic Procedure ............................................. 64
TRANSFER FLUID TEMPERATURE SENSOR ....... 66
Diagnostic Procedure ............................................. 66
ATP SWITCH, WAIT DETECTION SWITCH AND
NEUTRAL-4LO SWITCH .......................................... 69
Diagnostic Procedure ............................................. 69
CLUTCH PRESSURE SWITCH ................................ 72
Diagnostic Procedure ............................................. 72
LINE PRESSURE SWITCH ....................................... 74
Diagnostic Procedure ............................................. 74
DATA ERASE/DISPLAY ............................................ 76
Diagnostic Procedure ............................................. 76
SHIFT ACTUATOR ................................................... 77
Diagnostic Procedure ............................................. 77
SHIFT ACTUATOR POSITION SWITCH .................. 80
Diagnostic Procedure ............................................. 80
SHIFT ACTUATOR CIRCUIT .................................... 82
Diagnostic Procedure ............................................. 82
TROUBLE DIAGNOSES FOR SYMPTOMS ............. 85
Symptom 1. 4WD Shift Indicator Lamp Does Not
Turn ON (Although the ignition switch is turned ON,
all the 4WD indicator lamps do not turn ON for 1
second) ................................................................... 85
Symptom 2. 4WD Warning Lamp Does Not Turn ON
(Although the ignition switch is turned ON, the 4WD
warning lamp does not turn ON) ............................. 87
Symptom 3. 4WD Shift Indicator Lamp Does Not
Turn OFF (When 4WD shift switch is set from 4H
to 4LO, all the 4WD shift indicator lamps do not turn
off) ........................................................................... 88
Symptom 4. ATP Warning Lamp Does Not Turn ON
(When 4WD shift switch is set from 4H to 4LO with
the A/T selector lever in P position, the ATP warning
lamp does not turn on) ............................................ 89
Symptom 5. 4LO Indicator Lamp Does Not Turn ON
(When 4WD shift switch is set from 4H to 4LO posi-
tion, 4LO indicator lamp does not turn ON) ............ 90
Symptom 6. 4WD Shift Indicator Lamp Does Not
Indicate “LOCK” (When 4WD shift switch is set to
“4H”, 4WD shift indicator lamp does not indicate
“LOCK”) .................................................................. 91
Symptom 7. 4WD Shift Indicator Lamp Repeats
Flickering (4WD Shift Indicator Lamp Keeps Flick-
ering) ...................................................................... 92
Symptom 8. Tight Corner Braking Symptom (Tight
Corner Braking Symptom Occurs-Hydraulic Sys-
tem Failure) ............................................................ 93
Symptom 9. 4WD System Does Not Operate (The
Vehicle Cannot Be Put Into 4WD Mode-Hydraulic
System Failure) ...................................................... 94
Component Inspection ............................................ 95
4WD SHIFT SWITCH .......................................... 95
2-4WD SHIFT SOLENOID VALVE AND TRANS-
FER FLUID TEMPERATURE SENSOR .............. 95
4WD SOLENOID VALVE, CLUTCH PRESSURE SWITCH AND LINE PRESSURE SWITCH .........95
TRANSFER DROPPING RESISTOR ..................96
ATP SWITCH, NEUTRAL-4LO SWITCH AND
WAIT DETECTION SWITCH ...............................96
TRANSFER MOTOR ...........................................96
TRANSFER MOTOR RELAY ...............................97
TRANSFER SHIFT RELAY (HIGH & LOW) .........97
ACTUATOR AND ACTUATOR POSITION
SWITCH ...............................................................97
TRANSFER CONTROL UNIT ...................................98
Removal and Installation .........................................98
REMOVAL ............................................................98
INSTALLATION ....................................................98
FRONT OIL SEAL .....................................................99
Removal and Installation .........................................99
REMOVAL ............................................................99
INSTALLATION .................................................. 100
REAR OIL SEAL ..................................................... 101
Removal and Installation ....................................... 101
REMOVAL .......................................................... 101
INSTALLATION .................................................. 101
SIDE OIL SEAL ....................................................... 103
Removal and Installation ....................................... 103
REMOVAL .......................................................... 103
INSTALLATION .................................................. 103
TRANSFER CONTROL DEVICE ............................ 104
Removal and Installation ....................................... 104
AIR BREATHER HOSE ........................................... 105
Removal and Installation ....................................... 105
TRANSFER MOTOR ............................................... 106
Removal and Installation ....................................... 106
REMOVAL .......................................................... 106
INSTALLATION ..................................................... 106
TRANSFER OIL FILTER ......................................... 107
Removal and Installation ....................................... 107
REMOVAL .......................................................... 107
INSTALLATION .................................................. 107
REMOVAL AND INSTALLATION ............................ 109
Removal ................................................................ 109
Installation ............................................................. 109
OVERHAUL .............................................................110
Transfer Components ...........................................110
REAR CASE ............................................................112
Disassembly ..........................................................112
CENTER CASE .......................................................113
Disassembly ..........................................................113
FRONT DRIVE SHAFT AND DRIVE CHAIN .....115
MAINSHAFT AND CLUTCH DRUM ..................116
CLUTCH PISTON ..............................................118
CONTROL VALVE .............................................119
MAINSHAFT REAR BEARING .......................... 122
MAIN OIL PUMP ................................................ 122
SUB OIL PUMP ................................................. 123
OIL FILTER ........................................................ 124
FRONT CASE .......................................................... 125
Disassembly .......................................................... 125
SHIFT ROD COMPONENTS ............................. 125
PLANETARY CARRIER, SUN GEAR AND
INTERNAL GEAR .............................................. 127

