Transfer: Other Infiniti M45 III

Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.

Information necessary to service the system safely is included in SUPPLEMENTAL RESTRAINT SYSTEM and SEAT BELTS .

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1. Before connecting or disconnecting the AWD control unit harness connector, turn ignition switch "OFF" and disconnect battery ground cable. Because battery voltage is applied to AWD control unit even if ignition switch is turned "OFF".
2. When connecting or disconnecting pin connectors into or from AWD control unit, take care not to damage pin terminals (bend or break). When connecting pin connectors, make sure that there are no bends or breaks on AWD control unit pin terminal.
3. Before replacing AWD control unit, perform AWD control unit input/output signal inspection and make sure whether AWD control unit functions properly or not. Refer To " «AWD CONTROL UNIT INPUT/OUTPUT SIGNAL REFERENCE VALUES»(ref-239130-S00035031392006072700000) ".

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Service Notice or Precautions

1. Do not reuse transfer fluid, once it has been drained.
2. Check the fluid level or replace the fluid only with the vehicle parked on level ground.
3. During removal or installation, keep inside of transfer clear of dust or dirt.
4. Replace all tires at the same time. Always use tires of the proper size and the same brand and pattern. Fitting improper size and unusual wear tires applies excessive force to vehicle mechanism and can cause longitudinal vibration.
5. Disassembly should be done in a clean work area, it is preferable to work in dustproof area.
6. Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter.
7. All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or reassembly.
8. 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.
9. Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them with a new ones if necessary.
10. Gaskets, seals and O-rings should be replaced any time when the transfer is disassembled.
11. In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tightening sequence is specified, use it.
12. Observe the specified torque when assembling.
13. Clean and flush the parts sufficiently and blow-dry them.
14. Be careful not to damage sliding surfaces and mating surfaces.
15. Clean inner parts with lint-free cloth or towels. Do not use cotton work gloves and rags to prevent adhering fibers.

Special Service Tools

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

SPECIAL SERVICE TOOLS Tool number (Kent-Moore No.) Tool name Description ST27862000 ( - ) Drift a: 62.5 mm (2.461 in) dia. b: 42 mm (1.65 in) dia. Installing front oil seal KV381054S0 (J-34286) Puller Removing rear oil seal ST30720000 (J-25405) Drift a: 77 mm (3.03 in) dia. b: 55.5 mm (2.185 in) dia. Installing rear oil seal Installing mainshaft oil seal KV40104830 ( - ) Drift a: 70 mm (2.76 in) dia. b: 63.5 mm (2.500 in) dia. Installing rear oil seal KV38100300 (J-25523) Drift a: 54 mm (2.13 in) dia. b: 46 mm (1.81 in) dia. c: 32 mm (1.26 in) dia. Removing mainshaft bearing ST33052000 ( - ) Drift a: 28 mm (1.10 in) dia. b: 22 mm (0.87 in) dia. Removing mainshaft assembly ST30611000 (J-25742-1) Drift bar a: 350 mm (1.10 in) b: 25 mm (1.10 in) dia. c: M12 x 1.5P Removing rear bearing ST35321000 ( - ) Drift a: 49 mm (1.93 in) dia. b: 41 mm (1.61 in) dia. Removing rear bearing Installing mainshaft assembly ST31214000 (J-25269-B) Drift a: 34 mm (1.34 in) dia. b: 25.5 mm (1.004 in) dia. Removing front drive shaft front bearing Removing front drive shaft rear bearing KV38104010 ( - ) Drift a: 67 mm (2.64 in) dia. b: 49 mm (1.93 in) dia. Installing front drive shaft rear bearing Installing rear bearing ST33200000 (J-26082) Drift a: 60 mm (2.36 in) dia. b: 44.5 mm (1.752 in) dia. Installing front drive shaft front bearing ST30621000 (J-25742-5) Drift a: 80 mm (3.15 in) dia. b: 59 mm (2.32 in) dia. Installing mainshaft bearing

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Commercial Service Tools

COMMERCIAL SERVICE TOOLS Tool name Description Puller Removing companion flange Flange wrench Removing and installing self-lock nut Puller Removing front drive shaft front bearing Removing front drive shaft rear bearing Power tool Loosening bolts and nuts

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AWD CONTROL UNIT

1. Controls distribution of drive power between rear-wheel drive (0: 100) and AWD (50: 50) conditions according to signals from sensors.
2. Self-diagnosis can be done with CONSULT-II.

