NISSAN X-TRAIL 2001 Service Repair Manual

CLUTCH RELEASE MECHANISM
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CLUTCH RELEASE MECHANISMPFP:30502
Removal and InstallationECS008BF
REMOVAL
1. Remove manual transaxle from the vehicle.
●Refer to MT-15, "Removal and Installation" .
2. Remove release bearing, holder spring, and withdrawal lever from inside the clutch housing.
3. Remove dust cover.
4. Remove retainer spring from the withdrawal lever.
INSPECTION AFTER REMOVAL
●If release bearing is seized, damaged, not properly centered or
does not rotate smoothly, replace it.
●If contact surface of the withdrawal lever is excessively worn,
replace it.
●If dust cover is cracked, replace it.
INSTALLATION
CAUTION:
●Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or quiver. Wipe off any grease oozing
from the parts.
●Be careful not to bring any grease into contact with the clutch disk facing, pressure plate surface,
or flywheel surface.
SCIA0328E
SCL733

CL-14
CLUTCH RELEASE MECHANISM
1. Following the instructions below, apply grease to the specified points.
CAUTION:
Wipe off any old grease, debris, or powdery residue left on the grease applying surfaces.
●Evenly apply a 1-mm thick coating of recommended grease to withdrawal lever and holder spring slid-
ing surface.
●Apply recommended grease to withdrawal lever ball pin contact surface and inner slots of the release
bearing. The grease surface should be level with the surrounding area.
●Apply a thin coat of recommended grease evenly to the release bearing sliding surface. Install release
bearing. Wipe off any excess grease that oozes from the parts and then remove release bearing.
2. Install in the reverse order of the removal.
SCL815

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CL-15
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CLUTCH DISC, CLUTCH COVER AND FLYWHEELPFP:30100
Removal and InstallationECS008BG
—QR engine models—
—YD engine models—
CAUTION:
Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface, or
flywheel surface.
REMOVAL
1. Remove manual transaxle from the vehicle.
●Refer to MT-15, "Removal and Installation" .
2. Loosen clutch cover mounting bolts evenly. Remove clutch cover and clutch disc.
SCIA0329E
SCIA0813E

CL-16
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc
●Measure circumferential runout relative to the clutch disc center
spline. If it is outside the specification, replace the clutch disc.
●Measure clutch disc spline and input shaft spline backlash at the
circumference of the disc. If outside the specification, replace.
●Using calipers, measure the depth to the clutch disc facing rivet
heads. If it exceeds the allowable wear limit, replace the clutch
disc.
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using a diaphragm adjusting wrench (special service tool).
●Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
NOTE:
●Worn thrust ring will generate a beating noise when tapped at
the rivet with a hammer.
●Broken thrust ring will make a clinking sound when cover is
shaken up and down.
●If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.
Flywheel Runout
Using a dial gauge, measure runout at the flywheel clutch contact
surface. If runout is outside the specification, replace the flywheel. If
a trace of burn or discoloration is found on the surface, repair it with
sandpaper.
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch cover mounting hole). Runout limit/diameter of the area to be measured:
1.0 mm (0.039 in) or less/230 mm(9.06 in) dia.
Maximum allowable spline backlash:
1.0 mm (0.039 in)
SCL221
Facing wear limit (depth to the rivet head):
0.3 mm (0.012 in)
SCL229
Tolerance for diaphragm spring lever unevenness:
0.7 mm (0.028 in)
SCL466-C
Allowable flywheel runout:
Vehicles with QR engine models:
Refer to EM-97, "
Flywheel Deflection" .
Vehicles with YD engine models:
Refer to EM-218, "
Flywheel Deflection" .AEM100

