Nissan Hardbody Truck D21 Series 1994 Service Manual – PDF DOWNLOAD

Description

Nissan Hardbody Truck D21 Series 1994 Service Manual – PDF DOWNLOAD

FILE DETAILS:

Nissan Hardbody Truck D21 Series 1994 Service Manual – PDF DOWNLOAD

Language : English
Pages : 1319
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Nissan Hardbody Truck D21 Series 1994 Service Manual – PDF DOWNLOAD

QUICKREFERENCEINDEX0
TABLEOFCONTENTS1
PREPARATIONANDPRECAUTIONS3
SpecialServiceTools3
ServiceNotice4
RE4R01A5
DESCRIPTION5
Cross-SectionalView5
HydraulicControlCircuits6
RL4R01A7
DESCRIPTION7
Cross-SectionalView7
HydraulicControlCircuits8
RE4R01A&RL4R01A9
DESCRIPTION9
ShiftMechanism9
RE4R01A11
DESCRIPTION11
ControlSystem11
RE4R01A&RL401A13
TROUBLEDIAGNOSES13
Contents13
SelfDiagnosis39
TROUBLEDIAGNOSES-A/TShiftLockSystem95
Contents95
ON-VEHICLESERVICE106
ControlValveAssemblyandAccumulatorsInspection106
RevolutionSensorReplacement-RE4R01A107
RearOilSealReplacement108
ParkingComponentsInspection108
GovernorValve-RL4R01A109
ThrottleWireAdjustment-RL4R01A109
InhibitorSwitchAdjustment110
ManualControlLinkageAdjustment110
KickdownSwitchAdjustment111
REMOVALANDINSTALLATION112
Removal112
Installation113
MAJOROVERHAUL115
RE4R01A115
RL4R01A117
OilChannel-RE4R01A119
OilChannel-RL4R01A120
LocationsofNeedleBearings,ThrustWashersandSnapRings121
DISASSEMBLY122
Disassembly122
REPAIRFORCOMPONENTPARTS136
OilPump-RE4R01AandRL401A136
ControlValveAssembly-RE4R01A140
ControlValveAssembly-RL4R01A146
ControlValveUpperBody-RE4R01A151
ControlValveUpperBody-RL4R01A157
ControlValveLowerBody-RE4R01A161
ControlValveLowerBody-RL4R01A163
GovernorValveAssembly-RL4R01A165
OilDistributor166
ReverseClutch-RE4R01AandRL4R01A167
HighClutch-RE401AandRL4R01A171
ForwardandOverrunClutches-RE401AandRL4R01A173
Low&ReverseBrake-RE4R01AandRL4R01A177
ForwardClutchDrumAssembly-RE4R01AandRL4R01A181
RearInternalGearandForwardClutchHub-RE4R01AandRL4R01A183
BandServoPistonAssembly-RE4R01AandRL4R01A186
ParkingPawlComponents-RE4R01AandRL4R01A190
ASSEMBLY192
Assembly(1)192
Adjustment201
Assembly(2)204
SERVICEDATAANDSPECIFICATIONS(SDS)211
GeneralSpecifications211
SpecificationsandAdjustment211
QUICKREFERENCEINDEX0
TABLEOFCONTENTS218
GENERALSERVICING219
Precautions219
CircuitBreakerInspection219
ClipandFastener219
BODYEND223
FrontEnd223
RearEnd-TRUCK224
BodyRearEnd-WAGON225
BackDoorWindowOpener-WAGON227
DOOR229
FrontDoor229
RearDoow-WAGON230
PowerDoorLock-TRUCK232
PowerDoorLock-WAGON235
PowerWindow241
INSTRUMENTPANEL244
INTERIORANDEXTERIOR246
Interior-TRUCK246
Interior-WAGON249
Exterior252
SEAT258
FrontSeat258
JumpSeat-KingCabModel259
RearSeat-WAGON260
HeatedSeat261
WINDSHIELDANDWINDOWS263
WindshieldandBackDoorWindows263
BackWindow-TRUCK265
RearSideWindow-TRUCK266
RearSideWindow(2nd)-WAGON267
SUNROOF268
ServiceProcedure268
MIRROR269
DoorMirror269
CABANDREARBODY272
CabBody-TRUCK272
RearBody-TRUCK272
CabBody-WAGON272
BodyMounting-TRUCK273
BodyMounting-WAGON274
BODYALIGNMENT275
EngineCompartment276
Underbody-TRUCK277
Underbody-WAGON285
QUICKREFERENCEINDEX0
TABLEOFCONTENTS289
PRECAUTIONSANDPREPARATION290
Precautions290
SpecialServiceTools290
CommercialServiceTools290
CHECKANDADJUSTMENT291
CheckingBrakeFluidLevel291
CheckingBrakeSystem291
ChangingBrakeFluid291
