RFD

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rfd

D DRIVELINE/AXLE

SECTION

REAR FINAL DRIVE C

RFD

CONTENTS

WITHOUT ELECTRONIC LOCKING DIFFER- SERVICE DATA AND SPECIFICATIONS (SDS) ..... 33 F

ENTIAL

General Specifications ........................................... 33 Inspection and Adjustment .................................... 33

PRECAUTIONS ......................................................... 3 Service Notice or Precautions ................................. 3

DIFFERENTIAL SIDE GEAR CLEARANCE ...... 33 G PRELOAD TORQUE .......................................... 33

PREPARATION .......................................................... 4

BACKLASH ........................................................ 33

Special Service Tools .............................................. 4 Commercial Service Tools ....................................... 7

COMPANION FLANGE RUNOUT ...................... 33 SELECTIVE PARTS ........................................... 34

NOISE, VIBRATION, AND HARSHNESS (NVH)

TROUBLESHOOTING ............................................... 8 WITH ELECTRONIC LOCKING DIFFEREN-

NVH Troubleshooting Chart .................................... 8 DESCRIPTION ........................................................... 9

TIAL

Cross-Sectional View .............................................. 9 PRECAUTIONS ....................................................... 35

DIFFERENTIAL GEAR OIL ..................................... 10

Precautions for Supplemental Restraint System

Changing Differential Gear Oil .............................. 10

(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-

FILLING .............................................................. 10

SIONER" ................................................................ 35

Checking Differential Gear Oil ............................... 10 FRONT OIL SEAL ....................................................11

Precautions ............................................................ 35 K Service Notice or Precaution ................................. 36

Removal and Installation ........................................11

Wiring Diagrams and Trouble Diagnosis ............... 36

REMOVAL ...........................................................11 PREPARATION ........................................................ 37

INSTALLATION .................................................. 12

Special Service Tools ............................................ 37 L

CARRIER COVER ................................................... 13

Commercial Service Tools ..................................... 40

Removal and Installation ....................................... 13 NOISE, VIBRATION AND HARSHNESS (NVH)

REMOVAL .......................................................... 13 TROUBLESHOOTING ............................................. 41 M

INSTALLATION .................................................. 13

NVH Troubleshooting Chart .................................. 41

REAR FINAL DRIVE ASSEMBLY ........................... 14 DIFFERENTIAL GEAR OIL ..................................... 42

Removal and Installation ....................................... 14

Changing Differential Gear Oil ............................... 42

REMOVAL .......................................................... 14

FILLING .............................................................. 42

INSTALLATION .................................................. 14

Checking Differential Gear Oil ............................... 42

Disassembly and Assembly .................................. 15 DIFFERENTIAL LOCK SYSTEM ............................. 43

COMPONENTS ................................................. 15

Cross-sectional View ............................................. 43

ASSEMBLY INSPECTION AND ADJUSTMENT... 16

Differential Lock Operation .................................... 44

DISASSEMBLY .................................................. 19

System Description ................................................ 44

INSPECTION AFTER DISASSEMBLY .............. 23

DIFFERENTIAL LOCK SOLENOID ................... 44

SELECTION ADJUSTING WASHERS .............. 24

DIFFERENTIAL LOCK POSITION SWITCH ...... 44

ASSEMBLY ........................................................ 27

DIFFERENTIAL LOCK CONTROL UNIT ........... 44

DIFFERENTIAL LOCK MODE SWITCH ............ 44

DIFF LOCK INDICATOR LAMP ......................... 44

System Diagram .................................................... 45

Revision: October 2004

RFD-1

2005 Titan

COMPONENTS FUNCTION DESCRIPTION ..... 45 CAN Communication ............................................. 45
SYSTEM DESCRIPTION ................................... 45 TROUBLE DIAGNOSIS ........................................... 46
Fail-safe Function .................................................. 46 How to Perform Trouble Diagnosis ........................ 46
BASIC CONCEPT .............................................. 46 Location of Electrical Parts .................................... 47 Wiring Diagram -- DIFLOC -- ............................... 48 Trouble Diagnosis Chart for Symptoms ................. 50 Differential Lock Control Unit Input/Output Signal Reference Values .................................................. 50
DIFFERENTIAL LOCK CONTROL UNIT INSPECTION TABLE ......................................... 50 CONSULT-II Function (DIFF LOCK) ...................... 52 CONSULT-II SETTING PROCEDURE ............... 52 SELF-DIAG RESULTS MODE ............................ 53 DATA MONITOR MODE ..................................... 55 TROUBLE DIAGNOSIS FOR SYSTEM ................... 56 Power Supply Circuit For Differential Lock Control Unit ........................................................................ 56 CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE ............................................... 56 DIFFERENTIAL LOCK CONTROL UNIT TERMINALS AND REFERENCE VALUE .................. 56 DIAGNOSTIC PROCEDURE ............................. 57 Differential Lock Control Unit ................................. 58 DIAGNOSTIC PROCEDURE ............................. 58 Differential Lock Mode Switch ............................... 58 CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE ............................................... 58 DIFFERENTIAL LOCK CONTROL UNIT TERMINALS AND REFERENCE VALUE .................. 58 DIAGNOSTIC PROCEDURE ............................. 59 COMPONENT INSPECTION ............................. 61 Differential Lock Position Switch ............................ 62 CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE ............................................... 62 DIFFERENTIAL CONTROL UNIT TERMINALS AND REFERENCE VALUE ................................ 62 DIAGNOSTIC PROCEDURE ............................. 63 COMPONENT INSPECTION ............................. 65 Differential Lock Solenoid Relay ............................ 65 CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE ............................................... 65 DIAGNOSTIC PROCEDURE ............................. 65 Differential Lock Solenoid ...................................... 66

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE ...............................................66 DIFFERENTIAL LOCK CONTROL UNIT TERMINALS AND REFERENCE VALUE ..................66 DIAGNOSTIC PROCEDURE ..............................67 COMPONENT INSPECTION ..............................70 ABS System ...........................................................70 DIAGNOSTIC PROCEDURE ..............................70 CAN Communication Line ......................................71 DIAGNOSTIC PROCEDURE ..............................71 TROUBLE DIAGNOSIS FOR SYMPTOMS .............72 DIFF LOCK Indicator Lamp Does Not Turn ON .....72 DIAGNOSTIC PROCEDURE ..............................72 DIFF LOCK Indicator Lamp Does Not Change ......75 DIAGNOSTIC PROCEDURE ..............................75 DIFF LOCK Indicator Lamp Sometimes Flashes ...76 DIAGNOSTIC PROCEDURE ..............................76 DIFFERENTIAL LOCK CONTROL UNIT .................78 Removal and Installation ........................................78 REMOVAL ...........................................................78 INSTALLATION ...................................................78 FRONT OIL SEAL ....................................................79 Removal and Installation ........................................79 REMOVAL ...........................................................79 INSTALLATION ...................................................80 CARRIER COVER ....................................................81 Removal and Installation ........................................81 REMOVAL ...........................................................81 INSTALLATION ...................................................81 REAR FINAL DRIVE ASSEMBLY ............................82 Removal and Installation ........................................82 REMOVAL ...........................................................82 INSTALLATION ...................................................82 Disassembly and Assembly ...................................83 COMPONENTS ..................................................83 ASSEMBLY INSPECTION AND ADJUSTMENT...84 DISASSEMBLY ...................................................87 INSPECTION AFTER DISASSEMBLY ...............91 SELECTION ADJUSTING WASHERS ...............92 ASSEMBLY .........................................................94 SERVICE DATA AND SPECIFICATIONS (SDS) .....99 General Specifications ...........................................99 Inspection and Adjustment .....................................99 PRELOAD TORQUE ..........................................99 BACKLASH .........................................................99 COMPANION FLANGE RUNOUT ......................99 SELECTIVE PARTS .........................................100

Revision: October 2004

RFD-2

2005 Titan

PRECAUTIONS
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

PRECAUTIONS Service Notice or Precautions

PFP:00001
A
EDS001OQ

q Check for the correct installation status prior to removal or disassembly. If matching marks are required,

be certain they do not interfere with the function of the parts when applied.

q Overhaul should be done in a clean work area, it is preferable to work in dustproof area.

q Before disassembly, using steam or white gasoline, completely remove sand and mud from the exterior of

the unit, preventing them from entering into the unit during disassembly or assembly.

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 be replaced any time when the unit is disassembled.

RFD

q In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tightening sequence is specified, observe it.

q Clean and flush the parts sufficiently and blow-dry them.

q Be careful not to damage sliding surfaces and mating surfaces.

q When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,

and foreign materials from the application and mounting surfaces.

q Always use shop paper for cleaning the inside of components.

q Avoid using cotton gloves or shop rags to prevent entering of lint. q During assembly, observe the specified tightening torque, and apply new differential gear oil, petroleum G
jelly, or multi-purpose grease as specified for each vehicle, if necessary.

Revision: October 2004

RFD-3

2005 Titan

PREPARATION
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

PREPARATION

PFP:00002

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name

Description

EDS001OR

KV40104000 (--) Flange wrench a: 85 mm (3.35 in) dia. b: 65 mm (2.56 in) dia.

Removing and installing drive pinion nut

ST33290001 (J-34286) Puller

NT659
Removing front oil seal

ST15310000 (--) Drift a: 96mm (3.77 in) dia. b: 84 mm (3.30 in) dia.
ST3127S000 (J-25765-A) Preload gauge set 1. GG91030000
(J-25765) Torque wrench 2. HT62940000 (1/2) (--) Socket adapter 3. HT62900000 (3/8) (--) Socket adapter
-- (C-4164) Adjuster tool
KV10111100 (J-37228) Seal cutter
Revision: October 2004

ZZA0601D

Installing front oil seal

NT115
Inspecting drive pinion bearing preload and total preload

NT124
Removing and installing side bearing adjuster

WDIA0192E

Removing carrier cover

S-NT046
RFD-4

2005 Titan

Tool number (Kent-Moore No.) Tool name ST30021000 (J-22912-01) Puller
ST33081000 (--) Adapter a: 43 mm (1.69 in) dia. b: 33.5 mm (1.32 in) dia.
ST23550000 (--) Pin punch a: 4.5 mm (0.177 in) dia.
-- (8144) Pinion block
-- (6740) Cone
-- (6741) Screw
-- (6739) Pinion height lock
Revision: October 2004

PREPARATION
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]
Description
A

Removing drive pinion rear bearing inner

race

ZZA0700D ZZA1000D

Removing and installing side bearing inner race

RFD

Removing and installing lock pin

NT410

Adjusting pinion gear height

J
SDIA2599E
Adjusting pinion gear height
K

L
SDIA2601E
Adjusting pinion gear height
M

SDIA2602E

Adjusting pinion gear height

SDIA2603E
RFD-5

2005 Titan

Tool number (Kent-Moore No.) Tool name
-- (D-115-2) Scooter block
TBD Arbor disc
-- (D-115-3) Arbor
ST01500001 (--) Drift a: 89mm (3.50 in) dia. b: 79 mm (3.11 in) dia.
ST30022000 (--) Drift a: 46 mm (1.81 in) dia. b: 110 mm (4.33 in) dia.
ST33022000 (--) Drift a: 49 mm (1.92 in) dia. b: 67 mm (2.63 in) dia.

PREPARATION
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]
Description
Adjusting pinion gear height

SDIA2604E

Adjusting pinion gear height

SDIA2605E

Adjusting pinion gear height

SDIA2606E

Installing drive pinion rear bearing outer race

ZZA0811D

Installing drive pinion rear bearing outer race

NT660
Installing drive pinion front bearing outer race

NT660

Revision: October 2004

RFD-6

2005 Titan

Tool number (Kent-Moore No.) Tool name
-- (C-4040) Installer
KV38100300 (J-25523) Drift a: 54 mm (2.13 in) dia. b: 46 mm (1.81 in) dia. c: 32mm (1.26 in) dia.
Commercial Service Tools
Tool name Puller
Puller
Power tool

PREPARATION
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]
Description
A

Installing drive pinion rear bearing inner

race

SDIA2607E

Installing side bearing inner race

C RFD

ZZA1046D

F
EDS001OS

Description

Removing companion flange and side

bearing inner race

NT077

Removing side bearing inner race

K
ZZB0823D
Loosening bolts and nuts
L

M
PBIC0190E

Revision: October 2004

RFD-7

2005 Titan

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

Reference page

Possible cause and SUSPECTED PARTS

Symptom ×: Applicable

Revision: October 2004

Noise

×××××××××××××

Gear tooth rough

RFD-8

Gear contact improper

RFD-16, "Tooth Contact"

Tooth surfaces worn

Backlash incorrect

RFD-17, "Backlash"

Companion flange excessive runout

RFD-18, "Companion Flange Runout"

Gear oil improper

MA-26, "Checking Final Drive Oil"

PROPELLER SHAFT

PR-3, "NVH Troubleshooting Chart"

AXLE AND SUSPENSION

RAX-4, "NVH Troubleshooting Chart", RSU-4, "NVH Troubleshooting Chart"

TIRES ROAD WHEEL

WT-3, "NVH Troubleshooting Chart"

AXLE SHAFT

RAX-4, "NVH Troubleshooting Chart"

PFP:00003

EDS001OT

2005 Titan

BRAKES

BR-5, "NVH Troubleshooting Chart"

STEERING

PS-5, "NVH Troubleshooting Chart"

DESCRIPTION Cross-Sectional View
1. Companion flange 4. Differential case 7. Side gear

DESCRIPTION
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]
PFP:00000
A
EDS001OU
B

RFD

2. Drive pinion 5. Pinion mate gear 8. Pinion mate shaft

3. Drive gear 6. Axle shaft

SDIA2636E

Revision: October 2004

RFD-9

2005 Titan

DIFFERENTIAL GEAR OIL
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

DIFFERENTIAL GEAR OIL

PFP:KLD30

Changing Differential Gear Oil

EDS002HV

Refer to MA-27, "Changing Final Drive Oil" .

FILLING Refer to MA-26, "Checking Final Drive Oil" .

Checking Differential Gear Oil

EDS002HW

Refer to MA-26, "Checking Final Drive Oil" .

Revision: October 2004

RFD-10

2005 Titan

FRONT OIL SEAL
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

FRONT OIL SEAL
Removal and Installation
REMOVAL

PFP:38189
A
EDS001OX

1. Remove rear propeller shaft. Refer to PR-8, "Removal and Installation" .

2. Remove wheel and tire assemblies.

3. Remove brake calipers and rotors. Refer to BR-29, "Removal and Installation of Brake Caliper and Disc

Rotor" .

4. Using an inch-pound, torque wrench, rotate the pinion three or four times.

5. Record the rotating torque.

6. Loosen drive pinion nut while holding companion flange using

RFD

Tool.

Tool number : KV40104000 ( -- ) E

7. Put matching mark on the thread edge of drive pinion. The mark should be in line with the mark on companion flange.
CAUTION: For matching mark, use paint. Do not damage drive pinion.

LDIA0122E

8. Remove companion flange using a suitable tool.

J
SDIA2590E
K
L

9. Remove front oil seal using Tool.
Tool number : ST33290001 (J-34286)
CAUTION: Be careful not to damage axle housing.

LDIA0123E

Revision: October 2004

RFD-11

LDIA0124E
2005 Titan

FRONT OIL SEAL
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]
INSTALLATION 1. Apply multi-purpose grease to oil seal lips. Install front oil seal
into axle housing using Tool.
Tool number : ST15310000 ( -- )
CAUTION: q Do not reuse oil seal. q When installing, do not incline oil seal.

2. Align the matching mark of drive pinion with the mark of companion flange, then install companion flange.

LDIA0125E

SDIA2590E

3. Assemble washer if required and new drive pinion nut on pinion gear and tighten nut until there is zero bearing end play.
CAUTION: Do not reuse drive pinion nut and washer.
4. Rotate drive pinion using an inch-pound torque wrench and flange wrench. Rotating torque should be equal to the reading recorded in step 5 above during removal plus an additional 0.56 N·m (5 in-lb).

Tool number : KV40104000 ( -- )

5. If the rotating torque is low, continue to tighten drive pinion nut in 6.8 N·m (5 ft-lb) increments until proper rotating torque is achieved. Refer to RFD-15, "COMPONENTS" .

LDIA0122E

CAUTION: Do not loosen drive pinion nut to decrease drive pinion rear bearing rotating torque and do not exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. If the minimum tightening torque is reached prior to reaching the required rotating torque, collapsible spacer may have been damaged. Replace collapsible spacer.

