Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Xterra 2005-2007.2009 Approved Nissan Xterra 2005 TF
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D DRIVELINE/AXLE
A
B
SECTION
TRANSFER C
TF
E
CONTENTS
PRECAUTIONS ......................................................... 4. 4WD SHIFT SWITCH AND INDICATOR LAMP... 16 F
Precautions for Supplemental Restraint System 4WD WARNING LAMP ...................................... 17 .
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- ATP WARNING LAMP (FOR A/T MODELS) ...... 17 .
SIONER" ................................................................. 4
. System Diagram .................................................... 18
. G
Precautions for Transfer Assembly and Transfer COMPONENTS FUNCTION .............................. 18 .
Control Unit Replacement ....................................... 4 . CAN Communication ............................................. 19 .
CHECK 4WD SHIFT INDICATOR PATTERN ...... 4 . SYSTEM DESCRIPTION ................................... 19 .
H
METHOD FOR ADJUSTMENT WITH 4WD TROUBLE DIAGNOSIS ........................................... 20 .
SHIFT SWITCH AT "2WD" ................................... 5 . How to Perform Trouble Diagnosis ........................ 20 .
METHOD FOR ADJUSTMENT WITH 4WD BASIC CONCEPT .............................................. 20 .
SHIFT SWITCH AT "4H" OR "4LO" ...................... 5 . Location of Electrical Parts .................................... 21 . I
Precautions ............................................................. 6
. Circuit Diagram -- M/T MODELS -- ..................... 22 .
Service Notice ......................................................... 6
. Wiring Diagram -- T/F -- ...................................... 23 .
Wiring Diagrams and Trouble Diagnosis ................. 7 . M/T MODELS ..................................................... 23. J
PREPARATION .......................................................... 8
. Circuit Diagram -- A/T MODELS -- ...................... 29 .
Special Service Tools .............................................. 8. Wiring Diagram -- T/F -- ...................................... 30 .
Commercial Service Tools ..................................... 10 . A/T MODELS ...................................................... 30
.
K
NOISE, VIBRATION AND HARSHNESS (NVH) Trouble Diagnosis Chart for Symptoms ................. 36 .
TROUBLESHOOTING ..............................................11 . Transfer Control Unit Input/Output Signal Refer-
NVH Troubleshooting Chart ...................................11 . ence Values ........................................................... 36
.
TRANSFER FLUID .................................................. 12 . TRANSFER CONTROL UNIT INSPECTION L
Replacement ......................................................... 12
. TABLE ................................................................ 36
.
DRAINING .......................................................... 12
. CONSULT-II Function (ALL MODE AWD/4WD) .... 43 .
FILLING .............................................................. 12
. FUNCTION ......................................................... 43
. M
Inspection .............................................................. 12
. CONSULT-II SETTING PROCEDURE ............... 43 .
FLUID LEAKAGE AND FLUID LEVEL ............... 12 . SELF-DIAG RESULT MODE .............................. 44 .
4WD SYSTEM ......................................................... 13. DATA MONITOR MODE ..................................... 45 .
Cross-section View ............................................... 13 . Self-Diagnostic Procedure ..................................... 46 .
Power Transfer ...................................................... 14
. SELF-DIAGNOSTIC PROCEDURE (WITH
POWER TRANSFER DIAGRAM ....................... 14 . CONSULT-II) ...................................................... 46
.
POWER TRANSFER FLOW .............................. 15 . SELF-DIAGNOSTIC PROCEDURE (WITHOUT
System Description ............................................... 15 . CONSULT-II) ...................................................... 46
.
TRANSFER CONTROL DEVICE ....................... 15 . ERASE SELF-DIAGNOSIS ................................ 49 .
WAIT DETECTION SWITCH ............................. 15 . TROUBLE DIAGNOSIS FOR SYSTEM ................... 50 .
4LO SWITCH ..................................................... 15 . Power Supply Circuit For Transfer Control Unit ..... 50 .
ATP SWITCH (A/T MODELS) ............................ 15 . CONSULT-II REFERENCE VALUE IN DATA
PNP SWITCH (M/T MODELS) ........................... 15 . MONITOR MODE ............................................... 50 .
