Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Pathfinder 1999-2003 Approved Nissan Pathfinder 2003 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 REMOVAL AND INSTALLATION OF TRANSFER
ALL-MODE 4WD SYSTEM ...........................................43 CONTROL UNIT ......................................................89
Cross-sectional View .................................................43 INSPECTION OF TRANSFER CONTROL UNIT..........89
Control System ..........................................................44 TRANSFER CONTROL UNIT INSPECTION TABLE ....90
ALL-MODE 4WD TRANSFER BASIC CONTROL ........45 DTC U1000 CAN COMMUNICATION LINE (WITH
HYDRAULIC CONTROL CIRCUITS ...........................45 VDC)...............................................................................96
OUTLINE ................................................................45 Description .................................................................96
CONTROL SYSTEM DIAGRAM ................................46 On Board Diagnosis Logic.........................................96
INDICATIONS OF 4WD WARNING LAMP..................46 Possible Cause..........................................................96
CAN Communication (With VDC)..............................47 DTC Confirmation Procedure ....................................96
SYSTEM DESCRIPTION ..........................................47 WITH CONSULT-II ..............................................96
INPUT/OUTPUT SIGNAL CHART..............................47 WITH GST .........................................................96
Location of Electrical Parts........................................49 Diagnostic Procedure ................................................97
Description of Electrical Parts ...................................50 VEHICLE SPEED SENSOR (FRONT
TRANSFER MOTOR ................................................50 REVOLUTION SENSOR) (WITHOUT VDC) .................98
WAIT DETECTION SWITCH .....................................50 Diagnostic Procedure ................................................98
2-4WD SHIFT SOLENOID VALVE .............................51 4WD SOLENOID VALVE.............................................101
LINE PRESSURE SWITCH .......................................51
Diagnostic Procedure ..............................................101
Circuit Diagram for Quick Pinpoint Check.................52
2-4WD SHIFT SOLENOID VALVE AND 4WD
Wiring Diagram - TF -................................................53
SHIFT SWITCH............................................................103
ON BOARD DIAGNOSTIC SYSTEM
Diagnostic Procedure ..............................................103
DESCRIPTION ...............................................................62
TRANSFER MOTOR AND TRANSFER MOTOR
Trouble Diagnosis without CONSULT-II ....................62
RELAY .........................................................................107
DESCRIPTION ........................................................62
Diagnostic Procedure ..............................................107
SELF-DIAGNOSTIC PROCEDURE............................63
TRANSFER FLUID TEMPERATURE SENSOR..........110
INDICATIONS OF 4WD WARNING LAMP..................64
Trouble Diagnosis with CONSULT-II .........................65 Diagnostic Procedure ..............................................110
CONSULT-II FUNCTION ...........................................65 ATP SWITCH, WAIT DETECTION SWITCH AND
SELF-DIAGNOSIS ...................................................65 NEUTRAL-4LO SWITCH.............................................113
SELF-DIAGNOSTIC ITEMS ......................................67 Diagnostic Procedure ..............................................113
DATA MONITOR......................................................68 CLUTCH PRESSURE SWITCH ..................................117
DATA MONITOR ITEMS ...........................................70 Diagnostic Procedure ..............................................117
REFERENCE VALUE IN DATA MONITOR MODE ......72 LINE PRESSURE SWITCH .........................................120
WORK SUPPORT ....................................................75 Diagnostic Procedure ..............................................120
CLUTCH FORCE RELEASE LIMIT ADJUSTMENT .....76 ABS OPERATION SIGNAL (WITHOUT VDC) ...........123
TROUBLE DIAGNOSIS - INTRODUCTION..................77 Diagnostic Procedure ..............................................123
Introduction ................................................................77 DATA ERASE/DISPLAY .............................................125
DESCRIPTION ........................................................77 Diagnostic Procedure ..............................................125
DIAGNOSTIC WORKSHEET.....................................77
SHIFT ACTUATOR......................................................126
Work Flow..................................................................79
Diagnostic Procedure ..............................................126
HOW TO PERFORM TROUBLE DIAGNOSES FOR
SHIFT ACTUATOR POSITION SWITCH ....................129
QUICK AND ACCURATE REPAIR .............................79
Diagnostic Procedure ..............................................129
TROUBLE DIAGNOSIS - BASIC INSPECTION ...........80
SHIFT ACTUATOR CIRCUIT ......................................131
Listen to Customer Complaints .................................80
Diagnostic Procedure ..............................................131
Transfer Fluid Check .................................................80
TROUBLE DIAGNOSES FOR SYMPTOMS ...............135
Road Test...................................................................80
PREPARATION FOR ROAD TEST ............................80
Symptom 1. 4WD Shift Indicator Lamp Does Not
1. CHECK BEFORE ENGINE IS STARTED ...............81 Turn ON ...................................................................135
2. CHECK AT IDLE ..................................................82 Symptom 2. 4WD Warning Lamp Does Not Turn
3. CRUISE TEST .....................................................86 ON............................................................................137