6. Install rear propeller shaft. Refer to PR-8, "Removal and Installation" .

7. Check gear lubricant level and fill with proper lubricant if required. Refer to MA-26, "Checking Final Drive Oil" .

8. Install brake rotors, calipers, wheel and tire assemblies. Refer to BR-29, "Removal and Installation of Brake Caliper and Disc Rotor" .

Revision: October 2004

RFD-12

2005 Titan

CARRIER COVER
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

CARRIER COVER
Removal and Installation
REMOVAL 1. Drain gear oil. Refer to MA-27, "DRAINING" . 2. Remove carrier cover.
q Disconnect parking brake cable from carrier cover. q Disconnect brake tube from carrier cover.

PFP:38351
A
EDS001OY
B
C

RFD

E
LDIA0126E

INSTALLATION

1. Apply sealant to mating surface of carrier cover.

q Use Genuine Silicone RTV or equivalent. Refer to GI-45, "Recommended Chemical Products and Sealants" .
CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
2. Install carrier cover on axle housing and tighten carrier cover bolts to the specified torque. Refer to RFD-15, "COMPONENTS" .
3. Connect parking brake cable and brake tube to carrier cover.

SDIA2639E

4. Fill with new gear oil until oil level reaches the specified limit near filler plug mounting hole. Refer to MA-

26, "Checking Final Drive Oil" .

Revision: October 2004

RFD-13

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

REAR FINAL DRIVE ASSEMBLY

PFP:38300

Removal and Installation
REMOVAL

EDS001OZ

CAUTION: q Be careful not to damage spline, companion flange and front oil seal when removing propeller
shaft.

q Before removing final drive assembly or rear axle assembly, disconnect ABS sensor harness connector from the assembly and move it away from final drive/rear axle assembly area. Failure to do so may result in sensor wires being damaged and sensor becoming inoperative.

1. Drain rear final drive gear oil. Refer to MA-27, "DRAINING" .

2. Remove rear propeller shaft. Refer to PR-8, "Removal and Installation" .

q Plug rear end of transfer.

3. Remove axle shaft. Refer to RAX-6, "Removal and Installation" .

4. Support rear final drive using a suitable jack.

5. Disconnect the following components from rear final drive.

q Brake tube block connectors. Refer to BR-13, "Removal and Installation of Rear Brake Piping and Brake Hose" .

q ABS sensor wire harness. Refer to BRC-39, "Removal and Installation" (without VDC), BRC-150, "Removal and Installation" (with VDC).

q Parking brake cable.

q Brake tube.

6. Disconnect brake hose from brake tube at the mounting clip on top of axle housing. Then remove the metal clip to disconnect brake line from the mounting clip on top of axle housing.

7. Remove rear shock absorber lower bolts. Refer to RSU-7, "Removal and Installation" .

8. Remove leaf spring U-bolt nuts. Refer to RSU-8, "Removal and Installation" .

9. Remove rear final drive assembly.

LDIA0126E

INSTALLATION Note the following, and installation is in the reverse order of removal. q Fill with new gear oil until oil level reaches the specified limit near filler plug mounting hole. Refer to MA-
26, "Checking Final Drive Oil" . q Bleed the air from brake system. Refer to BR-11, "Bleeding Brake System" .

Revision: October 2004

RFD-14

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

Disassembly and Assembly
COMPONENTS

EDS001P0
A

RFD

1. Drive pinion nut 4. Front oil seal 7. Axle housing 10. Side bearing cap 13. Filler plug 16. Drive pinion rear bearing 19. Side bearing 22. Pinion mate thrust washer 25. Lock pin 28. Breather
Revision: October 2004

2. Drive pinion nut washer 5. Front bearing thrust washer 8. Drain plug 11. Adjuster lock plate 14. Drive pinion 17. Collapsible spacer 20. Differential case 23. Pinion mate gear 26. Side gear thrust washer

WDIA0112E
3. Companion flange 6. Drive pinion front bearing 9. Axle shaft assembly 12. Carrier cover 15. Drive pinion height adjusting washer 18. Side bearing adjuster 21. Drive gear 24. Pinion mate shaft 27. Side gear

RFD-15

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]
ASSEMBLY INSPECTION AND ADJUSTMENT Total Preload Torque 1. Turn drive pinion in both directions several times to set bearing
rollers. 2. Check total preload using Tool.
Tool number : ST3127S000 (J-25765-A)

Total preload (with oil seal)

Gear ratio 2.937 Type:

2.49 - 5.27 N·m (0.26 - 0.53 kg-m, 22- 46 in-lb)

Gear ratio 3.357 Type: 2.38 - 5.16 N·m (0.25 - 0.52 kg-m, 21 - 45 in-lb)

PDIA0309E

NOTE: Total preload torque = Pinion bearing torque + Side bearing torque
q If measured value is out of the specification, disassemble it to check and adjust each part. Adjust pinion bearing preload and side bearing preload. Adjust pinion bearing preload first, then adjust side bearing preload.

When the preload torque is large On pinion bearings: Replace collapsible spacer. On side bearings: Loosen side bearing adjuster.

When the preload is small
On pinion bearings: Tighten drive pinion nut.
On side bearings: Tighten side bearing adjuster.
Tooth Contact Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive pinion. Gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check gear tooth contact pattern to obtain the best contact for low noise and long life. 1. Remove rear cover. Refer to RFD-19, "DISASSEMBLY" . 2. Thoroughly clean drive gear and drive pinion teeth. 3. Apply red lead to drive gear.
CAUTION: Apply red lead to both the faces of 3 to 4 gears at 4 locations evenly spaced on drive gear.

4. Hold companion flange steady by hand and rotate drive gear in both directions.

PDIA0321E

Revision: October 2004

RFD-16

PDIA0322E
2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]
A

RFD

SDIA2591E

5. If outside the standard, adjust drive pinion height adjusting washer and backlash. Refer to RFD-25, "Drive

Pinion Height Adjusting Washer" , RFD-17, "Backlash" .

Backlash

1. Remove rear cover. Refer to RFD-19, "DISASSEMBLY" .

2. Check drive gear to drive pinion backlash using a dial indicator

at several points.

Drive gear to drive pinion backlash:

0.08 - 0.13 mm (0.0031 - 0.0051 in)

3. If outside the standard, adjust side bearing adjuster.
CAUTION: Check tooth contact and total preload after adjusting side bearing adjuster. Refer to RFD-16, "Total Preload Torque" , RFD-16, "Tooth Contact" .
a. Remove adjuster lock plate.
b. Loosen side bearing cap bolts.
c. Tighten or loosen each side bearing adjusters using Tool.

J
K
SDIA2640E
L

Tool number : -- (C - 4164) M

PDIA0337E

Revision: October 2004

RFD-17

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]
d. In case of lots of backlash, loosen side bearing adjuster A and tighten side bearing adjuster B. In case of less backlash, loosen side bearing adjuster B and tighten side bearing adjuster A.

e. After adjusting backlash and tighten cap bolts to the specified torque. Refer to RFD-15, "COMPONENTS" .
f. Install adjuster lock plate and tighten to the specified torque. Refer to RFD-15, "COMPONENTS" .

PDIA0330E

Companion Flange Runout 1. Fit a dial indicator onto companion flange face (inner side of pro-
peller shaft mounting bolt holes).
2. Rotate companion flange to check for runout.

PDIA0331E

Runout limit : 0.10 mm (0.0039 in) or less

3. Fit a test indicator to the inner side of companion flange (socket diameter).
4. Rotate companion flange to check for runout.

Runout limit : 0.13 mm (0.0051 in) or less

5. If the runout value is outside the repair limit, follow the procedure below to adjust.

SDIA2078E

a. Check for runout while changing the phase between companion flange and drive pinion by 90° step, and search for the point where the runout is the minimum.

b. If the runout value is still outside of the limit after the phase has been changed, replace companion flange.

c. If the runout value still outside of the limit after companion flange has been replaced, check drive pinion bearing and drive pinion assembly.

Revision: October 2004

RFD-18

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

DISASSEMBLY

Differential Assembly

1. Remove carrier cover bolts.

2. Remove carrier cover using Tool. B
Tool number : KV10111100 (J-37228)

CAUTION:

q Be careful not to damage the mating surface.

q Do not insert flat-bladed screwdriver, this will damage the

mating surface.

RFD

3. For proper reinstallation, paint matching mark on one side of side bearing cap. CAUTION: q Side bearing caps are line-board for initial assembly. The matching marks are used to reinstall them in their original positions. q For matching mark, use paint. Do not damage side bearing cap.
4. Remove adjuster lock plates.
5. Remove side bearing caps.

SDIA2581E
E
F
G
H
PDIA0310E
I

6. Remove side bearing adjusters using Tool. Tool number : -- (C - 4164)

PDIA0311E

PDIA0337E

Revision: October 2004

RFD-19

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]
7. Keep side bearing outer races together with inner races. Do not mix them up. Also, keep side bearing adjusters together with bearing.
8. Remove side bearing adjusters from axle housing.

9. Remove side bearing inner races using suitable puller.
CAUTION: Be careful not to damage differential case.

PDIA0312E

10. For proper reinstallation, paint matching mark on differential case and drive gear. CAUTION: For matching mark, use paint. Do not damage differential case and drive gear.
11. Remove drive gear bolts. 12. Tap drive gear off differential case with a soft hammer.
CAUTION: Tap evenly all around to keep drive gear from binding.
13. Pull lock pin out of pinion mate shaft, using Tool. Tool number : ST23550000 ( -- )

SDIA2635E SDIA2238E

14. Remove pinion mate shaft.

PDIA0062E

Revision: October 2004

RFD-20

SDIA0031J
2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

15. Turn pinion mate gear, then remove pinion mate gear, pinion

mate thrust washer, side gear and side gear thrust washer from

differential case.

Drive Pinion Assembly 1. Remove differential case assembly. Refer to RFD-19, "Differential Assembly" . 2. Remove drive pinion nut and washer using Tool.
Tool number : KV40104000 ( -- )

SDIA0032J

RFD

3. Put a matching mark on the thread edge of drive pinion. The mark should be in line with the mark on companion flange.
CAUTION: For matching mark, use paint. Do not damage drive pinion.

PDIA0314E

4. Remove companion flange using a suitable Tool.

K
SDIA2590E
L

PDIA0315E

Revision: October 2004

RFD-21

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]
5. Remove front oil seal using Tool.
Tool number : ST33290001 (J-34286)
CAUTION: Be careful not to damage axle housing. 6. Remove front bearing thrust washer.

7. Remove drive pinion assembly and collapsible spacer from axle housing, using press.
CAUTION: Do not drop drive pinion assembly.
8. Remove drive pinion front bearing inner race from axle housing.

SDIA2586E

9. Tap drive pinion front bearing outer race uniformly with a brass bar or equivalent to remove. CAUTION: Be careful not to damage axle housing.
10. Tap drive pinion rear bearing outer race uniformly with a brass bar or equivalent for removal. CAUTION: Be careful not to damage axle housing.
11. Remove drive pinion rear bearing inner race and drive pinion height adjusting washer, using Tool.
Tool number : ST30021000 (J-22912-01)

PDIA0316E SDIA2641E

SDIA2236E

Revision: October 2004

RFD-22

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

INSPECTION AFTER DISASSEMBLY

Drive Gear and Drive Pinion

q If gear teeth do not mesh or line-up correctly, determine cause and adjust, repair, or replace as necessary.

q If gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new gears. q Drive gear and drive pinion are supplied in matched sets only. Matching numbers on both drive pinion and B
drive gear are etched for verification. If a new gear set is being used, verify the numbers of each pinion gear and drive gear before proceeding with assembly.
C
Bearing

q If found any chipped (by friction), pitted, worn, rusted, scratched mark, or unusual noise from bearing,

replace with new bearing assembly (as a new set).

RFD

q Bearing must be replaced with a new one whenever disassembled.

Side Gear, Pinion Mate and Pinion Mate Shaft

q Replace with a new one if found any cracks or damage on the surface of the tooth.

q Replace with a new one if found any worn or chipped mark on the contact sides of thrust washer.

q Replace both side gear and pinion mate gear as a set when replacing side gear or pinion mate gear. F
Side Gear Thrust Washer and Pinion Mate Thrust Washer

q Replace with a new one if found that it is chipped (by friction), damaged, or unusual worn.

Differential Case

q Replace with a new one if found any wear or cracks on the contact sides of differential case.

Revision: October 2004

RFD-23

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]
SELECTION ADJUSTING WASHERS Side Gear Thrust Washer 1. Place differential case straight up so that side gear to be mea-
sured comes upward.

2. Using a thickness gauge, measure the clearance between side gear back and differential case at 3 different points, while rotating side gear. Average the 3 readings, and then measure the clearance. (Measure the clearance of the other side as well.)
Side gear back clearance standard:
0.305 mm (0.0120 in) or less. (Each gear should rotate smoothly without excessive resistance during differential motion.)
CAUTION: To prevent side gear from tilting, insert thickness gauges with the same thickness from both sides. 3. If the back clearance is outside the standard, use a thicker/thinner side gear thrust washer to adjust.
When the back clearance is large:
Use a thicker thrust washer.
When the back clearance is small:
Use a thinner thrust washer.
CAUTION: Select a side gear thrust washer for right and left individually.

PDIA0460E SDIA0583E

Revision: October 2004

RFD-24

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

Drive Pinion Height Adjusting Washer

q Drive gear and drive pinion are supplied in matched sets only.

Matching numbers on both drive pinion and drive gear are

etched for verification. If a new gear set is being used, verify the

numbers of each drive pinion and drive gear before proceeding

with assembly.

SDIA2241E

RFD

q The mounting distance from the center line of drive gear to the back face of drive pinion for the Model 226

axle assembly is 109.5 mm (4.312 in).

On the button end of each drive pinion, there is etched a plus (+) number, a minus (-) number, or a zero

(0), which indicates the best running position for each particular gear set. This dimension is controlled by

a selective drive pinion height adjusting washer between drive pinion inner bearing race and drive pinion. For example: If a drive pinion is etched m+8 (+3), it would require 0.08 mm (0.003 in) less drive pinion F

height adjusting washer than a drive pinion etched "0". This means decreasing drive pinion height adjust-

ing washer thickness; increases the mounting distance of drive pinion to 109.6 mm (4.315 in). If a drive

pinion is etched m-8 (-3), it would require adding 0.08 mm (0.003 in) more to drive pinion height adjusting G

washer than would be required if drive pinion were etched "0". By adding 0.08 mm (0.003 in), the mount-

ing distance of drive pinion was decreased to 109.4 mm (4.309 in) which is just what m-8 (a-3) etching

indicated.

q To change drive pinion adjustment, use different drive pinion height adjusting washers which come in dif-

ferent thickness.

Use the following tables as a guide for selecting the correct drive pinion height adjusting washer thickness to add or subtract from the old drive pinion height adjusting washer.

OLD DRIVE

NEW DRIVE PINION MARKING mm (in)

PINION

MARKING

-4

-3

-2

-1

+0.20

+0.18

+0.15

+0.13

+0.10

+0.08

+0.05

+0.02

(+0.008) (+0.007) (+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001)

(0)

+0.18

+0.15

+0.13

+0.10

+0.08

+0.05

+0.02

-0.02

(+0.007) (+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001)

(0)

(-0.001)

+0.15

+0.13

+0.10

+0.08

+0.05

+0.02

-0.02

-0.05

(+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001)

(0)

(-0.001) (-0.002)

+0.13

+0.10

+0.08

+0.05

+0.02

-0.02

-0.05

-0.08

(+0.005) (+0.004) (+0.003) (+0.002) (+0.001)

(0)

(-0.001) (-0.002) (-0.003)

+0.10

+0.08

+0.05

+0.02

-0.02

-0.05

-0.08

-0.10

(+0.004) (+0.003) (+0.002) (+0.001)

(0)

(-0.001) (-0.002) (-0.003) (-0.004)

-1

+0.08

+0.05

+0.02

-0.02

-0.05

-0.08

-0.10

-0.13

(+0.003) (+0.002) (+0.001)

(0)

(-0.001) (-0.002) (-0.003) (-0.004) (-0.005)

-2

+0.05

+0.02

-0.02

-0.05

-0.08

-0.10

-0.13

-0.15

(+0.002) (+0.001)

(0)

(-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006)

-3

+0.02

-0.02

-0.05

-0.08

-0.10

-0.13

-0.15

-0.18

(+0.001)

(0)

(-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006) (-0.007)

-4

-0.02

-0.05

-0.08

-0.10

-0.13

-0.15

-0.18

-0.20

(0)

(-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006) (-0.007) (-0.008)

Revision: October 2004

RFD-25

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

1. Make sure all parts are clean and that drive pinion bearings are well lubricated.
2. Assemble drive pinion bearings into Tools.