BleedingBrakeSystem291
BRAKEHYRAULICLINE292
RemovalandInstallation293
Inspection293
BRAKEPEDALANDBRACKET294
RemovalandInstallation294
Inspection294
Adjustment295
MASTERCYLINDER296
Removal296
Disassembly296
Inspection297
Assembly297
Installation297
BRAKEBOOSTER298
RemovalandInstallation298
On-vehicleService298
Inspection298
VACUUMPIPING299
RemovalandInstallation299
Inspection299
LOADSENSINGVALVE300
Inspection(LSV)300
FRONTDISCBRAKE302
CL28VAandCL28VD302
PadReplacement303
RemovalandInstallation303
Disassembly304
Inspection304
Assembly305
RotorInspection305
REARDRUMBRAKE306
LT30AandLT26B306
BrakeDrumRemoval307
ShoeReplacement307
WheelCylinderInspection307
DrumInspection307
ShoeInstallation308
REARDISCBRAKE309
AD14VB309
PadReplacement309
RemovalandInstallation309
Inspection310
Assembly311
RotorInspection311
PARKINGDRUMBRAKE312
DS19HB-AD14VBModel312
ShoeReplacement312
DrumInspection313
PARKINGBRAKECONTROL314
RemovalandInstallation315
Inspection315
Adjustment315
REARWHEELANTI-LOCKBRAKESYSTEM316
SystemComponents316
HydraulicCircuit316
WiringDiagram317
RemovalandInstallation318
TROUBLEDIAGNOSES319
Contents319
SERVICEDATAANDSPECIFICATIONS(SDS)335
GeneralSpecifications335
InspectionandAdjustment336
QUICKREFERENCEINDEX0
TABLEOFCONTENTS337
PRECAUTIONSANDPREPARATION338
Precautions338
SpecialServiceTools338
CommercialServiceTools338
CLUTCHSYSTEM339
ClutchPedal340
INSPECTIONANDADJUSTMENT341
AdjustingClutchPedal341
BleedingProcedure342
HYDRAULICCLUTCHCONTROL343
ClutchMasterCylinder343
OperatingCylinder344
ClutchDamper345
CLUTCHRELEASEMECHANISM346
CLUTCHDISCANDCLUTCHCOVER348
ClutchDisc348
ClutchCoverandFlywheel349
SERVICEDATAANDSPECIFICATIONS(SDS)350
GeneralSpecifications350
InspectionandAdjustment350
QUICKREFERENCEINDEX0
TABLEOFCONTENTS351
PREPARATION/PRECAUTIONS353
SpecialServiceTool353
Precautions353
VG30E354
ENGINEANDEMISSIONCONTROLOVERALLSYSTEM354
ECCSComponentPartsLocation354
SystemChart355
SystemDiagram356
VacuumHoseDrawing357
WiringDiagram358
CircuitDiagram360
ENGINEANDEMISSIONCONTROLPARTSDESCRIPTION361
EngineControlModule(ECM)-ECCSControlModule361
CamshaftPositionSensor(CMPS)361
MassAirFlowSensor(MAFS)361
EngineCoolantTemperatureSensor(ECTS)362
ThrottlePositionSensor(TPS)&Soft/HardClosedThrottlePosition(CTP)Switch362
FuelInjector363
PressureRegulator363
HeatedOxygenSensor(HO2S)363
FuelPump363
PowerTransistor&IgnitionCoil364
IdleAirControlValve(IACV)-AirRegulator364
IdleAirAdjusting(IAA)Unit364
IdleAirControlValve(IACV)-AuxiliaryAirControl(AAC)Valve364
PowerSteeringOilPressureSwitch365
VehicleSpeedSensor(VSS)365
KnockSensor(KS)365
ExhaustGasRecirculation(EGR)Valve365
EGRControl(EGRC)-BPTValve365
EGRControl(EGRC)-SolenoidValve366
FuelFilter366
CheckConnectorforECCSCheckerBox366
EGRTemperatureSensor366
ENGINEANDEMISSIONCONTROLSYSTEMDESCRIPTION367
MultiportFuelInjection(MFI)System367
DistributorIgnition(DI)System369
IdleAirControl(IAC)System370
FuelPump371
ExhaustGasRecirculation(EGR)System371
AccelerationCutControl372
Fail-safeSystem372
IDLESPEED/IGNITIONTIMING/IDLEMIXTURERATIOINSPECTION374
TROUBLEDIAGNOSES379
Contents379
MULTIPORTFUELINJECTIONSYSTEMINSPECTION489
ReleasingFuelPressure489
FuelPressureCheck489
InjectorRemoval489
EVAPORATIVEEMISSIONSYSTEM491
Description491
Inspection491