TF-3
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Revision: August 20072004 QX56 FRONT CASE ......................................................... 131
Inspection ............................................................. 131
PLANETARY CARRIER .................................... 131
SUN GEAR ....................................................... 131
INTERNAL GEAR ............................................. 131
SHIFT ROD COMPONENTS ............................ 131
CENTER CASE ...................................................... 133
Inspection ............................................................. 133
BEARINGS ........................................................ 133
SUB-OIL PUMP ................................................ 133
MAIN OIL PUMP ............................................... 133
MAINSHAFT ..................................................... 133
CONTROL VALVE ............................................ 134
CLUTCH ............................................................ 134
FRONT CASE ......................................................... 136
Assembly .............................................................. 136
PLANETARY CARRIER, SUN GEAR AND
INTERNAL GEAR ............................................. 136
SHIFT ROD ASSEMBLY ................................... 139CENTER CASE .......................................................140
Assembly ..............................................................140
OIL FILTER ........................................................140
SUB OIL PUMP .................................................140
MAIN OIL PUMP ...............................................141
CONTROL VALVE .............................................142
CLUTCH PISTON ..............................................144
MAINSHAFT AND CLUTCH DRUM ..................145
FRONT DRIVE SHAFT AND DRIVE CHAIN .....148
ASSEMBLY .............................................................149
Final Assembly .....................................................149
SERVICE DATA AND SPECIFICATIONS (SDS) ....153
General Specifications ..........................................153
Inspection and Adjustment ...................................153
CLEARANCE BETWEEN INNER GEAR AND
OUTER GEAR ...................................................153
CLUTCH ............................................................153
PINION GEAR END PLAY ................................153
CLEARANCE BETWEEN SHIFT FORK AND
SLEEVE ............................................................153
SELECTIVE PARTS ..........................................153

TF-10
ALL-MODE 4WD SYSTEM
Revision: August 20072004 QX56
ALL-MODE 4WD SYSTEMPFP:00000
Cross-sectional ViewEDS0017N
LDIA0053E
1. Center case 2. Chain 3. Multiple disc clutch
4. Rear case 5. Main shaft 6. Clutch hub assembly
7. Sub oil pump 8. Transfer motor 9. Control valve
10. Front drive shaft 11. Drain plug 12. 2-4 sleeve
13. Sun gear assembly 14. L-H sleeve 15. Planetary carrier assembly
16. Internal gear 17. Front case

