2005 NISSAN NAVARA warning

TF-1
TRANSFER
D DRIVELINE/AXLE
CONTENTS
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SECTIONTF
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TRANSFER
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 4
Precautions for Transfer Assembly and Transfer
Control Unit Replacement ........................................ 4
CHECK 4WD SHIFT INDICATOR PATTERN ....... 4
METHOD FOR ADJUSTMENT WITH 4WD
SHIFT SWITCH AT “2WD” .................................... 5
METHOD FOR ADJUSTMENT WITH 4WD
SHIFT SWITCH AT “4H” OR “4LO” ....................... 5
Precautions .............................................................. 6
Service Notice .......................................................... 6
Wiring Diagrams and Trouble Diagnosis .................. 7
PREPARATION ........................................................... 8
Special Service Tools ............................................... 8
Commercial Service Tools ...................................... 10
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ...............................................11
NVH Troubleshooting Chart .................................... 11
TRANSFER FLUID ................................................... 12
Replacement .......................................................... 12
DRAINING ........................................................... 12
FILLING ............................................................... 12
Inspection ............................................................... 12
FLUID LEAKAGE AND FLUID LEVEL ................ 12
4WD SYSTEM .......................................................... 13
Cross-Section View ................................................ 13
Power Transfer ....................................................... 14
POWER TRANSFER DIAGRAM ........................ 14
POWER TRANSFER FLOW ............................... 15
System Description ................................................ 15
TRANSFER CONTROL DEVICE ........................ 15
WAIT DETECTION SWITCH .............................. 15
4LO SWITCH ...................................................... 15
ATP SWITCH ...................................................... 15
TRANSFER CONTROL UNIT ............................. 15
TRANSFER SHIFT RELAY ................................. 15
TRANSFER SHUT OFF RELAY ......................... 15
4WD SHIFT SWITCH AND INDICATOR LAMP... 164WD WARNING LAMP ....................................... 17
ATP WARNING LAMP (A/T MODELS) ................ 17
System Diagram ..................................................... 18
COMPONENTS FUNCTION ............................... 18
CAN Communication .............................................. 19
SYSTEM DESCRIPTION .................................... 19
TROUBLE DIAGNOSIS ............................................ 20
How to Perform Trouble Diagnosis ......................... 20
BASIC CONCEPT ............................................... 20
Location of Electrical Parts ..................................... 21
A/T MODELS ....................................................... 21
M/T MODELS ...................................................... 22
Circuit Diagram ....................................................... 23
A/T MODELS ....................................................... 23
M/T MODELS ...................................................... 24
Wiring Diagram — T/F — ....................................... 25
A/T MODELS ....................................................... 25
M/T MODELS ...................................................... 31
Trouble Diagnosis Chart for Symptoms .................. 38
Transfer Control Unit Input/Output Signal Refer-
ence Values ............................................................ 38
TRANSFER CONTROL UNIT INSPECTION
TABLE ................................................................. 38
CONSULT-II Function (ALL MODE AWD/4WD) ..... 44
FUNCTION .......................................................... 44
CONSULT-II SETTING PROCEDURE ................ 44
SELF-DIAG RESULT MODE ............................... 45
DATA MONITOR MODE ...................................... 47
Self-Diagnostic Procedure ...................................... 49
SELF-DIAGNOSTIC PROCEDURE (WITH
CONSULT-II) ....................................................... 49
SELF-DIAGNOSTIC PROCEDURE (WITHOUT
CONSULT-II) ....................................................... 49
ERASE SELF-DIAGNOSIS ................................. 51
TROUBLE DIAGNOSIS FOR SYSTEM .................... 52
Power Supply Circuit For Transfer Control Unit ...... 52
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 52
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 52

TF-2
DIAGNOSTIC PROCEDURE .............................. 53
COMPONENT INSPECTION .............................. 54
Transfer Control Unit .............................................. 54
DIAGNOSTIC PROCEDURE .............................. 54
Output Shaft Revolution Signal (TCM) ................... 55
DIAGNOSTIC PROCEDURE .............................. 55
Vehicle Speed Sensor (ABS) .................................. 55
DIAGNOSTIC PROCEDURE .............................. 55
4LO Switch ............................................................. 56
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 56
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 56
DIAGNOSTIC PROCEDURE .............................. 57
COMPONENT INSPECTION .............................. 59
4WD Shift Switch .................................................... 59
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 59
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 59
DIAGNOSTIC PROCEDURE .............................. 60