Tool number

A: -- (8144) B: -- (6740)

C: -- (6741)

3. Install drive pinion bearing inner race and drive pinion height adjusting washer to axle housing using tool as shown.

SDIA2242E

4. Turn the assembly several times to seat drive pinion bearings.

PDIA0318E

5. Measure the turning torque, using Tool.

Tool number

: ST3127S000 (J-25765-A)

Turning torque specification : 1.2 - 2.8 N-m (0.13 - 0.28 kg-m, 11 - 24 in-lb)

6. Tighten side bearing caps to the specified torque installing Tools as shown.

Tool number

A: -- (6739)

B: -- (D-115-2)

C: -- TBD

D: -- (D-115-3)

Revision: October 2004

RFD-26

PDIA0319E
PDIA0320E
SDIA2646E
2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

7. Put scooter block on pinion height block. Make sure that dial

indicator is level adjusting pressure with a hand. Dial indicator

indicates "0".

8. Slide dial indicator along arbor. Record the maximum.

9. Adjust drive pinion height adjusting washer so that the maximum

will be "0".

ASSEMBLY Drive Pinion Assembly 1. Press a drive pinion rear bearing outer race into axle housing,
using Tools.
Tool number A: ST01500001 ( -- )
B: ST30022000 ( -- )
CAUTION: Do not reuse drive pinion rear bearing.

SDIA2647E

RFD

2. Press a drive pinion front bearing outer race into axle housing, using Tool. Tool number : ST33022000 ( -- ) CAUTION: Do not reuse drive pinion front bearing.
3. Select drive pinion height adjusting washer. Refer to RFD-25, "Drive Pinion Height Adjusting Washer" .
4. Press a drive pinion rear bearing inner race and drive pinion height adjusting washer to drive pinion, using Tool. Tool number : -- (C - 4040) CAUTION: Do not reuse drive pinion rear bearing.
5. Apply gear oil to drive pinon rear bearing and drive pinon front bearing.
6. Install drive pinion front bearing inner race in axle housing. 7. Install front bearing thrust washer to axle housing.

PDIA0323E

K
PDIA0324E
L

SDIA2592E

Revision: October 2004

RFD-27

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]
8. Apply multi-purpose grease to front oil seal lip. Install front oil seal into axle housing using Tool.
Tool number : ST15310000 ( -- )
CAUTION: q Do not reuse oil seal. q When installing, do not incline oil seal.

9. Install collapsible spacer to drive pinion. And then install drive pinion assembly in axle housing.
CAUTION: q Do not reuse collapsible spacer.
q Be careful not to damage front oil seal.

PDIA0326E

10. Align the matching mark of drive pinion with the mark of companion flange.

SDIA2595E

11. Install companion flange onto drive pinion. Tap companion flange with a soft hammer until fully seated.
CAUTION: Be careful not to damage companion flange and front oil seal.

12. Install drive pinion nut and drive pinion nut washer. Tighten drive pinion nut until total preload is within specification. q The threaded portion of drive pinion and drive pinion nut should be free from oil or grease.
Tool number : KV40104000 ( -- )
CAUTION: Do not reuse drive pinion nut and drive pinion nut washer.

Revision: October 2004

RFD-28

SDIA2590E
PDIA0328E
PDIA0313E
2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

13. Tighten drive pinion nut by very small degrees until the specified

preload is achieved. When checking the preload, turn drive pin-

ion in both directions several times to set the bearing rollers,

using Tool.

Tool number : ST3127S000 (J-25765-A)

Pinion bearing preload
: 1.7 - 3.8 N·m (0.18 - 0.38 kg-m, 15 - 33 in-lb)
a. This procedure will have to be repeated if: q Maximum preload is achieved before the minimum drive pinion nut torque is reached. q Minimum preload is not achieved before maximum drive pinion nut torque is reached.
Differential Assembly 1. Assemble side gear thrust washers with the same thickness as
the ones installed prior to disassembly or reinstall the old ones on side gears. 2. Assemble side gear and side gear thrust washer into differential case.

PDIA0309E

RFD

3. Align 2 pinion mate gears in diagonally opposite positions, then rotate and assemble them into differential case after assembling pinion mate thrust washer to pinion mate gear.

H
SDIA0193J
I
J

4. Align lock pin holes on differential case and shaft, and assemble pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to RFD-24, "Side Gear Thrust Washer" .

SDIA0036J

SDIA0037J

Revision: October 2004

RFD-29

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]
6. Drive a lock pin into pinion mate shaft, using Tool.
Tool number : ST23550000 ( -- )
CAUTION: Do not reuse lock pin.

7. Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly.

PDIA0062E

SPD322
8. Align the matching mark of differential case with the mark of drive gear, then install drive gear.

9. Apply thread locking sealant into the thread hole of drive gear. q Use Genuine Medium Strength Thread Locking Sealant or equivalent. Refer to GI-45, "Recommended Chemical Products and Sealants" . CAUTION: Drive gear back and threaded holes shall be cleaned and decreased sufficiently.
10. Install drive gear on the bolts, and then tighten to the specified torque. Refer to RFD-15, "COMPONENTS" . CAUTION: q Do not reuse the bolts. q Tighten bolts in a crisscross fashion.

Revision: October 2004

RFD-30

SDIA2593E
SDIA2594E
SDIA0247J
2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

11. Press side bearing inner races to differential case using Tools.

Tool number A: KV38100300 (J-25523)

B: ST33081000 ( -- )

CAUTION:

Do not reuse side bearing.

12. Install side bearing adjusters into axle housing.

SDIA2240E

RFD

13. Apply gear oil to side bearings. Install differential case assembly with side bearing outer races into axle housing.

G
PDIA0381E
H
I

14. Align paint matching mark on side bearing caps with that on axle housing and install side bearing caps on axle housing.
CAUTION: Do not tighten at this point. This allows further tightening of side bearing adjusters.

PDIA0312E

15. Tighten each side bearing adjusters using Tool.
Tool number : -- (C - 4164)
16. Adjusting backlash of drive gear and drive pinion. Refer to RFD17, "Backlash" .
17. Check total preload. Refer to RFD-16, "Total Preload Torque" . 18. Check tooth contact. Refer to RFD-16, "Tooth Contact" .

Revision: October 2004

RFD-31

PDIA0329E
PDIA0337E
2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

19. Apply sealant to mating surface of carrier cover.
q Use Genuine Silicone RTV or equivalent. Refer to GI-45, "Recommended Chemical Products and Sealants" .
CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
20. Install carrier cover on axle housing and tighten carrier cover bolts with the specified torque. Refer to RFD-15, "COMPONENTS" .

SDIA2639E

Revision: October 2004

RFD-32

2005 Titan

SERVICE DATA AND SPECIFICATIONS (SDS)
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications

PFP:00030
A
EDS001P1

Engine Vehicle grade

Standard

VK56DE

Tow package or off road package

Transmission

5A/T

Final drive model Gear ratio

M226

2.937

3.357

Number of pinion gears Number of teeth (Drive gear / drive pinion)

47/16

47/14

RFD

Oil capacity (Approx.)

(US pt, lmp pt)

2.01 (4-1/4, 3-1/2)

Drive pinion adjustment spacer type
Inspection and Adjustment
DIFFERENTIAL SIDE GEAR CLEARANCE
Item

Collapsible Standard

E
EDS001P2
Unit: mm (in) F

Side gear backlash (Clearance between side gear and differential case)

0.305 (0.0120) or less.
(Each gear should rotate smoothly without excessive resistance during differ- G
ential motion.)

PRELOAD TORQUE
Item Total preload (Drive pinion torque to rotate plus) Drive pinion bearing preload
BACKLASH
Item Drive gear to drive pinion gear

Unit: N·m (kg-m, in-lb) H

Specification

Gear ratio 2.937 Type

Gear ratio 3.357 type

2.49 - 5.27 (0.26 - 0.53, 22 - 46)

2.38 - 5.16 (0.25 - 0.52, 21 - 45)

1.7 - 3.8 (0.18 - 0.38, 15 - 33)

J
Unit: mm (in)

Standard

0.08 - 0.13 (0.0031 - 0.0051)

COMPANION FLANGE RUNOUT
Item Companion flange face Inner side of companion flange

Runout limit 0.10 (0.0039) or less 0.13 (0.0051) or less

Unit: mm (in) L M

Revision: October 2004

RFD-33

2005 Titan

SERVICE DATA AND SPECIFICATIONS (SDS)
[WITHOUT ELECTRONIC LOCKING DIFFERENTIAL]

SELECTIVE PARTS Side Gear Thrust Washer

Unit: mm (in)

Thickness

Package part number*

0.76 (0.030) 0.79 (0.031) 0.81 (0.032) 0.84 (0.033) 0.86 (0.034)

38424 8S101

0.89 (0.035) 0.91 (0.036) 0.94 (0.037) 0.97 (0.038) 0.99 (0.039)

38424 8S102

*Always check with the parts department for the latest parts information.

Drive Pinion Height Adjusting Washer

Unit: mm (in)

Thickness

Package part number*

0.076 (0.030) 0.079 (0.031) 0.081 (0.032) 0.084 (0.033) 0.086 (0.034)

38151 8S101

0.089 (0.035) 0.091 (0.036) 0.094 (0.037) 0.097 (0.038) 0.099 (0.039)

38151 8S102

0.102 (0.040) 0.104 (0.041) 0.107 (0.042) 0.109 (0.043) 0.112 (0.044)

38151 8S103

0.114 (0.045) 0.117 (0.046) 0.119 (0.047) 0.122 (0.048) 0.124 (0.049)

38151 8S104

0.127 (0.050) 0.130 (0.051) 0.132 (0.052) 0.135 (0.053) 0.137 (0.054)

38151 8S105

*Always check with the Parts Department for the latest parts information.

Revision: October 2004

RFD-34

2005 Titan

PRECAUTIONS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

PRECAUTIONS

PFP:00001

Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT A

BELT PRE-TENSIONER"

EDS001P3

The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along B

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:

RFD

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

EDS001P4

q Before connecting or disconnecting differential lock control

unit harness connector, turn ignition switch "OFF" and dis-

connect the battery cable from the negative terminal.

Because battery voltage is applied to differential lock con-

trol unit even if ignition switch is turned "OFF".

q When connecting or disconnecting pin connectors into or from differential lock control unit, take care not to damage pin terminals (bend or break). When connecting pin connectors make sure that there are not any bends or breaks on differential lock control unit pin terminal.

SEF289H

q Before replacing differential lock control unit, perform differential lock control unit input/output signal inspection and make sure whether differential lock control unit functions properly or not. Refer to RFD-50, "Differential Lock Control Unit Input/Output Signal Reference Values" .

SEF291H

Revision: October 2004

RFD-35

SDIA1848E
2005 Titan

PRECAUTIONS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

Service Notice or Precaution

EDS001P5

q Check for the correct installation status prior to removal or disassembly. If matching marks are required, be certain they do not interfere with the function of the parts when applied.
q Overhaul should be done in a clean work area, it is preferable to work in dustproof area.
q Before disassembly, using steam or white gasoline, completely remove sand and mud from the exterior of the unit, preventing them from entering into the unit during disassembly or assembly.
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 be replaced any time when the unit is disassembled.
q In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tightening sequence is specified, observe it.
q Clean and flush the parts sufficiently and blow-dry them.
q Be careful not to damage sliding surfaces and mating surfaces.
q When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil, and foreign materials from the application and mounting surfaces.
q Always use shop paper for cleaning the inside of components.
q Avoid using cotton gloves or shop rags to prevent entering of lint.
q During assembly, observe the specified tightening torque, and apply new differential gear oil, petroleum jelly, or multi-purpose grease as specified for each vehicle, if necessary.

Wiring Diagrams and Trouble Diagnosis

EDS001P6

When reading wiring diagrams, refer to the following: q GI-14, "How to Read Wiring Diagrams". q PG-4, "POWER SUPPLY ROUTING CIRCUIT". When performing trouble diagnosis, refer to the following: q GI-9, "How to Follow Trouble Diagnoses". q GI-27, "How to Perform Efficient Diagnosis for an Electrical Incident".

Revision: October 2004

RFD-36

2005 Titan

PREPARATION
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

PREPARATION

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name

Description

PFP:00002
A
EDS001P7
B

KV40104000 (--) Flange wrench a: 85 mm (3.35 in) dia. b: 65 mm (2.56 in) dia.

Removing and installing drive pinion nut
C RFD

ST33290001 (J-34286) Puller

NT659

Removing front oil seal

ZZA0601D NT115 NT124

G
Installing front oil seal
H

Inspecting drive pinion bearing preload

and total preload

M
Removing and installing side bearing adjuster

KV10111100 (J-37228) Seal cutter

WDIA0192E

Removing carrier cover

S-NT046

Revision: October 2004

RFD-37

2005 Titan

Tool number (Kent-Moore No.) Tool name ST30021000 (J-22912-01) Puller
ST33081000 (--) Adapter a: 43 mm (1.69 in) dia. b: 33.5 mm (1.32 in) dia.
-- (8144) Pinion block
-- (6740) Cone
-- (6741) Screw
-- (6739) Pinion height lock
-- (D-115-2) Scooter block
Revision: October 2004

PREPARATION
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
Description
Removing drive pinion rear bearing inner race

ZZA0700D

Removing and installing side bearing inner race

ZZA1000D

Adjusting pinion gear height

SDIA2599E

Adjusting pinion gear height

SDIA2601E

Adjusting pinion gear height

SDIA2602E

Adjusting pinion gear height

SDIA2603E

Adjusting pinion gear height

SDIA2604E
RFD-38

2005 Titan

Tool number (Kent-Moore No.) Tool name TBD Arbor disc
-- (D-115-3) Arbor
ST01500001 (--) Drift a: 89mm (3.50 in) dia. b: 79 mm (3.11 in) dia.
ST30022000 (--) Drift a: 46 mm (1.81 in) dia. b: 110 mm (4.33 in) dia.
ST33022000 (--) Drift a: 49 mm (1.92 in) dia. b: 67 mm (2.63 in) dia.
-- (C-4040) Installer
KV38100300 (J-25523) Drift a: 54 mm (2.13 in) dia. b: 46 mm (1.81 in) dia. c: 32mm (1.26 in) dia.
Revision: October 2004

PREPARATION
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
Description
A
Adjusting pinion gear height
B

SDIA2605E

Adjusting pinion gear height

C RFD

SDIA2606E

Installing drive pinion rear bearing outer

race

ZZA0811D

H
Installing drive pinion rear bearing outer race
I

J
NT660

Installing drive pinion front bearing outer

race

NT660

Installing drive pinion rear bearing inner

race

SDIA2607E

Installing side bearing inner race

ZZA1046D
RFD-39

2005 Titan

Commercial Service Tools
Tool name Puller

PREPARATION
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
EDS001P8
Description Removing companion flange and side bearing inner race

Puller

NT077
Removing side bearing inner race

Power tool

ZZB0823D

Loosening bolts and nuts

PBIC0190E

Revision: October 2004

RFD-40

2005 Titan

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. B

E
Reference page
F

Possible cause and SUSPECTED PARTS

Symptom ×: Applicable

Revision: October 2004

Noise

×××××××××××××

RFD-41

Gear tooth rough

Gear contact improper

RFD-84, "Tooth Contact"

Tooth surfaces worn

Backlash incorrect

RFD-85, "Backlash"

Companion flange excessive runout

RFD-86, "Companion Flange Runout"

Gear oil improper

MA-26, "Checking Final Drive Oil"

PROPELLER SHAFT

PR-3, "NVH Troubleshooting Chart"

AXLE AND SUSPENSION

RAX-4, "NVH Troubleshooting Chart", RSU-4, "NVH Troubleshooting Chart"

TIRES ROAD WHEEL

WT-3, "NVH Troubleshooting Chart"

AXLE SHAFT

RAX-4, "NVH Troubleshooting Chart"

PFP:00003
A
EDS001P9

2005 Titan

BRAKES

BR-5, "NVH Troubleshooting Chart"

STEERING

PS-5, "NVH Troubleshooting Chart"

RFD

DIFFERENTIAL GEAR OIL
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

DIFFERENTIAL GEAR OIL

PFP:KLD30

Changing Differential Gear Oil

EDS002HX

Refer to MA-27, "Changing Final Drive Oil" .

