2005 NISSAN NAVARA transmission

MODELD40 SERIES
2005 NISSAN EUROPE S.A.S.
All rights reserved. No part of this Electronic Service Manual may be reproduced or stored in a retrieval system, or transmitted in any
form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Nissan
Europe S.A.S., Paris, France.
A GENERAL INFORMATION
B ENGINE
C TRANSMISSION/TRANSAXLE
D DRIVELINE/AXLE
E SUSPENSION F BRAKES
G STEERING H RESTRAINTS
I BODY
J AIR CONDITIONER
K ELECTRICAL
L MAINTENANCE
M INDEXGI General Information
EM Engine Mechanical
LU Engine Lubrication System
CO Engine Cooling System
EC Engine Control System
FL Fuel System
EX Exhaust System
ACC Accelerator Control System
CL Clutch
MTManualTransmission
AT Automatic Transmission
TF Transfer
PR Propeller Shaft
FFD Front Final Drive
RFD Rear Final Drive
FAX Front Axle
RAX Rear Axle
FSU Front Suspension
RSU Rear Suspension
WT Road Wheels & Tires
BR Brake System
PB Parking Brake System
BRC Brake Control System
PS Power Steering System
SB Seat Belts
SRS Supplemental Restraint System (SRS)
BL Body, Lock & Security System
GW Glasses, Window System & Mirrors
RF Roof
EI Exterior & Interior
IP Instrument Panel
SE Seat
ATC Automatic Air Conditioner
MTC Manual Air Conditioner
SC Starting & Charging System
LT Lighting System
DI Driver Information System
WW Wiper, Washer & Horn
BCS Body Control System
LAN LAN System
AV Audio, Visual & Telephone System
ACS Auto Cruise Control System
PG Power Supply, Ground & Circuit Elements
MA Maintenance
IDX Alphabetical Index
QUICK REFERENCE INDEX
A
B
C
D
E
F
G
H
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K
L
M

AT-1
AUTOMATIC TRANSMISSION
C TRANSMISSION/TRANSAXLE
CONTENTS
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SECTIONAT
A
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AT
AUTOMATIC TRANSMISSION
INDEX FOR DTC ........................................................ 5
Alphabetical Index .................................................... 5
DTC No. Index ......................................................... 6
PRECAUTIONS .......................................................... 7
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 7
Precautions .............................................................. 7
Wiring Diagrams and Trouble Diagnosis .................. 8
PREPARATION ........................................................... 9
Special Service Tools ............................................... 9
Commercial Service Tools ...................................... 10
A/T FLUID ..................................................................11
Changing A/T Fluid ................................................. 11
Checking A/T Fluid ................................................. 12
A/T CONTROL SYSTEM .......................................... 14
Cross-Sectional View (2WD Models) ..................... 14
Cross-Sectional View (4WD Models) ..................... 15
Shift Mechanism ..................................................... 16
TCM Function ......................................................... 27
CAN Communication .............................................. 28
Input/Output Signal of TCM .................................... 28
Line Pressure Control ............................................ 29
Shift Control ........................................................... 30
Lock-up Control ...................................................... 31
Engine Brake Control ............................................. 32
Control Valve .......................................................... 33
TROUBLE DIAGNOSIS ............................................ 34
DTC Inspection Priority Chart ................................ 34
Fail-safe ................................................................. 34
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ..................................................... 36
A/T Electrical Parts Location .................................. 41
Circuit Diagram ...................................................... 42
Inspections Before Trouble Diagnosis .................... 43
Check Before Engine Is Started ............................. 46
Check at Idle .......................................................... 47
Cruise Test - Part 1 ................................................ 48
Cruise Test - Part 2 ................................................ 50
Cruise Test - Part 3 ................................................ 51Vehicle Speed at Which Gear Shifting Occurs ....... 52
Vehicle Speed at Which Lock-up Occurs/Releases... 52
Symptom Chart ....................................................... 53
TCM Input/Output Signal Reference Values ........... 76
CONSULT-II Function (A/T) .................................... 77
Diagnostic Procedure Without CONSULT-II ........... 89
DTC U1000 CAN COMMUNICATION LINE .............. 91
Description .............................................................. 91
On Board Diagnosis Logic ...................................... 91
Possible Cause ....................................................... 91
DTC Confirmation Procedure ................................. 91
Wiring Diagram — AT — CAN ................................ 92
Diagnostic Procedure ............................................. 93
DTC P0615 START SIGNAL CIRCUIT ..................... 94
Description .............................................................. 94
CONSULT-II Reference Value ................................ 94
On Board Diagnosis Logic ...................................... 94
Possible Cause ....................................................... 94
DTC Confirmation Procedure ................................. 94
Wiring Diagram — AT — STSIG ............................ 95
Diagnostic Procedure ............................................. 96
DTC P0700 TCM ....................................................... 98
Description .............................................................. 98
On Board Diagnosis Logic ...................................... 98
Possible Cause ....................................................... 98
DTC Confirmation Procedure ................................. 98
Diagnostic Procedure ............................................. 98
DTC P0705 PARK/NEUTRAL POSITION SWITCH... 99
Description .............................................................. 99
CONSULT-II Reference Value ................................ 99
On Board Diagnosis Logic ...................................... 99
Possible Cause ....................................................... 99
DTC Confirmation Procedure ................................. 99
Wiring Diagram — AT — PNP/SW .......................100
Diagnostic Procedure ...........................................101
DTC P0720 VEHICLE SPEED SENSOR A/T (REV-
OLUTION SENSOR) ...............................................103
Description ............................................................103
CONSULT-II Reference Value ..............................103
On Board Diagnosis Logic ....................................103

