2005 NISSAN NAVARA service

RFD-1
REAR FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
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SECTIONRFD
A
B
RFD
REAR FINAL DRIVE
WITH LIMITED SLIP DIFFERENTIAL
PRECAUTIONS .......................................................... 3
Limited Slip Differential (LSD) Performance Judge-
ment ......................................................................... 3
METHOD FOR TROUBLESHOOTING ................. 3
Service Notice or Precautions .................................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 5
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 7
NVH Troubleshooting Chart ..................................... 7
DESCRIPTION ............................................................ 8
Cross-Sectional View ............................................... 8
DIFFERENTIAL GEAR OIL ........................................ 9
Changing Differential Gear Oil ................................. 9
DRAINING ............................................................. 9
FILLING ................................................................. 9
Checking Differential Gear Oil .................................. 9
OIL LEAKAGE AND OIL LEVEL ........................... 9
FRONT OIL SEAL .................................................... 10
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION .................................................... 11
CARRIER COVER .................................................... 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
REAR FINAL DRIVE ASSEMBLY ............................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
Disassembly and Assembly ................................... 15
COMPONENTS .................................................. 15
ASSEMBLY INSPECTION AND ADJUSTMENT... 16
DISASSEMBLY ................................................... 19
INSPECTION AFTER DISASSEMBLY ............... 22
SELECTION ADJUSTING WASHERS ............... 23
ASSEMBLY ......................................................... 24SERVICE DATA AND SPECIFICATIONS (SDS) ...... 31
General Specifications ............................................ 31
Inspection and Adjustment ..................................... 31
PRELOAD TORQUE ........................................... 31
BACKLASH ......................................................... 31
COMPANION FLANGE RUNOUT ....................... 31
SELECTIVE PARTS ............................................ 32
WITH ELECTRONIC LOCKING DIFFEREN-
TIAL
PRECAUTIONS ........................................................ 33
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” ................................................................. 33
Precautions for Differential Case Assembly and Dif-
ferential Lock Control Unit Replacement ................ 33
CHECK DIFF LOCK INDICATOR LAMP ............. 33
METHOD FOR ADJUSTMENT ........................... 34
Precautions ............................................................. 34
Service Notice or Precaution .................................. 35
Wiring Diagrams and Trouble Diagnosis ................ 35
PREPARATION ......................................................... 36
Special Service Tools ............................................. 36
Commercial Service Tools ...................................... 37
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .............................................. 39
NVH Troubleshooting Chart ................................... 39
DIFFERENTIAL GEAR OIL ...................................... 40
Changing Differential Gear Oil ................................ 40
DRAINING ........................................................... 40
FILLING ............................................................... 40
Checking Differential Gear Oil ................................ 40
OIL LEAKAGE AND OIL LEVEL ......................... 40
DIFFERENTIAL LOCK SYSTEM .............................. 41
Cross-sectional View .............................................. 41
Differential Lock Operation ..................................... 42
System Description ................................................. 42
DIFFERENTIAL LOCK SOLENOID .................... 42
DIFFERENTIAL LOCK POSITION SWITCH ....... 42