COMPONENT INSPECTION .............................. 62
Wait Detection Switch ............................................. 63
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 63
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 63
DIAGNOSTIC PROCEDURE .............................. 64
COMPONENT INSPECTION .............................. 66
PNP Switch Signal (TCM) ...................................... 66
DIAGNOSTIC PROCEDURE .............................. 66
Actuator Motor ........................................................ 67
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 67
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 67
DIAGNOSTIC PROCEDURE .............................. 68
COMPONENT INSPECTION .............................. 74
Actuator Position Switch ......................................... 75
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 75
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 75
DIAGNOSTIC PROCEDURE .............................. 76
Transfer Control Device .......................................... 78
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 78
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 78
DIAGNOSTIC PROCEDURE .............................. 79
Engine Speed Signal (ECM) ................................... 81
DIAGNOSTIC PROCEDURE .............................. 81
CAN Communication Line ...................................... 82
DIAGNOSTIC PROCEDURE .............................. 82
ATP Switch ............................................................. 82
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 82
TRANSFER CONTROL UNIT TERMINALS ANDREFERENCE VALUE .......................................... 82
DIAGNOSTIC PROCEDURE ............................... 83
COMPONENT INSPECTION ............................... 85
Park/Neutral Position Switch ................................... 85
TRANSFER CONTROL UNIT TERMINALS AND
REFERENCE VALUE .......................................... 85
DIAGNOSTIC PROCEDURE ............................... 85
COMPONENT INSPECTION ............................... 87
TROUBLE DIAGNOSIS FOR SYMPTOMS .............. 88
4WD Shift Indicator Lamp and 4LO Indicator Lamp
Do Not Turn ON ...................................................... 88
SYMPTOM: .......................................................... 88
DIAGNOSTIC PROCEDURE ............................... 89
4WD Warning Lamp Does Not Turn ON ................. 91
SYMPTOM: .......................................................... 91
DIAGNOSTIC PROCEDURE ............................... 92
4WD Shift Indicator Lamp or 4LO Indicator Lamp
Does Not Change ................................................... 94
SYMPTOM: .......................................................... 94
DIAGNOSTIC PROCEDURE ............................... 95
ATP Warning Lamp Does Not Turn ON .................. 96
SYMPTOM: .......................................................... 96
DIAGNOSTIC PROCEDURE ............................... 96
4WD Shift Indicator Lamp Repeats Flashing .......... 98
SYMPTOM: .......................................................... 98
DIAGNOSTIC PROCEDURE ............................... 98
4WD Warning Lamp Flashes Slowly ....................... 99
SYMPTOM: .......................................................... 99
DIAGNOSTIC PROCEDURE ............................... 99
TRANSFER CONTROL UNIT .................................100
Removal and Installation .......................................100
REMOVAL ..........................................................100
INSTALLATION ..................................................100
FRONT OIL SEAL ...................................................101
Removal and Installation .......................................101
REMOVAL ..........................................................101
INSTALLATION ..................................................102
REAR OIL SEAL .....................................................103
Removal and Installation .......................................103
REMOVAL ..........................................................103
INSTALLATION ..................................................103
TRANSFER CONTROL DEVICE ............................105
Removal and Installation .......................................105
REMOVAL ..........................................................105
INSTALLATION ..................................................105
AIR BREATHER HOSE ...........................................107
Removal and Installation .......................................107
A/T MODELS .....................................................107
M/T MODELS .....................................................109
TRANSFER ASSEMBLY ......................................... 111
Removal and Installation ....................................... 111
REMOVAL .......................................................... 111
INSTALLATION ..................................................112
Disassembly and Assembly ..................................112
COMPONENTS .................................................112
DISASSEMBLY ..................................................114
INSPECTION AFTER DISASSEMBLY ..............119
ASSEMBLY ........................................................120

TF-4
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EDS003ID
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
lTo avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Transfer Assembly and Transfer Control Unit ReplacementEDS0031A
lWhen replacing transfer assembly or transfer control unit, check the 4WD shift indicator pattern and
adjustment of the position between transfer assembly and transfer control unit if necessary.