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AWD SYSTEM

Turns ON when there is a malfunction in AWD system. It indicates that fail-safe mode is engaged and vehicle change to rear-wheel drive or shifting driving force-AWD (Front-wheels still have some driving torque). Also turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately for 1 seconds after the engine starts if system is normal.

AWD Warning Lamp Indication

AWD WARNING LAMP INDICATION CHART

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FUNCTION

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

FUNCTION CHART

CONSULT-II SETTING PROCEDURE

Refer to " CONSULT-II START PROCEDURE ".

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1. Perform "CONSULT-II Start Procedure". Refer to " «CONSULT-II START PROCEDURE»(ref-239095-S42554850072006072700000) ".
2. Start engine and drive at 30 km/h (19 MPH) or more for approx. 1 minute.
3. Stop vehicle. With engine at idle, touch "SELF-DIAG RESULTS". Display shows malfunction experienced since the last erasing operation. NOTE: The details for "TIME" are as follow: "0": Error currently detected with AWD control unit. Except for "0": Error detected in the past and memorized with AWD control unit. Detects frequency of driving after DTC occurs (frequency of turning ignition switch "ON/OFF").

Display Item List

DISPLAY ITEM LIST

DISPLAY ITEM LIST

AWD CONTROL UNIT PART NUMBER

Ignore the AWD control unit part number displayed in the "ECU PART NUMBER".

Refer to parts catalog to order the AWD control unit.

Data are reference value.

DATA ARE REFERENCE VALUE CHART

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1. CHECK POWER SUPPLY Turn ignition switch "OFF". Disconnect AWD control unit harness connector. Turn ignition switch "ON". (Do not start engine.) Check voltage between AWD control unit harness connector terminals and ground. CONNECTOR TERMINAL VOLTAGE CHART Connector Terminal Voltage (Approx.) F109 7 - Ground Battery voltage 9 - Ground Turn ignition switch "OFF". Check voltage between AWD control unit harness connector terminals and ground. CONNECTOR TERMINAL VOLTAGE CHART Connector Terminal Voltage (Approx.) F109 7 - Ground 0V 9 - Ground Battery voltage OK or NG OK: GO TO 2. NG: Check the following. If any items are damaged, repair or replace damaged parts. 10A fuse [No.33, located in the fuse block (J/B)] 10A fuse [No.82, located in the IPDM E/R] Harness for short or open between battery and AWD control unit harness connector terminal 9 Harness for short or open between ignition switch and AWD control unit harness connector terminal 7 Ignition switch. Refer to " «POWER SUPPLY ROUTING CIRCUIT»(ref-239118-S13057560952006072600000) ".
2. CHECK GROUND CIRCUIT Turn ignition switch "OFF". Disconnect AWD control unit harness connector. Check continuity between AWD control unit harness connector F109 terminals 10, 11 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.
3. CHECK DTC Start engine. Does AWD warning lamp turn OFF? YES: INSPECTION END NO: Perform the self-diagnosis, repair or replace damaged parts. Refer to , " «SELF-DIAG RESULT MODE»(ref-239130-S07977950972006072700000) ".

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE

Data are reference value.

REFERENCE VALUE IN DATA MONITOR MODE CHART

Data are reference value.