RFD-2
DIFFERENTIAL LOCK CONTROL UNIT ............ 42
DIFFERENTIAL LOCK MODE SWITCH ............. 42
DIFF LOCK INDICATOR LAMP ........................... 42
System Diagram ..................................................... 43
COMPONENTS FUNCTION DESCRIPTION ...... 43
CAN Communication .............................................. 43
SYSTEM DESCRIPTION .................................... 43
TROUBLE DIAGNOSIS ............................................ 44
Fail-safe Function ................................................... 44
How to Perform Trouble Diagnosis ......................... 44
BASIC CONCEPT ............................................... 44
Location of Electrical Parts ..................................... 45
Wiring Diagram — DIFLOC — ................................ 46
Trouble Diagnosis Chart for Symptoms .................. 48
Differential Lock Control Unit Input/Output Signal
Reference Values ................................................... 48
DIFFERENTIAL LOCK CONTROL UNIT
INSPECTION TABLE .......................................... 48
CONSULT-II Function (DIFF LOCK) ....................... 50
FUNCTION .......................................................... 50
CONSULT-II SETTING PROCEDURE ................ 50
SELF-DIAG RESULTS MODE ............................. 51
DATA MONITOR MODE ...................................... 53
TROUBLE DIAGNOSIS FOR SYSTEM .................... 54
Power Supply Circuit For Differential Lock Control
Unit ......................................................................... 54
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 54
DIFFERENTIAL LOCK CONTROL UNIT TER-
MINALS AND REFERENCE VALUE ................... 54
DIAGNOSTIC PROCEDURE .............................. 55
Differential Lock Control Unit .................................. 56
DIAGNOSTIC PROCEDURE .............................. 56
Differential Lock Mode Switch ................................ 56
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 56
DIFFERENTIAL LOCK CONTROL UNIT TER-
MINALS AND REFERENCE VALUE ................... 56
DIAGNOSTIC PROCEDURE .............................. 57
COMPONENT INSPECTION .............................. 59
Differential Lock Position Switch ............................. 60
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 60
DIFFERENTIAL CONTROL UNIT TERMINALS
AND REFERENCE VALUE ................................. 60
DIAGNOSTIC PROCEDURE .............................. 61
COMPONENT INSPECTION .............................. 63
Differential Lock Solenoid Relay ............................. 63
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 63DIAGNOSTIC PROCEDURE ............................... 63
Differential Lock Solenoid ....................................... 64
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 64
DIFFERENTIAL LOCK CONTROL UNIT TER-
MINALS AND REFERENCE VALUE ................... 64
DIAGNOSTIC PROCEDURE ............................... 65
COMPONENT INSPECTION ............................... 68
ABS System ............................................................ 68
DIAGNOSTIC PROCEDURE ............................... 68
CAN Communication Line ....................................... 69
DIAGNOSTIC PROCEDURE ............................... 69
TROUBLE DIAGNOSIS FOR SYMPTOMS .............. 70
DIFF LOCK Indicator Lamp Does Not Turn ON ...... 70
DIAGNOSTIC PROCEDURE ............................... 70
DIFF LOCK Indicator Lamp Does Not Change ....... 73
DIAGNOSTIC PROCEDURE ............................... 73
DIFF LOCK Indicator Lamp Sometimes Flashes .... 74
DIAGNOSTIC PROCEDURE ............................... 74
DIFFERENTIAL LOCK CONTROL UNIT .................. 76
Removal and Installation ......................................... 76
REMOVAL ............................................................ 76
INSTALLATION .................................................... 76
FRONT OIL SEAL ..................................................... 77
Removal and Installation ......................................... 77
REMOVAL ............................................................ 77
INSTALLATION .................................................... 78
CARRIER COVER ..................................................... 80
Removal and Installation ......................................... 80
REMOVAL ............................................................ 80
INSTALLATION .................................................... 80
REAR FINAL DRIVE ASSEMBLY ............................. 81
Removal and Installation ......................................... 81
REMOVAL ............................................................ 81
INSTALLATION .................................................... 81
Disassembly and Assembly .................................... 82
COMPONENTS ................................................... 82
ASSEMBLY INSPECTION AND ADJUSTMENT...83
DISASSEMBLY .................................................... 86
INSPECTION AFTER DISASSEMBLY ................ 90
SELECTION ADJUSTING WASHERS ................ 90
ASSEMBLY .......................................................... 91
SERVICE DATA AND SPECIFICATIONS (SDS) ....100
General Specifications ..........................................100
Inspection and Adjustment ....................................100
PRELOAD TORQUE .........................................100
BACKLASH ........................................................100
COMPANION FLANGE RUNOUT .....................100
SELECTIVE PARTS ..........................................101