FILLING Refer to MA-26, "Checking Final Drive Oil" .

Checking Differential Gear Oil

EDS002HY

Refer to MA-26, "Checking Final Drive Oil" .

Revision: October 2004

RFD-42

2005 Titan

DIFFERENTIAL LOCK SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

DIFFERENTIAL LOCK SYSTEM Cross-sectional View

PFP:28496
A
EDS001PC

RFD

1. Companion flange 4. Differential case 7. Side gear 10. Pinion mate shaft 13. Cam ring

2. Drive pinion 5. Pinion mate gear 8. Spring 11. Pressure plate

3. Drive gear

SDIA2519E

6. Axle shaft

9. Differential lock solenoid

12. Differential lock position switch

Revision: October 2004

RFD-43

2005 Titan

DIFFERENTIAL LOCK SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

Differential Lock Operation

EDS001PD

1. Differential lock solenoid operates pressure plate. 2. Pressure plate presses cam ring. 3. Engage cam ring and side gear, and then differential is locked.

SDIA2498E

System Description
DIFFERENTIAL LOCK SOLENOID

EDS001PE

It is operated by signal from differential lock control unit, and it operates pressure plate so as to switch lock/ unlock.

DIFFERENTIAL LOCK POSITION SWITCH
It detects that differential is in lock or unlock by pressure plate position, and sends it to differential lock control unit.

DIFFERENTIAL LOCK CONTROL UNIT q Differential lock control unit controls differential lock solenoid by input signals of each sensor and each
switch. q As a fail-safe function, differential lock disengages, if malfunction is detected in differential lock system. q Self-diagnosis can be done with CONSULT-II.

DIFFERENTIAL LOCK MODE SWITCH Able to select differential lock and unlock.

DIFF LOCK INDICATOR LAMP The following is the indications of indicator lamp.

Condition

DIFF LOCK indicator lamp

Differential lock/unlock

ON/OFF

Differential lock standby condition

Flashing: 1 time/2 seconds

Differential lock system malfunction

OFF (Even if differential lock mode switch is turned ON)

Lamp check

Turns ON when ignition switch is turned ON. Turns OFF after engine start.

NOTE: Differential lock standby condition is the condition that differential lock mode switch is ON and differential is unlocked.

Revision: October 2004

RFD-44

2005 Titan

System Diagram

DIFFERENTIAL LOCK SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
EDS001PF
A

RFD

COMPONENTS FUNCTION DESCRIPTION

SDIA2500E
G

Component parts

Function

q Controls differential lock solenoid and switches differential lock/unlock.

Differential lock control unit

q As a fail-safe function, differential lock disengages, if malfunction is detected in differential lock

system.

Differential lock solenoid

Controls pressure plate by current from differential lock control unit.

Differential lock position switch Detects that differential is lock or unlock condition.

Differential lock mode switch Able to select differential lock or unlock.

DIFF LOCK indicator lamp

Illuminates that differential is in lock or lock standby condition.

Transmits the following signals via CAN communication to differential lock control unit.

ABS actuator and electric unit (control unit)

q Vehicle speed signal

q VDC operation signal

Transmits the following signal via CAN communication to differential lock control unit.

Transfer control unit

q 4WD shift switch signal

CAN Communication
SYSTEM DESCRIPTION
Refer to LAN-7, "CAN COMMUNICATION" .

EDS001PG
M

Revision: October 2004

RFD-45

2005 Titan

TROUBLE DIAGNOSIS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

TROUBLE DIAGNOSIS

PFP:00004

Fail-safe Function

EDS001PH

If any malfunction occurs in differential lock system, and control unit detects the malfunction, DIFF LOCK indicator lamp on combination meter does not turn ON to indicate system malfunction. Differential lock control unit turns differential lock solenoid OFF.

How to Perform Trouble Diagnosis
BASIC CONCEPT

EDS001PI

q To perform trouble diagnosis, it is the most important to have understanding about vehicle systems (control and mechanism) thoroughly.

q It is also important to clarify customer complaints before inspection. First of all, reproduce symptoms, and understand them fully. Ask customer about his/her complaints carefully. In some cases, it will be necessary to check symptoms by driving vehicle with customer.

CAUTION: Customers are not professional. It is dangerous to make an easy guess like "maybe the customer means that...," or "maybe the customer mentions this symptom".

SEF233G

q It is essential to check symptoms right from the beginning in order to repair malfunctions completely. For intermittent malfunctions, reproduce symptoms based on interview with customer and past examples. Do not perform inspection on ad hoc basis. Most intermittent malfunctions are caused by poor contacts. In this case, it will be effective to shake suspected harness or connector by hand. When repairing without any symptom diagnosis, you cannot judge if malfunctions have actually been eliminated.
q After completing diagnosis, always erase diagnostic memory. Refer to RFD-54, "How to Erase Self-diagnostic Results" .
q For intermittent malfunctions, move harness or harness connector by hand. Then check for poor contact or reproduced open circuit.

SEF234G

Revision: October 2004

RFD-46

2005 Titan

TROUBLE DIAGNOSIS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

Location of Electrical Parts

EDS001PJ
A

RFD

L
BDIA0015E
M

Revision: October 2004

RFD-47

2005 Titan

TROUBLE DIAGNOSIS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

Wiring Diagram -- DIFLOC --

EDS001PK

Revision: October 2004

RFD-48

BDWA0052E
2005 Titan

TROUBLE DIAGNOSIS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
A B C RFD E F G H I J K L M

Revision: October 2004

RFD-49

BDWA0053E
2005 Titan

TROUBLE DIAGNOSIS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

Trouble Diagnosis Chart for Symptoms

EDS001PL

If DIFF LOCK indicator lamp does not turn ON after engine start, perform self-diagnosis. Refer to RFD-53, "SELF-DIAG RESULTS MODE" .

Symptom

Condition

Check item

Reference page

CAN communication line

DIFF LOCK indicator lamp does not turn ON. (DIFF LOCK indicator lamp check)

Ignition switch: ON

Power supply and ground for differential lock control unit

RFD-72

Combination meter

DIFF LOCK indicator lamp does not change.

q Engine running
q Differential lock mode switch: ON

Combination meter Differential lock mode switch CAN communication line

RFD-75

q Engine running DIFF LOCK indicator lamp sometimes flashes. q Differential lock mode
switch: ON

Combination meter Differential lock mode switch Differential lock position switch Differential inner parts

RFD-76

Differential Lock Control Unit Input/Output Signal Reference Values
DIFFERENTIAL LOCK CONTROL UNIT INSPECTION TABLE
Specifications with CONSULT-II

EDS001PM

Monitor item [Unit]

Content

Condition

Display value

BATTERY VOLT [V]

Power supply voltage for differential lock control unit

Ignition switch: ON

Battery voltage

2WD

4WD MODE [2H/4H/ 4Lo]

Condition of 4WD shift switch

4WD shift switch (Engine running)

4LO

4Lo

Vehicle stopped

0 km/h (0 mph)

VHCL S/SEN-R [km/h] or [mph]

Wheel speed (Rear wheel right)

Vehicle running
CAUTION: Check air pressure of tire under standard condition.

Approximately equal to the indication on speedometer (Inside of ±10%)

Vehicle stopped

0 km/h (0 mph)

VHCL S/SEN-L [km/h] or Wheel speed (Rear wheel

[mph]

left)

Vehicle running
CAUTION: Check air pressure of tire under standard condition.

Approximately equal to the indication on speedometer (Inside of ±10%)

Vehicle stopped

0 km/h (0 mph)

VHCL S/SEN-RL [km/h] or [mph]

Wheel speed (Average value of rear wheel right and left)

Vehicle running
CAUTION: Check air pressure of tire under standard condition.

Approximately equal to the indication on speedometer (Inside of ±10%)

D-LOCK SW SIG [ON/ Condition of differential

OFF]

lock mode switch

Differential lock mode switch: ON Differential lock mode switch: OFF

ON OFF

D-LOCK SIG [ON/OFF]

Control status of differential lock

q Vehicle stopped q Engine running q VDC OFF switch: ON q 4WD shift switch: 4LO

Differential lock mode switch: ON
Differential lock mode switch: OFF

ON OFF

Revision: October 2004

RFD-50

2005 Titan

TROUBLE DIAGNOSIS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

Monitor item [Unit] RELAY ON [ON/OFF]
RELAY MTR [ON/OFF]
SOL MTR [ON/OFF] IND MTR [ON/OFF]
D-LOCK POS SW [ON/ OFF]

Content Operating condition of differential lock solenoid relay (integrated in differential lock control unit)
Control status of differential lock solenoid relay (integrated in differential lock control unit)
Control status of differential lock solenoid
Control status of DIFF LOCK indicator lamp
Condition of differential lock position switch

Condition

q Vehicle stopped q Engine running q VDC OFF switch: ON q 4WD shift switch: 4LO

Differential lock mode switch: ON
Differential lock mode switch: OFF

q Vehicle stopped q Engine running q VDC OFF switch: ON q 4WD shift switch: 4LO

Differential lock mode switch: ON
Differential lock mode switch: OFF

q Vehicle stopped q Engine running q VDC OFF switch: ON q 4WD shift switch: 4LO

Differential lock mode switch: ON
Differential lock mode switch: OFF

DIFF LOCK indicator lamp: ON

DIFF LOCK indicator lamp: OFF

q Vehicle stopped q Engine running q VDC OFF switch: ON q 4WD shift switch: 4LO

Differential lock mode switch: ON (DIFF LOCK indicator lamp: ON)
Differential lock mode switch: OFF (DIFF LOCK indicator lamp: OFF)

Display value ON OFF ON OFF ON OFF ON OFF ON
OFF

Specifications Between Differential Lock Control Unit Terminals

DIFFERENTIAL LOCK CONTROL UNIT TERMINAL CONNECTOR LAYOUT

A B C RFD E F G H I

L
SDIA2573E

Data are reference value and are measured between each terminal and ground.

Terminal

Wire color

Item

Condition

M
Data (Approx.)

L Power supply

Ignition switch: ON Ignition switch: OFF

Battery voltage 0V

L Power supply

Ignition switch: ON Ignition switch: OFF

Battery voltage 0V

B Ground

Always

P CAN-L

L CAN-H

Differential lock mode switch (ON)

Ignition switch: ON

Differential lock mode switch: ON Differential lock mode switch: OFF

Battery voltage 0V

B Ground

Always

Revision: October 2004

RFD-51

2005 Titan

TROUBLE DIAGNOSIS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

Terminal

Wire color

Item

Condition

Data (Approx.)

q Vehicle stopped

Differential lock mode switch: ON 0V

q Engine running

V Differential lock solenoid (-)

q VDC OFF switch: ON Differential lock mode switch: OFF Battery voltage

q 4WD shift switch: 4LO

q Vehicle stopped

Differential lock mode switch: ON 0V

q Engine running

Y Differential lock solenoid (+)

q VDC OFF switch: ON Differential lock mode switch: OFF Battery voltage

q 4WD shift switch: 4LO

G/W K-LINE (CONSULT-II signal)

Y/R

Power supply (Memory back-up)

Ignition switch: ON Ignition switch: OFF

Battery voltage Battery voltage

W/R

Differential lock position switch

q Vehicle stopped q Engine running q VDC OFF switch: ON q 4WD shift switch: 4LO

Differential lock mode switch: ON (DIFF LOCK indicator lamp: ON)
Differential lock mode switch: OFF (DIFF LOCK indicator lamp: OFF)

0V Battery voltage

L DIFF LOCK indicator lamp Ignition switch: ON

DIFF LOCK indicator lamp: ON DIFF LOCK indicator lamp: OFF

0V Battery voltage

Differential lock mode switch (OFF)

Ignition switch: ON

Differential lock mode switch: ON 0V Differential lock mode switch: OFF Battery voltage

CAUTION: When using a circuit tester to measure voltage for inspection, be sure not to extend forcibly any connector terminals.

CONSULT-II Function (DIFF LOCK)

EDS001PN

CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.

DIFF LOCK Diagnostic test mode

Function

Reference page

SELF-DIAGNOSTIC RESULTS q Displays diff lock self-diagnostic results.

RFD-53

DATA MONITOR

q Displays diff lock input/output data in the time.

RFD-55

CAN DIAG SUPPORT MNTR q The results of transmit/receive diagnosis of CAN communication can be read.

CONSULT-II SETTING PROCEDURE
CAUTION: If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which carry out CAN communication.
q For details, refer to the separate "CONSULT-II Operations Manual".
1. Turn ignition switch "OFF".
2. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector on vehicle.
3. Turn ignition switch "ON".

BDIA0013E

Revision: October 2004

RFD-52

2005 Titan

TROUBLE DIAGNOSIS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
4. Touch "START (NISSAN BASED VHCL)". A

5. Touch "DIFF LOCK". If "DIFF LOCK" is not indicated, go to GI-38, "CONSULT-II Data Link Connector (DLC) Circuit" .
6. Perform each diagnostic test mode according to each service procedure.

BCIA0029E

RFD

BCIA0030E

SELF-DIAG RESULTS MODE

Operation Procedure

1. Perform "CONSULT-II SETTING PROCEDURE". Refer to RFD-52, "CONSULT-II SETTING PROCE-

DURE" .

2. With engine at idle, touch "SELF-DIAG RESULTS".

Display shows malfunction experienced since the last erasing

operation.

NOTE:

q The details for "TIME" are as follow:

"0": Error currently detected with differential lock control

unit.

Except for "0": Error detected in the past and memorized with differential lock control unit. Detects frequency of driving after DTC occurs (frequency of turning ignition switch "ON/OFF").

L
SDIA2547E

Display Item List
Items (CONSULT-II screen terms)

Diagnostic item is detected when...

M
Check item

*INITIAL START* [P1833]

q Due to removal of battery which cuts off power supply to differential control unit, self-diagnosis memory function is suspended.

RFD-56, "Power Supply Circuit For Differential Lock Control Unit"

CONTROL UNIT 1 [P1834]

q Malfunction is detected in the memory (RAM) system of differen- RFD-58, "Differential Lock Con-

tial lock control unit.

trol Unit"

CONTROL UNIT 2 [P1835]

q Malfunction is detected in the memory (ROM) system of differen- RFD-58, "Differential Lock Con-

tial lock control unit.

trol Unit"

CONTROL UNIT 3 [P1836]

q Malfunction is detected in the memory (EEPROM) system of dif- RFD-58, "Differential Lock Con-

ferential lock control unit.

trol Unit"

CONTROL UNIT 4 [P1837]

q AD converter system of differential lock control unit is malfunctioning.

RFD-58, "Differential Lock Control Unit"

ON SW [P1838]

q More than two switch inputs are simultaneously detected due to RFD-58, "Differential Lock Mode

short circuit of differential lock mode switch.

Switch"

Revision: October 2004

RFD-53

2005 Titan

TROUBLE DIAGNOSIS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

Items (CONSULT-II screen terms)

Diagnostic item is detected when...

Check item

POSI SW ON [P1839]

q When differential lock position switch is ON, rotation difference occurs in wheel speed (rear wheel right and left).

RFD-62, "Differential Lock Position Switch"

RELAY [P1844]

q Differential lock control unit detects as irregular by comparing target value with monitor value.

RFD-65, "Differential Lock Solenoid Relay", RFD-66, "Differential Lock Solenoid"

SOL CIRCUIT [P1847]

q Malfunction is detected in differential lock control unit internal cir- RFD-66, "Differential Lock Sole-

cuit.

noid"

SOL DISCONNECT [P1848]

q Differential lock solenoid internal circuit or harness is open. q Differential lock solenoid relay does not switch to ON position.

RFD-66, "Differential Lock Solenoid"

SOL SHORT [P1849]

q Differential lock solenoid internal circuit or harness is shorted.

RFD-66, "Differential Lock Solenoid"

SOL CURRENT [P1850]

q Differential lock solenoid relay does not switch to OFF position.

RFD-66, "Differential Lock Solenoid"

ABS SYSTEM [C1203]

q Malfunction related to wheel sensor has been detected by ABS actuator and electric unit (control unit).

RFD-70, "ABS System"

CAN COMM CIRCUIT [U1000]

q Malfunction has been detected from CAN communication line.

