Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Pathfinder 1999-2003 Approved Nissan Pathfinder 2002 tf
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GI
TRANSFER
MA
SECTION TF EM
LC
EC
FE
CONTENTS CL
PREPARATION ...............................................................4 INSPECTION ...........................................................26
ASSEMBLY .............................................................26
MT
Special Service Tools ..................................................4
Commercial Service Tools ...........................................9 Main Gear ..................................................................26
DISASSEMBLY ........................................................26
AT
INSPECTION ...........................................................27
TX10A
ASSEMBLY .............................................................27
NOISE, VIBRATION AND HARSHNESS (NVH) Front Case .................................................................27
TROUBLESHOOTING ...................................................10 REMOVAL ...............................................................27
NVH Troubleshooting Chart.......................................10 INSTALLATION........................................................28
TRANSFER .............................................................10 Front Case Cover ......................................................28 PD
DESCRIPTION ...............................................................11 REMOVAL ...............................................................28
Cross-sectional View .................................................11 INSTALLATION........................................................28
ON-VEHICLE SERVICE ................................................12 Bearing Retainer........................................................28 AX
Replacing Oil Seal .....................................................12 REMOVAL ...............................................................28
INSTALLATION........................................................28
CENTER CASE OIL SEAL ........................................12
SHIFT SHAFT OIL SEAL ..........................................12 Center Case...............................................................29 SU
REAR OIL SEAL ......................................................13 REMOVAL ...............................................................29
Position Switch Check ...............................................13 INSTALLATION........................................................29
Rear Case..................................................................29 BR
REMOVAL AND INSTALLATION .................................14
REMOVAL ...............................................................29
Removal.....................................................................14
INSTALLATION........................................................29
Installation..................................................................14
Shift Control Components .........................................30
ST
M/T MODEL ............................................................14
INSPECTION ...........................................................30
A/T MODEL .............................................................14
ASSEMBLY....................................................................31 RS
OVERHAUL ...................................................................15
SERVICE DATA AND SPECIFICATIONS (SDS) .........38
Transfer Gear Control................................................15
General Specifications...............................................38
Case Components .....................................................16
Gear Components .....................................................17
Gear End Play ...........................................................38 BT
Available Snap Ring ..................................................38
Shift Control Components .........................................18
MAINSHAFT FRONT BEARING ................................38
DISASSEMBLY..............................................................19 HA
MAINSHAFT REAR BEARING ..................................38
REPAIR FOR COMPONENT PARTS ...........................23 MAIN GEAR BEARING.............................................38
Mainshaft ...................................................................23 Available Shim ...........................................................39
DISASSEMBLY ........................................................23 COUNTER GEAR REAR BEARING ...........................39 SC
INSPECTION ...........................................................24
ASSEMBLY .............................................................24
ATX14A EL
Front Drive Shaft .......................................................25
DISASSEMBLY ........................................................25 PRECAUTIONS .............................................................40
INSPECTION ...........................................................25 Supplemental Restraint System (SRS) AIR
ASSEMBLY .............................................................25 BAG and SEAT BELT PRE-TENSIONER.............40
IDX
Counter Gear .............................................................25 Precautions ................................................................40
DISASSEMBLY ........................................................25
Service Notice............................................................41
CONTENTS (Cont'd)
Wiring Diagrams and Trouble Diagnosis...................41 VEHICLE SPEED SENSOR (FRONT
ALL-MODE 4WD SYSTEM ...........................................42 REVOLUTION SENSOR) ..............................................91