TRANSFER CONTROL UNIT ............................ 15 . TRANSFER CONTROL UNIT TERMINALS AND
TRANSFER RELAYS 1/2 ................................... 15 . REFERENCE VALUE ......................................... 50 .
TRANSFER SHUT OFF RELAYS 1/2 ................ 15 . DIAGNOSTIC PROCEDURE ............................. 51 .
Revision: February 2006 TF-1 2005 Xterra
COMPONENT INSPECTION ............................. 53 . COMPONENT INSPECTION ..............................86 .
Transfer Control Unit ............................................. 53
. Park/Neutral Position Switch (M/T Models) ...........86 .
DIAGNOSTIC PROCEDURE ............................. 53 . TRANSFER CONTROL UNIT TERMINALS AND
Output Shaft Revolution Signal (TCM) .................. 53 . REFERENCE VALUE .........................................86 .
DIAGNOSTIC PROCEDURE ............................. 53 . DIAGNOSTIC PROCEDURE ..............................86 .
Vehicle Speed Sensor (ABS) ................................. 54 . COMPONENT INSPECTION ..............................88 .
DIAGNOSTIC PROCEDURE ............................. 54 . TROUBLE DIAGNOSIS FOR SYMPTOMS .............89 .
4LO Switch ............................................................ 55
. 4WD Shift Indicator Lamp and 4LO Indicator Lamp
CONSULT-II REFERENCE VALUE IN DATA Do Not Turn ON .....................................................89
.
MONITOR MODE ............................................... 55 . SYMPTOM: .........................................................89
.
TRANSFER CONTROL UNIT TERMINALS AND DIAGNOSTIC PROCEDURE ..............................90 .
REFERENCE VALUE ......................................... 55 . 4WD Warning Lamp Does Not Turn ON ................92 .
DIAGNOSTIC PROCEDURE ............................. 56 . SYMPTOM: .........................................................92
.
COMPONENT INSPECTION ............................. 58 . DIAGNOSTIC PROCEDURE ..............................93 .
4WD Shift Switch ................................................... 58
. 4WD Shift Indicator Lamp or 4LO Indicator Lamp
CONSULT-II REFERENCE VALUE IN DATA Do Not Change ......................................................95
.
MONITOR MODE ............................................... 58 . SYMPTOM: .........................................................95
.
TRANSFER CONTROL UNIT TERMINALS AND DIAGNOSTIC PROCEDURE ..............................95 .
REFERENCE VALUE ......................................... 58 . ATP Warning Lamp Does Not Turn ON .................96 .
DIAGNOSTIC PROCEDURE ............................. 59 . SYMPTOM: .........................................................96
.
COMPONENT INSPECTION ............................. 62 . DIAGNOSTIC PROCEDURE ..............................97 .
Wait Detection Switch ............................................ 62
. 4WD Shift Indicator Lamp Repeats Flashing .........99 .
CONSULT-II REFERENCE VALUE IN DATA SYMPTOM: .........................................................99
.
MONITOR MODE ............................................... 62 . DIAGNOSTIC PROCEDURE ..............................99 .
TRANSFER CONTROL UNIT TERMINALS AND 4WD Warning Lamp Flashes Slowly .................... 100 .
REFERENCE VALUE ......................................... 62 . SYMPTOM: ....................................................... 100
.
DIAGNOSTIC PROCEDURE ............................. 63 . DIAGNOSTIC PROCEDURE ............................ 100 .
COMPONENT INSPECTION ............................. 66 . TRANSFER CONTROL UNIT ................................ 101 .
PNP Switch Signal (A/T models) ........................... 66 . Removal and Installation ...................................... 101
.
DIAGNOSTIC PROCEDURE ............................. 66 . REMOVAL ......................................................... 101
.
Actuator Motor ....................................................... 67
. INSTALLATION ................................................. 101
.
CONSULT-II REFERENCE VALUE IN DATA FRONT OIL SEAL .................................................. 102
.
MONITOR MODE ............................................... 67 . Removal and Installation ...................................... 102
.
TRANSFER CONTROL UNIT TERMINALS AND REMOVAL ......................................................... 102
.
REFERENCE VALUE ......................................... 67 . INSTALLATION ................................................. 103
.