MONITOR ITEM CONDITION DISPLAY VALUE CHART

While Driving, AWD Warning Lamp Flashes Rapidly (When Flashing in Approx. 1 Minute and Then Turning OFF)

Note. Rapid flashing: 2 times/second

This symptom protects drivetrain parts when a heavy load is applied to the electric controlled coupling and multiple disc clutch temperature increases. Also, optional distribution of torque sometimes becomes rigid before lamp flashes rapidly. Both cases are not malfunction.

When this symptom occurs, stop vehicle and allow it to idle for some times. Flashing will stop and system will be restored.

While Driving, AWD Warning Lamp Flashes Slowly (When Continuing to Flash until Turning Ignition Switch OFF)

Note. Slow flashing: 1 time/2 seconds

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1. CHECK TIRE Check the following. Tire pressure Wear condition Longitudinal tire size (There is no difference between longitudinal tires.) OK or NG OK: GO TO 2. NG: Drive at vehicle speed of 20 km/h (12 MPH) or more for 5 seconds or more after repairing or replacing damaged parts. (Initialize improper size tire information.)
2. CHECK INPUT SIGNAL OF TIRE DIAMETER With CONSULT-II Start engine. Drive at 20 km/h (12 MPH) or more for approx. 200 seconds. Select "DATA MONITOR" mode for "ALL MODE AWD/4WD" with CONSULT-II. Check monitor "DIS-TIRE MONI". Display of "DIS-TIRE MONI" "0-4mm": INSPECTION END Except for "0-4mm": GO TO 3.
3. CHECK AWD CONTROL UNIT Check AWD control unit input/output signal. Refer to , " «AWD CONTROL UNIT INPUT/OUTPUT SIGNAL REFERENCE VALUES»(ref-239130-S00035031392006072700000) ". OK or NG OK: GO TO 4. NG: Check AWD control unit pin terminals for damage or loose connection with harness connector. If any items are damaged, repair or replace damaged parts.
4. SYMPTOM CHECK Check again. OK or NG OK: INSPECTION END NG: Replace AWD control unit.

Cases

Check items below. If necessary, replace them with new ones.

1. Contact surfaces of bearing for wear, damage, etc.
2. Damage and cracks of case.

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Bearing

Check items below. If necessary, replace them with new ones.

1. Damage and rough rotation of bearing.

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Shaft

Check items below. If necessary, replace them with new one.

1. Damage, peeling, dent, uneven wear, bending, etc. of shaft.

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Gears and Chain

Check items below. If necessary, replace them with new ones.

1. Excessive wear, damage, peeling, etc. of gear and chain.

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1. Install front drive shaft front bearing, using the drift. Tool number: ST33200000 (J-26082)
2. Install front drive shaft rear bearing, using the drift. Tool number: KV38104010 ( - )
3. Install drive chain to front drive shaft. CAUTION: Identification mark of drive chain should be in the side of front bearing of front drive shaft.
4. Install drive chain to mainshaft, and then install tap front drive shaft with plastic hammer. Press-fit rear bearing of front drive shaft to rear case. CAUTION: Be careful not to tap drive chain.
5. Install front case to rear case. Refer to , " «FRONT CASE AND REAR CASE»(ref-239130-S21170667552006072700000) ".

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1. Install needle bearing to mainshaft. CAUTION: Apply ATF to periphery of needle bearing.
2. Install sprocket and electric controlled coupling to mainshaft.
3. Install spacer to main shaft.
4. Install snap ring to mainshaft. CAUTION: Do not reuse snap ring.
5. Install mainshaft assembly to rear case, then install front case and rear case. Refer to , " «FRONT CASE AND REAR CASE»(ref-239130-S21170667552006072700000) ".

