Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 2003-2005 Approved Nissan Frontier 2005 RFD
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D DRIVELINE/AXLE
A
SECTION RFD
REAR FINAL DRIVE
B
C
RFD
E
CONTENTS
C200 4WD MODELS ................................................... 35
. F
Inspection and Adjustment .................................... 35
.
PRECAUTIONS ......................................................... 4
. DRIVE GEAR RUNOUT ..................................... 35 .
Service Notice or Precautions ................................. 4 . DIFFERENTIAL SIDE GEAR CLEARANCE ...... 35 . G
PREPARATION .......................................................... 5
. PRELOAD TORQUE .......................................... 35 .
Special Service Tools .............................................. 5
. BACKLASH ........................................................ 35
.
Commercial Service Tools ....................................... 7 . COMPANION FLANGE RUNOUT ...................... 36 .
NOISE, VIBRATION AND HARSHNESS (NVH) H
SELECTIVE PARTS ........................................... 36.
TROUBLESHOOTING ............................................... 8 .
NVH Troubleshooting Chart .................................... 8 .
DESCRIPTION ........................................................... 9
.
M226 WITHOUT ELECTRONIC LOCKING
I
Cross-Sectional View .............................................. 9. DIFFERENTIAL
DIFFERENTIAL GEAR OIL ..................................... 10 . PRECAUTIONS ....................................................... 37.
Changing Differential Gear Oil .............................. 10 . Service Notice or Precautions ............................... 37 . J
DRAINING .......................................................... 10
. PREPARATION ........................................................ 38
.
FILLING .............................................................. 10
. Special Service Tools ............................................ 38.
Checking Differential Gear Oil ............................... 10 . Commercial Service Tools ..................................... 41 .
OIL LEAKAGE AND OIL LEVEL ........................ 10 . K
NOISE, VIBRATION, AND HARSHNESS (NVH)
FRONT OIL SEAL ....................................................11 . TROUBLESHOOTING ............................................. 42 .
Removal and Installation ........................................11 . NVH Troubleshooting Chart .................................. 42 .
REMOVAL ...........................................................11
. DESCRIPTION ......................................................... 43
. L
INSTALLATION .................................................. 12 . Cross-Sectional View ............................................ 43 .
CARRIER COVER ................................................... 13 . DIFFERENTIAL GEAR OIL ..................................... 44 .
Removal and Installation ....................................... 13 . Changing Differential Gear Oil ............................... 44 . M
REMOVAL .......................................................... 13
. DRAINING .......................................................... 44
.
INSTALLATION .................................................. 13 . FILLING .............................................................. 44
.
REAR FINAL DRIVE ASSEMBLY ........................... 14 . Checking Differential Gear Oil ............................... 44 .
Removal and Installation ....................................... 14 . OIL LEAKAGE AND OIL LEVEL ........................ 44 .
REMOVAL .......................................................... 14
. FRONT OIL SEAL .................................................... 45.
INSTALLATION .................................................. 14 . Removal and Installation ....................................... 45 .
Disassembly and Assembly .................................. 15 . REMOVAL .......................................................... 45
.
COMPONENTS ................................................. 15 . INSTALLATION .................................................. 47 .
ASSEMBLY INSPECTION AND ADJUSTMENT 17 ... CARRIER COVER ................................................... 48 .
DISASSEMBLY .................................................. 21 . Removal and Installation ....................................... 48 .
INSPECTION AFTER DISASSEMBLY .............. 24 . REMOVAL .......................................................... 48
.
ADJUSTMENT AND SELECTION ADJUSTING INSTALLATION .................................................. 48 .
WASHERS ......................................................... 25
. REAR FINAL DRIVE ASSEMBLY ........................... 49 .
ASSEMBLY ........................................................ 30
. Removal and Installation ....................................... 49 .
SERVICE DATA AND SPECIFICATIONS (SDS) ..... 35 . REMOVAL .......................................................... 49
.
General Specifications .......................................... 35 .
2WD MODELS ................................................... 35 .