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
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INSTALLATION
1. Apply recommended grease to clutch disc and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or quiver. Wipe off any grease oozing
from the parts.
2. Install clutch disc and clutch cover. Pre-tighten mounting bolts
and install clutch aligning bar.
3. Tighten clutch cover attaching bolts evenly in two steps in the
order shown in the figure.
4. Install manual transaxle.
●Refer to MT-15, "Removal and Installation" .
Engine type Tool number
QR engine KV30100100
YD engine ST20630000
First step:
: 10 - 19 N·m (1.0 - 2.0 kg-m, 8 - 14 ft-lb)
Final step:
QR engine models
: 35 - 44 N·m (3.5 - 4.5 kg-m, 26 - 32 ft-lb)
YD engine models
: 22 - 29 N·m (2.2 - 3.0 kg-m, 16 - 21 ft-lb)
SCIA0909E

CL-18
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Clutch Control SystemECS008BH
Clutch Master CylinderECS008BI
Clutch Operating CylinderECS008BJ
Clutch DiscECS008BK
Clutch CoverECS008BL
Clutch PedalECS001WL
Type of clutch controlHydraulic
Inner diameter15.87 mm (5/8 in)
Inner diameter19.05 mm (3/4 in)
Engine type QR20DE QR25DE YD22DDTi
Model240
Facing size
(outer dia. x inner dia. x thickness)240 mm x 160 mm x 3.5 mm (9.45 in x 6.30 in x 0.138 in)
Thickness of disc assembly with load 7.90 - 8.30 mm (0.3110 - 0.3268 in) with 5,688 N (580 kg, 1,279lb)
Wear limit of facing surface to rivet head 0.3 mm (0.012 in)
Runout limit/diameter of the area to be
measured1.0 mm (0.039 in) or less/ 230 mm (9.06 in) dia.
Maximum spline backlash
(at outer edge of disc)1.0 mm (0.039 in)
Engine type QR20DE QR25DE YD22DDTi
Model 240<0003000300030003000300030003000300030003000300030003000300030003000300030003000300030003000300030003000300030003000300030003000300030003000300030003000300030003000300030003000300030003000300030003000300
030003000300030003[ 250
Set-load 4,903 N (500 kg, 1,103 lb) 5,884 N (600 kg, 1,323 lb) 6,865 N (700 kg, 1,544 lb)
Diaphragm spring lever height 37.0 - 39.0 mm (1.457 - 1.535 in)
Uneven limit diaphragm spring toe height 0.7 mm (0.028 in) or less
Engine type QR20DE QR25DE YD22DDTi
Pedal height RHD models 171 - 181mm (6.73 - 7.13 in)
LHD models 167 - 177mm (6.57 - 6.97 in)
Pedal height at
clutch disengagement RHD models 85 mm (3.35 in) or more
LHD models 85 mm (3.35 in) or more
Pedal free play [Looseness at clevis pin] 9 - 16 mm (0.35 - 0.63 in) [1.0 - 3.0 mm (0.039 - 0.118 in)]
Clearance between clutch switch
thread end and stopper rubber 0.1 - 1.0 mm (0.004 - 0.039 in)