CRANKCASEEMISSIONCONTROLSYSTEM493
Description493
Inspection493
SERVICEDATAANDSPECIFICATIONS(SDS)494
GeneralSpecifications494
InspectionandAdjustment494
KA24E495
ENGINEEMISSIONCONTROLOVERALLSYSTEM495
ECCSComponentPartsLocation495
SystemDiagram497
SystemChart498
CircuitDiagram499
WiringDiagram500
ENGINEANDEMISSIONCONTROLPARTSDESCRIPTION502
EngineControlModule(ECM)-ECCSControlModule502
CamshaftPositionSensor(CMPS)502
MassAirFlowSensor(MAFS)502
EngineCoolantTemperatureSensor(ECTS)503
ThrottlePositionSensor(TPS)&SoftClosedThrottlePosition(CTP)Switch503
FuelInjector503
PressureRegulator504
OxygenSensor(O2S)504
FuelPump504
PowerTransistor505
IdleAirAdjusting(IAA)Unit505
IdleAirControlValve(IACV)-AuxiliaryAirControl(AAC)Valve505
PowerSteeringOilPressureSwitch505
VehicleSpeedSensor(VSS)505
ExhaustGasRecirculation(EGR)Valve506
EGRControl(EGRC)-BPTValve506
PulsedSeconaryAirInjection(PAIR)Valve(PAIRvalve)506
PulsedSecondaryAirInjection(PAIRC)SolenoidValve506
EGRControl(EGRC)-SolenoidValve506
SCVControlSolenoidValve506
FuelFilter507
CarbonCanister507
CheckConnectorforECCSCheckerBox507
EGRTemperataureSensor507
IntakeAirTemperatureSensor507
ENGINEANDEMISSIONCONTROLSYSTEMDESCRIPTION508
MultiportFuelInjection(MFI)System508
DistributorIgnition(DI)System510
IdleAirControl(IAC)System511
FuelPumpControl512
PulsedSeconaryAirInjection(PAIR)System512
ExhaustGasRecirculation(EGR)System513
SwirlControlValve(SCV)Control514
AccelerationCutControl515
Fail-safeSystem515
IDLESPEED/IGNITIONTIMING/IDLEMIXTURERATIOINSPECTION516
TROUBLEDIAGNOSES521
Contents521
MULTIPORTFUELINJECTIONSYSTEMINSPECTION636
ReleasingFuelPressure636
FuelPressureCheck636
InjectorRemovalandInstallation637
FastIdleInspectionandAdjustment637
EVAPORATIVEEMISSIONSYSTEM639
Description639
Inspection639
CRANKCASEEMISSIONCONTROLSYSTEM641
Description641
Inspection641
SERVICEDATAANDSPECIFICATIONS(SDS)642
GeneralSpecifications642
InspectionandAdjustment642
QUICKREFERENCEINDEX0
TABLEOFCONTENTS643
HARNESSCONNECTOR645
Description645
STANDARDIZEDRELAY646
NormalOpen,NormalClosedandMixedTypeRelays646
TypeofStandardizedRelays646
POWERSUPPLYROUTING648
Fuse648
FusibleLink648
WiringDiagram649
BATTERY650
HowtoHandleBattery650
ServiceDataandSpecifications(SDS)653
STARTINGSYSTEM654
WiringDiagram654
Construction656
ServiceDataandSpecifications(SDS)659
CHARGINGSYSTEM660
WiringDiagram660
Construction661
ServiceDataandSpecifications(SDS)662
COMBINATIONSWITCH663
Check663
Replacement664
HEADLAMP665
Operation(DaytimelightsystemforCanada)665
Schematic(DaytimelightsystemforCanada)665
WiringDiagram(DaytimelightsystemforCanada)666
WiringDiagram(ExceptforCanada)667
AimingAdjustment668
EXTERIORLAMP670
Clearance,License,TailandStopLamps/WiringDiagram670
Back-upLamp/WiringDiagram672
TurnSignalandHazardWarningLamps/WiringDiagram673
CombinationFlasherUnitCheck675
BulbSpecifications675
INTERIORLAMP676
Illumination/WiringDiagram676
InteriorLamp/WiringDiagram678
METERSANDGAUGES680
CombinationMeter680
WiringDiagram681
Inspection/FuelGaugeandWaterTemperatureGauge682
FuelTankGaugeUnitCheck683
ThermalTransmitterCheck683
OilPressureSwitchCheck683
VehicleSpeedSensorSignalCheck683
WARNINGLAMPSANDCHIME684
A/TIndicatorLamp/WiringDiagram684
WarningLamps/Schematic685
WarningLamps/WiringDiagram686