AT-4
Sensor 2 ...............................................................218
Parking Components (2WD Models Only) ............230
Rear Oil Seal ........................................................237
Revolution Sensor Components (2WD Models
Only) .....................................................................238
AIR BREATHER HOSE ...........................................243
Removal and Installation ......................................243
A/T FLUID COOLER ...............................................244
Removal and Installation ......................................244
TRANSMISSION ASSEMBLY ................................247
Removal and Installation ......................................247
OVERHAUL .............................................................251
Components .........................................................251
Oil Channel ...........................................................259
Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings ..........................261
DISASSEMBLY .......................................................263
Disassembly .........................................................263
REPAIR FOR COMPONENT PARTS ......................281
Oil Pump ...............................................................281
Front Sun Gear, 3rd One-way Clutch ...................284Front Carrier, Input Clutch, Rear Internal Gear .....286
Mid Sun Gear, Rear Sun Gear, High and Low
Reverse Clutch Hub ..............................................291
High and Low Reverse Clutch ..............................296
Direct Clutch .........................................................298
ASSEMBLY .............................................................300
Assembly (1) .........................................................300
Adjustment ............................................................313
Assembly (2) .........................................................316
SERVICE DATA AND SPECIFICATIONS (SDS) ....323
General Specifications ..........................................323
Stall Speed ............................................................323
Line Pressure ........................................................323
Vehicle Speed at Which Gear Shifting Occurs ......324
Vehicle Speed at Which Lock-Up Occurs/Releases.324
A/T Fluid Temperature Sensor ..............................324
Vehicle Speed Sensor A/T (Revolution Sensor) ...325
Turbine Revolution Sensor ....................................325
Reverse Brake ......................................................325
Total End Play .......................................................325