Revision: November 2005 RFD-1 2005 Frontier
INSTALLATION ................................................... 49
. Differential Lock Control Unit Input/Output Signal
Disassembly and Assembly ................................... 50 . Reference Values ...................................................85 .
COMPONENTS .................................................. 50
. DIFFERENTIAL LOCK CONTROL UNIT
ASSEMBLY INSPECTION AND ADJUSTMENT 51 ... INSPECTION TABLE ..........................................85 .
DISASSEMBLY .................................................. 54
. CONSULT-II Function (DIFF LOCK) ......................87 .
INSPECTION AFTER DISASSEMBLY ............... 58 . FUNCTION .........................................................87 .
SELECTION ADJUSTING WASHERS ............... 59 . CONSULT-II SETTING PROCEDURE ...............87 .
ASSEMBLY ........................................................ 62
. SELF-DIAG RESULTS MODE ............................88 .
SERVICE DATA AND SPECIFICATIONS (SDS) ..... 68 . DATA MONITOR MODE .....................................90 .
General Specifications ........................................... 68
. TROUBLE DIAGNOSIS FOR SYSTEM ...................91 .
Inspection and Adjustment .................................... 68
. Power Supply Circuit For Differential Lock Control
DIFFERENTIAL SIDE GEAR CLEARANCE ...... 68 . Unit .........................................................................91
.
PRELOAD TORQUE .......................................... 68 . CONSULT-II REFERENCE VALUE IN DATA
BACKLASH ........................................................ 68
. MONITOR MODE ...............................................91 .
COMPANION FLANGE RUNOUT ...................... 68 . DIFFERENTIAL LOCK CONTROL UNIT TER-
SELECTIVE PARTS ........................................... 69. MINALS AND REFERENCE VALUE ..................91 .
DIAGNOSTIC PROCEDURE ..............................92 .
M226 WITH ELECTRONIC LOCKING DIFFER- Differential Lock Control Unit .................................93 .
DIAGNOSTIC PROCEDURE ..............................93 .
ENTIAL
Differential Lock Mode Switch ................................93 .
PRECAUTIONS ........................................................ 70
. CONSULT-II REFERENCE VALUE IN DATA
Precautions for Supplemental Restraint System MONITOR MODE ...............................................93 .
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- DIFFERENTIAL LOCK CONTROL UNIT TER-
SIONER" ................................................................ 70
. MINALS AND REFERENCE VALUE ..................93 .
Precautions ............................................................ 70
. DIAGNOSTIC PROCEDURE ..............................94 .
Service Notice or Precaution ................................. 71 . COMPONENT INSPECTION ..............................96 .
Wiring Diagrams and Trouble Diagnosis ............... 71 . Differential Lock Position Switch ............................97 .
PREPARATION ........................................................ 72
. CONSULT-II REFERENCE VALUE IN DATA
Special Service Tools ............................................ 72. MONITOR MODE ...............................................97 .
Commercial Service Tools ..................................... 75 . DIFFERENTIAL CONTROL UNIT TERMINALS
NOISE, VIBRATION AND HARSHNESS (NVH) AND REFERENCE VALUE .................................97 .
TROUBLESHOOTING ............................................. 76 . DIAGNOSTIC PROCEDURE ..............................98 .
NVH Troubleshooting Chart ................................... 76 . COMPONENT INSPECTION ............................ 100 .
DIFFERENTIAL GEAR OIL ..................................... 77 . Differential Lock Solenoid Relay .......................... 100 .
Changing Differential Gear Oil ............................... 77 . CONSULT-II REFERENCE VALUE IN DATA
DRAINING .......................................................... 77
. MONITOR MODE ............................................. 100 .
FILLING .............................................................. 77
. DIAGNOSTIC PROCEDURE ............................ 100 .
Checking Differential Gear Oil ............................... 77 . Differential Lock Solenoid .................................... 101 .