WarningChime/WiringDiagram688
DiodeCheck689
SeatBeltTimerCheck689
WarningChimeCheck689
WIPERANDWASHER690
FrontWiperandWasher/WiringDiagram690
RearWiperandWiper/WiringDiagram691
WindshieldWiperInstallation692
WasherNozzleAdjustment693
CheckValve693
WiperAmplifierCheck693
HORN,CIGARETTELIGHTER,CLOCK694
WiringDiagram694
REARWINDOWDEFOGGER695
WiringDiagram695
FilamentCheck697
FilamentRepair698
AUDIO699
Audio/WiringDiagram699
LocationofAntenna701
RadioFuseCheck701
AntennaTrimmerAdjustment701
ElementCheck702
ElementRepair702
AUTOMATICSPEEDCONTROLDEVICE(ASCD)703
Schematic703
WiringDiagram704
ASCDWireAdjustment705
TroubleDiagnoses706
LOCATIONOFELECTRICALUNITS717
EngineCompartment717
PassengerCompartment718
HARNESSLAYOUT721
Outline721
MainHarness722
InstrumentHarness727
EngineHarness728
EngineControlHarness730
BackDoorandRearWiperHarness732
ChassisandTailHarness733
FrontDoorHarness734
RearDoorHarness735
RoomLampHarness736
SUPERMULTIPLEJUNCTION(SMJ)0
QUICKREFERENCEINDEX0
TABLEOFCONTENTS737
PRECAUTIONS738
PartsRequiringAngularTightening738
LiquidGasketApplicationProcedure738
PREPARATION739
SpecialServiceTools739
CommercialServiceTools741
VG30E742
OUTERCOMPONENTPARTS742
COMPRESSIONPRESSURE744
MeasurementofCompressionPressure744
OILPAN745
Removal745
Installation747
TIMINGBELT748
Removal749
Inspection750
Installation751
OILSEALREPLACEMENT754
CYLINDERHEAD756
Removal757
Disassembly759
Inspection760
Assembly765
Installation766
ENGINEREMOVAL770
Removal771
CYLINDERBLOCK772
Disassembly773
Inspection773
Assembly779
SERVICEDATAANDSPECIFICATIONS(SDS)782
GeneralSpecifications782
InspectionandAdjustment782
KA24E788
OUTERCOMPONENTPARTS788
COMPRESSIONPRESSURE789
MeasurementofCompressionPressure789
OILPAN790
Removal790
Installation790
TIMINGCHAIN791
Removal791
Inspection792
Installation792
OILSEALREPLACEMENT795
CYLINDERHEAD797
Removal798
Disassembly800
Inspection800
Assembly805
Installation806
ENGINEREMOVAL809
CYLINDERBLOCK811
Disassembly812
Inspection812
Assembly818
SERVICEDATAANDSPECIFICATIONS(SDS)821
GeneralSpecifications821
InspectionandAdjustment821
QUICKREFERENCEINDEX0
TABLEOFCONTENTS828
PRECAUTIONSANDPREPARATION829
Precautions829
SpecialServiceTools829
CommercialServiceTools829
FRONTAXLEANDFRONTSUSPENSION830
ON-VEHICLESERVICE833
FrontAxleandFrontSuspensionParts833
FrontWheelBearing834
FrontWheelAlignment836
DriveShaft841
FRONTAXLE842
FRONTAXLE(4WD)845
Manual-lockFree-runningHub845
Auto-lockFree-runningHub846
FRONTAXLE852
WheelHubandRotorDisc852
KnuckleSpindle853
FRONTAXLE(4WD)856
DriveShaft856
FRONTSUSPENSION863
ShockAbsorber865
TorsionBarSpring865
StabilizerBar868
UpperLink869
TensionRodorCompressionRod870
LowerLink871
UpperBallJointandLowerBallJoint872
ADJUSTABLESHOCKABSORBER874
Description874
Schematic874
WiringDiagram875
TerminalCheck876
ShockAbsorberCheck877
SERVICEDATAANDSPECIFICATIONS(SDS)878
GeneralSpecifications878
InspectionandAdjustment879
QUICKREFERENCEINDEX0
TABLEOFCONTENTS881
ACCELERATORCONTROLSYSTEM882
AdjustingAcceleratorWire882
FUELSYSTEM883
EXHAUSTSYSTEM885
ModelSelection0
QUICKREFERENCEINDEX890
FOREWORD891
GI-GeneralInformation0
MA-Maintenance0
EM-EngineMechanical0
LC-EngineLubrication&CoolingSystems0
EF&EC-EngineFuel&EmissionControlSystem0
FE-AcceleratorControl,Fuel&ExhaustSystems0