PRECAUTIONS
AT-7
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PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
ECS00IPT
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.
PrecautionsECS00IPR
lBefore connecting or disconnecting the A/T assembly har-
ness connector, turn ignition switch OFF and disconnect
the battery cable from the negative terminal. Because bat-
tery voltage is applied to TCM even if ignition switch is
turned OFF.
lAfter performing each TROUBLE DIAGNOSIS, perform
“DTC Confirmation Procedure”.
If the repair is completed the DTC should not be displayed
in the “DTC Confirmation Procedure”.
lAlways use the specified brand of ATF. Refer toMA-14, "REC-
OMMENDED FLUIDS AND LUBRICANTS".
lUse lint-free paper not cloth rags during work.
lAfter replacing ATF, dispose of the waste oil using the methods prescribed by law, ordinance, etc.
lBefore proceeding with disassembly, thoroughly clean the outside of the transmission. It is important to
prevent the internal parts from becoming contaminated by dirt or other foreign matter.
lDisassembly should be done in a clean work area.
lUse lint-free paper or towels for wiping parts clean. Common shop rags can leave fibers that could inter-
fere with the operation of the transmission.
lPlace disassembled parts in order for easier and proper assembly.
lAll parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
lGaskets, seals and O-rings should be replaced any time the transmission is disassembled.
lIt is very important to perform functional tests whenever they are indicated.
lThe valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place disassembled valve body parts in order for easier and proper assembly. Care will also prevent
springs and small parts from becoming scattered or lost.
lProperly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
lBefore assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, or hold bearings and washers in place during assembly. Do not use grease.
lExtreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
lAfter overhaul, refill the transmission with new ATF.
lWhen the drain plug is removed, only some of the ATF is drained. Old ATF will remain in torque converter
and A/T fluid cooling system.
Always follow the procedures under “Changing A/T Fluid” in the AT section when changing A/T fluid. Refer
toAT-11, "
Changing A/T Fluid",AT-12, "Checking A/T Fluid".
SEF289H

AT-16
A/T CONTROL SYSTEM
Shift Mechanism
ECS00FWH
The A/T uses compact triple planetary gear systems to improve power transmission efficiency, simplify con-
struction and reduce weight.
It also employs an optimum shift control and super wide gear ratios. They improve starting performance and
acceleration during medium and high-speed operation.
CONSTRUCTION
FUNCTION OF CLUTCH AND BRAKE
1. Front brake 2. Input clutch 3. Direct clutch
4. High and low reverse clutch 5. Reverse brake 6. Forward brake
7. Low coast brake 8. 1st one-way clutch 9. Forward one-way clutch
10. 3rd one-way clutch 11. Front sun gear 12. Input shaft
13. Mid internal gear 14. Front internal gear 15. Rear carrier
16. Rear sun gear 17. Mid sun gear 18. Front carrier
19. Mid carrier 20. Rear internal gear 21. Output shaft
22. Parking gear 23. Parking pawl
PCIA0002J
Name of the Part Abbreviation Function
Front brake (1) FR/B Fastens the front sun gear (11).
Input clutch (2) I/CConnects the input shaft (12), the front internal gear (14) and the mid internal gear
(13).
Direct clutch (3) D/C Connects the rear carrier (15) and the rear sun gear (16).
High and low reverse clutch (4) HLR/C Connects the mid sun gear (17) and the rear sun gear (16).
Reverse brake (5) R/B Fastens the rear carrier (15).
Forward brake (6) Fwd/B Fastens the mid sun gear (17).
Low coast brake (7) LC/B Fastens the mid sun gear (17).
1st one-way clutch (8) 1st OWCAllows the rear sun gear (16) to turn freely forward relative to the mid sun gear (17)
but fastens it for reverse rotation.
Forward one-way clutch (9) Fwd OWCAllows the mid sun gear (17) to turn freely in the forward direction but fastens it for
reverse rotation.
3rd one-way clutch (10) 3rd OWCAllows the front sun gear (11) to turn freely in the forward direction but fastens it for
reverse rotation.