CHECK 4WD SHIFT INDICATOR PATTERN
1. Set 4WD shift switch to “2WD”, “4H”, “4LO”, “4H” and “2WD” in order. Stay at each switch position for at
least 2 seconds.
2. Confirm 4WD shift indicator lamp and 4LO indicator lamp are changed properly as follows.
lIf OK, the position between transfer assembly and transfer control unit is correct.
lIf NG, the position is different between transfer assembly and transfer control unit.
Adjust the position between transfer assembly and transfer control unit. Refer to pattern table below.
Transfer position adjustment pattern
NOTE:
Method of adjustment can be chosen voluntarily, according to location of 4WD shift switch.
SDIA3289E
4WD shift switch condition Refer procedure
4WD shift switch is under “2WD” condition when engine is being stopped.TF-5, "
METHOD FOR ADJUSTMENT WITH 4WD
SHIFT SWITCH AT“2WD”"
4WD shift switch is under “4H” or “4LO” condition when engine is being stopped.TF-5, "METHOD FOR ADJUSTMENT WITH 4WD
SHIFT SWITCH AT“4H”OR“4LO”"

4WD SYSTEM
TF-17
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4WD WARNING LAMP
Turns ON or flashes when there is a malfunction in 4WD system.
Also turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately 1 sec-
ond after the engine starts if system is normal.
4WD Warning Lamp Indication
NOTE:
4WD warning lamp is turned on when the following one or more parts are malfunctioning.
lVehicle speed signal
[from ABS actuator and electric unit (control unit)]
lCAN communication line
lAD converter
lEngine speed signal
l4WD shift switch
lWait detection switch
lActuator motor
lTransfer control device
lTransfer shut off relay
lTransfer shift relay
lPNP switch signal
ATP WARNING LAMP (A/T MODELS)
When A/T selector lever is in “P” position, vehicle may move because A/T parking mechanism does not oper-
ate when transfer is under neutral condition. ATP warning lamp is turned on to indicate this condition to the
driver.
Condition 4WD warning lamp
Lamp checkTurns ON when ignition switch is turned ON.
Turns OFF after engine start.
4WD system malfunctionON
(For indicated malfunction items, see the “NOTE”)
During self-diagnosis Flashes at malfunction mode.
Large difference in diameter of front/
rear tiresSlow flashing: 1 time/2 seconds
(Continues to flash until ignition switch is turned OFF)
Other than above (system normal) OFF

TF-18
4WD SYSTEM
System Diagram
EDS0031M
COMPONENTS FUNCTION
SDIA3416E
Component parts Function
Transfer control unit Controls transfer control device and switches 4HÛ4LO under 4WD condition and 2WDÛ4WD.
Transfer control device Actuator motor and actuator position switch are integrated so as to switch driving modes.
Actuator motor Controls shift rod by signals from transfer control unit.
Actuator position switch Detects actuator motor position.
Wait detection switch Detects that transfer is under 4WD condition.
4LO switch Detects that transfer is under 4LO condition.
AT P s w i t c h
(A/T models)Detects that transfer is under neutral condition.
4WD shift switch Able to select from 2WD, 4H or 4LO.
4WD warning lamp
lIlluminates if malfunction is detected in electrical system of 4WD system.
lThere is 1 blink in 2 seconds if rotation difference of front wheels and rear wheels is large.
ATP warning lamp
(A/T models)Indicates that A/T parking mechanism does not operate when A/T selector lever is in “P” position
and transfer is under neutral condition.
4WD shift indicator lamp Displays driving condition selected by 4WD shift switch.