DIAGNOSTIC PROCEDURE ............................. 69 . REAR OIL SEAL .................................................... 104
.
COMPONENT INSPECTION ............................. 75 . Removal and Installation ...................................... 104
.
Actuator Position Switch ........................................ 76. REMOVAL ......................................................... 104
.
CONSULT-II REFERENCE VALUE IN DATA INSTALLATION ................................................. 104
.
MONITOR MODE ............................................... 76 . TRANSFER CONTROL DEVICE ........................... 106 .
TRANSFER CONTROL UNIT TERMINALS AND Removal and Installation ...................................... 106
.
REFERENCE VALUE ......................................... 76 . REMOVAL ......................................................... 106
.
DIAGNOSTIC PROCEDURE ............................. 77 . INSTALLATION ................................................. 106
.
Transfer Control Device ......................................... 79. AIR BREATHER HOSE .......................................... 108 .
CONSULT-II REFERENCE VALUE IN DATA Removal and Installation ...................................... 108
.
MONITOR MODE ............................................... 79 . TRANSFER ASSEMBLY ........................................ 109 .
TRANSFER CONTROL UNIT TERMINALS AND Removal and Installation ...................................... 109
.
REFERENCE VALUE ......................................... 79 . REMOVAL ......................................................... 109
.
DIAGNOSTIC PROCEDURE ............................. 80 . INSTALLATION ................................................. 109
.
Engine Speed Signal ............................................. 82. Disassembly and Assembly ................................. 110 .
DIAGNOSTIC PROCEDURE ............................. 82 . COMPONENTS ................................................ 110 .
CAN Communication Line ..................................... 83 . DISASSEMBLY ................................................. 112
.
DIAGNOSTIC PROCEDURE ............................. 83 . INSPECTION AFTER DISASSEMBLY ............. 117 .
ATP Switch ............................................................ 83
. ASSEMBLY ....................................................... 118
.
CONSULT-II REFERENCE VALUE IN DATA PLANETARY CARRIER ......................................... 127 .
MONITOR MODE ............................................... 83 . Disassembly and Assembly ................................. 127 .
TRANSFER CONTROL UNIT TERMINALS AND DISASSEMBLY ................................................. 127
.
REFERENCE VALUE ......................................... 83 . INSPECTION AFTER DISASSEMBLY ............. 128 .
DIAGNOSTIC PROCEDURE ............................. 84 . ASSEMBLY ....................................................... 129
.
Revision: February 2006 TF-2 2005 Xterra
FRONT DRIVE SHAFT .......................................... 131 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 136 .
Disassembly and Assembly ................................ 131 . General Specifications ......................................... 136
. A
DISASSEMBLY ................................................ 131
. Inspection and Adjustment .................................. 136 .
INSPECTION AFTER DISASSEMBLY ............ 131 . PINION GEAR END PLAY ............................... 136 .
ASSEMBLY ...................................................... 132
. CLEARANCE BETWEEN SHIFT FORK AND B
SHIFT CONTROL .................................................. 133
. SLEEVE ........................................................... 136
.
Disassembly and Assembly ................................ 133 .
DISASSEMBLY (A/T MODELS) ....................... 133 .
DISASSEMBLY (M/T MODELS) ...................... 133 . C
INSPECTION AFTER DISASSEMBLY ............ 134 .
ASSEMBLY (A/T MODELS) ............................. 134 .
ASSEMBLY (M/T MODELS) ............................ 135 . TF
E
F
G
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Revision: February 2006 TF-3 2005 Xterra
PRECAUTIONS
PRECAUTIONS PFP:00001
Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER" EDS002M4
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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:
G To 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.
G Improper 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.
G Do 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 Transfer Assembly and Transfer Control Unit Replacement EDS002M5
When replacing transfer assembly or transfer control unit, check the 4WD shift indicator pattern and adjust-
ment of the position between transfer assembly and transfer control unit if necessary.
CHECK 4WD SHIFT INDICATOR PATTERN
1. Set 4WD shift switch to "2WD", "4H", "4LO", "4H" and "2WD" in order. Stay at each switch position for at
least 2 seconds.
2. Confirm 4WD shift indicator lamp and 4LO indicator lamp change properly as follows.
G If OK, the position between transfer assembly and transfer control unit is correct.
