2005 NISSAN NAVARA control unit

RFD-1
REAR FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
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SECTIONRFD
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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-33
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
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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)

RFD-34
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
PRECAUTIONS
METHOD FOR ADJUSTMENT
1. Perform erase self-diagnosis with differential lock control unit. Refer toRFD-52, "How to Erase Self-diag-
nostic Results".
2. Check differential lock control unit input/output signal. Refer toRFD-48, "
Differential Lock Control Unit
Input/Output Signal Reference Values".
3. Check DIFF LOCK indicator lamp. Refer toRFD-33, "
CHECK DIFF LOCK INDICATOR LAMP".
lIf DIFF LOCK indicator lamp is not proper according to the above patterns.
Install new differential lock control unit or check for mechanical malfunction of rear final drive assembly
and retry the above (DIFF LOCK indicator lamp) check.
(If differential lock control unit or rear final drive assembly is replaced from another vehicle, the new dif-
ferential control unit must be replaced first.)
PrecautionsEDS003AH
lBefore connecting or disconnecting differential lock control
unit harness connector, turn ignition switch “OFF” and dis-
connect the battery cables. Because battery voltage is
applied to differential lock control unit even if ignition
switch is turned “OFF”.
lWhen connecting or disconnecting pin connectors into or
from differential lock control unit, take care not to damage
pin terminals (bend or break).
When connecting pin connectors make sure that there are
not any bends or breaks on differential lock control unit pin
terminal.
lBefore replacing differential lock control unit, perform dif-
ferential lock control unit input/output signal inspection
and make sure whether differential lock control unit func-
tions properly or not. Refer toRFD-48, "
Differential Lock
Control Unit Input/Output Signal Reference Values".
SEF289H
SEF291H
SDIA1848E

RFD-42
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
DIFFERENTIAL LOCK SYSTEM
Differential Lock Operation
EDS003AQ
1. Differential lock solenoid operates pressure plate.
2. Pressure plate presses cam ring.
3. Engage cam ring and side gear, and then differential is locked.
System DescriptionEDS003AR
DIFFERENTIAL LOCK SOLENOID
It is operated by signal from differential lock control unit, and it operates pressure plate so as to switch lock/
unlock.
DIFFERENTIAL LOCK POSITION SWITCH
It detects that differential is in lock or unlock by pressure plate position, and sends it to differential lock control
unit.
DIFFERENTIAL LOCK CONTROL UNIT
lDifferential lock control unit controls differential lock solenoid by input signals of each sensor and each
switch.
lAs a fail-safe function, differential lock disengages, if malfunction is detected in differential lock system.
lSelf-diagnosis can be done with CONSULT-II.
DIFFERENTIAL LOCK MODE SWITCH
Able to select differential lock and unlock.
DIFF LOCK INDICATOR LAMP
The following is the indications of indicator lamp.
NOTE:
Differential lock standby condition is the condition that differential lock mode switch is ON and differential is unlocked.
SDIA2498E
Condition DIFF LOCK indicator lamp
Differential lock/unlock ON/OFF
Differential lock standby condition Flashing: 1 time/2 seconds
Differential lock system malfunction OFF (Even if differential lock mode switch is turned ON)
Lamp checkTurns ON when ignition switch is turned ON.
Turns OFF after engine start.

DIFFERENTIAL LOCK SYSTEM
RFD-43
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
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System DiagramEDS003AS
COMPONENTS FUNCTION DESCRIPTION
CAN CommunicationEDS003AT
SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
For details, refer toDI-65, "
CAN Communication Unit".
SDIA2500E
Component parts Function
Differential lock control unit
lControls differential lock solenoid and switches differential lock/unlock.
lAs a fail-safe function, differential lock disengages, if malfunction is detected in differential lock
system.
Differential lock solenoid Controls pressure plate by current from differential lock control unit.
Differential lock position switch Detects that differential is lock or unlock condition.
Differential lock mode switch Able to select differential lock or unlock.
DIFF LOCK indicator lamp Illuminates that differential is in lock or lock standby condition.
ABS actuator and electric unit
(control unit)Transmits the following signals via CAN communication to differential lock control unit.
lVehicle speed signal
Transfer control unitTransmits the following signal via CAN communication to differential lock control unit.
l4WD shift switch signal