OIL LEAKAGE AND OIL LEVEL ........................ 77 . CONSULT-II REFERENCE VALUE IN DATA
DIFFERENTIAL LOCK SYSTEM ............................. 78 . MONITOR MODE ............................................. 101 .
Cross-sectional View ............................................. 78. DIFFERENTIAL LOCK CONTROL UNIT TER-
Differential Lock Operation .................................... 79 . MINALS AND REFERENCE VALUE ................ 101 .
System Description ................................................ 79
. DIAGNOSTIC PROCEDURE ............................ 102 .
DIFFERENTIAL LOCK SOLENOID .................... 79 . COMPONENT INSPECTION ............................ 105 .
DIFFERENTIAL LOCK POSITION SWITCH ...... 79 . ABS System ......................................................... 105 .
DIFFERENTIAL LOCK CONTROL UNIT ........... 79 . DIAGNOSTIC PROCEDURE ............................ 105 .
DIFFERENTIAL LOCK MODE SWITCH ............ 79 . CAN Communication Line .................................... 106 .
DIFF LOCK INDICATOR LAMP .......................... 79 . DIAGNOSTIC PROCEDURE ............................ 106 .
System Diagram .................................................... 80
. TROUBLE DIAGNOSIS FOR SYMPTOMS ........... 107 .
COMPONENTS FUNCTION DESCRIPTION ..... 80 . DIFF LOCK Indicator Lamp Does Not Turn ON ... 107 .
CAN Communication ............................................. 80 . DIAGNOSTIC PROCEDURE ............................ 107 .
SYSTEM DESCRIPTION ................................... 80 . DIFF LOCK Indicator Lamp Does Not Change .... 110 .
TROUBLE DIAGNOSIS ........................................... 81 . DIAGNOSTIC PROCEDURE ............................ 110 .
Fail-safe Function .................................................. 81
. DIFF LOCK Indicator Lamp Sometimes Flashes . 111
How to Perform Trouble Diagnosis ........................ 81 . DIAGNOSTIC PROCEDURE ............................ 111 .
BASIC CONCEPT .............................................. 81 . DIFFERENTIAL LOCK CONTROL UNIT ............... 113 .
Location of Electrical Parts .................................... 82 . Removal and Installation ...................................... 113 .
Wiring Diagram -- DIFLOC -- ............................... 83 . REMOVAL ......................................................... 113 .
Trouble Diagnosis Chart for Symptoms ................. 85 . INSTALLATION ................................................. 113 .
Revision: November 2005 RFD-2 2005 Frontier
FRONT OIL SEAL ..................................................114
. INSTALLATION ................................................ 118
.
Removal and Installation ......................................114
. Disassembly and Assembly ................................. 119 . A
REMOVAL .........................................................114
. COMPONENTS ................................................ 119
.
INSTALLATION .................................................116
. ASSEMBLY INSPECTION AND ADJUSTMENT 120 .
CARRIER COVER ..................................................117
. DISASSEMBLY ................................................ 123
. B
Removal and Installation ......................................117
. INSPECTION AFTER DISASSEMBLY ............. 127 .
REMOVAL .........................................................117
. SELECTION ADJUSTING WASHERS ............. 128 .
INSTALLATION .................................................117
. ASSEMBLY ...................................................... 130
.
REAR FINAL DRIVE ASSEMBLY ..........................118 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 135 . C
Removal and Installation ......................................118
. General Specifications ......................................... 135
.
REMOVAL .........................................................118
. Inspection and Adjustment .................................. 135.
PRELOAD TORQUE ........................................ 135 . RFD
BACKLASH ...................................................... 135
.
COMPANION FLANGE RUNOUT .................... 135 .
SELECTIVE PARTS ......................................... 136 . E
F
G
H
I
J
K
L
M
Revision: November 2005 RFD-3 2005 Frontier
PRECAUTIONS
[C200]
PRECAUTIONS PFP:00001
Service Notice or Precautions EDS0026E
G Check 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.
G Overhaul should be done in a clean work area, it is preferable to work in dust proof area.