TROUBLE DIAGNOSIS - GENERAL Symptom 3. 4WD Shift Indicator Lamp Does Not
DESCRIPTION ...............................................................89 Turn OFF .................................................................139
Transfer Control Unit Terminals and Reference Symptom 4. ATP Warning Lamp Does Not Turn
Value ..........................................................................89 ON............................................................................139
TF-2
CONTENTS (Cont'd) GI
Symptom 5. 4LO Indicator Lamp Does Not Turn REMOVAL AND INSTALLATION ...............................156
ON............................................................................141 Removal...................................................................156 MA
Symptom 6. 4WD Shift Indicator Lamp Does Not Installation................................................................156
Indicate 4H............................................................143 OVERHAUL .................................................................157
Symptom 7. 4WD Shift Indicator Lamp Repeats Transfer Gear Control..............................................157 EM
Flickering..................................................................144 Transfer Components ..............................................158
Symptom 8. Tight Corner Braking Symptom...........145 DISASSEMBLY............................................................160
Symptom 9. 4WD System Does Not Operate.........146 Rear Case................................................................160
LC
COMPONENT INSPECTION .......................................148 DISASSEMBLY ......................................................160
4WD Shift Switch.....................................................148 Center Case.............................................................160 EC
2-4WD Shift Solenoid Valve and Transfer Fluid DISASSEMBLY ......................................................160
Temperature Sensor ................................................148 Front Case ...............................................................170
4WD Solenoid Valve, Clutch Pressure Switch DISASSEMBLY ......................................................170 FE
and Line Pressure Switch........................................148 REPAIR FOR COMPONENT PARTS .........................174
Front Revolution Sensor..........................................149 Front Case ...............................................................174
Transfer Dropping Resistor......................................149 INSPECTION .........................................................174 CL
ATP Switch, Neutral-4LO Switch and Wait Center Case.............................................................175
INSPECTION .........................................................175
Detection Switch ......................................................149 MT
ASSEMBLY..................................................................178
Transfer Motor .........................................................150
Front Case ...............................................................178
Transfer Motor Relay ...............................................150
ASSEMBLY ...........................................................178
Transfer Sub-harness ..............................................150
Center Case.............................................................182
AT
FRONT REVOLUTION SENSOR SUB-HARNESS
ASSEMBLY ...........................................................182
CONNECTOR ........................................................150
TRANSFER SWITCH ASSEMBLY SUB-HARNESS
Final Assembly.........................................................190
CONNECTOR ........................................................151 SERVICE DATA AND SPECIFICATIONS (SDS) .......193
TRANSFER TERMINAL CORD ASSEMBLY SUB- General Specifications.............................................193
HARNESS CONNECTOR .......................................151 Inner Gear and Outer Gear .....................................193 PD
Transfer Shift Relay (High & low)............................151 SUB-OIL PUMP .....................................................193
Actuator & Actuator Position Switch........................152 MAIN OIL PUMP ....................................................193
ACTUATOR ...........................................................152 Control Valve ...........................................................193 AX
ACTUATOR POSITION SWITCH ............................152 VALVE ..................................................................193
ON-VEHICLE SERVICE ..............................................153 SPRING ................................................................193
Clutch.......................................................................194 SU
Replacing Oil Seal ...................................................153
FRONT CASE OIL SEAL ........................................153 DRIVE PLATE .......................................................194
SHIFT SHAFT OIL SEAL ........................................154 DRIVEN PLATE .....................................................194
RETURN SPRING..................................................194
BR
REAR OIL SEAL ....................................................154
Transfer Motor .........................................................155 RETAINING PLATE................................................194
Seal Ring (Mainshaft side) ......................................195
REMOVAL .............................................................155 ST
INSTALLATION......................................................155 Bearing Race (Thrust needle bearing side) ............195
Transfer Oil Filter .....................................................155 Snap Ring (Sun gear side)......................................195
REMOVAL .............................................................155 RS
INSTALLATION......................................................155
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
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-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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