Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Titan 2004-2009 Approved Nissan Titan 2004 TF
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D DRIVELINE/AXLE
A
SECTION TF
TRANSFER
B
C
TF
E
CONTENTS
PRECAUTIONS ......................................................... 4. COMPONENTS FUNCTION DESCRIPTION ..... 18 . F
Precautions for Supplemental Restraint System CAN Communication ............................................. 19 .
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- ........................................................................... 19
.
SIONER" ................................................................. 4
. TROUBLE DIAGNOSIS ........................................... 20 . G
Precautions for Transfer Assembly and Transfer How to Perform Trouble Diagnosis ........................ 20 .
Control Unit Replacement ....................................... 4 . BASIC CONCEPT .............................................. 20 .
CHECK 4WD SHIFT INDICATOR PATTERN ...... 4 . Location of Electrical Parts .................................... 21 .
H
METHOD FOR ADJUSTMENT WITH 4WD Circuit Diagram ...................................................... 22 .
SHIFT SWITCH AT "2WD" ................................... 5 . Wiring Diagram -- T/F -- ...................................... 23 .
METHOD FOR ADJUSTMENT WITH 4WD Trouble Diagnosis Chart for Symptoms ................. 27 .
SHIFT SWITCH AT "4H" OR "4LO" ...................... 5 . Transfer Control Unit Input/Output Signal Refer- I
Precautions ............................................................. 6
. ence Values ........................................................... 27 .
Service Notice ......................................................... 6
. TRANSFER CONTROL UNIT INSPECTION
Wiring Diagrams and Trouble Diagnosis ................. 7 . TABLE ................................................................ 27. J
PREPARATION .......................................................... 8
. CONSULT-II Function ............................................ 31 .
Special Service Tools .............................................. 8. FUNCTION ......................................................... 31 .
Commercial Service Tools ..................................... 10 . CONSULT-II SETTING PROCEDURE ............... 31 .
K
NOISE, VIBRATION AND HARSHNESS (NVH) SELF-DIAG RESULT MODE .............................. 33 .
TROUBLESHOOTING ..............................................11 . DATA MONITOR MODE ..................................... 34 .
NVH Troubleshooting Chart ...................................11 . Self-Diagnostic Procedure ..................................... 36 .
TRANSFER FLUID .................................................. 12 . SELF-DIAGNOSTIC PROCEDURE (WITH L
Replacement ......................................................... 12
. CONSULT-II) ...................................................... 36 .
Inspection .............................................................. 12
. SELF-DIAGNOSTIC PROCEDURE (WITHOUT
4WD SYSTEM ......................................................... 13. CONSULT-II) ...................................................... 36 . M
Cross-section View ............................................... 13 . ERASE SELF-DIAGNOSIS ................................ 37 .
Power Transfer ...................................................... 14
. TROUBLE DIAGNOSIS FOR SYSTEM ................... 38 .
POWER TRANSFER DIAGRAM ....................... 14 . Power Supply Circuit For Transfer Control Unit ..... 38 .
POWER TRANSFER FLOW .............................. 15 . CONSULT-II REFERENCE VALUE IN DATA
System Description ............................................... 15 . MONITOR MODE ............................................... 38 .
TRANSFER CONTROL DEVICE ....................... 15 . TRANSFER CONTROL UNIT TERMINALS AND
WAIT DETECTION SWITCH ............................. 15 . REFERENCE VALUE ......................................... 38 .
4LO SWITCH ..................................................... 15 . DIAGNOSTIC PROCEDURE ............................. 39 .
ATP SWITCH ..................................................... 15 . COMPONENT INSPECTION ............................. 40 .
TRANSFER CONTROL UNIT ............................ 15 . Transfer Control Unit ............................................. 40 .
TRANSFER RELAY ........................................... 15 . DIAGNOSTIC PROCEDURE ............................. 40 .
4WD SHIFT SWITCH AND INDICATOR LAMP 16 ... Output Shaft Revolution Signal (TCM) .................. 41 .
4WD WARNING LAMP ...................................... 17 . DIAGNOSTIC PROCEDURE ............................. 41 .
ATP WARNING LAMP ....................................... 17 . Vehicle Speed Sensor (ABS) ................................. 42 .
System Diagram .................................................... 18. DIAGNOSTIC PROCEDURE ............................. 42 .
4LO Switch ............................................................ 42 .