PRECAUTIONS
RFD-3
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
[WITH LIMITED SLIP DIFFERENTIAL]PRECAUTIONSPFP:00001
Limited Slip Differential (LSD) Performance JudgementEDS003IG
lInspection is required when detecting any noise or malfunction while driving or turning. Improper condition
of oil or differential case assembly is suspected. Refer toRFD-3, "
METHOD FOR TROUBLESHOOTING"
.
METHOD FOR TROUBLESHOOTING
1. Check differential gear oil level and differential gear oil leakage. Refer toRFD-9, "Checking Differential
Gear Oil".
2. Changing differential gear oil. Refer toRFD-9, "
Changing Differential Gear Oil".
3. Start engine. Drive for 10 min.
4. Again changing differential gear oil. Refer toRFD-9, "
Changing Differential Gear Oil".
5. Start engine. Drive for 10 min. Check if any noise or improper oil condition is detected.
lIf OK, check differential gear oil level and differential gear oil leakage. Refer toRFD-9, "Checking Differ-
ential Gear Oil".
lIf NG, replace differential case assembly after checking each part of final drive. Refer toRFD-15, "Dis-
assembly and Assembly".
Service Notice or PrecautionsEDS0038Z
lCheck 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.
lOverhaul should be done in a clean work area, it is preferable to work in dust proof area.
lBefore disassembly completely remove sand and mud from the exterior of the unit, preventing them from
entering into the unit during disassembly or assembly.
lCheck appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with new ones if necessary.
lGaskets, seals and O-rings should be replaced any time the unit is disassembled.
lIn principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
lClean and flush the parts sufficiently and blow-dry them.
lBe careful not to damage sliding surfaces and mating surfaces.
lWhen applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.
lAlways use shop paper for cleaning the inside of components.
lAvoid using cotton gloves or shop rags to prevent entering of lint.
lDuring assembly, observe the specified tightening torque, and apply new differential gear oil, petroleum
jelly, or multi-purpose grease as specified.

RFD-4
[WITH LIMITED SLIP DIFFERENTIAL]
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsEDS003H7
Tool number
Tool nameDescription
ST3127S000
Preload gauge set
1. GG91030000
Torque wrench
2. HT62940000 (1/2²)
Socket adapter
3. HT62900000 (3/8²)
Socket adapterInspecting pinion bearing preload and
total preload
KV40104000
Flange wrench
a: 85 mm (3.35 in) dia.
b: 65 mm (2.56 in) dia.Removing and installing drive pinion
lock nut
KV381054S0
PullerRemoving front oil seal
KV10111100
Seal cutterRemoving carrier cover
KV38108800
Adjuster toolRemoving and installing side bearing
adjuster
ST30021000
PullerRemoving drive pinion rear bearing
inner race
NT124
NT659
ZZA0601D
S-NT046
WDIA0192E
ZZA0700D

PREPARATION
RFD-5
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
H
I
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K
L
MA
B
RFD
Commercial Service ToolsEDS003H8
ST30022000
Drift
a: 46 mm (1.81 in) dia.
b: 110 mm (4.33 in) dia.Installing drive pinion rear bearing outer
race
KV38100300
Drift
a: 54 mm (2.13 in) dia.
b: 46 mm (1.81 in) dia.
c: 32mm (1.26 in) dia.Installing side bearing inner race Tool number
Tool nameDescription
NT660
ZZA1046D
Tool nameDescription
Puller
lRemoving companion flange
lRemoving side bearing inner race
Drift
a: 96mm (3.77 in) dia.
b: 84 mm (3.30 in) dia.Installing front oil seal
Adapter
a: 43 mm (1.69 in) dia.Removing and installing side bearing
inner race
PullerRemoving side bearing inner race
Drift
a: 89 mm (3.50 in) dia.
b: 79 mm (3.11 in) dia.Installing drive pinion rear bearing outer
race
NT077
NT115
PDIA0893E
ZZB0823D
ZZA0811D