4LO indicator lamp Displays 4LO condition.
PNP switch
(M/T models)Detects that manual transmission is under neutral condition.
ABS actuator and electric unit
(control unit)Transmits the following signals via CAN communication to Transfer control unit.
lVehicle speed signal
lStop lamp switch signal (brake signal)

TF-38
TROUBLE DIAGNOSIS
Trouble Diagnosis Chart for Symptoms
EDS0031U
If 4WD warning lamp turns ON, perform self-diagnosis. Refer toTF-49, "Self-Diagnostic Procedure".
Transfer Control Unit Input/Output Signal Reference ValuesEDS0031V
TRANSFER CONTROL UNIT INSPECTION TABLE
Specifications with CONSULT-II
Symptom Condition Check item Reference page
4WD shift indicator lamp and 4LO indicator
lamp do not turn ON
(4WD shift indicator lamp and 4LO indicator
lamp check)Ignition switch: ONPower supply and ground for transfer
control unit
TF-88
Transfer shut off relay
Combination meter
4WD warning lamp does not turn ON
(4WD warning lamp check)Ignition switch: ONPower supply and ground for transfer
control unit
TF-91
Transfer shut off relay
Combination meter
4WD shift indicator lamp or 4LO indicator
lamp does not changeEngine running4WD shift switch
TF-94
Wait detection switch
4LO switch
AT P s w i t c h
Transfer inner parts
ATP warning lamp does not turn ON Engine runningCAN communication line
TF-96
4WD shift switch
PNP switch signal
AT P s w i t c h
Combination meter
Transfer inner parts
4WD shift indicator lamp repeats flashing Engine runningWait detection switch
TF-98
4LO switch
Transfer inner parts
4WD warning lamp flashes slowly
Slow flashing: 1 time/2 secondsWhile drivingTire size is different between front and
rear of vehicle.TF-99
Monitored item [Unit] Content Condition Display value
VHCL/S SEN·FR [km/h]
or [mph]Wheel speed (Front wheel)Vehicle stopped 0 km/h (0 mph)
Vehicle running
CAUTION:
Check air pressure of tire under standard condi-
tion.Approximately
equal to the indica-
tion on speedome-
ter (Inside of±10%)
VHCL/S SEN·RR [km/h]
or [mph]Wheel speed (Rear wheel)Vehicle stopped 0 km/h (0 mph)
Vehicle running
CAUTION:
Check air pressure of tire under standard condi-
tion.Approximately
equal to the indica-
tion on speedome-
ter (Inside of±10%)
ENGINE SPEED [rpm] Engine speedEngine stopped
(Engine speed: Less than 400 rpm)0rpm
Engine running
(Engine speed: 400 rpm or more)Approximately
equal to the indica-
tion on tachometer
BATTERY VOLT [V]Power supply voltage for
transfer control unitIgnition switch: ON Battery voltage

TF-40
TROUBLE DIAGNOSIS
SHIFT AC MON1 [ON/
OFF]Check signal for transfer
control unit signal output
lVehicle stopped
lEngine running
lFor A/T models, A/T
selector lever “N” posi-
tion with brake pedal
depressed.
lFor M/T models, M/T
shift lever neutral posi-
tion with clutch and
brake pedal depressed.4WD shift switch:
2WDto4Hor4Hto4LO
or 2WD to 4LOON
Except the above OFF
SHIFT ACT 2 [ON/OFF]Output condition to actua-
tor motor (counterclock-
wise)
lVehicle stopped
lEngine running
lFor A/T models, A/T
selector lever “N” posi-
tion with brake pedal
depressed.
lFor M/T models, M/T
shift lever neutral posi-
tion with clutch and
brake pedal depressed.4WD shift switch:
4LOto4Hor4Hto2WD
or 4LO to 2WDON
Except the above OFF
SHIFT AC MON2 [ON/
OFF]Check signal for transfer
control unit signal output
lVehicle stopped
lEngine running
lFor A/T models, A/T
selector lever “N” posi-
tion with brake pedal
depressed.
