2004 INFINITI QX56 fluid

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

PRECAUTIONS
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Revision: August 20072004 QX56
Service NoticeEDS0017L
1. Before proceeding with disassembly, thoroughly clean the outside of the all-mode 4WD transfer. It is
important to prevent the internal parts from becoming contaminated by dirt or other foreign matter.
2. Disassembly should be done in a clean work area.
3. Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere
with the operation of the all-mode 4WD transfer.
4. Place disassembled parts in order for easier and proper assembly.
5. All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
6. Gaskets, seals and O-rings should be replaced any time the all-mode 4WD transfer is disassembled.
7. It is very important to perform functional tests whenever they are indicated.
8. The valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place removed parts in a parts rack in order to replace them in correct positions and sequences. Care will
also prevent springs and small parts from becoming scattered or lost.
9. Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
10. Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, and to hold bearings and washers in place during assembly. Do not use grease.
11. Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
12. After overhaul, refill the transfer with new ATF.
13. When the all-mode 4WD transfer drain plug is removed, only some of the fluid is drained. Old all-mode
4WD transfer fluid will remain in torque converter and ATF cooling system. Always follow the proper pro-
cedure. Refer to MA-24, "
Changing Transfer Fluid" .
Wiring Diagrams and Trouble DiagnosisEDS001CE
When you read wiring diagrams, refer to the following:

GI-15, "How to Read Wiring Diagrams" .

PG-4, "POWER SUPPLY ROUTING CIRCUIT" for power distribution circuit.
When you perform trouble diagnosis, refer to the following:

GI-11, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES".

GI-27, "How to Perform Efficient Diagnosis for an Electrical Incident".

ALL-MODE 4WD SYSTEM
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Revision: August 20072004 QX56
CONTROL SYSTEM DIAGRAM
INDICATIONS OF 4WD WARNING LAMP
*: When 4WD warning lamp is ON, all the 4WD shift indicator lamps turn OFF.
CAN CommunicationEDS0017P
SYSTEM DESCRIPTION
Refer to LAN-5, "CAN COMMUNICATION" .
WDIA0075E
Condition Content 4WD warning lamp
During self-diagnosis Indicates the malfunction position by number of flickers. Flickers at malfunction mode.
Lamp check*Checks the lamp by turning ON during engine starting. After
engine starts, it turns OFF if there are no malfunctions.ON
Malfunction in 4WD system*Turns ON to indicate malfunction. When ignition switch is
turned to “OFF” or the malfunction is corrected, it turns OFF.ON
When vehicle is driven with different
diameters of front and rear tiresFlickers once every 2 seconds.
Turns OFF when ignition switch is “OFF”.Flickers once every 2 sec-
onds.
High fluid temperature in transfer unitWhen fluid temperature is high or fluid temperature sensor cir-
cuit is shorted, it flickers twice every second.
It turns OFF when fluid temperature becomes normal.Flickers twice a second.
Other than above (System is nor-
mal.)Lamp is OFF. OFF

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
TF-29
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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" .

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
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7. Touch “ECU INPUT SIGNALS” or “MAIN SIGNALS”.
8. Select “Numerical Display”, “Bar Chart Display” or “Line Graph
Display”.
9. Touch “SETTING” to set record conditions.
10. Touch “AUTO TRIG” or “MANU TRIG”.
11. Return to “SELECT MONITOR ITEM” on “DATA MONITOR”
screen and touch “START”.
12. Monitored data are displayed.
DATA MONITOR ITEMS
: Standard : Option
WDIA0084E
SAT9 7 3J
SMT963D
Item [Unit]Monitor item
Remarks ECU
INPUT
SIGNALSMAIN
SIGNALSSELEC-
TION
FROM
MENU
VHCL/SEN-FR [km/h], [MPH]Indicates average vehicle speed of ABS
front left/right wheel.
VHCL/SEN-RR [km/h], [MPH]Indicates average vehicle speed of ABS
rear left/right wheel.
Engine speed [rpm]—
Throttle position sensor—
Transfer fluid temperature sensor
[V]—
Battery voltage [V]—
2WD switch [ON-OFF] 2WD switch of 4WD shift switch
AUTO switch [ON-OFF] AUTO switch of 4WD shift switch
Lock switch [ON-OFF] 4H switch of 4WD shift switch
4L switch [ON-OFF] 4LO switch of 4WD shift switch

TF-38
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Revision: August 20072004 QX56
REFERENCE VALUE IN DATA MONITOR MODE
Indicated items
(Screen terms for CONSULT-II, “DATA
MONITOR” mode)Display Conditions
Throttle position sensor
(THRTL POS SEN) 0.0/8 - 8.0/8 Throttle valve fully closed to fully open
Transfer fluid temperature sensor
(FLUID TEMP SE)Approx. 1.5 - 0.5V Transfer fluid temperature approx. 20 - 80°C (68 - 176°F)
ABS operation switch
(ABS OPER SW)OFF ABS is not operating.
ON ABS is operating.
2WD position
(2WD SWITCH)ON 4WD shift switch is in “2WD”.
OFF Except the above condition
Lock position
(LOCK SWITCH)ON 4WD shift switch is in “4H”.
OFF Except the above condition
Neutral-4LO switch
(N POSI SW TF)
AT P s w i tc h
(ATP SWITCH)
Wait detection switch
(WAIT DETCT SW)4WD shift switch position2WD,
AUTO, 4H(N) 4LO
AT P s w i t c h O F F O N O F F
Neutral-4LO switch/Wait detec-
tion switch See Note.OFF ON
Note: When shifting into or out of “4LO” the switches turn ON when “Wait” function is oper-
ating and they turn OFF when “Wait” function is canceled.
Tran s fe r mo to r re lay
(MOTOR RELAY)
Transfer motor relay monitor
(MOTOR RELAY MON)Throttle valve4WD
shift
switchA/T selector
leverMotor relay/
Motor relay
monRemarks
Fully closed2WD — OFF —
AUTO,
4LOP, N O F F
ON for approx. 2 sec. after
shifting to “P” and “N”
Others ON
4HPOFF
ON for approx. 2 sec. after
shifting to “P”
Others ON
Line pressure switch
(LINE PRES SW)OFFThe vehicle has been left at room temperature for 5 min-
utes and more with ignition switch in “OFF” position.
ONIgnition switch in “ON”, and 4WD shift switch in “AUTO” or
“4H” and A/T selector lever in “D”.
Clutch pressure switch
(CL PRES SW)OFFIgnition switch in “ON”, and 4WD shift switch in “2WD”.
(“Wait” function is not operating.)
ONIgnition switch in “ON”, and 4WD shift switch in “AUTO” or
“4H” and A/T selector lever in “D”. (“Wait” function is not
operating.)
Vehicle speed
(VHCL/S COMP)0 km/h (0 MPH) — —
Control torque
(COMP CL TORQ)0 kg-m
4WD shift switch
(“Wait” function is not oper-
ating.)In “2WD” position
39 - 1,353 N·m
(4 - 138 kg-m, 29 - 998 ft.-lb.)In “AUTO” position
1,353 N·m
(138 kg-m, 998 ft.-lb.)In “4H” or “4LO” position
4WD solenoid
(DUTY SOLENOID)4% In “2WD” position
96 - 4% In “AUTO” position
4% In “4H” or “4LO” position