Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Pathfinder 2004-2007 Approved Nissan Pathfinder 2004 tf
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GI
TRANSFER
MA
SECTION TF EM
LC
EC
FE
CONTENTS CL
PREPARATION ...............................................................4 INSPECTION ...........................................................27
ASSEMBLY .............................................................27
MT
Special Service Tools ..................................................4
Commercial Service Tools ...........................................9 Main Gear ..................................................................27
DISASSEMBLY ........................................................27
AT
INSPECTION ...........................................................28
TX10A
ASSEMBLY .............................................................28
NOISE, VIBRATION AND HARSHNESS (NVH) Front Case .................................................................28
TROUBLESHOOTING ...................................................10 REMOVAL ...............................................................28
NVH Troubleshooting Chart.......................................10 INSTALLATION........................................................29
TRANSFER .............................................................10 Front Case Cover ......................................................29 PD
DESCRIPTION ...............................................................11 REMOVAL ...............................................................29
Cross-sectional View .................................................11 INSTALLATION........................................................29
ON-VEHICLE SERVICE ................................................12 Bearing Retainer........................................................29 AX
Replacing Oil Seal .....................................................12 REMOVAL ...............................................................29
INSTALLATION........................................................29
CENTER CASE OIL SEAL ........................................12
SHIFT SHAFT OIL SEAL ..........................................13 Center Case...............................................................30 SU
REAR OIL SEAL ......................................................13 REMOVAL ...............................................................30
Position Switch Check ...............................................14 INSTALLATION........................................................30
Rear Case..................................................................30 BR
REMOVAL AND INSTALLATION .................................15
REMOVAL ...............................................................30
Removal.....................................................................15
INSTALLATION........................................................30
Installation..................................................................15
Shift Control Components .........................................31
ST
M/T MODEL ............................................................15
INSPECTION ...........................................................31
A/T MODEL .............................................................15
ASSEMBLY....................................................................32 RS
OVERHAUL ...................................................................16
SERVICE DATA AND SPECIFICATIONS (SDS) .........39
Transfer Gear Control................................................16
General Specifications...............................................39
Case Components .....................................................17
Gear Components .....................................................18
Gear End Play ...........................................................39 BT
Available Snap Ring ..................................................39
Shift Control Components .........................................19
MAINSHAFT FRONT BEARING ................................39
DISASSEMBLY..............................................................20 HA
MAINSHAFT REAR BEARING ..................................39
REPAIR FOR COMPONENT PARTS ...........................24 MAIN GEAR BEARING.............................................39
Mainshaft ...................................................................24 Available Shim ...........................................................40
DISASSEMBLY ........................................................24 COUNTER GEAR REAR BEARING ...........................40 SC
INSPECTION ...........................................................25
ASSEMBLY .............................................................25
ATX14A EL
Front Drive Shaft .......................................................26
DISASSEMBLY ........................................................26 PRECAUTIONS .............................................................41
INSPECTION ...........................................................26 Supplemental Restraint System (SRS) AIR
ASSEMBLY .............................................................26 BAG and SEAT BELT PRE-TENSIONER.............41
IDX
Counter Gear .............................................................26 Precautions ................................................................41
DISASSEMBLY ........................................................26
Service Notice............................................................42
CONTENTS (Cont'd)
Wiring Diagrams and Trouble Diagnosis...................42 INSPECTION OF TRANSFER CONTROL UNIT..........88
ALL-MODE 4WD SYSTEM ...........................................43 TRANSFER CONTROL UNIT INSPECTION TABLE ....89
Cross-sectional View .................................................43 DTC U1000 CAN COMMUNICATION LINE (WITH
Control System ..........................................................44 VDC)...............................................................................95
ALL-MODE 4WD TRANSFER BASIC CONTROL ........45 Description .................................................................95