RFD-71, "CAN Communication Line"

NO DTC IS DETECTED.

FURTHER TESTING MAY q No NG item has been detected.

BE REQUIRED.

CAUTION: If "CAN COMM CIRCUIT [U1000]" is displayed with other DTCs, first perform the trouble diagnosis for CAN communication line.

How to Erase Self-diagnostic Results 1. Perform applicably inspection of malfunctioning item and then repair or replace. 2. Start engine and select "SELF-DIAG RESULTS" mode for "DIFF LOCK" with CONSULT-II. 3. Touch "ERASE" on CONSULT-II screen to erase DTC memory.
CAUTION: If memory cannot be erased, perform applicably diagnosis.

Revision: October 2004

RFD-54

2005 Titan

TROUBLE DIAGNOSIS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

DATA MONITOR MODE

Operation Procedure

1. Perform "CONSULT-II SETTING PROCEDURE". Refer to RFD-52, "CONSULT-II SETTING PROCEDURE" .

2. Touch "DATA MONITOR".

3. Select from "SELECT MONITOR ITEM", screen of data monitor mode is displayed.

NOTE:

When malfunction is detected, CONSULT-II performs REAL-TIME DIAGNOSIS.

Also, any malfunction detected while in this mode will be displayed at real time.

Display Item List

×: Standard : Not applicable RFD

SELECT MONITOR ITEM

Monitor item (Unit)

ECU INPUT

MAIN

SELECTION

Remarks

SIGNALS

SIGNALS FROM MENU

BATTERY VOLT [V] 4WD MODE [2H/4H/4Lo]

Power supply voltage for differential lock control unit.

4WD shift switch signal status via CAN communication line is displayed.

VHCL S/SEN-R [km/h] or [mph]

Wheel speed calculated by rear wheel sensor right signal is displayed.

VHCL S/SEN-L [km/h] or [mph]

Wheel speed calculated by rear wheel sensor left signal is displayed.

Average value between wheel speed cal-

VHCL S/SEN-RL [km/h] or [mph]

culated by rear wheel sensor right signal and rear wheel sensor left signal is dis-

played.

D-LOCK SW SIG [ON/OFF]

Condition of differential lock mode switch is displayed.

D-LOCK SIG [ON/OFF]

Control status of differential lock is displayed.

RELAY ON [ON/OFF]

Operating condition of differential lock

solenoid relay is displayed (integrated in

differential lock control unit).

RELAY MTR [ON/OFF]

Control status of differential lock solenoid

relay is displayed (integrated in differential lock control unit).

SOL MTR [ON/OFF] IND MTR [ON/OFF]

Control status of differential lock solenoid is displayed.

Control status of DIFF LOCK indicator lamp is displayed.

D-LOCK POS SW [ON/OFF]

Condition of differential lock position switch is displayed.

Voltage [V]

The value measured by the voltage probe is displayed.

Frequency [Hz]

DUTY-HI (high) [%] DUTY-LOW (low) [%] PLS WIDTH-HI [msec]

The value measured by the pulse probe is displayed.

PLS WIDTH-LOW [msec]

Revision: October 2004

RFD-55

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

TROUBLE DIAGNOSIS FOR SYSTEM

Power Supply Circuit For Differential Lock Control Unit
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE

Data are reference value.

Monitor item [Unit]

Content

Condition

BATTERY VOLT [V]

Power supply voltage for differential lock control unit

Ignition switch: ON

PFP:00000
EDS001PO
Display value Battery voltage

DIFFERENTIAL LOCK CONTROL UNIT TERMINALS AND REFERENCE VALUE

Data are reference value and are measured between each terminal and ground.

Terminal

Wire color

Item

Condition

Data (Approx.)

L Power supply

Ignition switch: ON Ignition switch: OFF

Battery voltage 0V

L Power supply

Ignition switch: ON Ignition switch: OFF

Battery voltage 0V

B Ground

Always

B Ground

Always

Y/R

Power supply (Memory back-up)

Ignition switch: ON Ignition switch: OFF

Battery voltage Battery voltage

CAUTION: When using a circuit tester to measure voltage for inspection, be sure not to extend forcibly any connector terminals.

Revision: October 2004

RFD-56

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

DIAGNOSTIC PROCEDURE

1. CHECK POWER SUPPLY

1. Turn ignition switch "OFF".
2. Disconnect differential lock control unit harness connector.
3. Check voltage between differential lock control unit harness connector terminals and ground.

Connector B77

Terminal (Wire color) 1 (L) - Ground 2 (L) - Ground
15 (Y/R) - Ground

Voltage (Approx.) 0V 0V
Battery voltage

B C RFD

SDIA2562E

4. Turn ignition switch "ON". (Do not start engine.)

5. Check voltage between differential lock control unit harness

connector terminals and ground.

Connector

Terminal (Wire color)

Voltage (Approx.)

1 (L) - Ground

B77

2 (L) - Ground

Battery voltage

15 (Y/R) - Ground

OK or NG
OK >> GO TO 2. NG >> Check the following. If any items are damaged, repair or
replace damaged parts.
q 10A fuse [No. 15 or 19, located in fuse block (J/B)]

I
SDIA2563E
J

q Harness for short or open between battery and differential lock control unit harness connector terminal 15 K
q Harness for short or open between ignition switch and differential lock control unit harness connector terminals 1 and 2

q Battery and ignition switch. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" .

2. CHECK GROUND CIRCUIT

1. Turn ignition switch "OFF".

2. Disconnect differential lock control unit harness connector.

3. Check continuity between differential lock control unit harness connector B77 terminals 3 (B), 10 (B) and ground.

Continuity should exist.

Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power
in harness or connectors.

SDIA2564E

Revision: October 2004

RFD-57

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
3. CHECK DIFFERENTIAL LOCK CONTROL UNIT

Check differential lock control unit input/output signal. Refer to RFD-50, "Differential Lock Control Unit Input/ Output Signal Reference Values" .
OK or NG
OK >> GO TO 4. NG >> Check differential lock control unit pin terminals for damage or loose connection with harness con-
nector. If any items are damaged, repair or replace damaged parts.
4. CHECK DTC

Perform the self-diagnosis, after driving a vehicle for a while.
OK or NG
OK >> INSPECTION END NG >> Replace differential lock control unit. Refer to RFD-78, "DIFFERENTIAL LOCK CONTROL UNIT"
.

Differential Lock Control Unit
DIAGNOSTIC PROCEDURE
1. PERFORM SELF-DIAGNOSIS

EDS001PP

With CONSULT-II 1. Turn ignition switch "ON". (Do not start engine.) 2. Select "SELF-DIAG RESULTS" mode for "DIFF LOCK" with CONSULT-II. 3. Touch "ERASE". 4. Turn ignition switch "OFF" and wait at least 10 seconds. 5. Perform the self-diagnosis again. Is the "CONTROL UNIT 1 [P1834]", "CONTROL UNIT 2 [P1835]", "CONTROL UNIT 3 [P1836]" or "CONTROL UNIT 4 [P1837]" displayed?
YES >> Replace differential lock control unit. Refer to RFD-78, "DIFFERENTIAL LOCK CONTROL UNIT" .
NO >> INSPECTION END

Differential Lock Mode Switch

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE

Data are reference value.

Monitor item

Content

Condition

D-LOCK SW SIG [ON/ Condition of differential

OFF]

lock mode switch

Differential lock mode switch: ON Differential lock mode switch: OFF

EDS001PQ
Display value ON OFF

DIFFERENTIAL LOCK CONTROL UNIT TERMINALS AND REFERENCE VALUE

Data are reference value and are measured between each terminal and ground.

Terminal

Wire color

Item

Condition

Data (Approx.)

Differential lock mode switch (ON)

Differential lock mode switch: ON Ignition switch: ON
Differential lock mode switch: OFF

Battery voltage 0V

Differential lock mode switch (OFF)

Differential lock mode switch: ON Ignition switch: ON
Differential lock mode switch: OFF

0V Battery voltage

CAUTION: When using a circuit tester to measure voltage for inspection, be sure not to extend forcibly any connector terminals.

Revision: October 2004

RFD-58

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

DIAGNOSTIC PROCEDURE

1. CHECK DIFFERENTIAL LOCK MODE SWITCH SIGNAL

With CONSULT-II 1. Start engine. 2. Select "DATA MONITOR" mode for "DIFF LOCK" with CONSULT-II. 3. Read out ON/OFF switching action of "D-LOCK SW SIG".

Monitor item

Condition

q Vehicle stopped D-LOCK SW SIG
q Engine running

Differential lock mode switch: ON
Differential lock mode switch: OFF

Display value ON
OFF

B C RFD E

Without CONSULT-II
1. Turn ignition switch "ON".
2. Check voltage between differential lock control unit harness connector terminals and ground.

Terminal Connector (Wire
color)

Condition

Differential lock mode

9 (G) -

switch: ON

Ground

Differential lock mode

switch: OFF

B77

Ignition switch: ON

Differential lock mode

22 (O) -

switch: ON

Ground

Differential lock mode

switch: OFF

OK or NG
OK >> GO TO 5. NG >> GO TO 2.

Voltage (Approx.)
Battery voltage
0V
0V
Battery voltage

SDIA2540E

J
SDIA2568E
K

Revision: October 2004

RFD-59

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
2. CHECK DIFFERENTIAL LOCK MODE SWITCH SUPPLY CIRCUIT

1. Turn ignition switch "ON".
2. Disconnect differential lock mode switch harness connector.
3. Check voltage between differential lock mode switch harness connector terminal 3 and ground.

Connector M149

Terminal (Wire color) 3 (R/B) - Ground

Voltage (Approx.) Battery voltage

SDIA2534E

4. Turn ignition switch "OFF".
5. Check voltage between differential lock mode switch harness connector terminal 3 and ground.

Connector

Terminal (Wire color)

Voltage (Approx.)

M149

3 (R/B) - Ground

OK or NG

OK >> GO TO 3. NG >> Check the following. If any items are damaged, repair or
replace damaged parts.
q 10A fuse [No. 15, located in fuse block (J/B)]

SDIA2643E

q Harness for short or open between ignition switch and differential lock mode switch harness connector terminals 3

q Ignition switch. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" .

3. CHECK DIFFERENTIAL LOCK MODE SWITCH

1. Turn ignition switch "OFF".
2. Disconnect differential lock mode switch harness connector. 3. Operate differential lock mode switch and check continuity
between differential lock mode switch terminals.

Connector

Terminal

Condition

M149

1-3 2-3

Differential lock mode switch: ON Differential lock mode switch: OFF Differential lock mode switch: ON Differential lock mode switch: OFF

OK or NG
OK >> GO TO 4. NG >> Replace differential lock mode switch.

Continuity No Yes Yes No

SDIA2535E

Revision: October 2004

RFD-60

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

4. CHECK HARNESS BETWEEN DIFFERENTIAL LOCK CONTROL UNIT AND DIFFERENTIAL LOCK

MODE SWITCH

1. Turn ignition switch "OFF".
2. Disconnect differential lock control unit harness connector and differential lock mode switch harness con- B nector.

3. Check continuity between the following terminals.

Differential lock control unit harness connector B77 terminal 9

(G) and differential lock mode switch harness connector M149

terminal 2 (G).

Differential lock control unit harness connector B77 terminal 22

RFD

(O) and differential lock mode switch harness connector M149

terminal 1 (O).

Continuity should exist.

Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 5. NG >> Repair or replace damaged parts.

SDIA2569E
F

5. CHECK DIFFERENTIAL LOCK CONTROL UNIT

Check differential lock control unit input/output signal. Refer to RFD-50, "Differential Lock Control Unit Input/

Output Signal Reference Values" .

OK or NG

OK >> GO TO 6.

>> Check differential lock control unit pin terminals for damage or loose connection with harness connector. If any items are damaged, repair or replace damaged parts.

6. CHECK DTC J Perform the self-diagnosis, after driving a vehicle for a while.

OK or NG

OK >> INSPECTION END

NG >> Replace differential lock control unit. Refer to RFD-78, "DIFFERENTIAL LOCK CONTROL UNIT"

COMPONENT INSPECTION

1. Turn ignition switch "OFF".

2. Disconnect differential lock mode switch harness connector.

3. Operate differential lock mode switch and check continuity

between differential lock mode switch terminals.

Connector

Terminal

Condition

M149

1-3 2-3

Differential lock mode switch: ON Differential lock mode switch: OFF Differential lock mode switch: ON Differential lock mode switch: OFF

4. If NG, replace differential lock mode switch.

Continuity No Yes Yes No

SDIA2535E

Revision: October 2004

RFD-61

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

Differential Lock Position Switch

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE

Data are reference value.

Monitor item

Content

Condition

D-LOCK POS SW [ON/ Condition of differential

OFF]

lock position switch

q Vehicle stopped q Engine running q VDC OFF switch: ON q 4WD shift switch: 4LO

Differential lock mode switch: ON (DIFF LOCK indicator lamp: ON)
Differential lock mode switch: OFF (DIFF LOCK indicator lamp: OFF)

EDS001PR
Display value ON
OFF

DIFFERENTIAL CONTROL UNIT TERMINALS AND REFERENCE VALUE

Data are reference value and are measured between each terminal and ground.

Terminal

Wire color

Item

Condition

Data (Approx.)

W/R

Differential lock position switch

q Vehicle stopped
q Engine running
q VDC OFF switch: ON
q 4WD shift switch: 4LO

Differential lock mode switch: ON (DIFF LOCK indicator lamp: ON)
Differential lock mode switch: OFF (DIFF LOCK indicator lamp: OFF)

0V Battery voltage

CAUTION: When using a circuit tester to measure voltage for inspection, be sure not to extend forcibly any connector terminals.

Revision: October 2004

RFD-62

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

DIAGNOSTIC PROCEDURE

1. CHECK DIFFERENTIAL LOCK POSITION SWITCH SIGNAL

With CONSULT-II 1. Start engine. 2. Select "DATA MONITOR" mode for "DIFF LOCK" with CONSULT-II. 3. Read out ON/OFF switching action of "D-LOCK POS SW SIG".

Monitor item
D-LOCK POS SW SIG

Condition

q Vehicle stopped
q Engine running
q VDC OFF switch: ON
q 4WD shift switch: 4LO

Differential lock mode switch: ON (DIFF LOCK indicator lamp: ON)
Differential lock mode switch: OFF (DIFF LOCK indicator lamp: OFF)

Display value ON
OFF

RFD

SDIA2538E

Without CONSULT-II
1. Start engine.
2. Check voltage between differential lock control unit harness connector terminal and ground.

Terminal Connector (Wire
color)

Condition

Differential lock mode q Vehicle stopped switch: ON

q Engine running (DIFF LOCK indicator

B77

20 (W/R) q VDC OFF switch: lamp: ON)

- Ground ON

Differential lock mode

q 4WD shift switch: switch: OFF

4LO

(DIFF LOCK indicator

lamp: OFF)

OK or NG
OK >> GO TO 5. NG >> GO TO 2.

2. CHECK GROUND CIRCUIT

Voltage (Approx.)
0V
Battery voltage

1. Turn ignition switch "OFF". 2. Disconnect differential lock position switch harness connector. 3. Check continuity between differential lock position switch har-
ness connector C16 terminal 3 (B) and ground.
Continuity should exist.
Also check harness for short to ground and short to power. OK or NG
OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power
in harness or connectors.

G H I J
SDIA2570E
K L M

SDIA2644E

Revision: October 2004

RFD-63

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
3. CHECK DIFFERENTIAL LOCK POSITION SWITCH

1. Turn ignition switch "OFF".
2. Disconnect differential lock position switch harness connector.
3. Remove differential lock position switch. Refer to RFD-83, "COMPONENTS" .
4. Pull differential lock position switch and check continuity between differential lock position switch harness connector terminals.

Connector

Terminal

Condition

Continuity

Pull differential position switch

Yes

C16

1-3

Release Differential position

switch

OK or NG
OK >> GO TO 4. NG >> Replace differential lock position switch.

SDIA2537E

4. CHECK HARNESS BETWEEN DIFFERENTIAL LOCK CONTROL UNIT AND DIFFERENTIAL LOCK
POSITION SWITCH

1. Turn ignition switch "OFF".
2. Disconnect differential lock control unit harness connector and differential lock position switch harness connector.
3. Check continuity between differential lock control unit harness connector B77 terminal 20 (W/R) and differential lock position switch harness connector C16 terminal 1 (W/R).
Continuity should exist.