ALL-MODE 4WD SYSTEM
TF-15
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Revision: August 20072004 QX56
Description of Electrical PartsEDS0017R
TRANSFER MOTOR
1. The transfer motor drives the sub-oil pump to provide proper lubrication and oil pressure control when the
vehicle is at standstill, during low-speed operations or is being driven in reverse.
2. The main oil pump is operated by the driving force of the mainshaft. In other words, sufficient oil pressure
buildup does not occur when the vehicle is at standstill or during low-speed operations. While the vehicle
is being driven in reverse, the main oil pump rotates in the reverse direction. Therefore the main oil pump
does not discharge oil pressure. During any of the above vehicle operations, the transfer motor drives the
sub-oil pump to compensate for insufficient oil pressure.
3. The transfer motor operates as follows:
1. The motor relay turns OFF in the 2WD mode.
2. The motor relay operates as described in the table below in modes other than the 2WD mode.
Ta b l e 1
Ta b l e 2
NOTE:
OFF (after 2.5 seconds have elapsed.)
4. 4WD shift switch, PNP switch, Neutral-4LO switch, vehicle speed sensor and throttle position sensor are
used in conjunction with the transfer motor.
WAIT DETECTION SWITCH
1. The wait detection switch releases the “booming” torque produced in the propeller shaft. After the release
of the “booming” torque, the wait detection switch helps provide the 4WD lock gear (clutch drum) shifts. A
difference may occur between the operation (“4LO” to “4H” shift only) of the 4WD shift switch and actual
drive mode. At this point, the wait detection switch senses an actual drive mode.
2. The wait detection switch operates as follows:
4WD lock gear (clutch drum) locked: ON
4WD lock gear (clutch drum) released: OFF
3. The wait detection switch senses an actual drive mode and the 4WD shift indicator lamp indicates the
vehicle drive mode.
2-4WD SHIFT SOLENOID VALVE
The 2-4WD shift solenoid valve operates to apply oil pressure to the wet, multiplate clutch, depending on the
drive mode. The driving force is transmitted to the front wheels through the clutch when the vehicle is set in the
4WD mode. Setting the vehicle in the 2WD mode requires no pressure buildup. In other words, pressure force
applied to the wet, multiplate clutch becomes zero.
PNP switch “R” position VFF (Vehicle speed) A/T position Motor relay drive command
ON — R ON
OFF0Positions other than the “P” or
“N” positionsON
—“P” or “N” position (See Table
2.)—
0 < VFF ≤ 50 km/h (31 MPH) — ON
50 km/h (31 MPH) < VFF < 55
km/h (34 MPH)—HOLD
55 km/h (34 MPH) ≤ VFF — OFF
A/T position N-4L SW 4WD modeThrottle position
0 - 0.07/8 0.07/8 - 1/8 1/8 - MAX
NOFFLOCK (4H) ON ON ON
Positions other than
the LOCK position
(2WD or AUTO)See NOTE. HOLD ON
ON — See NOTE. HOLD ON
P——See NOTE.HOLDON