CL-Clutch0
MT-ManualTransmission0
AT-AutomaticTransmission0
TF-Transfer0
PD-PropellerShaft&DifferentialCarrier0
FA-FrontAxle&FrontSuspension0
RA-RearAxle&RearSuspension0
BR-BrakeSystem0
ST-SteeringSystem0
BF-Body0
HA-Heater&AirConditioner0
EL-ElectricalSystem0
IDX-AlphabeticalIndex1
Foldout0
InchtoMetricConversion892
QuickReferenceChart893
QUICKREFERENCEINDEX0
TABLEOFCONTENTS894
PRECAUTIONS895
GeneralPrecautions895
PrecautionsforMultiportFuelInjectionSystemorECCSEngine896
PrecautionsforaThreeWayCatalyst897
EngineOils897
PrecautionsforFuel898
HOWTOUSETHISMANUAL899
HOWTOREADWIRINGDIAGRAM901
HOWTOFOLLOWFLOWCHARTINTROUBLEDIAGNOSES904
IDENTIFICATIONINFORMATION907
ModelVariation907
IdentificationNumber910
Dimensions913
Wheels&Tires914
LIFTINGPOINTSANDTOWTRUCKTOWING915
ScrewJack915
GarageJackandSafetyStand915
2-poleLift916
TowTruckTowing917
TIGHTENINGTORQUEOFSTANDARDBOLTS919
SAEJ1930TERMINOLOGYLIST920
SAEJ1930TerminologyList920
QUICKREFERENCEINDEX0
TABLEOFCONTENTS924
PRECAUTIONS925
Introduction925
Identification925
PrecautionsforWorkingwithHFC-134a(R-134a)926
GeneralRefrigerantPrecautions926
PrecautionsforRefrigerantConnection927
PrecautionsforServicingCompressor928
DESCRIPTION-OverallSystem929
Introduction-AutoAirConditioner929
Features-AutoAirConditioner929
ControlOperation930
ComponentLayout931
AirFlow932
DESCRIPTION-RefrigerationSystem933
RefrigerationCycle933
PREPARATION934
SpecialServiceTools934
HFC-134a(R-134a)ServiceToolsandEquipment935
PrecautionsforServiceEquipment937
SERVICEPROCEDURES939
HFC-134a(R-134a)ServiceProcedure939
RefrigerantLines941
CompressorMounting943
BeltTension943
FastIdleControlDevice(FICD)943
Condenser944
LUBRICATIONOIL-CheckingandAdjusting945
LubricationOil945
MaintenanceofOilQuantityinCompressor945
CheckingandAdjusting945
COMPRESSOR-ModelDVK-14C(ZEXELmake)947
CompressorClutch947
ThermalProtector949
DIAGNOSES-OverallSystem950
HowtoPerformTroubleDiagnosesforQuickandAccurateRepair950
OperationCheck951
PerformanceChart953
PerformanceTestDiagnoses954
TROUBLEDIAGNOSES-ManualAirConditioner959
TableofContents959
TROUBLEDIAGNOSES-AutoAirConditioner978
Contents978
SYSTEMDESCRIPTION-AutoAirConditioner1018
PushControlSystem1018
RemovalandInstallation1020
Overhaul-Pushcontrolunitassembly1020
OverviewofControlSystem1021
ControlSystemInputComponents1021
ControlSystemAutoAmplifier(Autoamp)1026
ControlSystemOutputComponents1029
SERVICEDATAANDSPECIFICATIONS(SDS)1039
GeneralSpecifications1039
InspectionandAdjustment1039
QUICKREFERENCEINDEX0
QUICKREFERENCEINDEX0
TABLEOFCONTENTS1050
PREPARATION/PRECAUTION1051
SpecialServiceTools1051
LiquidGasketApplicationProcedure1051
VG30E1052
ENGINELUBRICATIONSYSTEM1052
LubricationCircuit1052
OilPressureCheck1052
OilPump1053
ENGINECOOLINGSYSTEM1055
CoolingCircuit1055
SystemCheck1055
WaterPump1056
Thermostat1057
Radiator1057
CoolingFan1058
KA24E1059
ENGINELUBRICATIONSYSTEM1059
LubricationCircuit1059
OilPressureCheck1060
OilPump1060
ENGINECOOLINGSYSTEM1062
CoolingCircuit1062
SystemCheck1062
WaterPump1063
Thermostat1064
Radiator1065
CoolingFan1065
VG30E,KA24E1066
SERVICEDATAANDSPECIFICATIONS(SDS)1066
EngineLubricationSystem(VG30E)1066
EngineCoolingSystem(VG30E)1066
EngineLubricationSystem(KA24E)1066
EngingCoolingSystem(KA24E)1066