Also check harness for short to ground and short to power. OK or NG
OK >> GO TO 5. NG >> Repair or replace damaged parts.

5. CHECK DIFFERENTIAL LOCK CONTROL UNIT

SDIA2645E

Check differential lock control unit input/output signal. Refer to RFD-50, "Differential Lock Control Unit Input/ Output Signal Reference Values" .
OK or NG
OK >> GO TO 6. NG >> Check differential lock control unit pin terminals for damage or loose connection with harness con-
nector. If any items are damaged, repair or replace damaged parts.
6. CHECK DTC

Perform the self-diagnosis, after driving a vehicle for a while.
OK or NG
OK >> INSPECTION END NG >> Replace differential lock control unit. Refer to RFD-78, "DIFFERENTIAL LOCK CONTROL UNIT"
.

Revision: October 2004

RFD-64

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

COMPONENT INSPECTION

1. Turn ignition switch "OFF".

2. Disconnect differential lock position switch harness connector.

3. Remove differential lock position switch. Refer to RFD-83, "COMPONENTS" .

4. Pull differential lock position switch and check continuity

between differential lock position switch harness connector ter-

minals.

Connector

Terminal

Condition

Continuity

Pull differential position switch

Yes

C16

1-3

Release Differential position

switch

RFD

5. If NG, replace differential lock position switch.

Differential Lock Solenoid Relay

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE

Data are reference value.

Monitor item

Content

Condition

E
SDIA2537E
EDS001PS
F
Display value

RELAY ON [ON/OFF]

Operating condition of differential lock solenoid relay (integrated in differential lock control unit)

q Vehicle stopped q Engine running q VDC OFF switch: ON q 4WD shift switch: 4LO

Differential lock mode switch: ON
Differential lock mode switch: OFF

OFF
H

DIAGNOSTIC PROCEDURE

1. CHECK DIFFERENTIAL LOCK SOLENOID SYSTEM

Perform self-diagnosis. Refer to RFD-53, "SELF-DIAG RESULTS MODE" .

Is "RELAY [P1844]" displayed?

YES >> Perform trouble diagnosis for differential lock solenoid. Refer to RFD-66, "Differential Lock Sole-

noid" .

NO >> GO TO 2. K
2. CHECK DIFFERENTIAL LOCK SOLENOID RELAY SIGNAL

With CONSULT-II 1. Start engine. 2. Select "DATA MONITOR" mode for "DIFF LOCK" with CONSULT-II. 3. Read out ON/OFF switching action of "RELAY ON".

Monitor item

Condition

RELAY ON

q Vehicle stopped
q Engine running
q VDC OFF switch: ON
q 4WD shift switch: 4LO

OK or NG
OK >> GO TO 4. NG >> GO TO 3.

Differential lock mode switch: ON
Differential lock mode switch: OFF

Display value ON
OFF

L M
SDIA2642E

Revision: October 2004

RFD-65

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
3. CHECK DIFFERENTIAL LOCK CONTROL UNIT

Check differential lock control unit input/output signal. Refer to RFD-50, "Differential Lock Control Unit Input/ Output Signal Reference Values" .
OK or NG
OK >> GO TO 4. NG >> Check differential lock control unit pin terminals for damage or loose connection with harness con-
nector. If any item is damaged, repair or replace damaged parts.
4. CHECK DTC

Perform the self-diagnosis, after driving a vehicle for a while.
OK or NG
OK >> INSPECTION END NG >> Replace differential lock control unit. Refer to RFD-78, "DIFFERENTIAL LOCK CONTROL UNIT"
.

Differential Lock Solenoid

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE

Data are reference value.

Monitor item

Content

Condition

RELAY ON [ON/OFF]

Operating condition of differential lock solenoid relay (integrated in differential lock control unit)

q Vehicle stopped q Engine running q VDC OFF switch: ON q 4WD shift switch: 4LO

Differential lock mode switch: ON
Differential lock mode switch: OFF

RELAY MTR [ON/OFF]

Control status of differential lock solenoid relay (integrated in differential lock control unit)

q Vehicle stopped q Engine running q VDC OFF switch: ON q 4WD shift switch: 4LO

Differential lock mode switch: ON
Differential lock mode switch: OFF

SOL MTR [ON/OFF]

Control status of differential lock solenoid

q Vehicle stopped q Engine running q VDC OFF switch: ON q 4WD shift switch: 4LO

Differential lock mode switch: ON
Differential lock mode switch: OFF

EDS001PT
Display value ON OFF ON OFF ON OFF

DIFFERENTIAL LOCK CONTROL UNIT TERMINALS AND REFERENCE VALUE

Data are reference value and are measured between each terminal and ground.

Terminal

Wire color

Item

Condition

Data (Approx.)

q Vehicle stopped Differential lock mode switch: ON

q Engine running

V Differential lock solenoid (-) q VDC OFF

switch: ON

Differential lock mode switch: OFF

q 4WD shift switch: 4LO

0V Battery voltage

q Vehicle stopped Differential lock mode switch: ON

q Engine running

Y Differential lock solenoid (+) q VDC OFF

switch: ON

Differential lock mode switch: OFF

q 4WD shift switch: 4LO

0V Battery voltage

CAUTION: When using a circuit tester to measure voltage for inspection, be sure not to extend forcibly any connector terminals.

Revision: October 2004

RFD-66

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

DIAGNOSTIC PROCEDURE

1. CHECK DIFFERENTIAL SOLENOID SIGNAL

With CONSULT-II 1. Start engine. 2. Select "DATA MONITOR" mode for "DIFF LOCK" with CONSULT-II. 3. Read out ON/OFF switching action of "RELAY ON", "RELAY
MTR", "SOL MTR".

Monitor item

Condition

Display value

RELAY ON RELAY MTR SOL MTR

q Vehicle stopped
q Engine running
q VDC OFF switch: ON
q 4WD shift switch: 4LO

Differential lock mode switch: ON
Differential lock mode switch: OFF
Differential lock mode switch: ON
Differential lock mode switch: OFF
Differential lock mode switch: ON
Differential lock mode switch: OFF

ON OFF ON OFF ON OFF

Without CONSULT-II
1. Start engine. 2. Check voltage between differential lock control unit harness
connector terminal and ground.

Connector

Terminal (Wire color)

Condition

Differential

lock mode

11 (V) -

switch: ON

Ground q Vehicle stopped

Differential lock mode

q Engine running

switch: OFF

B77

q VDC OFF switch: ON Differential

12 (Y) -

q 4WD shift switch: 4LO

lock mode switch: ON

Ground

Differential

lock mode

switch: OFF

OK or NG
OK >> GO TO 6. NG >> GO TO 2.

Data (Approx.)
0V
Battery voltage
0V
Battery voltage

RFD

SDIA2539E

L
SDIA2565E
M

Revision: October 2004

RFD-67

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
2. CHECK DIFFERENTIAL LOCK SOLENOID CIRCUIT

1. Turn ignition switch "OFF".
2. Disconnect differential lock control unit harness connector.
3. Check resistance between differential lock control unit harness connector terminals 11 and 12.

Connector

Terminal (Wire color)

B77

11 (V) - 12 (Y)

OK or NG
OK >> GO TO 6. NG >> GO TO 3.

Resistance (Approx.) 3.4

3. CHECK DIFFERENTIAL LOCK SOLENOID RESISTANCE
1. Turn ignition switch "OFF". 2. Disconnect differential lock solenoid harness connector. 3. Check resistance between differential lock solenoid harness
connector C17 terminals 2 and 4.
2 - 4 : Approx. 3.4
OK or NG OK >> GO TO 4. NG >> Replace differential solenoid. Refer to RFD-87, "Differential Assembly" .

SDIA2566E

4. CHECK DIFFERENTIAL LOCK SOLENOID OPERATION

1. Turn ignition switch "OFF".
2. Disconnect differential lock solenoid harness connector.
3. Check operation by applying battery voltage to differential lock solenoid harness connector terminals.
CAUTION: Be sure to apply the voltage of the correct polarity to the respective terminals. Otherwise, the part may be damaged.

Connector

Terminal

C17

4 (Battery voltage) - 2 (Ground)

Does solenoid operate?
YES >> GO TO 5. NO >> Replace differential solenoid. Refer to RFD-87, "Differ-
ential Assembly" .

SDIA2531E SDIA2634E

Revision: October 2004

RFD-68

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

5. CHECK HARNESS BETWEEN DIFFERENTIAL LOCK CONTROL UNIT AND DIFFERENTIAL LOCK

SOLENOID

1. Turn ignition switch "OFF".
2. Disconnect differential lock control unit harness connector and differential lock solenoid harness connec- B tor.

3. Check continuity between the following terminals.

Differential lock control unit harness connector B77 terminal 11

(V) and differential lock solenoid harness connector C17 termi-

nal 2 (V).

Differential lock control unit harness connector B77 terminal 12

RFD

(Y) and differential lock solenoid harness connector C17 termi-

nal 4 (Y).

11 (V) - 2 (V)

: Continuity should exist.

12 (Y) - 4 (Y)

: Continuity should exist.

Also check harness for short to ground and short to power. OK or NG
OK >> GO TO 6. NG >> Repair or replace damaged parts.
6. CHECK DIFFERENTIAL LOCK CONTROL UNIT

SDIA2567E
F
G

Check differential lock control unit input/output signal. Refer to RFD-50, "Differential Lock Control Unit Input/ H Output Signal Reference Values" .

OK or NG

OK >> GO TO 7.

NG >> Check differential lock control unit pin terminals for damage or loose connection with harness con-

nector. If any items are damaged, repair or replace damaged parts.

7. CHECK DTC

Perform the self-diagnosis, after driving a vehicle for a while.

OK or NG

OK >> INSPECTION END

NG >> Replace differential lock control unit. Refer to RFD-78, "DIFFERENTIAL LOCK CONTROL UNIT"

Revision: October 2004

RFD-69

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
COMPONENT INSPECTION 1. Turn ignition switch "OFF". 2. Disconnect differential lock solenoid harness connector. 3. Check resistance between differential lock solenoid harness
connector C17 terminal 2 and 4.
2 - 4 : Approx. 3.4
4. If NG, replace differential lock solenoid. Refer to RFD-87, "Differential Assembly" .

5. Check operation by applying battery voltage to differential lock solenoid harness connector terminals.
CAUTION: Be sure to apply the voltage of the correct polarity to the respective terminals. Otherwise, the part may be damaged.

Connector

Terminal

C17

4 (Battery voltage) - 2 (Ground)

6. If NG, replace differential lock solenoid.

SDIA2531E

ABS System
DIAGNOSTIC PROCEDURE
1. CHECK DTC WITH ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)

SDIA2634E EDS001PU

Perform self-diagnosis with ABS actuator and electric unit (control unit). Refer to BRC-24, "SELF-DIAGNOSIS" . Is any malfunction detected by self-diagnosis?
YES >> Check the malfunctioning system. NO >> GO TO 2.
2. CHECK DIFFERENTIAL LOCK CONTROL UNIT
Check differential lock control unit input/output signal. Refer to RFD-50, "Differential Lock Control Unit Input/ Output Signal Reference Values" . OK or NG
OK >> GO TO 3. NG >> Check differential lock control unit pin terminals for damage or loose connection with harness con-
nector. If any items are damaged, repair or replace damaged parts.
3. CHECK DTC
Perform the self-diagnosis, after driving a vehicle for a while. OK or NG
OK >> INSPECTION END NG >> Perform self-diagnosis with ABS actuator and electric unit (control unit) again. Refer to BRC-24,
"SELF-DIAGNOSIS" .

Revision: October 2004

RFD-70

2005 Titan

TROUBLE DIAGNOSIS FOR SYSTEM
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

CAN Communication Line
DIAGNOSTIC PROCEDURE
1. CHECK CAN COMMUNICATION CIRCUIT

EDS001PV
A

With CONSULT-II

1. Turn ignition switch "ON" and start engine.

2. Select "SELF-DIAG RESULTS" mode for "DIFF LOCK" with in CONSULT-II. C
3. Perform the self-diagnosis.

Is the "CAN COMM CIRCUIT [U1000]" displayed?

YES >> Go to LAN-5, "Precautions When Using CONSULT-II" .

RFD

NO >> INSPECTION END

F
SDIA1850E
G

Revision: October 2004

RFD-71

2005 Titan

TROUBLE DIAGNOSIS FOR SYMPTOMS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

TROUBLE DIAGNOSIS FOR SYMPTOMS

PFP:00007

DIFF LOCK Indicator Lamp Does Not Turn ON

EDS001PW

SYMPTOM: DIFF LOCK indicator lamp does not turn ON for approx. 1 second when turning ignition switch to "ON".

DIAGNOSTIC PROCEDURE
1. CHECK SYSTEM FOR CAN COMMUNICATION LINE

Perform self-diagnosis. Refer to RFD-53, "SELF-DIAG RESULTS MODE" . Is "CAN COMM CIRCUIT" displayed?
YES >> Perform trouble diagnosis for CAN communication line. Refer to RFD-71, "CAN Communication Line"
NO >> GO TO 2.
2. CHECK DIFFERENTIAL LOCK CONTROL UNIT POWER SUPPLY

1. Turn ignition switch "OFF".
2. Disconnect differential lock control unit harness connector.
3. Check voltage between differential lock control unit harness connector terminals and ground.

Connector B77

Terminal (Wire color) 1 (L) - Ground 2 (L) - Ground
15 (Y/R) - Ground

Voltage (Approx.) 0V 0V
Battery voltage

SDIA2562E

4. Turn ignition switch "ON". (Do not start engine.)
5. Check voltage between differential lock control unit harness connector terminals and ground.

Connector

Terminal (Wire color)

Voltage (Approx.)

1 (L) - Ground

B77

2 (L) - Ground

Battery voltage

15 (Y/R) - Ground

OK or NG
OK >> GO TO 3. NG >> Check the following. If any items are damaged, repair or
replace damaged parts.
q 10A fuse [No. 15 or 19, located in fuse block (J/B)]

SDIA2563E

q Harness for short or open between battery and differential lock control unit harness connector terminal 15
q Harness for short or open between ignition switch and differential lock control unit harness connector terminals 1 and 2
q Battery and ignition switch. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" .

Revision: October 2004

RFD-72

2005 Titan

TROUBLE DIAGNOSIS FOR SYMPTOMS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

3. CHECK DIFFERENTIAL LOCK CONTROL UNIT GROUND CIRCUIT A

1. Turn ignition switch "OFF".

2. Disconnect differential lock control unit harness connector.

3. Check continuity between differential lock control unit harness

connector B77 terminals 3 (B), 10 (B) and ground.

Continuity should exist. C
Also check harness for short to ground and short to power.

OK or NG

OK >> GO TO 4.

RFD

NG >> Repair open circuit or short to ground or short to power

in harness or connectors.

4. CHECK COMBINATION METER POWER SUPPLY CIRCUIT
1. Turn ignition switch "OFF". 2. Disconnect combination meter harness connector. 3. Check voltage between combination meter harness connector
terminal and ground

E
SDIA2564E
F G

Connector

Terminal (Wire color)

Voltage (Approx.)

M24

24 (O/L) - Ground

PDIA0228E

4. Turn ignition switch "ON". (Do not start engine.)

5. Check voltage between combination meter harness connector

terminal and ground.

Connector

Terminal (Wire color)

Voltage (Approx.)

M24

24 (O/L) - Ground

OK or NG

OK >> GO TO 5. NG >> Check the following. If any items are damaged, repair or
replace damaged parts.
q 10A fuse [No.14, located in the fuse block (J/B)]

M
SDIA2396E

q Harness for short or open between ignition switch and combination meter harness connector terminal 24

q Ignition switch. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" .

Revision: October 2004

RFD-73

2005 Titan

TROUBLE DIAGNOSIS FOR SYMPTOMS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
5. CHECK HARNESS BETWEEN DIFFERENTIAL LOCK CONTROL UNIT AND COMBINATION METER
1. Turn ignition switch "OFF". 2. Disconnect differential lock control unit harness connector and combination meter harness connector. 3. Check continuity between differential lock control unit harness
connector B77 terminal 21 (L) and combination meter harness connector M24 terminal 14 (L)
Continuity should exist.
Also check harness for short to ground and short to power. OK or NG
OK >> GO TO 6. NG >> Repair or replace damaged parts.