G Before disassembly completely remove sand and mud from the exterior of the unit, preventing them from
entering into the unit during disassembly or assembly.
G Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary.
G Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.
G In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
G Clean and flush the parts sufficiently and blow-dry them.
G Be careful not to damage sliding surfaces and mating surfaces.
G When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.
G Always use shop paper for cleaning the inside of components.
G Avoid using cotton gloves or shop rags to prevent entering of lint.
G During assembly, observe the specified tightening torque, and apply new differential gear oil, petroleum
jelly, or multi-purpose grease as specified.
Revision: November 2005 RFD-4 2005 Frontier
PREPARATION
[C200]
PREPARATION PFP:00002
A
Special Service Tools EDS0026F
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
B
(Kent-Moore No.) Description
Tool name
KV38108300 Removing and installing drive pinion lock nut
(J-44195) C
Flange wrench
RFD
NT771
KV38100500 Installing front oil seal E
(J-25273) a: 80 mm (3.15 in) dia.
Drift b: 60 mm (2.36 in) dia.
F
ZZA0811D
G
ST3127S000 Measuring pinion bearing preload and total
(J-25765-A) preload
Preload gauge
1: GG91030000 H
(J-25765)
Torque wrench
2: HT62940000
( -- ) I
Socket adapter (1/2)
3: HT62900000 NT124
( -- )
J
Socket adapter (3/8)
KV10111100 Removing rear cover
(J-37228)
Seal cutter K
L
S-NT046
ST3306S001 Removing and installing side bearing inner
( -- ) race M
Differential side bearing puller set a: 28.5 mm (1.122 in) dia.
1: ST33051001 b: 38 mm (1.50 in) dia.
(J-22888-20)
Puller
2: ST33061000
(J-8107-2)
NT072
Base
ST30031000 Removing pinion rear bearing inner race
(J-22912-01)
Puller
ZZA0700D
Revision: November 2005 RFD-5 2005 Frontier
PREPARATION
[C200]
Tool number
(Kent-Moore No.) Description
Tool name
KV38100600 Installing side bearing adjusting washer
(J-25267) a: 8 mm (0.31 in)
Drift b: R42.5 mm (1.673 in)
NT528
ST30621000 Installing pinion rear bearing outer race
(J-25742-5) a: 79 mm (3.11 in) dia.
Drift b: 59 mm (2.32 in) dia.
ZZA1000D
ST30613000 Installing pinion front bearing outer race
(J-25742-3) a: 72 mm (2.83 in) dia.
Drift b: 48 mm (1.89 in) dia.
ZZA1000D
ST30611000 Installing pinion front bearing outer race
(J-25742-1) [Use with ST30613000 (J-25742-3) and
Drift bar ST30621000 (J-25742-5)]
S-NT090
ST30901000 Installing pinion rear bearing inner race
(J-26010-01) a: 79 mm (3.11 in) dia.
Drift b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.
ZZA0978D
ST3323 0000 Installing side bearing inner race
(J-25805-01) a: 51 mm (2.01 in) dia.
Drift b: 41 mm (1.61 in) dia.
c: 28.5 mm (1.122 in) dia.
NT085
-- Measuring turning torque
(J-8129)
Spring gauge
NT127
Revision: November 2005 RFD-6 2005 Frontier
PREPARATION
[C200]
Tool number
(Kent-Moore No.) Description A
Tool name
-- Adjusting bearing preload and pinion gear
(J-34309) height B
Differential shim selector tool
C
NT134
-- Selecting pinion height adjusting washer RFD
(J-25269-4)
Side bearing disc (2 Req'd)
E
NT136
F
Commercial Service Tools EDS0026G
Tool name Description
Spacer Installing pinion front bearing inner race
G
a: 60 mm (2.36 in) dia.
b: 36 mm (1.42 in) dia.
c: 30 mm (1.18 in) H
ZZA1133D I
Power tool Loosening nuts and bolts
J
K
PBIC0190E
L
M
Revision: November 2005 RFD-7 2005 Frontier
Symptom
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