Revision: January 2005 TF-1 2004 Titan
CONSULT-II REFERENCE VALUE IN DATA DIAGNOSTIC PROCEDURE ..............................71 .
MONITOR MODE ............................................... 42 . 4WD Shift Indicator Lamp or 4LO Indicator Lamp
TRANSFER CONTROL UNIT TERMINALS AND Do Not Change ......................................................73
.
REFERENCE VALUE ......................................... 42 . SYMPTOM: .........................................................73
.
DIAGNOSTIC PROCEDURE ............................. 43 . DIAGNOSTIC PROCEDURE ..............................73 .
COMPONENT INSPECTION ............................. 44 . ATP Warning Lamp Does Not Turn ON .................74 .
4WD Shift Switch ................................................... 45
. SYMPTOM: .........................................................74
.
CONSULT-II REFERENCE VALUE IN DATA DIAGNOSTIC PROCEDURE ..............................74 .
MONITOR MODE ............................................... 45 . 4WD Shift Indicator Lamp Repeats Flashing .........76 .
TRANSFER CONTROL UNIT TERMINALS AND SYMPTOM: .........................................................76
.
REFERENCE VALUE ......................................... 45 . DIAGNOSTIC PROCEDURE ..............................77 .
DIAGNOSTIC PROCEDURE ............................. 46 . 4WD Warning Lamp Flashes Slowly ......................77 .
COMPONENT INSPECTION ............................. 48 . SYMPTOM: .........................................................77
.
Wait Detection Switch ............................................ 49
. DIAGNOSTIC PROCEDURE ..............................78 .
CONSULT-II REFERENCE VALUE IN DATA TRANSFER CONTROL UNIT ..................................79 .
MONITOR MODE ............................................... 49 . Removal and Installation ........................................79
.
TRANSFER CONTROL UNIT TERMINALS AND REMOVAL ...........................................................79
.
REFERENCE VALUE ......................................... 49 . INSTALLATION ...................................................79
.
DIAGNOSTIC PROCEDURE ............................. 50 . FRONT OIL SEAL ....................................................80
.
COMPONENT INSPECTION ............................. 51 . Removal and Installation ........................................80
.
PNP Switch Signal ................................................. 52
. REMOVAL ...........................................................80
.
DIAGNOSTIC PROCEDURE ............................. 52 . INSTALLATION ...................................................81
.
Actuator Motor ....................................................... 53
. REAR OIL SEAL ......................................................82
.
CONSULT-II REFERENCE VALUE IN DATA Removal and Installation ........................................82
.
MONITOR MODE ............................................... 53 . REMOVAL ...........................................................82
.
TRANSFER CONTROL UNIT TERMINALS AND INSTALLATION ...................................................82
.
REFERENCE VALUE ......................................... 53 . TRANSFER CONTROL DEVICE .............................84 .
DIAGNOSTIC PROCEDURE ............................. 54 . Removal and Installation ........................................84
.
COMPONENT INSPECTION ............................. 56 . REMOVAL ...........................................................84
.
Actuator Position Switch ........................................ 57. INSTALLATION ...................................................84
.
CONSULT-II REFERENCE VALUE IN DATA AIR BREATHER HOSE ............................................86 .
MONITOR MODE ............................................... 57 . Removal and Installation ........................................86
.
TRANSFER CONTROL UNIT TERMINALS AND TRANSFER ASSEMBLY ..........................................87 .
REFERENCE VALUE ......................................... 57 . Removal and Installation ........................................87
.
DIAGNOSTIC PROCEDURE ............................. 58 . REMOVAL ...........................................................87
.
Transfer Control Device ......................................... 60. INSTALLATION ...................................................87
.
CONSULT-II REFERENCE VALUE IN DATA Disassembly and Assembly ...................................88 .
MONITOR MODE ............................................... 60 . COMPONENTS ..................................................88 .
TRANSFER CONTROL UNIT TERMINALS AND DISASSEMBLY ...................................................90
.
REFERENCE VALUE ......................................... 60 . INSPECTION AFTER DISASSEMBLY ...............95 .
DIAGNOSTIC PROCEDURE ............................. 61 . ASSEMBLY .........................................................96
.
Engine Speed Signal ............................................. 63. PLANETARY CARRIER ......................................... 104 .