6. CHECK DIFF LOCK INDICATOR LAMP CIRCUIT

SDIA2572E

1. Turn ignition switch "OFF". 2. Check combination meter. Refer to DI-8, "Combination Meter" . OK or NG
OK >> GO TO 7. NG >> Replace combination meter. Refer to DI-25, "Removal and Installation of Combination Meter" .
7. CHECK SYMPTOM

Check again. OK or NG
OK >> INSPECTION END NG >> GO TO 8.
8. CHECK DIFFERENTIAL LOCK CONTROL UNIT

Check differential lock control unit input/output signal. Refer to RFD-50, "Differential Lock Control Unit Input/ Output Signal Reference Values" .
OK or NG
OK >> INSPECTION END NG >> Check differential lock control unit pin terminals for damage or loose connection with harness con-
nector. If any items are damaged, repair or replace damaged parts.

Revision: October 2004

RFD-74

2005 Titan

TROUBLE DIAGNOSIS FOR SYMPTOMS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

DIFF LOCK Indicator Lamp Does Not Change

EDS001PX

SYMPTOM:

DIFF LOCK indicator lamp does not change when turning differential lock mode switch to "ON" after

engine start.

B
DIAGNOSTIC PROCEDURE

1. CHECK DIFF LOCK INDICATOR LAMP

C Confirm DIFF LOCK indicator lamp when ignition switch is turned to ON.

Does DIFF LOCK indicator lamp turn on?

YES >> GO TO 2.

RFD

NO >> Go to RFD-72, "DIFF LOCK Indicator Lamp Does Not Turn ON" .

2. CHECK SELF-DIAGNOSTIC RESULTS

Perform self-diagnosis. Refer to RFD-53, "SELF-DIAG RESULTS MODE" .

Is any malfunction detected by self-diagnosis?

YES >> Check the malfunctioning system.

NO >> GO TO 3.

3. CHECK SYSTEM FOR DIFFERENTIAL LOCK MODE SWITCH

Perform trouble diagnosis for differential lock mode switch system. Refer to RFD-58, "Differential Lock Mode

Switch" .

OK or NG

OK >> GO TO 4.
NG >> Repair or replace damaged parts. I
4. CHECK DIFF LOCK INDICATOR LAMP CIRCUIT

1. Turn ignition switch "OFF".

2. Check combination meter. Refer to DI-8, "Combination Meter" .

OK or NG

OK >> GO TO 5.

NG >> Replace combination meter. Refer to DI-25, "Removal and Installation of Combination Meter" .

5. CHECK SYMPTOM

Check again.

OK or NG

OK >> INSPECTION END

NG >> GO TO 6.

6. CHECK DIFFERENTIAL LOCK CONTROL UNIT

Revision: October 2004

RFD-75

2005 Titan

TROUBLE DIAGNOSIS FOR SYMPTOMS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

DIFF LOCK Indicator Lamp Sometimes Flashes

EDS001PY

SYMPTOM: DIFF LOCK indicator lamp sometimes flashes when it turns ON or OFF during driving.

DIAGNOSTIC PROCEDURE
1. CHECK DIFF LOCK INDICATOR LAMP

Confirm DIFF LOCK indicator lamp when ignition switch is turned to ON. Does DIFF LOCK indicator lamp turn on?
YES >> GO TO 2. NO >> Go to RFD-72, "DIFF LOCK Indicator Lamp Does Not Turn ON" .
2. CHECK SELF-DIAGNOSTIC RESULTS

Perform self-diagnosis. Refer to RFD-53, "SELF-DIAG RESULTS MODE" . Is any malfunction detected by self-diagnosis?
YES >> Check the malfunctioning system. NO >> GO TO 3.
3. CHECK SYSTEM FOR DIFFERENTIAL LOCK MODE SWITCH

Perform trouble diagnosis for differential lock mode switch system. Refer to RFD-58, "Differential Lock Mode Switch" . OK or NG
OK >> GO TO 4. NG >> Repair or replace damaged parts.
4. CHECK SYSTEM FOR DIFFERENTIAL POSITION SWITCH

Perform trouble diagnosis for differential lock position switch system. Refer to RFD-62, "Differential Lock Position Switch" . OK or NG
OK >> GO TO 5. NG >> Repair or replace damaged parts.
5. CHECK SYMPTOM

Check again. OK or NG
OK >> INSPECTION END NG >> GO TO 6.
6. CHECK DIFFERENTIAL LOCK CONTROL UNIT

Check differential lock control unit input/output signal. Refer to RFD-50, "Differential Lock Control Unit Input/ Output Signal Reference Values" .
OK or NG
OK >> GO TO 7. NG >> Check differential lock control unit pin terminals for damage or loose connection with harness con-
nector. If any items are damaged, repair or replace damaged parts.

Revision: October 2004

RFD-76

2005 Titan

TROUBLE DIAGNOSIS FOR SYMPTOMS
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

7. CHECK DIFFERENTIAL INNER PARTS A

1. Disassemble rear final drive assembly. Refer to RFD-83, "Disassembly and Assembly" .

2. Check differential inner parts.

OK or NG

OK >> INSPECTION END
NG >> Repair or replace damaged parts. C

RFD

Revision: October 2004

RFD-77

2005 Titan

DIFFERENTIAL LOCK CONTROL UNIT
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

DIFFERENTIAL LOCK CONTROL UNIT

PFP:28496

Removal and Installation
REMOVAL

EDS001PZ

1. Disconnect the battery cable from the negative terminal.

2. Remove jack and tools.

3. Remove both rear seats. Refer to SE-100, "Removal and Installation" .

4. Remove rear lower finisher LH. Refer to EI-39, "REAR" .

5. Remove rear upper finisher LH. Refer to EI-39, "REAR" .

6. Remove seatback latch striker LH. Refer to SE-101, "Disassembly and Assembly" .

7. Remove upper bracket of center seat belt retractor and belt assembly. Refer to SB-8, "Removal and Installation of Rear Seat Belt" .

8. Remove the necessary push pins and reposition rear panel out of the way. Refer to EI-39, "REAR" .

9. Reposition the carpet to access differential lock control unit to disconnect connector.

10. Remove the two nuts and remove differential lock control unit.

INSTALLATION Note the following, and installation is in the reverse order of removal. q When installing differential lock control unit, tighten nuts to the specified torque.
Differential lock control unit nuts : 5.1 N·m (0.52 kg-m, 45 in-lb)

LDIA0156E

Revision: October 2004

RFD-78

2005 Titan

FRONT OIL SEAL
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

FRONT OIL SEAL
Removal and Installation
REMOVAL

PFP:38189
A
EDS001Q0

1. Remove rear propeller shaft. Refer to PR-8, "Removal and Installation" .

2. Remove wheel and tire assemblies.

3. Remove brake calipers and rotors. Refer to BR-29, "Removal and Installation of Brake Caliper and Disc

Rotor" .

4. Using an inch-pound, torque wrench, rotate the pinion three or four times.

5. Record the rotating torque.

6. Loosen drive pinion nut while holding companion flange using

RFD

Tool.

Tool number : KV40104000 ( -- ) E

7. Put matching mark on the thread edge of drive pinion. The mark should be in line with the mark on companion flange.
CAUTION: For matching mark, use paint. Do not damage drive pinion.

LDIA0122E

8. Remove companion flange using a suitable tool.

J
SDIA2590E
K
L

9. Remove front oil seal using Tool.
Tool number : ST33290001 (J-34286)
CAUTION: Be careful not to damage axle housing.

LDIA0123E

Revision: October 2004

RFD-79

LDIA0124E
2005 Titan

FRONT OIL SEAL
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
INSTALLATION 1. Apply multi-purpose grease to oil seal lips. Install front oil seal
into axle housing using Tool.
Tool number : ST15310000 ( -- )
CAUTION: q Do not reuse oil seal. q When installing, do not incline oil seal.

2. Align the matching mark of drive pinion with the mark of companion flange, then install companion flange.

LDIA0125E

SDIA2590E

3. Assemble washer if required and new drive pinion nut on pinon gear and tighten nut until there is zero bearing end play.
CAUTION: Do not reuse drive pinion nut and washer.
4. Rotate drive pinion using an inch-pound torque wrench and flange wrench. Rotating torque should be equal to the reading recorded in step 5 above during removal plus an additional 0.56 N·m (5 in-lb).

Tool number : KV40104000 ( -- )

5. If the rotating torque is low, continue to tighten drive pinion nut in 6.8 N·m (5 ft-lb) increments until proper rotating torque is achieved. Refer to RFD-83, "COMPONENTS" .

LDIA0122E

6. Install rear propeller shaft. Refer to PR-8, "Removal and Installation" .

7. Check gear lubricant level and fill with proper lubricant if required. Refer to MA-26, "Checking Final Drive Oil" .

8. Install brake rotors, calipers, wheel and tire assemblies. Refer to BR-29, "Removal and Installation of Brake Caliper and Disc Rotor" .

Revision: October 2004

RFD-80

2005 Titan

CARRIER COVER
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

CARRIER COVER
Removal and Installation
REMOVAL 1. Remove drain plug and drain gear oil. Refer to MA-27, "DRAINING" . 2. Remove carrier cover.
q Disconnect parking brake cable from carrier cover. q Disconnect brake tube from carrier cover.

PFP:38351
A
EDS001Q1
B
C

RFD

E
LDIA0126E

INSTALLATION

1. Apply sealant to mating surface of carrier cover.

q Use Genuine Silicone RTV or equivalent. Refer to GI-45, "Recommended Chemical Products and Sealants" .
CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
2. Install carrier cover on axle housing and tighten carrier cover bolts to the specified torque. Refer to RFD-83, "COMPONENTS" .
3. Connect parking brake cable and brake tube to carrier cover.

SDIA2639E

4. Fill with new gear oil until oil level reaches the specified limit near filler plug mounting hole. Refer to MA-

26, "Checking Final Drive Oil" .

Revision: October 2004

RFD-81

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

REAR FINAL DRIVE ASSEMBLY

PFP:38300

Removal and Installation
REMOVAL

EDS001Q2

CAUTION: q Be careful not to damage spline, companion flange and front oil seal when removing propeller
shaft.

1. Drain rear final drive gear oil. Refer to MA-27, "DRAINING" .

2. Remove rear propeller shaft. Refer to PR-8, "Removal and Installation" .

q Plug rear end of transfer.

3. Remove axle shaft. Refer to RAX-6, "Removal and Installation" .

4. Support rear final drive using a suitable jack.

5. Disconnect the following components from rear final drive.

q Brake tube block connectors. Refer to BR-13, "Removal and Installation of Rear Brake Piping and Brake Hose" .

q ABS sensor wire harness. Refer to BRC-40, "Removal and Installation" .

q Parking brake cable.

q Brake tube.

q Differential lock position switch harness connector. q Differential lock solenoid harness connector.

LDIA0126E

LDIA0158E
6. Disconnect brake hose from brake tube at the mounting clip on top of axle housing. Then remove the metal clip to disconnect brake line from the mounting clip on top of axle housing.
7. Remove rear shock absorber lower bolts. Refer to RSU-7, "Removal and Installation" . 8. Remove leaf spring U-bolt nuts. Refer to RSU-8, "Removal and Installation" . 9. Remove rear final drive assembly.
INSTALLATION Note the following, and installation is in the reverse order of removal. q Fill with new gear oil until oil level reaches the specified limit near filler plug mounting hole. Refer to MA-
26, "Checking Final Drive Oil" . q Bleed the air from brake system. Refer to BR-11, "Bleeding Brake System" .

Revision: October 2004

RFD-82

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

Disassembly and Assembly
COMPONENTS

EDS001Q3
A

RFD

1. Drive pinion nut 4. Front oil seal 7. Axle housing 10. Sensor connector 13. Side bearing cap 16. Filler plug 19. Drive pinion rear bearing 22. Side bearing 25. Differential lock solenoid

2. Drive pinion nut washer 5. Front bearing thrust washer 8. Differential lock position switch 11. Drain plug 14. Adjuster lock plate 17. Drive pinion 20. Collapsible spacer 23. Differential case assembly 26. Solenoid washer

WDIA0113E
3. Companion flange 6. Drive pinion front bearing 9. Breather 12. Axle shaft assembly 15. Carrier cover 18. Drive pinion height adjusting washer 21. Side bearing adjuster 24. Drive gear

Revision: October 2004

RFD-83

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
ASSEMBLY INSPECTION AND ADJUSTMENT Total Preload Torque 1. Turn drive pinion in both directions several times to set bearing
rollers. 2. Check total preload using preload gauge set.
Tool number : ST3127S000 (J-25765-A)

Total preload (with oil seal) 2.38 - 5.16 N·m (0.25 - 0.52 kg-m, 21 - 45 in-lb)
NOTE: Total preload torque = Pinion bearing torque + Side bearing torque q If measured value is out of the specification, disassemble it to
check and adjust each part. Adjust the pinion bearing preload and the side bearing preload. Adjust the pinion bearing preload first, then adjust the side bearing preload.
When the preload torque is large On pinion bearings: Replace collapsible spacer. On side bearings: Loosen side bearing adjuster.

PDIA0309E

When the preload is small
On pinion bearings: Tighten drive pinion nut.
On side bearings: Tighten side bearing adjuster.
Tooth Contact Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive pinion. Gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check gear tooth contact pattern to obtain the best contact for low noise and long life. 1. Remove rear cover. Refer to RFD-87, "DISASSEMBLY" . 2. Thoroughly clean drive gear and drive pinion teeth. 3. Apply red lead to drive gear.
CAUTION: Apply red lead to both the faces of 3 to 4 gears at 4 locations evenly spaced on drive gear.

4. Hold companion flange steady by hand and rotate drive gear in both directions.

SDIA2623E

Revision: October 2004

RFD-84

PDIA0322E
2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
A

RFD

SDIA2591E

5. If outside the standard, adjust drive pinion height adjusting washer and backlash. Refer to RFD-92, "Drive

Pinion Height Adjusting Washer" , RFD-85, "Backlash" .

Backlash

1. Remove rear cover. Refer to RFD-87, "DISASSEMBLY" .

2. Check drive gear to drive pinion backlash using a dial indicator

at several points.

Drive gear to drive pinion backlash

: 0.08 - 0.13 mm (0.0031 - 0.0051 in)

3. If outside the standard, adjust side bearing adjuster.
CAUTION: Check tooth contact and total preload after adjusting side bearing adjuster. Refer to RFD-84, "Total Preload Torque" , RFD-84, "Tooth Contact" .
a. Remove adjuster lock plate.
b. Loosen side bearing cap bolts.
c. Tighten or loosen each side bearing adjusters using Tool.

J
K
SDIA2640E
L

Tool number : -- (C - 4164) M

PDIA0337E

Revision: October 2004

RFD-85

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
d. In case of lots of backlash, loosen side bearing adjuster A and tighten side bearing adjuster B. In case of less backlash, loosen side bearing adjuster B and tighten side bearing adjuster A.

e. After adjusting backlash and tighten cap bolts to the specified torque. Refer to RFD-83, "COMPONENTS" .
f. Install adjuster lock plate and tighten to the specified torque. Refer to RFD-83, "COMPONENTS" .
CAUTION: Install adjuster lock plate to grooving of differential lock solenoid.

PDIA0330E

Companion Flange Runout 1. Fit a dial indicator onto companion flange face (inner side of pro-
peller shaft mounting bolt holes).
2. Rotate companion flange to check for runout.

SDIA2582E

Runout limit : 0.10 mm (0.0039 in) or less

3. Fit a test indicator to the inner side of companion flange (socket diameter).
4. Rotate companion flange to check for runout.

Runout limit : 0.13 mm (0.0051 in) or less

5. If the runout value is outside the repair limit, follow the procedure below to adjust.

SDIA2078E

a. Check for runout while changing the phase between companion flange and drive pinion by 90° step, and search for the point where the runout is the minimum.

b. If the runout value is still outside of the limit after the phase has been changed, replace companion flange.

c. If the runout value still outside of the limit after companion flange has been replaced, check drive pinion bearing and drive pinion assembly.

Revision: October 2004

RFD-86

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

DISASSEMBLY

Differential Assembly

1. Remove carrier cover bolts.

2. Remove carrier cover using Tool. B
Tool number : KV10111100 (J-37228)

CAUTION:

q Be careful not to damage the mating surface.

q Do not insert flat-bladed screwdriver, this will damage the

mating surface.