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
TF-29
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Revision: August 20072004 QX56
Flickering pattern or flick-
ering conditionMalfunction Check items
2 Rear revolution sensor circuit is shorted or open.Refer to AT- 11 2 , "
DTC P0720 VEHI-
CLE SPEED SENSOR A/T (REVO-
LUTION SENSOR)" .
3 4WD solenoid valve circuit is shorted or open.Refer to TF-60, "
Diagnostic Proce-
dure" .
42-4WD shift solenoid valve circuit is shorted or 2WD switch of
4WD shift switch is shorted.Refer to TF-62, "
Diagnostic Proce-
dure" .
5 Transfer motor relay circuit is shorted or open.Refer to TF-64, "
Diagnostic Proce-
dure" .
6If unexpected signal is detected because of ABS wheel sensor
malfunction or communications error within the vehicle.Refer to BRC-38, "
Wheel Sensor
System Inspection" .
7 When malfunction in CAN communication system is detected.Refer to LAN-5, "
CAN COMMUNICA-
TION" .
8 A/D converter of transfer control unit functions improperly.Refer to EC-351, "
DTC P0605 ECM"
.
9 Transfer fluid temperature sensor circuit is open.Refer to TF-66, "
Diagnostic Proce-
dure" .
10 Neutral-4LO switch circuit is shorted or open.Refer to TF-69, "
Diagnostic Proce-
dure" .
112-4WD shift solenoid valve circuit, 2WD switch of 4WD shift
switch circuit or clutch pressure switch circuit is shorted or open.Refer to TF-62, "
Diagnostic Proce-
dure" or TF-72, "Diagnostic Proce-
dure" .
12 Line pressure switch circuit is shorted or open.Refer to TF-74, "
Diagnostic Proce-
dure" .
13 Engine speed signal circuit is shorted or open.Refer to AT- 11 5 , "
DTC P0725
ENGINE SPEED SIGNAL" .
14 Throttle position sensor circuit is shorted or open.Refer to EC-351, "
DTC P0605 ECM"
.
15 Malfunction in power supply circuit of transfer control unit. Power supply of transfer control unit
16 4WD shift switch circuit is shorted.Refer to TF-62, "
Diagnostic Proce-
dure" .
17 ABS operation signal circuit is shorted.Refer to BRC-54, "
CAN Communica-
tion System Inspection" .
18ATP switch, wait detection switch or neutral-4LO switch circuit is
shorted or open.Refer to TF-69, "
Diagnostic Proce-
dure" .
19Transfer control device actuator motor is malfunctioning. (Mal-
functions are detected when actuator motor fails to operate while
shifting from “4H” to “4LO” or vice versa.)Refer to TF-77, "
Diagnostic Proce-
dure" or TF-82, "Diagnostic Proce-
dure" .
20Transfer control device actuator motor arm position sensing
switch is malfunctioning.Refer to TF-80, "
Diagnostic Proce-
dure" or TF-82, "Diagnostic Proce-
dure" .
21Transfer control device actuator circuit is shorted or open. (Mal-
functions are detected when motor relay circuit is open/shorted or
relay monitor circuit is open/shorted.)Refer to TF-77, "
Diagnostic Proce-
dure" , TF-80, "Diagnostic Proce-
dure" or TF-82, "Diagnostic
Procedure" .
22If VDC operation signal is being input because of VDC malfunc-
tion or communication error within the vehicle.Refer to BRC-40, "
ABS/TCS/VDC
Control Unit Inspection" .
23If TCS operation signal is being input because of TCS malfunction
or communication error within the vehicle.Refer to BRC-40, "
ABS/TCS/VDC
Control Unit Inspection" .
24If unexpected signal is input because of AT PNP switch circuit or
communication error within the vehicle.Refer to AT- 1 0 9 , "
DTC P0705 PARK/
NEUTRAL POSITION SWITCH" .
Repeats flickering every
2 to 5 sec.Circuits that the self-diagnosis covers have no malfunction. —

TF-32
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Revision: August 20072004 QX56
6. Touch “SELF-DIAG RESULTS” on SELECT DIAG MODE
screen.
7. Self-diagnostic results are displayed.
SELF-DIAGNOSTIC ITEMS
BCIA0031E
Detected items
(Screen terms for CONSULT-II,
“SELF-DIAG RESULT” mode)Malfunction is detected when... Check items
Revolution sensor (rear)
(VHCL SPEED SEN·RR)

Signal from vehicle speed sensor 1 (installed on A/T) is
not input due to open circuit.

Improper signal is input while driving.Refer to AT- 11 2 , "
DTC P0720
VEHICLE SPEED SENSOR A/T
(REVOLUTION SENSOR)" .
4WD solenoid valve
(DUTY SOLENOID)

Proper voltage is not applied to solenoid valve due to
open or short circuit.Refer to TF-60, "
Diagnostic Proce-
dure" .
2-4WD shift solenoid valve
(2-4WD SOLENOID)Refer to TF-62, "
Diagnostic Proce-
dure" .
Tran s fe r mo to r re lay
(MOTOR RELAY)

Motor does not operate properly due to open or short cir-
cuit in transfer motor or motor relay.Refer to TF-64, "Diagnostic Proce-
dure" .
Transfer fluid temperature sensor
(FLUID TEMP SENSOR)

Signal voltage from fluid temperature sensor is abnor-
mally high (T/F fluid temperature is abnormally low)
while driving.Refer to TF-66, "Diagnostic Proce-
dure" .
Neutral-4LO switch
(N POSI SW TF)

Improper signal is input while driving.Refer to TF-69, "Diagnostic Proce-
dure" .
Clutch pressure
(CLUTCH PRESSURE)

Improper signal is input due to open or short circuit.