HYDRAULIC CONTROL CIRCUITS ...........................45 On Board Diagnosis Logic.........................................95
OUTLINE ................................................................45 Possible Cause..........................................................95
CONTROL SYSTEM DIAGRAM ................................46 DTC Confirmation Procedure ....................................95
INDICATIONS OF 4WD WARNING LAMP..................46 WITH CONSULT-II ..............................................95
CAN Communication (With VDC)..............................47 WITH GST .........................................................95
SYSTEM DESCRIPTION ..........................................47 Diagnostic Procedure ................................................96
Location of Electrical Parts........................................48 VEHICLE SPEED SENSOR (FRONT
Description of Electrical Parts ...................................49 REVOLUTION SENSOR) (WITHOUT VDC) .................97
TRANSFER MOTOR ................................................49 Diagnostic Procedure ................................................97
WAIT DETECTION SWITCH .....................................49 4WD SOLENOID VALVE.............................................100
2-4WD SHIFT SOLENOID VALVE .............................50
Diagnostic Procedure ..............................................100
LINE PRESSURE SWITCH .......................................50
2-4WD SHIFT SOLENOID VALVE AND 4WD
Circuit Diagram for Quick Pinpoint Check.................51
SHIFT SWITCH............................................................102
Wiring Diagram - TF -................................................52
Diagnostic Procedure ..............................................102
ON BOARD DIAGNOSTIC SYSTEM
TRANSFER MOTOR AND TRANSFER MOTOR
DESCRIPTION ...............................................................61
RELAY .........................................................................106
Trouble Diagnosis without CONSULT-II ....................61
Diagnostic Procedure ..............................................106
DESCRIPTION ........................................................61
TRANSFER FLUID TEMPERATURE SENSOR..........109
SELF-DIAGNOSTIC PROCEDURE............................62
INDICATIONS OF 4WD WARNING LAMP..................63 Diagnostic Procedure ..............................................109
Trouble Diagnosis with CONSULT-II .........................64 ATP SWITCH, WAIT DETECTION SWITCH AND
CONSULT-II FUNCTION ...........................................64 NEUTRAL-4LO SWITCH.............................................112
SELF-DIAGNOSIS ...................................................64 Diagnostic Procedure ..............................................112
SELF-DIAGNOSTIC ITEMS ......................................66 CLUTCH PRESSURE SWITCH ..................................116
DATA MONITOR......................................................67 Diagnostic Procedure ..............................................116
DATA MONITOR ITEMS ...........................................69 LINE PRESSURE SWITCH .........................................119
REFERENCE VALUE IN DATA MONITOR MODE ......71 Diagnostic Procedure ..............................................119
WORK SUPPORT ....................................................73 ABS OPERATION SIGNAL (WITHOUT VDC) ...........122
CLUTCH FORCE RELEASE LIMIT ADJUSTMENT .....74 Diagnostic Procedure ..............................................122
TROUBLE DIAGNOSIS - INTRODUCTION..................76 DATA ERASE/DISPLAY .............................................124
Introduction ................................................................76 Diagnostic Procedure ..............................................124
DESCRIPTION ........................................................76
SHIFT ACTUATOR......................................................125
DIAGNOSTIC WORKSHEET.....................................76
Diagnostic Procedure ..............................................125
Work Flow..................................................................78
SHIFT ACTUATOR POSITION SWITCH ....................128
HOW TO PERFORM TROUBLE DIAGNOSES FOR
QUICK AND ACCURATE REPAIR .............................78
Diagnostic Procedure ..............................................128
TROUBLE DIAGNOSIS - BASIC INSPECTION ...........79 SHIFT ACTUATOR CIRCUIT ......................................130
Listen to Customer Complaints .................................79 Diagnostic Procedure ..............................................130
Transfer Fluid Check .................................................79 TROUBLE DIAGNOSES FOR SYMPTOMS ...............134
Road Test...................................................................79 Symptom 1. 4WD Shift Indicator Lamp Does Not
PREPARATION FOR ROAD TEST ............................79 Turn ON ...................................................................134
1. CHECK BEFORE ENGINE IS STARTED ...............80 Symptom 2. 4WD Warning Lamp Does Not Turn
2. CHECK AT IDLE ..................................................81 ON............................................................................136
3. CRUISE TEST .....................................................85 Symptom 3. 4WD Shift Indicator Lamp Does Not
TROUBLE DIAGNOSIS - GENERAL Turn OFF .................................................................138
DESCRIPTION ...............................................................88 Symptom 4. ATP Warning Lamp Does Not Turn
Transfer Control Unit Terminals and Reference ON............................................................................138
Value ..........................................................................88 Symptom 5. 4LO Indicator Lamp Does Not Turn
REMOVAL AND INSTALLATION OF TRANSFER ON............................................................................140
CONTROL UNIT ......................................................88
TF-2
CONTENTS (Cont'd) GI
Symptom 6. 4WD Shift Indicator Lamp Does Not Removal...................................................................155