RFD

3. Remove differential sensor connector bolts and differential lock solenoid connector.

SDIA2581E
E F

4. For proper reinstallation, paint matching mark on one side of side bearing cap. CAUTION: q Side bearing caps are line-board for initial assembly. The matching marks are used to reinstall them in their original positions. q For matching mark, use paint. Do not damage side bearing cap.
5. Remove adjuster lock plates.
6. Remove side bearing caps.

H
SDIA2585E
I

SDIA2583E

SDIA2587E

Revision: October 2004

RFD-87

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
7. Remove side bearing adjusters using Tool. Tool number : -- (C - 4164)

8. Keep side bearing outer races together with inner races. Do not mix them up. Also, keep side bearing adjusters together with bearing.
9. Remove side bearing adjusters from axle housing.
10. Remove bracket of differential lock position switch connector and bolts. 11. Remove differential lock position switch. 12. Remove side bearing inner race and washer using Tool.
Tool number : ST33081000 ( -- ) CAUTION: Be careful not to damage differential case assembly and differential lock solenoid. 13. Remove differential lock solenoid and solenoid washer.
14. Remove side bearing inner race using Tool. Tool number : ST33081000 ( -- )
CAUTION: Be careful not to damage differential case assembly.

PDIA0337E SDIA2588E SDIA2584E SDIA2589E

Revision: October 2004

RFD-88

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

15. For proper reinstallation, paint matching mark on differential

case assembly and drive gear.

CAUTION:

For matching mark, use paint. Do not damage differential

case and drive gear.

16. Remove drive gear mounting bolts.

17. Tap drive gear off differential case assembly with a soft hammer.

CAUTION:

Tap evenly all around to keep drive gear from binding.

Drive Pinion Assembly 1. Remove differential case assembly. Refer to RFD-87, "Differential Assembly" . 2. Remove drive pinion nut and washer using Tool.
Tool number : KV40104000 ( -- )

SDIA2238E

RFD

3. Put a matching mark on the thread edge of drive pinion. The mark should be in line with the mark on companion flange.
CAUTION: For matching mark, use paint. Do not damage drive pinion.

PDIA0314E

4. Remove companion flange using a suitable tool.

K
SDIA2590E
L

PDIA0315E

Revision: October 2004

RFD-89

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
5. Remove front oil seal using Tool.
Tool number : ST33290001 (J-34286)
CAUTION: Be careful not to damage axle housing. 6. Remove front bearing thrust washer.

7. Remove drive pinion assembly and collapsible spacer from axle housing, using suitable press.
CAUTION: Do not drop drive pinion assembly.
8. Remove drive pinion front bearing inner race from axle housing.

SDIA2586E

PDIA0316E SDIA2641E

SDIA2236E

Revision: October 2004

RFD-90

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

INSPECTION AFTER DISASSEMBLY

Drive Gear and Drive Pinion

q If the gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or replace as necessary.
q If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new gears. B

q Drive gear and drive pinion are supplied in matched sets only. Matching numbers on both drive pinion and

drive gear are etched for verification. If a new gear set is being used, verify the numbers of each pinion

gear and drive gear before proceeding with assembly.

Bearing

If found any chipped (by friction), pitted, worn, rusted, scratched mark, or unusual noise from the bearing, replace with new bearing assembly (as a new set).

RFD

q Bearing must be replaced with a new one whenever disassembled.

Differential Case Assembly

q If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new differential case assembly.

q If the movement is not smooth when pushing cam ring of differential case assembly with a hand.

Differential Lock Solenoid

q If the operating part of differential lock solenoid is not smooth, perform component inspection. Refer to

RFD-70, "COMPONENT INSPECTION" .

Revision: October 2004

RFD-91

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
SELECTION ADJUSTING WASHERS
Drive Pinion Height Adjusting Washer
q Drive gear and drive pinion are supplied in matched sets only. Matching numbers on both drive pinion and drive gear are etched for verification. If a new gear set is being used, verify the numbers of each drive pinion and drive gear before proceeding with assembly.

SDIA2241E

q The mounting distance from the center line of drive gear to the back face of drive pinion for the Model 226 axle assembly is 109.5 mm (4.312 in). On the button end of each drive pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0), which indicates the best running position for each particular gear set. This dimension is controlled by a selective drive pinion height adjusting washer between drive pinion inner bearing race and drive pinion. For example: If a drive pinion is etched m+8 (+3), it would require 0.08 mm (0.003 in) less drive pinion height adjusting washer than a drive pinion etched "0". This means decreasing drive pinion height adjusting washer thickness; increases the mounting distance of drive pinion to 109.6 mm (4.315 in). If a drive pinion is etched m-8 (-3), it would require adding 0.08 mm (0.003 in) more to drive pinion height adjusting washer than would be required if drive pinion were etched "0". By adding 0.08 mm (0.003 in), the mounting distance of drive pinion was decreased to 109.4 mm (4.309 in) which is just what m-8 (a-3) etching indicated.
q To change drive pinion adjustment, use different drive pinion height adjusting washers which come in different thickness.
q Use the following tables as a guide for selecting the correct drive pinion height adjusting washer thickness to add or subtract from the old drive pinion height adjusting washer.

OLD DRIVE PINION
MARKING +4 +3 +2 +1 0 -1 -2 -3 -4

-4
+0.20 (+0.008)
+0.18 (+0.007)
+0.15 (+0.006)
+0.13 (+0.005)
+0.10 (+0.004)
+0.08 (+0.003)
+0.05 (+0.002)
+0.02 (+0.001)
0 (0)

-3
+0.18 (+0.007)
+0.15 (+0.006)
+0.13 (+0.005)
+0.10 (+0.004)
+0.08 (+0.003)
+0.05 (+0.002)
+0.02 (+0.001)
0 (0)
-0.02 (-0.001)

NEW DRIVE PINION MARKING mm (in)

-2

-1

+0.15 (+0.006)
+0.13 (+0.005)
+0.10 (+0.004)
+0.08 (+0.003)
+0.05 (+0.002)
+0.02 (+0.001)
0 (0)
-0.02 (-0.001)
-0.05 (-0.002)

+0.13 (+0.005)
+0.10 (+0.004)
+0.08 (+0.003)
+0.05 (+0.002)
+0.02 (+0.001)
0 (0)
-0.02 (-0.001)
-0.05 (-0.002)
-0.08 (-0.003)

+0.10 (+0.004)
+0.08 (+0.003)
+0.05 (+0.002)
+0.02 (+0.001)
0 (0)
-0.02 (-0.001)
-0.05 (-0.002)
-0.08 (-0.003)
-0.10 (-0.004)

+0.08 (+0.003)
+0.05 (+0.002)
+0.02 (+0.001)
0 (0)
-0.02 (-0.001)
-0.05 (-0.002)
-0.08 (-0.003)
-0.10 (-0.004)
-0.13 (-0.005)

+0.05 (+0.002)
+0.02 (+0.001)
0 (0)
-0.02 (-0.001)
-0.05 (-0.002)
-0.08 (-0.003)
-0.10 (-0.004)
-0.13 (-0.005)
-0.15 (-0.006)

+3
+0.02 (+0.001)
0 (0)
-0.02 (-0.001)
-0.05 (-0.002)
-0.08 (-0.003)
-0.10 (-0.004)
-0.13 (-0.005)
-0.15 (-0.006)
-0.18 (-0.007)

+4
0 (0)
-0.02 (-0.001)
-0.05 (-0.002)
-0.08 (-0.003)
-0.10 (-0.004)
-0.13 (-0.005)
-0.15 (-0.006)
-0.18 (-0.007)
-0.20 (-0.008)

Revision: October 2004

RFD-92

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

1. Make sure all parts are clean and that drive pinion bearings are

well lubricated.

2. Assemble drive pinion bearings into the tools.

Tool number

A: -- (8144)

B: -- (6740)

C: -- (6741)

3. Install drive pinion bearing inner race and drive pinion height adjusting washer to axle housing using tool as shown.

SDIA2242E

RFD

4. Turn the assembly several times to seat drive pinion bearings.

G
PDIA0318E
H

5. Measure the turning torque, using Tool.

Tool number

: ST3127S000 (J-25765-A)

Turning torque specification : 1.2 - 2.8 N-m (0.13 - 0.28 kg-m, 11 - 24 in-lb)

J
PDIA0319E
K L M

6. Tighten side bearing caps to the specified torque installing tools as shown.

Tool number

A: -- (6739)

B: -- (D-115-2)

C: -- TBD

D: -- (D-115-3)

Revision: October 2004

RFD-93

PDIA0320E
SDIA2646E
2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
7. Put scooter block on pinion height block. Make sure that dial indicator is level adjusting pressure with a hand. Dial indicator indicates "0".
8. Slide dial indicator along arbor. Record the maximum.
9. Adjust drive pinion height adjusting washer so that the maximum will be "0".

ASSEMBLY Drive Pinion Assembly 1. Press a drive pinion rear bearing outer race into axle housing,
using Tool. Tool number A: ST01500001 ( -- ) B: ST30022000 ( -- )
CAUTION: Do not reuse drive pinion rear bearing.
2. Press a drive pinion front bearing outer race into axle housing, using Tool. Tool number : ST33022000 ( -- ) CAUTION: Do not reuse drive pinion front bearing.
3. Select drive pinion height adjusting washer. Refer to RFD-92, "Drive Pinion Height Adjusting Washer" .
4. Press a drive pinion rear bearing inner race and drive pinion height adjusting washer to drive pinion, using Tool. Tool number : -- (C - 4040) CAUTION: Do not reuse drive pinion rear bearing.
5. Apply gear oil to drive pinon rear bearing and drive pinon front bearing.
6. Install drive pinion front bearing inner race in axle housing. 7. Install front bearing thrust washer to axle housing.

SDIA2647E PDIA0323E PDIA0324E SDIA2592E

Revision: October 2004

RFD-94

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

8. Apply multi-purpose grease to front oil seal lip. Install front oil

seal into axle housing using Tool.

Tool number : ST15310000 ( -- )

CAUTION:

q Do not reuse oil seal.

q When installing, do not incline oil seal.

9. Install collapsible spacer to drive pinion. And then install drive pinion assembly in axle housing.
CAUTION: q Do not reuse collapsible spacer.
q Be careful not to damage front oil seal.

PDIA0326E

RFD

10. Align the matching mark of drive pinion with the mark of companion flange.

G
SDIA2595E
H
I

11. Install companion flange onto drive pinion. Tap companion flange with a soft hammer until fully seated.
CAUTION: Be careful not to damage companion flange and front oil seal.

SDIA2590E

Revision: October 2004

RFD-95

PDIA0328E
PDIA0313E
2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

13. Tighten drive pinion nut by very small degrees until the specified preload is achieved. When checking the preload, turn drive pinion in both directions several times to set the bearing rollers, using Tool.
Tool number : ST3127S000 (J-25765-A)

Pinion bearing preload: 1.7 - 3.8 N·m (0.18 - 0.38 kg-m, 15 - 33 in-lb)
a. This procedure will have to be repeated if: q Maximum preload is achieved before the minimum drive pinion nut torque is reached. q Minimum preload is not achieved before maximum drive pinion nut torque is reached.
Differential Assembly 1. Align the matching mark of differential case assembly with the
mark of drive gear, then install drive gear.

PDIA0309E

2. Apply thread locking sealant into the thread hole of drive gear. q Use Genuine Medium Strength Thread Locking Sealant or equivalent. Refer to GI-45, "Recommended Chemical Products and Sealants" . CAUTION: The drive gear back and threaded holes shall be cleaned and decreased sufficiently.
3. Install drive gear on the bolts, and then tighten to the specified torque. Refer to RFD-83, "COMPONENTS" . CAUTION: q Do not reuse the bolts. q Tighten bolts in a crisscross fashion.

SDIA2593E SDIA2594E SDIA0247J

Revision: October 2004

RFD-96

2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

4. Press side bearing inner races to differential case assembly

using Tool.

Tool number : ST33081000 ( -- )

CAUTION:

Do not reuse side bearing.

5. Install differential lock solenoid and washer. 6. Press side bearing inner races to differential case assembly
using Tool.
Tool number A: KV38100300 (J-25523) B: ST33081000 ( -- )

SDIA2630E

RFD

G
SDIA2631E

7. Apply sealant to threads of differential lock position switch. q Use Genuine Silicone RTV or equivalent. Refer to GI-45, "Recommended Chemical Products and H Sealants" .

CAUTION: Remove old sealant adhering to axle housing and differential lock position switch. Also remove I

any moisture, oil, or foreign material adhering to application and axle housing and differential lock

position switch.

8. Install differential lock position switch on axle housing and

tighten differential lock position switch bolts with the specified

torque. Refer to RFD-83, "COMPONENTS" .

9. Install side bearing adjusters into axle housing.

M
SDIA2633E

Revision: October 2004

RFD-97

PDIA0381E
2005 Titan

REAR FINAL DRIVE ASSEMBLY
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
10. Apply gear oil to side bearings. Install differential case assembly with side bearing outer races into axle housing.
11. Apply multi-purpose grease to sensor connector.
CAUTION: Do not reuse sensor connector.

12. Connect differential lock solenoid harness and sensor connector. Then install it to axle housing, tighten to the specified torque. Refer to RFD-83, "COMPONENTS" .

SDIA2588E

13. Align paint matching mark on side bearing caps with that on axle housing and install side bearing caps on axle housing.
CAUTION: Do not tighten at this point. This allows further tightening of side bearing adjusters.

14. Tighten each side bearing adjusters using adjuster tool.
Tool number : -- (C - 4164)
15. Adjusting backlash of drive gear and drive pinion. Refer to RFD85, "Backlash" .
16. Check total preload. Refer to RFD-84, "Total Preload Torque" . 17. Check tooth contact. Refer to RFD-84, "Tooth Contact" .

18. Apply sealant to mating surface of carrier cover.
q Use Genuine Silicone RTV or equivalent. Refer to GI-45, "Recommended Chemical Products and Sealants" .
CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
19. Install carrier cover on axle housing and tighten carrier cover bolts with the specified torque. Refer to RFD-83, "COMPONENTS" .

Revision: October 2004

RFD-98

SDIA2585E
SDIA2632E
PDIA0337E
SDIA2639E
2005 Titan

SERVICE DATA AND SPECIFICATIONS (SDS)
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications

PFP:00030
A
EDS001Q4

Engine

Transmission

Final drive model

Gear ratio

Number of pinion gears

Number of teeth (Drive gear / drive pinion)

Oil capacity (Approx.)

(US pt, lmp pt)

Drive pinion adjustment spacer type

VK56DE 5A/T M226 3.357 2 47/14
2.01 (4-1/4, 3-1/2) Collapsible

B C RFD

Inspection and Adjustment
PRELOAD TORQUE
Item Total preload (Drive pinion torque to rotate plus) Drive pinion bearing preload
BACKLASH
Item Drive gear to drive pinion gear

EDS001Q5

Unit: N·m (kg-m, in-lb)

Specification

2.38 - 5.16 (0.25 - 0.52, 21 - 45)

1.7 - 3.8 (0.18 - 0.38, 15 - 33)
G

Standard 0.08 - 0.13 (0.0031 - 0.0051)

Unit: mm (in)
H

COMPANION FLANGE RUNOUT
Item Companion flange face Inner side of companion flange

Runout limit 0.10 (0.0039) or less 0.13 (0.0051) or less

Unit: mm (in) I J

Revision: October 2004

RFD-99

2005 Titan

SERVICE DATA AND SPECIFICATIONS (SDS)
[WITH ELECTRONIC LOCKING DIFFERENTIAL]

SELECTIVE PARTS Drive Pinion Height Adjusting Washer

Unit: mm (in)

Thickness

Package part number*

0.076 (0.030) 0.079 (0.031) 0.081 (0.032) 0.084 (0.033) 0.086 (0.034)

38151 8S101

0.089 (0.035) 0.091 (0.036) 0.094 (0.037) 0.097 (0.038) 0.099 (0.039)

38151 8S102

0.102 (0.040) 0.104 (0.041) 0.107 (0.042) 0.109 (0.043) 0.112 (0.044)

38151 8S103

0.114 (0.045) 0.117 (0.046) 0.119 (0.047) 0.122 (0.048) 0.124 (0.049)

38151 8S104

0.127 (0.050) 0.130 (0.051) 0.132 (0.052) 0.135 (0.053) 0.137 (0.054)

38151 8S105

*Always check with the Parts Department for the latest parts information.

Revision: October 2004

RFD-100

2005 Titan

FrameMaker SGML 5.5.6p145 Acrobat Distiller 4.05 for Windows