A/T CONTROL SYSTEM
AT-17
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CLUTCH AND BAND CHART
l—Operates
l—Operates during “progressive” acceleration.
l—Operates and effects power transmission while coasting.
l—Line pressure is applied but does not affect power transmission.
l—Operates under conditions shown in HLR/C Operating Condition
l—Operates under conditions shown in LC/B Operating Condition. Delay control is applied during “D” (4,3,2,1)
“N” shift.
l*1: A/T will not shift to 5th when overdrive control switch is set in OFF position.Shift position I/C HLR/C D/C R/B FR/B LC/B Fwd/B1st
OWCFwd
OWC3rd
OWCRemarks
PPARK POSITION
RREVERSE POSI-
TION
NNEUTRAL POSI-
TION
D*11st
Automatic shift
1Û2Û3Û4Û5 2nd
3rd
4th
5th
31st
Automatic shift
1Û2Û3Ü4 2nd
3rd
4th
21st
Automatic shift
1Û2Ü3Ü4 2nd
3rd
4th
11st
Locks (held sta-
tionary in 1st
gear)
1Ü2Ü3Ü4 2nd
3rd
4th
SCIA5642E

AT-18
A/T CONTROL SYSTEM
POWER TRANSMISSION
“N” Position
Since both the forward brake and the reverse brake are released, torque from the input shaft drive is not trans-
mitted to the output shaft.
“P” Position
lThe same as for the “N” position, both the forward brake and the reverse brake are released, so torque
from the input shaft drive is not transmitted to the output shaft.
lThe parking pawl linked with the select lever meshes with the parking gear and fastens the output shaft
mechanically.
1. Front brake 2. Input clutch 3. Direct clutch
4. High and low reverse clutch 5. Reverse brake 6. Forward brake
7. Low coast brake 8. 1st one-way clutch 9. Forward one-way clutch
10. 3rd one-way clutch 11. Front sun gear 12. Input shaft
13. Mid internal gear 14. Front internal gear 15. Rear carrier
16. Rear sun gear 17. Mid sun gear 18. Front carrier
19. Mid carrier 20. Rear internal gear 21. Output shaft
22. Parking gear 23. Parking pawl
PCIA0003J

AT-28
A/T CONTROL SYSTEM
CAN Communication
ECS00FWJ
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 toLAN-30,
"CAN Communication Unit".
Input/Output Signal of TCMECS00FWK
*1: Spare for vehicle speed sensor·A/T (revolution sensor)
*2: Spare for accelerator pedal position signal
*3: If these input and output signals are different, the TCM triggers the fail-safe function.
*4: Used as a condition for starting self-diagnosis; if self-diagnosis are not started, it is judged that there is some kind of error.
*5: Input by CAN communications.
*6: Output by CAN communications.Control itemLine
pressure
controlVehicle
speed
controlShift
controlLock-up
controlEngine
brake
controlFail-safe
function
(*3)Self-diag-
nostics
function
InputAccelerator pedal position signal
(*5)XXXXXX X
Vehicle speed sensor A/T
(revolution sensor)XXXXXX X
Vehicle speed sensor MTR
(*1) (*5)X
Closed throttle position signal
(*5)X(*2) X X X X(*4)
Wide open throttle position signal
(*5)XX(*4)
Turbine revolution sensor 1 X X X X X
Turbine revolution sensor 2
(for 4th speed only)XXXXX
Engine speed signals
(*5)XXXXXX X
Stop lamp switch signal
(*5)XXX X(*4)
A/T fluid temperature sensors 1, 2 X X X X X X
ASCDOperation signal
(*5)XXX
Overdrive cancel signal
(*5)X
OutputDirect clutch solenoid
(ATF pressure switch 5)XX X X
Input clutch solenoid
(ATF pressure switch 3)XX X X
High and low reverse clutch solenoid
(ATF pressure switch 6)XX X X
Front brake solenoid
(ATF pressure switch 1)XX X X
Low coast brake solenoid
(ATF pressure switch 2)XX XX X
Line pressure solenoid X X X X X X X
TCC solenoid X X X
Self-diagnosis table
(*6)X
Starter relayXX