QUICKREFERENCEINDEX0
TABLEOFCONTENTS1067
PREPARATION1068
SpecialServiceTool1068
GENERALMAINTENANCE1069
PERIODICMAINTENANCE1071
Schedule11072
Schedule21073
RECOMMENDEDFLUIDSANDLUBRICANTS1074
FluidsandLubricants1074
SAEViscosityNumber1075
VG30E1076
ENGINEMAINTENANCE1076
CheckingDriveBelts1076
ChangingEngineCoolant1077
CheckingFuelLines1078
ChangingFuelFilter1078
ChangingAirCleanerFilter1078
ChangingEngineOil1079
ChangingOilFilter1079
ChangingSparkPlugs1080
CheckingVaporLines1080
KA24E1081
ENGINEMAINTENANCE1081
CheckingDriveBelts1081
ChangingEngineCoolant1081
CheckingFuelLines1082
ChangingFuelFilter1082
ChangingAirCleanerFilter1083
ChangingEngineOil1083
ChangingOilFilter1084
ChangingSparkPlugs1084
CheckingVaporLines1085
ChangingPulsedSecondaryAirInjection(PAIR)Valve(PAIRvalve)Filter1085
ChangingPositiveCrankcaseVentilation(PCV)Filter1085
CHASSISANDBODYMAINTENANCE1086
CheckingExhaustSystem1086
CheckingClutchFluidLevelandLeaks1086
CheckingM/TOil1086
ChangingM/TOil1086
CheckingWaterEntry-For4WDmodel1086
CheckingA/TFluid1086
ChangingA/TFluid1087
CheckingTransferOil1087
ChangingTransferOil1087
CheckingPropellerShaft1088
CheckingDifferentialGearOil1088
ChangingDifferentialGearOil1088
BalancingWhels1089
TireRotation1089
CheckingBrakeFluidLevelandLeaks1089
CheckingBrakeSystem1089
CheckingDiscBrake1089
CheckingDrumBrake1090
CheckingSteeringGearandLinkage1091
CheckingPowerSteeringFluidandLines1091
CheckingSteeringGearOilLevelandLeaks1091
LubricatingHoodLatches,LocksandHinges1092
CheckingSeatBelts,Buckles,Retractors,AnchorsandAdjusters1093
SERVICEDATAANDSPECIFICATIONS(SDS)1094
EngineMaintenance1094
ChassisandBodyMaintenance1094
QUICKREFERENCEINDEX0
TABLEOFCONTENTS1095
FS5W71C1096
PREPARATION1096
SpecialServiceTools1096
CommercialServiceTools1097
FS5R30A1098
PREPARATION1098
SpecialServiceTools1098
CommercialServiceTool1099
FS5W71C&FS5R30A1100
ON-VEHICLESERVICE1100
CheckingM/TOil1100
ReplacingRearOilseal-2WDModel1100
REMOVALANDINSTALLATION1101
Removal-2WDModel1101
Removal-4WDModel1101
Installation1102
FS5W71C1104
MAJOROVERHAUL1104
CaseComponents1104
GearComponents-2WDmodel1105
GearComponents-4WDmodel1106
ShiftControlComponents-2WDmodel1107
ShiftControlComponents-4WDmodel1108
DISASSEMBLY1109
CaseComponents1109
ShiftControlComponents1109
GearComponents1111
INSPECTION1113
ShiftControlComponents1113
GearComponents1113
ASSEMBLY1115
GearComponents1115
ShiftControlComponents1122
CaseComponents1123
FS5R30A1127
MAJOROVERHAUL1127
CaseComponents1127
GearComponents1128
ShiftControlComponents1130
DISASSEMBLY1131
CaseComponents1131
ShiftControlComponents1132
GearComponents1133
INSPECTION1137
ShiftControlComponents1137
GearComponents1137
ASSEMBLY1139
GearComponents1139
ShiftControlComponents1147
CaseComponents1148
FS5W71C&FS5R30A1150
SERVICEDATAANDSPECIFICATIONS(SDS)1150
GeneralSpecifications1150
FS5W71C1151
InspectionandAdjustment1151
FS5R30A1153
InspectionandAdjustment1153
QUICKREFERENCEINDEX0
TABLEOFCONTENTS1155
PREPARATION1157
SpecialServiceTools1157
PropellerShaft1162
PROPELLERSHAFT1162
On-vehicleService1164
RemovalandInstallation1164
Inspection1164
Disassembly1165
Assembly1166
Finaldrive1168
ON-VEHICLESERVICE1168
FrontOilSealReplacement(Frontfinaldrive)1168
FrontOilSealReplacement1168
