2005 NISSAN NAVARA checking oil

MT-1
MANUAL TRANSMISSION
C TRANSMISSION/TRANSAXLE
CONTENTS
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SECTIONMT
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MT
MANUAL TRANSMISSION
PRECAUTIONS .......................................................... 2
Service Notice or Precautions .................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 6
NVH Troubleshooting Chart ..................................... 6
DESCRIPTION ............................................................ 7
Cross-Sectional View ............................................... 7
DOUBLE-CONE SYNCHRONIZER ...................... 8
TRIPLE-CONE SYNCHRONIZER ........................ 8
M/T OIL ....................................................................... 9
Changing M/T Oil ..................................................... 9
DRAINING ............................................................. 9
FILLING ................................................................. 9
Checking M/T Oil ...................................................... 9
OIL LEAKAGE AND OIL LEVEL ........................... 9
REAR OIL SEAL ...................................................... 10
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION .................................................... 11
POSITION SWITCH .................................................. 12
Checking ................................................................ 12
BACK-UP LAMP SWITCH .................................. 12
PARK/NEUTRAL POSITION (PNP) SWITCH ..... 12SHIFT CONTROL ..................................................... 13
Removal and Installation ........................................ 13
COMPONENTS ................................................... 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
INSPECTION AFTER INSTALLATION ................ 14
AIR BREATHER HOSE ............................................ 15
Removal and Installation ........................................ 15
TRANSMISSION ASSEMBLY .................................. 16
Removal and Installation from Vehicle ................... 16
COMPONENTS ................................................... 16
REMOVAL ........................................................... 17
INSTALLATION ................................................... 18
Disassembly and Assembly .................................... 19
COMPONENTS ................................................... 19
DISASSEMBLY ................................................... 25
INSPECTION AFTER DISASSEMBLY ................ 40
ASSEMBLY ......................................................... 44
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 67
General Specifications ............................................ 67
Gear End Play ........................................................ 68
Snap Rings ............................................................. 68
Baulk Ring Clearance ............................................. 69

M/T OIL
MT-9
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M/T OILPFP:KLD20
Changing M/T OilECS00ID3
DRAINING
1. Start engine and let it run to warm up transmission.
2. Stop engine. Remove drain plug and gasket and then drain oil.
3. Set a gasket on drain plug and install it to transmission case. Tighten drain plug to the specified torque.
Refer toMT-19, "
Case Components".
CAUTION:
Do no reuse gasket.
FILLING
1. Remove filler plug and gasket. Fill with new oil until oil level reaches the specified limit near filler plug
mounting hole.
2. After refilling oil, check oil level. Set a gasket to filler plug, then install it to transmission case. Tighten filler
plug to the specified torque. Refer toMT-19, "
Case Components".
CAUTION:
Do no reuse gasket.
Checking M/T OilECS00ID4
OIL LEAKAGE AND OIL LEVEL
lMake sure that oil is not leaking from transmission or around it.
lCheck oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
Do not start engine while checking oil level.
lSet a gasket on filler plug and install it to transmission case.
Tighten filler plug to the specified torque. Refer toMT-19, "
Case
Components".
CAUTION:
Do not reuse gasket.Oil grade and viscosity: Refer toMA-14, "
Fluids and Lubricants".
Oil capacity
2WD models:
Approx. 3.99 (7 Imp pt)
4WD models:
Approx. 4.32 (7-5/8 Imp pt)
PCIB0268E

REAR OIL SEAL
MT-11
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MT
INSTALLATION
Note the following, and install in the reverse order of removal.
lFor 2WD models
Drive the rear oil seal (1) and dust seal (2) using the drift.
CAUTION:
Do not incline the dust seal and rear oil seal during installa-
tion.
(A): Seal lip
lFor 4WD models
Drive the rear oil seal using the drift.
CAUTION:
Do not incline the rear oil seal during installation.
lCheck the transmission oil level after installation. Refer toMT-9,
"Checking M/T Oil". Tool number
For oil seal : ST33200000
For dust seal : KV38100500
Dimension “H
1”: 1.2 - 2.2 mm (0.047 - 0.087 in)
Dimension “H
2”: 0.5 - 1.5 mm (0.020 - 0.059 in)
PCIB1660E
Tool number : ST33200000
Dimension “A”: -0.5 - 0.5 mm (-0.020 - 0.020 in)
PCIB1632E

REFRIGERANT LINES
MTC-131
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MTC
Checking for Refrigerant LeaksEJS0062F
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.
Checking System for Leaks Using the Fluorescent Leak DetectorEJS0062G
1. Check A/C system for leaks using the UV lamp and safety goggles [SST: J-42220] in a low sunlight area
(area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a
bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain open-
ing indicates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner [SST: J-43872] to prevent future mis-
diagnosis.
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.
Dye InjectionEJS0062H
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm
2,50
psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool [SST: J-41459].
3. Connect the injector tool to the A/C Low-pressure side service fitting.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture’s operat-
ing instructions).
6. With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system
connection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.