Cross-sectional View .................................................42 Diagnostic Procedure ................................................91
Control System ..........................................................43 4WD SOLENOID VALVE...............................................94
ALL-MODE 4WD TRANSFER BASIC CONTROL ........44 Diagnostic Procedure ................................................94
HYDRAULIC CONTROL CIRCUITS ...........................44 2-4WD SHIFT SOLENOID VALVE AND 4WD
OUTLINE ................................................................44 SHIFT SWITCH..............................................................96
CONTROL SYSTEM DIAGRAM ................................45 Diagnostic Procedure ................................................96
INDICATIONS OF 4WD WARNING LAMP..................45
TRANSFER MOTOR AND TRANSFER MOTOR
Location of Electrical Parts........................................46
RELAY .........................................................................100
Description of Electrical Parts ...................................47
Diagnostic Procedure ..............................................100
TRANSFER MOTOR ................................................47
TRANSFER FLUID TEMPERATURE SENSOR..........103
WAIT DETECTION SWITCH .....................................47
Diagnostic Procedure ..............................................103
2-4WD SHIFT SOLENOID VALVE .............................48
LINE PRESSURE SWITCH .......................................48 ATP SWITCH, WAIT DETECTION SWITCH AND
Circuit Diagram for Quick Pinpoint Check.................49 NEUTRAL-4LO SWITCH.............................................106
Wiring Diagram - TF -................................................50 Diagnostic Procedure ..............................................106
ON BOARD DIAGNOSTIC SYSTEM CLUTCH PRESSURE SWITCH ..................................110
DESCRIPTION ...............................................................59 Diagnostic Procedure ..............................................110
Trouble Diagnosis without CONSULT-II ....................59 LINE PRESSURE SWITCH .........................................113
DESCRIPTION ........................................................59 Diagnostic Procedure ..............................................113
SELF-DIAGNOSTIC PROCEDURE............................60 ABS OPERATION SIGNAL.........................................116
INDICATIONS OF 4WD WARNING LAMP..................61 Diagnostic Procedure ..............................................116
Trouble Diagnosis with CONSULT-II .........................62 DATA ERASE/DISPLAY .............................................118
SELF-DIAGNOSIS ...................................................62 Diagnostic Procedure ..............................................118
SELF-DIAGNOSTIC ITEMS ......................................63 SHIFT ACTUATOR......................................................119
DATA MONITOR......................................................65 Diagnostic Procedure ..............................................119
DATA MONITOR ITEMS ...........................................66 SHIFT ACTUATOR POSITION SWITCH ....................122
REFERENCE VALUE IN DATA MONITOR MODE ......68 Diagnostic Procedure ..............................................122
WORK SUPPORT ....................................................70
SHIFT ACTUATOR CIRCUIT ......................................124
CLUTCH FORCE RELEASE LIMIT ADJUSTMENT .....71
Diagnostic Procedure ..............................................124
TROUBLE DIAGNOSIS - INTRODUCTION..................73
TROUBLE DIAGNOSES FOR SYMPTOMS ...............128
Introduction ................................................................73
Symptom 1. 4WD Shift Indicator Lamp Does Not
DESCRIPTION ........................................................73
DIAGNOSTIC WORKSHEET.....................................73
Turn ON ...................................................................128
Work Flow..................................................................75 Symptom 2. 4WD Warning Lamp Does Not Turn
HOW TO PERFORM TROUBLE DIAGNOSES FOR ON............................................................................130
QUICK AND ACCURATE REPAIR .............................75 Symptom 3. 4WD Shift Indicator Lamp Does Not
TROUBLE DIAGNOSIS - BASIC INSPECTION ...........76 Turn OFF .................................................................132
Listen to Customer Complaints .................................76 Symptom 4. ATP Warning Lamp Does Not Turn
Transfer Fluid Check .................................................76 ON............................................................................132
Road Test...................................................................76 Symptom 5. 4LO Indicator Lamp Does Not Turn
PREPARATION FOR ROAD TEST ............................76 ON............................................................................134
1. CHECK BEFORE ENGINE IS STARTED ...............77 Symptom 6. 4WD Shift Indicator Lamp Does Not
2. CHECK AT IDLE ..................................................78 Indicate 4H............................................................136
3. CRUISE TEST .....................................................82 Symptom 7. 4WD Shift Indicator Lamp Repeats
TROUBLE DIAGNOSIS - GENERAL Flickering..................................................................137
DESCRIPTION ...............................................................85 Symptom 8. Tight Corner Braking Symptom...........138
Transfer Control Unit Terminals and Reference Symptom 9. 4WD System Does Not Operate.........139
Value ..........................................................................85 COMPONENT INSPECTION .......................................141