Indicate 4H............................................................142 Installation................................................................155 MA
Symptom 7. 4WD Shift Indicator Lamp Repeats OVERHAUL .................................................................156
Flickering..................................................................143 Transfer Gear Control..............................................156
Symptom 8. Tight Corner Braking Symptom...........144 Transfer Components ..............................................157 EM
Symptom 9. 4WD System Does Not Operate.........145 DISASSEMBLY............................................................159
COMPONENT INSPECTION .......................................147 Rear Case................................................................159
4WD Shift Switch.....................................................147 DISASSEMBLY ......................................................159
LC
2-4WD Shift Solenoid Valve and Transfer Fluid Center Case.............................................................159
Temperature Sensor ................................................147 DISASSEMBLY ......................................................159 EC
4WD Solenoid Valve, Clutch Pressure Switch Front Case ...............................................................169
and Line Pressure Switch........................................147 DISASSEMBLY ......................................................169
Front Revolution Sensor..........................................148 REPAIR FOR COMPONENT PARTS .........................173 FE
Transfer Dropping Resistor......................................148 Front Case ...............................................................173
ATP Switch, Neutral-4LO Switch and Wait INSPECTION .........................................................173
Detection Switch ......................................................148 Center Case.............................................................174 CL
INSPECTION .........................................................174
Transfer Motor .........................................................149
ASSEMBLY..................................................................177
Transfer Motor Relay ...............................................149 MT
Front Case ...............................................................177
Transfer Sub-harness ..............................................149
ASSEMBLY ...........................................................177
FRONT REVOLUTION SENSOR SUB-HARNESS
Center Case.............................................................181
CONNECTOR ........................................................149
ASSEMBLY ...........................................................181
AT
TRANSFER SWITCH ASSEMBLY SUB-HARNESS
CONNECTOR ........................................................150 Final Assembly.........................................................189
TRANSFER TERMINAL CORD ASSEMBLY SUB- SERVICE DATA AND SPECIFICATIONS (SDS) .......192
HARNESS CONNECTOR .......................................150 General Specifications.............................................192
Transfer Shift Relay (High & low)............................150 Inner Gear and Outer Gear .....................................192
Actuator & Actuator Position Switch........................151 SUB-OIL PUMP .....................................................192 PD
ACTUATOR ...........................................................151 MAIN OIL PUMP ....................................................192
ACTUATOR POSITION SWITCH ............................151 Control Valve ...........................................................192
ON-VEHICLE SERVICE ..............................................152 VALVE ..................................................................192 AX
Replacing Oil Seal ...................................................152 SPRING ................................................................192
FRONT CASE OIL SEAL ........................................152 Clutch.......................................................................193
SHIFT SHAFT OIL SEAL ........................................153 DRIVE PLATE .......................................................193 SU
REAR OIL SEAL ....................................................153 DRIVEN PLATE .....................................................193
Transfer Motor .........................................................154 RETURN SPRING..................................................193
RETAINING PLATE................................................193 BR
REMOVAL .............................................................154
INSTALLATION......................................................154 Seal Ring (Mainshaft side) ......................................194
Transfer Oil Filter .....................................................154 Bearing Race (Thrust needle bearing side) ............194
ST
REMOVAL .............................................................154 Snap Ring (Sun gear side)......................................194
INSTALLATION......................................................154
REMOVAL AND INSTALLATION ...............................155 RS
BT
HA
SC
EL
IDX
TF-3
PREPARATION
Special Service Tools
Special Service Tools NATF0093
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.) Description
Tool name
KV38108300 Removing companion flange nut
(J44195) Installing companion flange nut
Companion flange
wrench
NT771
ST30021000 Removing low gear
(J22912-01) Removing counter gear front bearing
Puller (Use with ST36710010)
Removing L & H hub
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
NT411
ST30031000 Removing counter gear rear bearing
(J22912-01) (Use with ST36710010)
Puller a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
NT411
ST33290001 Removing center case oil seal
(J25810-A) Removing rear oil seal
Puller a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
NT414
ST33051001 Removing companion flange
(J22888) a: 135 mm (5.31 in)
Puller b: 100 mm (3.94 in)
c: 130 mm (5.12 in)
NT657
ST30720000 1 Installing center case oil seal
1 (J25273) 2 Installing rear oil seal
2 (J25405) a: 77 mm (3.03 in) dia.