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1. Install breather tube, with plastic hammer. CAUTION: Pay attention to the direction of breather tube.
2. Install baffle plate to rear case, and tighten bolt to the specified torque. Refer to , " «COMPONENTS»(ref-239130-S31705017512006072700000) ".
3. Install rear bearing to rear case, using the drift. Tool number: KV38104010 ( - ) CAUTION: Apply ATF to inside of rear bearing.
4. Install snap ring to rear case. CAUTION: Do not reuse snap ring.
5. Install mainshaft assembly to rear case, using the drift. Tool number: ST35321000 ( - ) CAUTION: ATF should be applied to contact surface of mainshaft and rear bearing.
6. Install O-ring to transfer assembly harness connector. CAUTION: Do not reuse O-ring. Apply ATF to O-ring.
7. Install transfer assembly harness connector into rear case.
8. Install retainer to transfer assembly harness connector.
9. Set temperature sensor and tighten bolt to the specified torque. Refer to , " «COMPONENTS»(ref-239130-S31705017512006072700000) ".
10. Hold electric controlled coupling harness with oil cover hold plate, install oil cover to rear case, and tighten bolt to the specified torque. Refer to , " «COMPONENTS»(ref-239130-S31705017512006072700000) ". CAUTION: The harness should be guided by a cut portion.
11. Install oil gutter to rear case. CAUTION: The tip of oil gutter should be put into rear case groove.
12. Install drive chain to front drive shaft. CAUTION: Identification mark of drive chain should be in the side of front bearing of front drive shaft.
13. Install drive chain to mainshaft, and then install tap front drive shaft with plastic hammer. Press-fit rear bearing of front drive shaft to rear case. CAUTION: Be careful not to tap drive chain.
14. Install mainshaft bearing to front case, using the drift. Tool number: ST30621000 (J-25742-5)
15. Install snap ring to front case. CAUTION: Do not reuse snap ring.
16. Apply liquid gasket to mating surface of rear case. Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-239095-S40339598692006072700000) ". CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces. Refer to «GENERAL INFORMATION»(ref-239095)
17. Set front case to rear case. CAUTION: Be careful not to damage the mating surface transmission side.
18. Tighten front case and rear case fixing bolts to the specified torque. Refer to , " «COMPONENTS»(ref-239130-S31705017512006072700000) ". BOLTS SYMBOL BOLT LENGTH SPECIFICATION Bolts symbol Quantity Bolt length "l" mm (in) A 11 42 (1.65) B 1 162 (6.38) C 1 97 (3.82) TORX bolts 1 40 (1.57)
19. Install spacer to mainshaft. CAUTION: Apply ATF to spacer.
20. Install rear oil seal to rear case, using the drifts. Dimension A: 6.7 - 7.3 mm (0.264 - 0.287 in) Tool number A: ST30720000 (J-25405) B: KV40104830 ( - ) CAUTION: Do not reuse rear oil seal. Apply ATF to rear oil seal. When installing, do not incline rear oil seal.
21. Install companion flange while align the matching mark of mainshaft with the mark of companion flange.
22. Tighten self-lock nut to the specified torque, with flange wrench. Refer to , " «COMPONENTS»(ref-239130-S31705017512006072700000) ". CAUTION: Do not reuse self-lock nut.
23. Install mainshaft oil seal until it is flush with end face of front case, using the drift. Tool number: ST30720000 (J-25405) CAUTION: Do not reuse mainshaft oil seal. Apply ATF to mainshaft oil seal. When installing, do not incline mainshaft oil seal.
24. Install front oil seal until it is flush with end face of front case, using the drift. Tool number: ST27862000 ( - ) CAUTION: Do not reuse front oil seal. Apply ATF to front oil seal. When installing, do not incline front oil seal.
25. Apply sealant to threads of drain plug. Then install it to rear case and tighten to the specified torque. Refer to , " «COMPONENTS»(ref-239130-S31705017512006072700000) ". Use Genuine Silicone RTV or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-239095-S40339598692006072700000) ". CAUTION: Remove old sealant and oil adhering to threads.
26. Set gasket to filler plug. Install it to rear case and tighten to the specified torque. Refer to , " «COMPONENTS»(ref-239130-S31705017512006072700000) ". CAUTION: Do not reuse gasket. After oil is filled, tighten filler plug to specified torque.