DIAGNOSTIC PROCEDURE ............................. 63 . Disassembly and Assembly ................................. 104 .
CAN Communication Line ..................................... 64 . DISASSEMBLY ................................................. 104
.
DIAGNOSTIC PROCEDURE ............................. 64 . INSPECTION AFTER DISASSEMBLY ............. 105 .
ATP Switch ............................................................ 64
. ASSEMBLY ....................................................... 106
.
CONSULT-II REFERENCE VALUE IN DATA FRONT DRIVE SHAFT ........................................... 108 .
MONITOR MODE ............................................... 64 . Disassembly and Assembly ................................. 108 .
TRANSFER CONTROL UNIT TERMINALS AND DISASSEMBLY ................................................. 108
.
REFERENCE VALUE ......................................... 64 . INSPECTION AFTER DISASSEMBLY ............. 108 .
DIAGNOSTIC PROCEDURE ............................. 65 . ASSEMBLY ....................................................... 109
.
COMPONENT INSPECTION ............................. 66 . SHIFT CONTROL ................................................... 110
.
TROUBLE DIAGNOSIS FOR SYMPTOMS ............. 68 . Disassembly and Assembly ................................. 110 .
4WD Shift Indicator Lamp and 4LO Indicator Lamp DISASSEMBLY ................................................. 110
.
Do Not Turn ON ..................................................... 68
. INSPECTION AFTER DISASSEMBLY ............. 110 .
SYMPTOM: ......................................................... 68
. ASSEMBLY ....................................................... 111
.
DIAGNOSTIC PROCEDURE ............................. 68 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 112 .
4WD Warning Lamp Does Not Turn ON ................ 70 . General Specifications ......................................... 112
.
SYMPTOM: ......................................................... 70
.
Revision: January 2005 TF-2 2004 Titan
Pinion Gear End Play ...........................................112
.
Clearance Between Shift Fork and Sleeve ..........112 . A
B
C
TF
E
F
G
H
I
J
K
L
M
Revision: January 2005 TF-3 2004 Titan
PRECAUTIONS
PRECAUTIONS PFP:00001
Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER" UDS0008W
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:
q 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.
q 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.
q 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 UDS000DE
q When replacing transfer assembly or transfer control unit, check the 4WD shift indicator pattern and
adjustment 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 are changed properly as follows.
SDIA2481E
q If OK, the position between transfer assembly and transfer control unit is correct.
q 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: January 2005 TF-4 2004 Titan
PRECAUTIONS
Transfer position adjustment pattern
4WD shift switch condition Refer procedure
A
TF-5, "METHOD FOR ADJUSTMENT WITH 4WD
4WD shift switch is under "2WD" condition when engine is being stopped.
SHIFT SWITCH AT "2WD""
B
TF-5, "METHOD FOR ADJUSTMENT WITH 4WD
4WD shift switch is under "4H" or "4LO" condition when engine is being 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. (Stay 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. Stop vehicle and move A/T selector lever to "N" position with brake pedal depressed. (Stay for at least 2
seconds.) G
2. Turn 4WD shift switch to "4LO" position. (Stay for at least 2 seconds.)
3. Turn ignition switch "OFF".
H
4. Start engine.
5. Erase self-diagnosis. Refer to TF-34, "How to erase self-diagnostic results" (with CONSULT-II) or TF-37,
"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-
trol unit and retry the above check. J
Pattern B
1. Stop vehicle and move A/T selector lever to "N" position with brake pedal depressed. (Stay for at least 2
seconds.) K
2. Turn ignition switch "OFF".
3. Start engine.
L
4. Erase self-diagnosis. Refer to TF-34, "How to erase self-diagnostic results" (with CONSULT-II) or TF-37,
"ERASE SELF-DIAGNOSIS" (without CONSULT-II).
5. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer to TF-4, "CHECK 4WD SHIFT INDI-
M
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. (Stay for at least 10 second.)
2. Stop vehicle and move A/T selector lever to "N" position with brake pedal depressed. (Stay for at least 2
seconds.)
3. Turn 4WD shift switch to "2WD" position. (Stay for at least 2 seconds.)
4. Turn ignition switch "OFF".
5. Start engine.
6. Erase self-diagnosis. Refer to TF-34, "How to erase self-diagnostic results" (with CONSULT-II) or TF-37,
"ERASE SELF-DIAGNOSIS" (without CONSULT-II).
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.
