2005 NISSAN NAVARA Repair Workshop Manual

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Page 2969 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual TF-2
DIAGNOSTIC PROCEDURE .............................. 53
COMPONENT INSPECTION .............................. 54
Transfer Control Unit .............................................. 54
DIAGNOSTIC PR

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

Page 2970 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual TF-3
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TF PLANETARY CARRIER ......................................... 129
Disassembly and Assembly ................................. 129
DISASSEMBLY ..............................

Page 2971 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual 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

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”"

Page 2972 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual PRECAUTIONS
TF-5
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TF
METHODFORADJUSTMENTWITH4WDSHIFTSWITCHAT“2WD”
Select Adjustment Pattern
1. Start engine. Run engine for at least 10 seconds.
2. Check 4WD shift indicator

PRECAUTIONS
TF-5
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METHODFORADJUSTMENTWITH4WDSHIFTSWITCHAT“2WD”
Select Adjustment Pattern
1. Start engine. Run engine for at least 10 seconds.
2. Check 4WD shift indicator lamp and 4LO indicator lamp.
Pattern A
1. Stay in the below for at least 2 seconds.
lFor A/T models, stop the vehicle and move A/T selector lever to “N” position with the brake pedal
depressed.
lFor M/T models, stop the vehicle and move M/T shift lever to the neutral position with the brake and
clutch pedal depressed.
2. Turn 4WD shift switch to “4LO” position. Stay in "4LO" for at least 2 seconds.
3. Turn ignition switch “OFF”.
4. Start engine.
5. Erase self-diagnosis. Refer toTF-46, "
How to Erase Self-diagnostic Results"(with CONSULT-II) orTF-
51, "ERASE SELF-DIAGNOSIS"(without CONSULT-II).
6. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer toTF-4, "
CHECK 4WD SHIFT INDI-
CATOR PATTERN".
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.
Pattern B
1. Stay in the below for at least 2 seconds.
lFor A/T models, stop the vehicle and move A/T selector lever to “N” position with the brake pedal
depressed.
lFor M/T models, stop the vehicle and move M/T shift lever to the neutral position with the brake and
clutch pedal depressed.
2. Turn ignition switch “OFF”.
3. Start engine.
4. Erase self-diagnosis. Refer toTF-46, "
How to Erase Self-diagnostic Results"(with CONSULT-II) orTF-
51, "ERASE SELF-DIAGNOSIS"(without CONSULT-II).
5. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer toTF-4, "
CHECK 4WD SHIFT INDI-
CATOR PATTERN".
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.
METHODFORADJUSTMENTWITH4WDSHIFTSWITCHAT“4H”OR“4LO”
1. Start engine. Run the engine for at least 10 seconds.
2. Stay in the below for at least 2 seconds.
lFor A/T models, stop the vehicle and move A/T selector lever to “N” position with the brake pedal
depressed.
lFor M/T models, stop the vehicle and move M/T shift lever to the neutral position with the brake and
clutch pedal depressed.
3. Turn 4WD shift switch to “2WD” position. Stay in "2WD" for at least 2 seconds.
4. Turn ignition switch “OFF”.
5. Start engine.
6. Erase self-diagnosis. Refer toTF-46, "
How to Erase Self-diagnostic Results"(with CONSULT-II) orTF-
51, "ERASE SELF-DIAGNOSIS"(without CONSULT-II).
7. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer toTF-4, "
CHECK 4WD SHIFT INDI-
CATOR PATTERN".
Indicator lamp condition Refer procedure
When 4WD shift indicator lamp or 4LO indicator lamp is flashing.TF-5, "
Pattern A"
Except for above.TF-5, "Pattern B"

Page 2973 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual TF-6
PRECAUTIONS
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.
PrecautionsEDS0031B
lBefore connectin

TF-6
PRECAUTIONS
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.
PrecautionsEDS0031B
lBefore connecting or disconnecting the transfer control unit harness connector, turn ignition
switch “OFF” and disconnect the battery cables. Battery voltage is applied to transfer control unit
even if ignition switch is turned “OFF”.
lWhen connecting or disconnecting pin connectors into or
from transfer control unit, take care not to damage pin ter-
minals (bend or break).
When connecting pin connectors make sure that there are
not any bends or breaks on transfer control unit pin termi-
nals.
lBefore replacing transfer control unit, perform transfer con-
trol unit input/output signal inspection and make sure
whether transfer control unit functions properly or not.
Refer toTF-38, "
Transfer Control Unit Input/Output Signal
Reference Values".
Service NoticeEDS0031C
lAfter overhaul refill the transfer with new transfer fluid.
lCheck the fluid level or replace the fluid only with the vehicle parked on level ground.
lDuring removal or installation, keep inside of transfer clear of dust or dirt.
lDisassemblyshouldbedoneinacleanworkarea.
lBefore proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal
parts from becoming contaminated by dirt or other foreign matter.
lCheck for the correct installation status prior to removal or disassembly. If matchmarks are required, be
certain they do not interfere with the function of the parts when applied.
lAll parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
lCheck appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary.
lGaskets, seals and O-rings should replaced any time the transfer is disassembled.
lIn principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it.
lObserve the specified torque when assembling.
lClean and flush the parts sufficiently and blow-dry them.
lBe careful not to damage sliding surfaces and mating surfaces.
lUse lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere
with the operation of the transfer.
SEF291H
MEF040DB

Page 2974 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual PRECAUTIONS
TF-7
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Wiring Diagrams and Trouble DiagnosisEDS0031D
When reading wiring diagrams, refer to the following:
lGI-15, "How to Read Wiring Diagrams".
lPG-4, "POWER SUPP

Page 2975 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual TF-8
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsEDS0031E
Tool number
Tool nameDescription
KV40104000
Flange wrench
a: 85 mm (3.35 in)
b: 65 mm (2.56 in)
lRemoving self-lock nut
lInstalling

Page 2976 of 3171

NISSAN NAVARA 2005 Repair Workshop Manual PREPARATION
TF-9
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TF
ST35300000
Drift
a: 59 mm (2.32 in) dia.
b: 45 mm (1.77 in) dia.lRemoving carrier bearing
lInstalling metal bushing
lRemoving front bearing
ST30021000
Puller

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