Drift b: 55.5 mm (2.185 in) dia.
NT658
TF-4
PREPARATION
Special Service Tools (Cont'd)
Tool number GI
(Kent-Moore No.) Description
Tool name
MA
ST36710010 Removing counter gear front bearing
( -- ) (Use with ST30021000)
Drift Removing counter gear rear bearing
(Use with ST30031000)
EM
a: 34.5 mm (1.358 in) dia.
NT063
LC
ST33061000 Removing main gear bearing
(J8107-2) a: 28.5 mm (1.122 in) dia.
Drift b: 38 mm (1.50 in) dia.
EC
NT116
FE
ST30613000 1 Installing main gear bearing
1 (J25742-3) 2 Installing front case cover oil seal
2 (J34339) a: 72 mm (2.83 in) dia. CL
Drift b: 48 mm (1.89 in) dia.
MT
NT073
(J35864) Installing shift shaft oil seal
Drift a: 26 mm (1.02 in) dia. AT
b: 20 mm (0.79 in) dia.
c: 150 mm (5.91 in)
NT117
(J26092) Seating counter gear assembly
Drift a: 44.5 mm (1.752 in) dia. PD
b: 38.5 mm (1.516 in) dia.
AX
NT065
(J34291) Selecting counter gear rear bearing shim
Shim setting gauge set SU
BR
NT101
ST
(J34291-20) Selecting counter gear rear bearing shim
Plunger-shim setting
gauge
RS
NT118
BT
KV40100621 Installing front drive shaft bearing
(J26091) a: 76 mm (2.99 in) dia.
Drift b: 69 mm (2.72 in) dia. HA
SC
NT086
EL
IDX
TF-5
PREPARATION
Special Service Tools (Cont'd)
Tool number
(Kent-Moore No.) Description
Tool name
ST30032000 Installing front drive shaft bearing
( -- ) a: 38 mm (1.50 in) dia.
Base b: 80 mm (3.15 in) dia.
NT660
ST33052000 Removing front drive shaft bearing
( -- ) a: 28 mm (1.10 in) dia.
Adapter b: 22 mm (0.87 in) dia.
NT431
ST35271000 Installing rear oil seal
(J26091) Removing and installing press flange snap ring
Drift a: 72 mm (2.83 in) dia.
b: 63 mm (2.48 in) dia.
NT115
ST27863000 Removing and installing press flange snap ring
( -- ) a: 74.5 mm (2.933 in) dia.
Support ring b: 62.5 mm (2.461 in) dia.
NT661
KV40104710 Removing and installing press flange snap ring
( -- ) a: 76.3 mm (3.004 in) dia.
Support ring b: 67.9 mm (2.673 in) dia.
NT661
ST35291000 Removing mainshaft rear bearing
( -- ) a: 40 mm (1.57 in) dia.
Remover b: 29.5 mm (1.161 in) dia.
c: 22.5 mm (0.886 in) dia.
NT662
TF-6
PREPARATION
Special Service Tools (Cont'd)
Tool number GI
(Kent-Moore No.) Description
Tool name
MA
ST30090010 Removing mainshaft rear bearing
( -- ) a: 165 mm (6.50 in)
Remover b: 25 mm (0.98 in) dia.
c: M16 x P2.0
EM
LC
NT663 EC
KV38100500 Installing front drive shaft oil seal
( -- ) a: 80 mm (3.15 in) dia.
Drift b: 60 mm (2.36 in) dia. FE
NT115
CL
KV40100621 Installing mainshaft rear bearing
(J25273) a: 76 mm (2.99 in) dia. MT
Drift b: 69 mm (2.72 in) dia.
AT
NT104
KV32101100 Removing and installing L-H fork, 2-4 fork
( -- ) a: 6 mm (0.24 in) dia.
Pin punch PD
AX
NT410
ST3306S001 Installing mainshaft rear bearing
(J22888-D) Removing sun gear assembly SU
Differential side bearing a: 28.5 mm (1.122 in) dia.
puller set b: 38 mm (1.50 in) dia.