Revision: January 2005 TF-5 2004 Titan
PRECAUTIONS
Precautions UDS0008X
q Before connecting or disconnecting the transfer control
unit harness connector, turn ignition switch "OFF" and dis-
connect battery ground cable. Because battery voltage is
applied to transfer control unit even if ignition switch is
turned "OFF".
SEF289H
q 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-
nal.
SEF291H
q Before replacing transfer control unit, perform transfer con-
trol unit input/output signal inspection and make sure
whether transfer control unit functions properly or not.
Refer to TF-27, "Transfer Control Unit Input/Output Signal
Reference Values" .
MEF040DB
Service Notice UDS0008Y
q After overhaul refill the transfer with new transfer fluid.
q Check the fluid level or replace the fluid only with the vehicle parked on level ground.
q During removal or installation, keep inside of transfer clear of dust or dirt.
q Disassembly should be done in a clean work area.
q 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.
q 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.
q All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
q Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary.
q Gaskets, seals and O-rings should replaced any time the transfer is disassembled.
q In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it.
q Observe the specified torque when assembling.
q Clean and flush the parts sufficiently and blow-dry them.
q Be careful not to damage sliding surfaces and mating surfaces.
Revision: January 2005 TF-6 2004 Titan
PRECAUTIONS
q 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. A
Wiring Diagrams and Trouble Diagnosis UDS0008Z
When reading wiring diagrams, refer to the following: B
q GI-14, "How to Read Wiring Diagrams".
q PG-4, "POWER SUPPLY ROUTING CIRCUIT".
When performing trouble diagnosis, refer to the following: C
q GI-9, "How to Follow Trouble Diagnoses".
q GI-27, "How to Perform Efficient Diagnosis for an Electrical Incident".
TF
E
F
G
H
I
J
K
L
M
Revision: January 2005 TF-7 2004 Titan
PREPARATION
PREPARATION PFP:00002
Special Service Tools EDS0031D
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 q Removing self-lock nut
( -- ) q Installing self-lock nut
Flange wrench
a: 85 mm (3.35 in)
b: 65 mm (2.56 in)
NT659
ST33290001 q Removing front oil seal
(J-34286) q Removing rear oil seal
Puller
q Removing metal bushing
ZZA0601D
KV38100500 q Installing front oil seal
( -- ) q Installing rear oil seal
Drift
q Installing rear bearing
q Installing front bearing
a: 80 mm (3.15 in) dia.
b: 60 mm (2.36 in) dia.
ZZA0811D
KV40105310 q Installing dust cover
( -- ) a: 89 mm (3.50 in) dia.
Drift b: 80.7 mm (3.17 in) dia.
ZZA1003D
KV38100200 q Removing sun gear assembly
( -- ) q Removing input bearing
Drift
q Installing sun gear assembly
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.
ZZA1143D
ST30720000 q Installing input bearing
(J-25405) q Installing input oil seal
Drift
q Installing carrier bearing
a: 77 mm (3.03 in) dia.
b: 55 mm (2.17 in) dia.
ZZA0811D
KV32102700 q Installing mainshaft rear bearing
( -- ) a: 48 mm (1.89 in) dia.
Drift b: 41 mm (1.61 in) dia.
ZZA0534D
Revision: January 2005 TF-8 2004 Titan
PREPARATION
Tool number Description
(Kent-Moore No.) A
Tool name
KV40104830 q Installing input oil seal
( -- ) a: 70 mm (2.76 in) dia. B
Drift b: 63.5 mm (2.50 in) dia.
C
ZZA1003D
ST35300000 q Removing carrier bearing TF
( -- ) q Installing metal bushing
Drift
q Removing front bearing
a: 59 mm (2.32 in) dia. E
b: 45 mm (1.77 in) dia.
NT073
ST30021000 q Removing carrier bearing F
(J-22912-01) q Removing front bearing
Puller
q Removing rear bearing
G
ZZA0537D H
ST33710000 q Removing needle bearing
( -- ) q Removing metal bushing
Drift
q Removing rear bearing I
a: 89 mm (3.5 in)
b: 30 mm (1.18 in) dia.
c: 24 mm (0.94 in) dia. J
ZZA1057D
ST35325000 q Removing metal bushing
( -- ) a: 215 mm (8.46 in)
Drift bar K
b: 25 mm (0.98 in) dia.
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