Malfunction occurs in clutch pressure hydraulic circuit.(*1) Refer to TF-72, "
Diagnostic
Procedure" .
Line pressure
(LINE PRESSURE)

Improper signal is input due to open or short circuit.

Malfunction occurs in line pressure hydraulic circuit.(*1) Refer to TF-74, "
Diagnostic
Procedure" .
Engine speed signal (Note 1)
(ENGINE SPEED SIG)

Engine speed is abnormally low while driving.Refer to AT- 11 5 , "DTC P0725
ENGINE SPEED SIGNAL" .
Throttle position sensor
(THRTL POSI SEN)

Signal voltage from throttle position sensor is abnormally
high.

Signal voltage from throttle position sensor is abnormally
low when closed throttle position switch is OFF.Refer to EC-351, "
DTC P0605
ECM" .
Transfer control unit (ADC)
C/U (ADC)/THRTL SEN

Power supply voltage for A/D converter system of trans-
fer control unit is malfunctioning.Refer to EC-351, "DTC P0605
ECM" .
Battery voltage (Note 1)
(BATTERY VOLTAGE)

Power supply voltage for transfer control unit is abnor-
mally low while driving.Refer to TF-18, "Wiring Diagram —
T/F —" .
4WD shift switch
(4WD MODE SW)

More than two switch inputs are simultaneously detected
due to short circuit of 4WD shift switch.Refer to TF-62, "Diagnostic Proce-
dure" .
ABS operation signal (Note 4)
(ABS OPER SIGNAL)

When a malfunction signal due to disconnection or
shorting is detected.

When a defect signal is entered from the ABS control
unit.Refer to BRC-54, "
CAN Communi-
cation System Inspection" .
Wait detection switch (Note 2)
(WAIT DETECT SWITCH)

Improper signal is input due to open or short circuit.(*2) Refer to TF-69, "Diagnostic
Procedure" .

TF-36
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Revision: August 20072004 QX56
N position switch TF [ON-OFF] N position switch of transfer
Line pressure switch [ON-OFF] Line pressure switch
Clutch pressure switch [ON-OFF] Clutch pressure switch
ATP switch [ON-OFF]—
N position switch AT [ON-OFF] “N” position on A/T PNP switch
R position switch AT [ON-OFF] “R” position on A/T PNP switch
P position switch AT [ON-OFF] “P” position on A/T PNP switch
ABS operation switch [ON-OFF] ABS operation switch
Wait detection switch [ON-OFF] —
Throttle positionThrottle opening recognized by transfer
control unit
4WD-mode4WD-mode recognized by transfer control
unit (2WD, AUTO, 4H & 4LO)
Vehicle speed comp [km/h (MPH)]Vehicle speed recognized by transfer con-
trol unit
*Control torque [N·m (kg-m, ft.-lb.)]Calculated torque recognized by transfer
control unit
Duty solenoid valve [%]
(Transfer 4WD solenoid valve)—
2-4WD shift solenoid valve [ON-
OFF]
Control signal outputs of transfer control
unit Transfer motor relay [ON-OFF]
Shift activating 1 [ON-OFF]
Shift activating 2 [ON-OFF]
2-4WD shift solenoid valve monitor
[ON-OFF]
Check signal (re-input signal) of transfer
control unit control signal output is dis-
played. If circuit is shorted or open, ON/OFF
state does not change. Transfer motor relay monitor [ON-
OFF]
Shift activating monitor 1 [ON-OFF]
Shift activating monitor 2 [ON-OFF]
4WD fail lamp [ON-OFF]Transfer control unit control signal output for
4WD warning lamp (left)
Shift position switch 1 [ON-OFF] —
Shift position switch 2 [ON-OFF] —
2WD indicator lamp [ON-OFF]Transfer control unit control signal output for
4WD shift indicator lamp (rear)
AUTO indicator lamp [ON-OFF]Transfer control unit control signal output for
4WD shift indicator lamp (front & rear)
LOCK indicator lamp [ON-OFF]Transfer control unit control signal output for
4WD shift indicator lamp (center)
4LO indicator lamp [ON-OFF]Transfer control unit control signal output for
4WD shift indicator lamp (right) Item [Unit]Monitor item
Remarks ECU
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