lFor M/T models, M/T
shift lever neutral posi-
tion with clutch and
brake pedal depressed.4WD shift switch:
4LOto4Hor4Hto2WD
or 4LO to 2WDON
Except the above OFF
SHIFT ACT/R MON
[ON/OFF]Operating condition of
actuator motor relay (inte-
grated in transfer control
unit)
lVehicle stopped
lEngine running
lFor A/T models, A/T
selector lever “N” posi-
tion with brake pedal
depressed.
lFor M/T models, M/T
shift lever neutral posi-
tion with clutch and
brake pedal depressed.When 4WD shift switch is
operatedON
When 4WD shift switch is
not operatedOFF
SHIFT POS SW1 [ON/
OFF]Condition of actuator posi-
tion switch 1
lVehicle stopped
lEngine running
lFor A/T models, A/T
selector lever “N” posi-
tion with brake pedal
depressed.
lFor M/T models, M/T
shift lever neutral posi-
tion with clutch and
brake pedal depressed.4WD shift switch:
2WD and 4LOON
4WD shift switch: 4H OFF
SHIFT POS SW2 [ON/
OFF]Condition of actuator posi-
tion switch 24WD shift switch: 4LO ON
4WD shift switch:
2WD and 4HOFF
SHIFT POS SW3 [ON/
OFF]Condition of actuator posi-
tion switch 34WD shift switch:
2WD and 4HON
4WD shift switch: 4LO OFF
SHIFT POS SW4 [ON/
OFF]Condition of actuator posi-
tion switch 44WD shift switch:
4H and 4LOON
4WD shift switch: 2WD OFF
4WD FAIL LAMP [ON/
OFF]4WD warning lamp condi-
tion4WD warning lamp: ON ON
4WD warning lamp: OFF OFF Monitored item [Unit] Content Condition Display value

TROUBLE DIAGNOSIS
TF-43
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28 BR Actuator motor (+)
lVehicle stopped
lEngine running
lFor A/T models,
A/T selector
lever “N” position
with brake pedal
depressed.
lFor M/T models,
M/T shift lever
neutral position
with clutch and
brake pedal
depressed.When 4WD shift switch is operated
(while actuator motor is operating)Battery voltage
®0V
When 4WD shift switch is not operated 0V
31 G Actuator motor (-) Always 0V
32 B Ground Always 0V
33
(For M/T
models)P Park/Neutral position switch Ignition switch: ONM/T shift lever neutral position 0V
Except the above Battery voltage
35 V4WD shift indicator lamp
(Rear indicator)
Engine runningRear indicator of 4WD shift indicator
lamp: ON0V
Rear indicator of 4WD shift indicator
lamp: OFFBattery voltage
36 BR4WD shift indicator lamp
(Front and center indicator)Front and center indicator of 4WD shift
indicator lamp: ON0V
Front and center indicator of 4WD shift
indicator lamp: OFFBattery voltage
37 Y 4LO indicator lamp4LO indicator lamp: ON 0V
4LO indicator lamp: OFF Battery voltage
38 P 4WD warning lamp4WD warning lamp: ON 0V
4WD warning lamp: OFF Battery voltage
39
(For A/T
models)LG ATP warning lamp
lVehicle stopped
lEngine running
lA/T selector
lever “P” position
lBrake pedal
depressed4WD shift switch:
4H to 4LO or 4LO to 4H
(While actuator motor is operating.)Battery voltage
Except the above 0V
40 V Transfer shut off relayIgnition switch: ON 0V
Ignition switch: OFF
(5 seconds after ignition switch is turned OFF)Battery voltage
42 LG Transfer shift high relay
lVehicle stopped
lEngine running
lFor A/T models,
A/T selector
lever “N” position
with brake pedal
depressed.
lFor M/T models,
M/T shift lever
neutral position
with clutch and
brake pedal
depressed.4WD shift switch:
2WD to 4H or 4H to 4LO or 2WD to 4LO0V
Except the above Battery voltage TerminalWire
colorItem Condition Data (Approx.)