G If NG, the position is different between transfer assembly and transfer control unit.
Adjust the position between transfer assembly and transfer control unit. Refer to pattern table below.
Revision: February 2006 TF-4 2005 Xterra
PRECAUTIONS
Transfer position adjustment pattern
4WD shift switch condition Refer procedure
A
TF-5, "METHOD FOR ADJUSTMENT WITH 4WD
4WD shift switch is in "2WD" when engine is stopped.
SHIFT SWITCH AT "2WD""
B
TF-5, "METHOD FOR ADJUSTMENT WITH 4WD
4WD shift switch is in "4H" or "4LO" when engine is stopped.
SHIFT SWITCH AT "4H" OR "4LO""
NOTE:
Method of adjustment can be chosen voluntarily, according to location of 4WD shift switch. C
METHOD FOR ADJUSTMENT WITH 4WD SHIFT SWITCH AT "2WD"
Select Adjustment Pattern TF
1. Start engine. Run engine for at least 10 seconds.
2. Check 4WD shift indicator lamp and 4LO indicator lamp.
Indicator lamp condition Refer procedure
E
When 4WD shift indicator lamp or 4LO indicator lamp is flashing. TF-5, "Pattern A"
Except for above. TF-5, "Pattern B"
F
Pattern A
1. For A/T models, stop vehicle and move A/T selector lever to "N" position with brake pedal depressed. For
M/T models, shift M/T shift lever to neutral with brake pedal depressed. Stay in neutral for at least 2 sec- G
onds.
2. Turn 4WD shift switch to "4LO" position. Stay in "4LO" for at least 2 seconds.
3. Turn ignition switch "OFF". H
4. Start engine.
5. Erase self-diagnosis. Refer to TF-45, "How to Erase Self-diagnostic Results" (with CONSULT-II) or TF-
49, "ERASE SELF-DIAGNOSIS" (without CONSULT-II). I
6. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer to TF-4, "CHECK 4WD SHIFT INDI-
CATOR PATTERN" .
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con- J
trol unit and retry the above check.
Pattern B
1. For A/T models, stop vehicle and move A/T selector lever to "N" position with brake pedal depressed. For K
M/T models, shift M/T shift lever to neutral with brake pedal depressed. Stay in neutral for at least 2 sec-
onds.
2. Turn ignition switch "OFF". L
3. Start engine.
4. Erase self-diagnosis. Refer to TF-45, "How to Erase Self-diagnostic Results" (with CONSULT-II) or TF-
49, "ERASE SELF-DIAGNOSIS" (without CONSULT-II). M
5. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer to TF-4, "CHECK 4WD SHIFT INDI-
CATOR PATTERN" .
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.
METHOD FOR ADJUSTMENT WITH 4WD SHIFT SWITCH AT "4H" OR "4LO"
1. Start engine. Run the engine for at least 10 seconds.
2. For A/T models, stop vehicle and move A/T selector lever to "N" position with brake pedal depressed. For
M/T models, shift M/T shift lever to neutral with brake pedal depressed. Stay in neutral for at least 2 sec-
onds.
3. Turn 4WD shift switch to "2WD" position. Stay in "2WD" for at least 2 seconds.
4. Turn ignition switch "OFF".
5. Start engine.
6. Erase self-diagnosis. Refer to TF-45, "How to Erase Self-diagnostic Results" (with CONSULT-II) or TF-
49, "ERASE SELF-DIAGNOSIS" (without CONSULT-II).
Revision: February 2006 TF-5 2005 Xterra
PRECAUTIONS
7. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer to TF-4, "CHECK 4WD SHIFT INDI-
CATOR PATTERN" .
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.
Precautions EDS002M6
G Before connecting or disconnecting the transfer control
unit harness connector, turn ignition switch "OFF" and dis-
connect battery ground cable. Battery voltage is applied to
transfer control unit even if ignition switch is turned "OFF".
SEF289H
G When connecting or disconnecting pin connectors into or
from transfer control unit, take care not to damage pin ter-
minals (bend or break).
When connecting pin connectors make sure that there are
not any bends or breaks on transfer control unit pin termi-
nals.