SERVICE DATA AND SPECIFICATIONS (SDS)
RFD-31
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
H
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MA
B
RFD
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsEDS0039A
*: Option
Inspection and AdjustmentEDS0039B
PRELOAD TORQUE
Unit: N·m (kg-m, in-lb)
BACKLASH
Unit: mm (in)
COMPANION FLANGE RUNOUT
Unit: mm (in) Applied modelYD25DDTi
2WD 4WD
6M/T 5A/T 6M/T 5A/T
Grade SE, XE SE SE, XE* XE SE
Final drive modelM226
Gear ratio 3.538 3.357 3.692 3.538
Number of pinion gears 2
Number of teeth (Drive gear / drive pinion) 46/13 47/14 48/13 46/13
Oil capacity (Approx.)
(lmp pt)2.01 (3-1/2)
Drive pinion adjustment spacer type Collapsible
ItemSpecification
Gear ratio 3.357 type Gear ratio 3.538 type Gear ratio 3.692 type
To t a l p r e l o a d2.38 - 4.46
(0.25-0.45,21-39)2.34 - 4.34
(0.24 - 0.44, 21 - 38)2.32 - 4.34
(0.24 - 0.44, 21 - 38)
Pinion bearing preload 1.7 - 3.1 (0.18 - 0.31, 15 - 27)
Item Standard
Drive gear to drive pinion gear 0.08 - 0.13 (0.0031 - 0.0051)
Item Runout limit
Companion flange face 0.10 (0.0039) or less
Inner side of companion flange 0.13 (0.0051) or less

RFD-32
[WITH LIMITED SLIP DIFFERENTIAL]
SERVICE DATA AND SPECIFICATIONS (SDS)
SELECTIVE PARTS
Drive Pinion Height Adjusting Washer
Unit: mm (in)
*Always check with the Parts Department for the latest parts information.Thickness Package part number*
0.076 (0.030)
0.079 (0.031)
0.081 (0.032)
0.084 (0.033)
0.086 (0.034)38151 8S101
0.089 (0.035)
0.091 (0.036)
0.094 (0.037)
0.097 (0.038)
0.099 (0.039)38151 8S102
0.102 (0.040)
0.104 (0.041)
0.107 (0.042)
0.109 (0.043)
0.112 (0.044)38151 8S103
0.114 (0.045)
0.117 (0.046)
0.119 (0.047)
0.122 (0.048)
0.124 (0.049)38151 8S104
0.127 (0.050)
0.130 (0.051)
0.132 (0.052)
0.135 (0.053)
0.137 (0.054)38151 8S105

PRECAUTIONS
RFD-33
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
[WITH ELECTRONIC LOCKING DIFFERENTIAL]PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EDS003IE
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 Differential Case Assembly and Differential Lock Control Unit
Replacement
EDS003AG
lWhen replacing differential case assembly or differential lock control unit, check the DIFF LOCK indicator
pattern and adjustment of the position between differential case assembly and differential lock control unit
if necessary.
CHECK DIFF LOCK INDICATOR LAMP
1. Start engine. Run engine for at least 10 seconds.
2. Turn 4WD shift switch to “4LO” and confirm 4LO indicator lamp is turned on. Refer toTF-16, "
4WD SHIFT
SWITCH AND INDICATOR LAMP".
3. Stop vehicle and turn differential lock mode switch to “ON”.
4. Drive vehicle at 7 km/h (4 MPH) or less.
NOTE:
Differential case assembly must be given a rotation from rear left wheel and rear right wheel.
5. Check if DIFF LOCK indicator lamp flashes to turn on.
6. Check if DIFF LOCK indicator lamp and 4LO indicator lamp are changed properly as follows.
lIf each indication and state is OK, rear final drive assembly and differential lock control unit is working cor-
rectly.
lIf each indication and state is NG, rear final drive assembly and differential lock control unit is not working
correctly. Refer toRFD-34, "
METHOD FOR ADJUSTMENT".
Differential lock mode
switch4LO indicator lamp Vehicle speed (VSS)Differential case assem-
bly stateDIFF LOCK indicator
lamp
ONOFF7 km/h (4 MPH) < VSS
Disengage Flash VSS£7km/h(4MPH)
ON7 km/h (4 MPH) < VSS
VSS£7 km/h (4 MPH) Disengage®Engage Flash®ON
OFFOFF7 km/h (4 MPH) < VSS
Disengage OFF VSS£7km/h(4MPH)
ON7 km/h (4 MPH) < VSS
VSS£7km/h(4MPH)