RearCoverGasketReplacement1169
REMOVALANDINSTALLATION(Frontfinaldrive)1170
Removal1170
Installation1170
REMOVALANDINSTALLATION(Rearfinaldrive)1171
Removal1171
Installation1171
R180A1172
FRONTFINALDRIVE1172
DISASSEMBLY1173
Pre-inspection1173
FinalDriveHousing1173
DifferentialCase1175
ExtensionTubeandDifferentialSideShaft1176
INSPECTION1178
RingGearandDrivePinion1178
DifferentialCaseAssembly1178
Bearing1178
ADJUSTMENT1179
SideBearingPreload1179
PinionGearHeightandPinionBearingPreload1180
ToothContact1184
ASSEMBLY1185
ExtensionTubeandDifferentialSideShaft1185
DifferentialCase1185
FinalDriveHousing1186
R200A1190
FRONTFINALDRIVE1190
DISASSEMBLY1191
Pre-inspection1191
FinalDriveHousing1191
DifferentialCase1194
DifferentialSideShaft1194
INSPECTION1196
RingGearandDrivePinion1196
DifferentialCaseAssembly1196
Bearing1196
ADJUSTMENT1197
SideBearingPreload1197
PinionGearHeightandPinionBearingPreload1198
ToothContact1203
ASSEMBLY1204
DifferentialSideShaft1204
DifferentialCase1205
FinalDriveHousing1206
H190A1210
REARFINALDRIVE1210
DISASSEMBLY1211
Pre-inspection1211
DifferentialCarrier1211
DifferentialCase1213
INSPECTION1215
RingGearandDrivePinion1215
DifferentialCaseAssembly1215
Bearing1215
ADJUSTMENT1216
SideBearingPreload1216
PinionGearHeight1217
ToothContact1221
ASSEMBLY1222
DifferentialCase1222
DifferentialCarrier1223
H233B1227
REARFINALDRIVE1227
DISASSEMBLY1229
Pre-inspection1229
DifferentialCarrier1229
DifferentialCase1231
INSPECTION1233
RingGearandDrivePinion1233
DifferentialCaseAssembly1233
Bearing1233
LIMITEDSLIPDIFFERENTIAL1234
PreparationforDisassembly1234
Disassembly1234
Inspection1235
Adjustment1236
Assembly1237
ADJUSTMENT1240
PinionBearingPreloadandPinionGearHeight1240
ToothContact1244
ASSEMBLY1245
DifferentialCase-2-piniontype-1245
DifferentialCase-4-piniontype-1246
DifferentialCarrier1247
SERVICEDATAANDSPECIFICATIONS(SDS)1250
PropellerShaft1250
FinalDrive1252
QUICKREFERENCEINDEX0
TABLEOFCONTENTS1258
PRECAUTIONSANDPREPARATION1259
Precautions1259
SpecialServiceTools1259
CommercialServiceTools1259
REARAXLEANDREARSUSPENSION1260
ON-VEHICLESERVICE1261
RearAxleandRearSuspension1261
RearWheelBearing1261
REARAXLE1262
DrumBrakeType1262
DiskBrakeType1266
REARSUSPENSION1270
ShockAbsorber1271
LeafSpring1271
REARAXLEANDREARSUSPENSION1273
5-linkType1273
REARSUSPENSION1274
5-linkType1274
SERVICEDATAANDSPECIFICATIONS(SDS)1277
GeneralSpecifications1277
InspectionandAdjustment1278
QUICKREFERENCEINDEX0
TABLEOFCONTENTS1279
PRECAUTIONSANDPREPARATION1280
Precautions1280
SpecialServiceTools1280
CommercialServiceTools1281
ON-VEHICLESERVICE1282
SteeringSystem1282
CheckingSteeringWheelPlay1282
CheckingNeutralPositiononSteeringWheel1282
CheckingFrontWheelTurningAngle1283
CheckingandAdjustingDriveBelts1283
CheckingFluidLevel(Powersteering)1283
CheckingFluidLeakage(Powersteering)1283
BleedingHydraulicSystem(Powersteering)1284
CheckingSteeringWheelTurningTorque(Powersteering)1284
CheckingHydraulicSystem(PowerSteering)1285
STEERINGWHEELANDSTEERINGCOLUMN1286
RemovalandInstallation1286
DisassemblyandAssembly1287
Inspection1288
MANUALSTEERINGGEAR(Model:VB66K)1289
RemovalandInstallation1289
Disassembly1290
AssemblyandAdjustment1290
Inspection1293
POWERSTEERINGSYSTEM(Model:PB59K)1295
Description1295
POWERSTEERINGGEAR(Model:PB59K)1296