PS-1
POWER STEERING SYSTEM
G STEERING
CONTENTS
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SECTIONPS
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POWER STEERING SYSTEM
PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 2
Precautions for Steering System .............................. 2
PREPARATION ........................................................... 3
Special Service Tools [SST] ..................................... 3
Commercial Service Tools ........................................ 4
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ..................................... 5
POWER STEERING FLUID ........................................ 6
Checking Fluid Level ................................................ 6
Checking Fluid Leakage ........................................... 6
Air Bleeding Hydraulic System ................................. 6
STEERING WHEEL .................................................... 8
On-Vehicle Inspection and Service .......................... 8
CHECKING CONDITION OF INSTALLATION ...... 8
CHECKING STEERING WHEEL PLAY ................ 8
CHECKING NEUTRAL POSITION STEERING
WHEEL ................................................................. 8
CHECKING STEERING WHEEL TURNING
FORCE .................................................................. 8
CHECKING FRONT WHEEL TURNING ANGLE..... 9
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
STEERING COLUMN ................................................11
Removal and Installation ......................................... 11
COMPONENT ...................................................... 11
REMOVAL ............................................................ 11
INSPECTION AFTER REMOVAL ....................... 12
INSTALLATION ................................................... 12
INSPECTION AFTER INSTALLATION ............... 13
POWER STEERING GEAR AND LINKAGE ............ 14Removal and Installation ........................................ 14
COMPONENT ..................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 15
INSPECTION AFTER INSTALLATION ................ 15
Disassembly and Assembly .................................... 16
COMPONENT ..................................................... 16
DISASSEMBLY ................................................... 17
INSPECTION AFTER DISASSEMBLY ................ 18
ASSEMBLY ......................................................... 20
POWER STEERING OIL PUMP ............................... 25
On-Vehicle Inspection and Service ......................... 25
CHECKING RELIEF OIL PRESSURE ................ 25
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSTALLATION ................................................... 26
Disassembly and Assembly .................................... 26
COMPONENT ..................................................... 26
INSPECTION BEFORE DISASSEMBLY ............. 26
DISASSEMBLY ................................................... 27
INSPECTION AFTER DISASSEMBLY ................ 27
ASSEMBLY ......................................................... 28
HYDRAULIC LINE .................................................... 30
Component (RHD Models) ..................................... 30
Component (LHD Models) ...................................... 32
Removal and Installation ........................................ 33
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 34
Steering Wheel ....................................................... 34
Steering Angle ........................................................ 34
Steering Column ..................................................... 34
Steering Outer Socket and Inner Socket ................ 34
Steering Gear ......................................................... 35
Oil Pump ................................................................. 35
Steering Fluid .......................................................... 35

PS-6
POWER STEERING FLUID
POWER STEERING FLUID
PFP:KLF20
Checking Fluid LevelEGS001LD
lCheck fluid level with engine stopped.
lMake sure that fluid level is between MIN and MAX.
lFluid levels at HOT and COLD are different. Do not confuse
them.
CAUTION:
lThe fluid level should not exceed the MAX line. Excessive
fluid will cause fluid leakage from the cap.
lDo not reuse drained power steering fluid.
lRecommended fluid is Type DEXRONTMIII or equivalent.
Checking Fluid LeakageEGS001LE
Check hydraulic connections for fluid leakage, cracks, damage,
looseness, or wear.
1. Run engine until the fluid temperature reaches 50 to 80°C(122
to 176°F) in reservoir tank, and keep engine speed idle.
2. Turn steering wheel several times from full left stop to full right
stop.
3. Hold steering wheel at each lock position for five seconds and
carefully, check for fluid leakage.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 10 seconds. (There is the possibility that oil pump may
be damaged.)
4. If fluid leakage at connections is noticed, then loosen flare nut and then retighten. Do not over-tighten con-
nector as this can damage O-ring, washer and connector.
5. If fluid leakage from oil pump is noticed, check oil pump. Refer toPS-25, "
POWER STEERING OIL
PUMP".
6. Check steering gear boots for accumulation of fluid, indicating from steering gear.
Air Bleeding Hydraulic SystemEGS001LF
If air bleeding is not complete, the following symptoms can be observed.
lBubbles are created in reservoir tank.
lClicking noise can be heard from oil pump.
lExcessive buzzing in the oil pump
NOTE:
Fluid noise may occur in the steering gear or oil pump. This does not affect performance or durability of
the system.
1. Turn steering wheel several times from full left to full right stop with engine off.
CAUTION:
Turn steering wheel while filling reservoir tank with fluid so as not to lower fluid level below the
MIN line.
2. Start engine and hold steering wheel at each lock position for 3 seconds at idle to check for fluid leakage.
3. Repeat step 2 above several times at approximately 3 second intervals.
CAUTION:
Do not hold the steering wheel in a locked position for more than 10 seconds. (There is the possi-
bility that oil pump may be damaged.)
4. Check fluid for bubbles and while contamination.HOT : Fluid temperature 50 - 80°C (122 - 176°F)
COLD : Fluid temperature 0 - 30°C(32-86°F)
SGIA0232J
SGIA0506E