1: ST33051001 BR
( -- )
Puller
2: ST33061000
(J8107-2) ST
Adapter NT072
ST30911000 Installing mainshaft and planetary carrier assembly RS
( -- ) a: 98 mm (3.86 in) dia.
Puller b: 40.5 mm (1.594 in) dia.
BT
HA
NT664
SC
EL
IDX
TF-7
PREPARATION
Special Service Tools (Cont'd)
Tool number
(Kent-Moore No.) Description
Tool name
KV381054S0 Removing rear oil seal
( -- )
Outer race puller
NT665
KV40105230 Installing planetary carrier assembly
( -- ) a: 92 mm (3.62 in) dia.
Adapter b: 86 mm (3.39 in) dia.
c: 12 mm (0.47 in)
NT666
KV40105310 Installing planetary carrier assembly
( -- ) a: 89.1 mm (3.508 in) dia.
Support ring b: 80.7 mm (3.177 in) dia.
NT661
KV40105500 Installing planetary carrier assembly
( -- ) a: 69 mm (2.72 in) dia.
Support b: 52 mm (2.05 in) dia.
c: 120 mm (4.72 in) dia.
NT667
KV38100200 Installing transfer cover oil seal
( -- ) a: 65 mm (2.56 in) dia.
Drift b: 49 mm (1.93 in) dia.
NT673
KV31103300 Removing and installing press flange snap ring
( -- ) a: 76.3 mm (3.004 in) dia.
Drift b: 130 mm (5.12 in)
NT668
TF-8
PREPARATION
Special Service Tools (Cont'd)
Tool number GI
(Kent-Moore No.) Description
Tool name
MA
KV31103400 Installing clutch piston
( -- ) a: 88.5 mm (3.484 in) dia.
Clutch piston attachment b: 158 mm (6.22 in) dia.
1 Shaft-drift
EM
2 Guide-cylinder
LC
NT669 EC
(J35864) Installing oil seal
Drift
FE
CL
NT671
MT
AT
Commercial Service Tools NATF0094
Tool name Description
Puller Removing front drive shaft front bearing
Removing front drive shaft rear bearing
Removing main gear bearing PD
AX
NT077
Drift 1 Installing mainshaft rear bearing
2 Installing L & H hub SU
1 a: 50 mm (1.97 in) dia.
b: 42 mm (1.65 in) dia.
c: 180 mm (7.09 in) BR
2 a: 60 mm (2.36 in) dia.
NT117
b: 50 mm (1.97 in) dia.
c: 60 mm (2.36 in) ST
Power tool Loosening nuts and bolts
RS
BT
PBIC0190E HA
SC
EL
IDX
TF-9
NOISE, VIBRATION AND HARSHNESS (NVH) NATF0095
TROUBLESHOOTING TX10A
NVH Troubleshooting Chart
NVH Troubleshooting Chart NATF0095S01
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of inspection.
If necessary, repair or replace these parts.
TRANSFER NATF0095S0101
Refer to MA-22, "Checking
TF-17, 19
TF-17
TF-17
TF-19
TF-18
TF-18
Transfer Fluid".
Reference page
CHECK SPRING AND CHECK BALL (Worn or damaged)
SUSPECTED PARTS
BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)
LIQUID GASKET (Damaged)
(Possible cause)
GEAR (Worn or damaged)
FLUID (Level too high)
SHIFT FORK (Worn)
FLUID (Level low)
FLUID (Wrong)
Noise 1 2 3 3
Fluid leakage 3 1 2 2
Symptom
Hard to shift or will not shift 1 1
Jumps out of gear 1 2 2
TF-10
DESCRIPTION TX10A
Cross-sectional View
Cross-sectional View NATF0096
GI
MA
EM
LC
EC
FE
CL
MT
AT
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL
SMT164E
IDX
TF-11
ON-VEHICLE SERVICE TX10A
Replacing Oil Seal
Replacing Oil Seal NATF0097
CENTER CASE OIL SEAL NATF0097S01
1. Remove exhaust front tube and heat insulator. Refer to
"Removal", TF-15.
2. Remove front propeller shaft. Refer to PD-8, "Removal and
Installation".
3. Remove companion flange nut.
SMT844DB
4. Remove companion flange.
SMT802C
5. Remove center case oil seal.
SMT803C
6. Install center case oil seal.
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