Removal1296
PowerSteeringGearComponents1296
InspectionandAdjustment1297
Disassembly1298
Assembly1299
POWERSTEERINGSYSTEM(Model:PB48S)1302
Description1302
POWERSTEERINGGEAR(Model:PB48S)1303
Removal1303
PowerSteeringGearComponent1303
InspectionandAdjustment1304
Disassembly1305
Assembly1307
POWERSTEERINGOILPUMP1310
DisassemblyandAssembly1310
Pre-disassemblyInspection1310
Disassembly1311
Inspection1311
Assembly1312
STEERINGLINKAGE1313
RemovalandInstallation1313
Disassembly1314
Inspection1315
SERVICEDATAANDSPECIFICATIONS(SDS)1316
GeneralSpecifications1316
InspectionandAdjustment1316
QUICKREFERENCEINDEX0
TABLEOFCONTENTS1319
PREPARATION1320
SpecialServiceTools1320
CommercialServiceTools1322
ON-VEHICLESERVICE1323
CheckingTransferOil1323
ReplacingOilSeal1323
REMOVALANDINSTALLATION1325
Removal1325
Installation1325
TRANSFERGEARCONTROL1326
MAJOROVERHAUL1327
CaseComponents1327
Gearcomponents1328
ShiftControlComponents1329
DISASSEMBLY1330
REPAIRFORCOMPONENTPARTS1334
Mainshaft1334
FrontDriveShaft1336
CounterGear1337
MainGear1337
FrontCase1339
FrontCaseCover1339
BearingRetainer1340
RearCase1340
ShiftControlComponents1341
ASSEMBLY1342
SERVICEDATAANDSPECIFICATIONS(SDS)1349
GeneralSpecifications1349
InspectionandAdjustment1349

DESCRIPTION:

Nissan Hardbody Truck D21 Series 1994 Service Manual – PDF DOWNLOAD

Service Notice:

• Before proceeding with disassembly, thoroughly clean the outside of the transmission. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter.
• Disassembly should be done in a clean work area. • Use line-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere with the operation of the transmission.
• When disassembling parts, place them in order in a parts rack so that they can be put back into the unit in their proper positions. All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or reassembly.
• Gaskets, seals and O-rings should be replaced any time the transmission is disassembled. It is very important to perform functional tests whenever they are indicated. The valve body contains precision parts and requires extreme care when parts are removed and serviced.
• Place removed parts in order on a parts rack so they can be put back in the valve body in the same positions and sequences. Care will also prevent springs and small parts from becoming scattered or lost.
• • Properly installed valves, sleeves, plugs, etc. will slide along their bores in the valve body under their own weight. Before assembly, apply a coat of recommended ATF to all parts. Petroleum jelly may be applied to O-rings and seals and used to hold small bearings and washers in place during reassembly.
• Do not use grease. • Extreme care should be taken to avoid dam- age to O-rings, seals and gaskets when assembling. • During overhaul, if excessive foreign material is found in the oil pan or clogging the strainer, flush or replace ATF cooler as required. Refer to TROUBLE DIAGNOSES Remarks.
• AT-19 After overhaul, refill the transmission with new ATF. Even when the drain plug is removed, the old A/T fluid will remain in the torque converter and the A/T fluid cooling system. Always follow the procedures under “Changing A/T Fluid” in the MA section when changing A/T fluid.

G.B 25/02/25