PS-8
STEERING WHEEL
STEERING WHEEL
PFP:48430
On-Vehicle Inspection and ServiceEGS001LG
CHECKING CONDITION OF INSTALLATION
lCheck installation conditions of steering gear assembly, front suspension assembly, axle and steering col-
umn assembly.
lCheck if movement exists when steering wheel is moved up and down, to the left and right and to the axial
direction.
lCheck steering gear assembly mounting bolts and nuts for looseness. Refer toPS-14, "COMPONENT".
CHECKING STEERING WHEEL PLAY
lTurn steering wheel so that front wheels come to the straight-ahead position. Start engine and lightly turn
steering wheel to the left and right until front wheels start to move. Measure steering wheel movement on
the outer circumference.
lWhen the measurement value is outside the standard value, check backlash for each joint of steering col-
umn assembly and installation condition of steering gear assembly.
CHECKING NEUTRAL POSITION STEERING WHEEL
lMake sure that steering gear assembly, steering column assembly and steering wheel are installed in the
correct position.
lPerform neutral position inspection after wheel alignment. Refer toFSU-7, "Front Wheel Alignment".
lSet vehicle to the straight-ahead position and confirm steering wheel is in the neutral position.
lLoosen outer socket lock nut and turn inner socket to left and right equally to make fine adjustment if
steering wheel is not in the neutral position.
CHECKING STEERING WHEEL TURNING FORCE
1. Park vehicle on a level and dry surface, set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating temperature. [Make sure temperature of fluid is
approximately 50 to 80°C(122to176°F).]
4. Check steering wheel turning force when steering wheel has
been turned 360°from neutral position.
NOTE:
Multiply the distance (L) from the hook of spring scale to the
center of steering wheel by the measurement value with a spring
scale.
5. If steering wheel turning force is out of the specification, check
rack sliding force and relief hydraulic pressure of oil pump.
Regarding relief hydraulic pressure of oil pump, refer toPS-25,
"CHECKING RELIEF OIL PRESSURE".
a. Disconnect lower joint and steering knuckle from steering gear assembly. Refer toPS-11, "
COMPO-
NENT",FAX-5, "Removal and Installation".
b. Start and run engine at idle to make sure steering fluid has reached normal operating temperature.Steering wheel axial end play : 0 mm (0 in)
Steering wheel play : 0 - 35 mm (0 - 1.38 in)
Steering wheel turn-
ing force: Less than 39 N (4.0 kg-m, 8.8 lb)
SGIA1136E

POWER STEERING OIL PUMP
PS-25
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POWER STEERING OIL PUMPPFP:49110
On-Vehicle Inspection and ServiceEGS001LL
CHECKING RELIEF OIL PRESSURE
CAUTION:
Make sure that belt tension is normal before starting the following procedure.
1. Connect the hydraulic pressure gauge [SST] between oil pump
discharge connector and high-pressure hose. Bleed air from the
hydraulic circuit while opening valve fully. Refer toPS-6, "
Air
Bleeding Hydraulic System".
2. Start engine. Run engine until oil temperature reaches 50 to
80°C(122to176°F).
CAUTION:
lLeave the valve of the hydraulic pressure gauge [SST]
fully open while starting and running engine. If engine is
started with the valve closed, the hydraulic pressure in
oil pump goes up to the relief pressure along with
unusual increase of oil temperature.
lBe sure to keep hose clear or belts and other parts when
engineisstarted.
3. Fully close the hydraulic pressure gauge [SST] valve with
engine at idle and measure the relief oil pressure.
CAUTION:
Never keep valve closed for 10 seconds or longer.
4. Open the valve slowly after measuring. Repair oil pump is the
relief oil pressure is outside the standard. Refer toPS-26, "
Dis-
assembly and Assembly".
5. After inspection, disconnect the hydraulic pressure gauge [SST] from hydraulic circuit, then add fluid and
bleed air. Refer toPS-6, "
Air Bleeding Hydraulic System".
Removal and InstallationEGS001LM
REMOVAL
1. Drain power steering fluid from reservoir tank.
2. Remove radiator shroud. Refer toCO-11, "
Components".
3. Loosen drive belt. Refer toEM-12, "
DRIVE BELTS".
4. Remove drive belt from oil pump pulley.
5. Disconnect the pressure sensor electrical connector.
6. Remove piping of high pressure and low pressure (drain fluid from their pipings). Refer toPS-30,
"HYDRAULIC LINE".
7. Remove oil pump mounting bolts, and then remove power steering pump. Refer toPS-30, "
HYDRAULIC
LINE". Relief oil pressure:
8,500 - 9,300 kpa (86.7 - 94.9 kg/cm
2, 1,233 - 1,349 psi)
SGIA1225E