RFD-44
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
PFP:00004
Fail-safe FunctionEDS003AU
If any malfunction occurs in differential lock system, and control unit detects the malfunction, DIFF LOCK indi-
cator lamp on combination meter does not turn ON to indicate system malfunction. Differential lock control unit
turns differential lock solenoid OFF.
How to Perform Trouble DiagnosisEDS003AV
BASIC CONCEPT
lTo perform trouble diagnosis, it is the most important to have understanding about vehicle systems (con-
trol and mechanism) thoroughly.
lIt is also important to clarify customer complaints before inspec-
tion.
First of all, reproduce symptoms, and understand them fully.
Ask customer about his/her complaints carefully. In some cases,
it will be necessary to check symptoms by driving vehicle with
customer.
CAUTION:
Customers are not professional. It is dangerous to make an
easy guess like "maybe the customer means that...," or
"maybe the customer mentions this symptom".
lIt is essential to check symptoms right from the beginning in
order to repair malfunctions completely.
For intermittent malfunctions, reproduce symptoms based on
interview with customer and past examples. Do not perform
inspection on ad hoc basis. Most intermittent malfunctions are
caused by poor contacts. In this case, it will be effective to shake
suspected harness or connector by hand. When repairing with-
out any symptom diagnosis, you cannot judge if malfunctions
have actually been eliminated.
lAfter completing diagnosis, always erase diagnostic memory.
Refer toRFD-52, "
How to Erase Self-diagnostic Results".
lFor intermittent malfunctions, move harness or harness connec-
tor by hand. Then check for poor contact or reproduced open circuit.
SEF233G
SEF234G

RFD-48
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
TROUBLE DIAGNOSIS
Trouble Diagnosis Chart for Symptoms
EDS003AY
If DIFF LOCK indicator lamp does not turn ON after engine start, perform self-diagnosis. Refer toRFD-51, "SELF-DIAG RESULTSMODE".
Differential Lock Control Unit Input/Output Signal Reference ValuesEDS003AZ
DIFFERENTIAL LOCK CONTROL UNIT INSPECTION TABLE
Specifications with CONSULT-II
Symptom Condition Check itemReference
page
DIFF LOCK indicator lamp does not turn ON.
(DIFF LOCK indicator lamp check)Ignition switch: ONCAN communication line
RFD-70
Power supply and ground for differential
lock control unit
Combination meter
DIFF LOCK indicator lamp does not change.
lEngine running
lDifferential lock mode
switch: ONCombination meter
RFD-73Differential lock mode switch
CAN communication line
DIFF LOCK indicator lamp sometimes flashes.
lEngine running
lDifferential lock mode
switch: ONCombination meter
RFD-74Differential lock mode switch
Differential lock position switch
Differential inner parts
Monitor item [Unit] Content Condition Display value
BATTERY VOLT [V]Power supply voltage for
differential lock control unitIgnition switch: ON Battery voltage
4WD MODE [2H/4H/
4Lo]Condition of 4WD shift
switch4WD shift switch
(Engine running)2WD 2H
4H 4H
4LO 4Lo
VHCL S/SEN-R [km/h]
or [mph]Wheel speed
(Rear wheel right)Vehicle stopped 0 km/h (0 mph)
Vehicle running
CAUTION:
Check air pressure of tire under standard condition.Approximately
equal to the indi-
cation on speed-
ometer (Inside of
±10%)
VHCL S/SEN-L [km/h] or
[mph]Wheel speed
(Rear wheel left)Vehicle stopped 0 km/h (0 mph)
Vehicle running
CAUTION:
Check air pressure of tire under standard condition.Approximately
equal to the indi-
cation on speed-
ometer (Inside of
±10%)
VHCL S/SEN-RL [km/h]
or [mph]Wheel speed
(Average value of rear
wheel right and left)Vehicle stopped 0 km/h (0 mph)
Vehicle running
CAUTION:
Check air pressure of tire under standard condition.Approximately
equal to the indi-
cation on speed-
ometer (Inside of
±10%)
D-LOCK SW SIG [ON/
OFF]Condition of differential
lock mode switchDifferential lock mode switch: ON ON
Differential lock mode switch: OFF OFF
D-LOCK SIG [ON/OFF]Control status of differen-
tial lock
lVehicle stopped
lEngine running
l4WD shift switch: 4LODifferential lock mode
switch: ONON
Differential lock mode
switch: OFFOFF