REMOVAL AND INSTALLATION OF TRANSFER 4WD Shift Switch.....................................................141
CONTROL UNIT ......................................................85 2-4WD Shift Solenoid Valve and Transfer Fluid
INSPECTION OF TRANSFER CONTROL UNIT..........85
Temperature Sensor ................................................141
TRANSFER CONTROL UNIT INSPECTION TABLE ....86
TF-2
CONTENTS (Cont'd) GI
4WD Solenoid Valve, Clutch Pressure Switch DISASSEMBLY............................................................153
and Line Pressure Switch........................................141 Rear Case................................................................153 MA
Front Revolution Sensor..........................................142 DISASSEMBLY ......................................................153
Transfer Dropping Resistor......................................142 Center Case.............................................................153
ATP Switch, Neutral-4LO Switch and Wait DISASSEMBLY ......................................................153 EM
Detection Switch ......................................................142 Front Case ...............................................................163
Transfer Motor .........................................................143 DISASSEMBLY ......................................................163
Transfer Motor Relay ...............................................143 REPAIR FOR COMPONENT PARTS .........................167 LC
Transfer Sub-harness ..............................................143 Front Case ...............................................................167
INSPECTION .........................................................167
FRONT REVOLUTION SENSOR SUB-HARNESS
Center Case.............................................................168
EC
CONNECTOR ........................................................143
TRANSFER SWITCH ASSEMBLY SUB-HARNESS INSPECTION .........................................................168
CONNECTOR ........................................................144 ASSEMBLY..................................................................171 FE
TRANSFER TERMINAL CORD ASSEMBLY SUB- Front Case ...............................................................171
HARNESS CONNECTOR .......................................144 ASSEMBLY ...........................................................171
Transfer Shift Relay (High & low)............................144 Center Case.............................................................175 CL
Actuator & Actuator Position Switch........................145 ASSEMBLY ...........................................................175
ACTUATOR ...........................................................145 Final Assembly.........................................................183
ACTUATOR POSITION SWITCH ............................145 SERVICE DATA AND SPECIFICATIONS (SDS) .......187 MT
ON-VEHICLE SERVICE ..............................................146 General Specifications.............................................187
Replacing Oil Seal ...................................................146 Inner Gear and Outer Gear .....................................187
FRONT CASE OIL SEAL ........................................146 SUB-OIL PUMP .....................................................187
AT
SHIFT SHAFT OIL SEAL ........................................147 MAIN OIL PUMP ....................................................187
REAR OIL SEAL ....................................................147 Control Valve ...........................................................187
Transfer Motor .........................................................147 VALVE ..................................................................187
REMOVAL .............................................................147 SPRING ................................................................187
INSTALLATION......................................................147 Clutch.......................................................................188 PD
Transfer Oil Filter .....................................................148 DRIVE PLATE .......................................................188
REMOVAL .............................................................148 DRIVEN PLATE .....................................................188
INSTALLATION......................................................148 RETURN SPRING..................................................188 AX
REMOVAL AND INSTALLATION ...............................149 RETAINING PLATE................................................188
Removal...................................................................149 Seal Ring (Mainshaft side) ......................................189
Installation................................................................149 Bearing Race (Thrust needle bearing side) ............189 SU
OVERHAUL .................................................................150 Snap Ring (Sun gear side)......................................189
Transfer Gear Control..............................................150
Transfer Components ..............................................151 BR
ST
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 counter gear front bearing
(J22912-01) (Use with ST36710010)
Puller 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
RS
BT
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-16, 18
TF-16
TF-16
TF-18
TF-17
TF-17
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
SMT820D
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-14.
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.
6. Install center case oil seal.
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