SEF291H
G Before replacing transfer control unit, perform transfer con-
trol unit input/output signal inspection and make sure
transfer control unit functions properly. Refer to TF-36,
"Transfer Control Unit Input/Output Signal Reference Val-
ues" .
MEF040DB
Service Notice EDS002M7
G After overhaul refill the transfer with new transfer fluid.
G Check the fluid level or replace the fluid only with the vehicle parked on level ground.
G During removal or installation, keep inside of transfer clear of dust or dirt.
G Disassembly should be done in a clean work area.
G Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal
parts from becoming contaminated by dirt or other foreign matter.
G Check for the correct installation status prior to removal or disassembly. If matchmarks are required, be
certain they do not interfere with the function of the parts when applied.
G All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
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 replaced any time the transfer is disassembled.
Revision: February 2006 TF-6 2005 Xterra
PRECAUTIONS
G In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it. A
G Observe the specified torque when assembling.
G Clean and flush the parts sufficiently and blow-dry them.
G Be careful not to damage sliding surfaces and mating surfaces. B
G Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere
with the operation of the transfer.
C
Wiring Diagrams and Trouble Diagnosis EDS002M8
When reading wiring diagrams, refer to the following:
G GI-16, "How to Read Wiring Diagrams". TF
G PG-4, "POWER SUPPLY ROUTING CIRCUIT".
When performing trouble diagnosis, refer to the following:
G GI-11, "How to Follow Trouble Diagnoses". E
G GI-28, "How to Perform Efficient Diagnosis for an Electrical Incident".
F
G
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Revision: February 2006 TF-7 2005 Xterra
PREPARATION
PREPARATION PFP:00002
Special Service Tools EDS002M9
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.)
Tool name
KV40104000 G Removing self-lock nut
( -- ) G Installing self-lock nut
Flange wrench
a: 85 mm (3.35 in)
b: 65 mm (2.56 in)
NT659
KV381054S0 G Removing front oil seal
(J-34286) G Removing rear oil seal
Puller
G Removing metal bushing
ZZA0601D
KV38100500 G Installing front oil seal
( -- ) G Installing rear oil seal
Drift
G Installing rear bearing
G Installing front bearing
a: 80 mm (3.15 in) dia.
b: 60 mm (2.36 in) dia.
ZZA0811D
KV40105310 G Installing dust cover
( -- ) a: 89 mm (3.50 in) dia.
Drift b: 80.7 mm (3.17 in) dia.
ZZA1003D
KV38100200 G Removing sun gear assembly and planetary
( -- ) carrier assembly
Drift G Removing input bearing
G Installing sun gear assembly and planetary
carrier assembly
a: 65 mm (2.56 in) dia.
ZZA1143D b: 49 mm (1.93 in) dia.
ST30720000 G Installing input bearing
(J-25405) G Installing input oil seal
Drift
G Installing carrier bearing
a: 77 mm (3.03 in) dia.
b: 55 mm (2.17 in) dia.
ZZA0811D
KV32102700 G Installing mainshaft rear bearing
( -- ) a: 48 mm (1.89 in) dia.
Drift b: 41 mm (1.61 in) dia.
ZZA0534D
Revision: February 2006 TF-8 2005 Xterra
PREPARATION
Tool number Description
(Kent-Moore No.) A
Tool name
KV40104830 G Installing input oil seal
( -- ) a: 70 mm (2.76 in) dia. B
Drift b: 63.5 mm (2.50 in) dia.
C
ZZA1003D
ST35300000 G Removing carrier bearing TF
( -- ) G Installing metal bushing
Drift
G Removing front bearing
a: 59 mm (2.32 in) dia. E
b: 45 mm (1.77 in) dia.
NT073
ST30021000 G Removing carrier bearing
F
(J-22912-01) G Removing front bearing
Puller
G Removing rear bearing
G
ZZA0537D H
ST33710000 G Removing needle bearing
( -- ) G Removing metal bushing
Drift
G Removing rear bearing I
a: 24 mm (0.94 in)
b: 89 mm (3.5 in) dia.
c: 30 mm (1.18 in) dia. J
ZZA1057D
ST35325000 G Removing metal bushing
( -- ) a: 215 mm (8.46 in)
Drift bar K
b: 25 mm (0.98 in) dia.
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