MT-1
MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
CONTENTS
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SECTION
A
B
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MANUAL TRANSAXLE
PRECAUTIONS .......................................................... 3
Caution ..................................................................... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 6
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 7
NVH Troubleshooting Chart ..................................... 7
MANUAL TRANSAXLE ......................................... 7
DESCRIPTION ............................................................ 8
Cross-Sectional View ............................................... 8
DOUBLE-CONE SYNCHRONIZER ...................... 9
REVERSE GEAR NOISE PREVENTION FUNC-
TION (SYNCHRONIZING METHOD) ................... 9
M/T OIL ..................................................................... 10
Changing M/T Oil ................................................... 10
DRAINING ........................................................... 10
FILLING ............................................................... 10
Checking M/T Oil .................................................... 10
OIL LEAKAGE AND OIL LEVEL ......................... 10
SIDE OIL SEAL .........................................................11
Removal and Installation ......................................... 11
REMOVAL ............................................................ 11
INSTALLATION .................................................... 11
POSITION SWITCH .................................................. 12
Checking ................................................................ 12
BACK-UP LAMP SWITCH .................................. 12
PARK/NEUTRAL POSITION SWITCH ............... 12
CONTROL LINKAGE ............................................... 13
Removal and Installation of Control Device and
Cable ...................................................................... 13
AIR BREATHER HOSE ............................................ 14
Removal and Installation ........................................ 14
TRANSAXLE ASSEMBLY ........................................ 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
Component Parts (RS5F51A) ................................ 17CASE AND HOUSING COMPONENTS .............. 17
GEAR COMPONENTS ....................................... 18
SHIFT CONTROL COMPONENTS ..................... 20
FINAL DRIVE COMPONENTS ........................... 21
Component Parts (RS6F51A) ................................. 22
CASE AND HOUSING COMPONENTS .............. 22
GEAR COMPONENTS ....................................... 23
SHIFT CONTROL COMPONENTS ..................... 25
FINAL DRIVE COMPONENTS ........................... 26
Disassembly and Assembly (RS5F51A) ................. 26
DISASSEMBLY ................................................... 26
ASSEMBLY ......................................................... 30
Disassembly and Assembly (RS6F51A) ................. 35
DISASSEMBLY ................................................... 35
ASSEMBLY ......................................................... 39
Adjustment (RS5F51A) ........................................... 45
INPUT SHAFT END PLAY .................................. 45
MAINSHAFT END PLAY ..................................... 46
DIFFERENTIAL SIDE BEARING PRELOAD ...... 47
REVERSE IDLER GEAR END PLAY .................. 48
Adjustment (RS6F51A) ........................................... 49
INPUT SHAFT END PLAY .................................. 49
MAINSHAFT END PLAY ..................................... 50
DIFFERENTIAL SIDE BEARING PRELOAD ...... 51
REVERSE IDLER GEAR END PLAY .................. 52
INPUT SHAFT AND GEARS .................................... 54
Assembly and Disassembly (RS5F51A) ................. 54
DISASSEMBLY ................................................... 54
INSPECTION AFTER DISASSEMBLY ................ 55
ASSEMBLY ......................................................... 57
Assembly and Disassembly (RS6F51A) ................. 61
DISASSEMBLY ................................................... 61
INSPECTION AFTER DISASSEMBLY ................ 62
ASSEMBLY ......................................................... 64
MAINSHAFT AND GEARS ....................................... 68
Assembly and Disassembly (RS5F51A) ................. 68
DISASSEMBLY ................................................... 68
INSPECTION AFTER DISASSEMBLY ................ 69

MT-2
ASSEMBLY ......................................................... 71
Assembly and Disassembly (RS6F51A) ................. 76
DISASSEMBLY ................................................... 76
INSPECTION AFTER DISASSEMBLY ................ 77
ASSEMBLY ......................................................... 79
REVERSE IDLER SHAFT AND GEARS .................. 84
Assembly and Disassembly (RS5F51A) ................. 84
DISASSEMBLY ................................................... 84
INSPECTION AFTER DISASSEMBLY ................ 84
ASSEMBLY ......................................................... 85
Assembly and Disassembly (RS6F51A) ................. 85
DISASSEMBLY ................................................... 85
INSPECTION AFTER DISASSEMBLY ................ 85
ASSEMBLY ......................................................... 86
FINAL DRIVE ............................................................ 87
Assembly and Disassembly (RS5F51A) ................. 87
PRE-INSPECTION .............................................. 87
DISASSEMBLY ................................................... 87
INSPECTION AFTER DISASSEMBLY ................ 88
ASSEMBLY ......................................................... 88
Assembly and Disassembly (RS6F51A) ................. 90
PRE-INSPECTION .............................................. 90
DISASSEMBLY ................................................... 91
INSPECTION AFTER DISASSEMBLY ................ 92
ASSEMBLY ......................................................... 92
SHIFT CONTROL ...................................................... 95
Inspection (RS5F51A) ............................................ 95
SHIFT FORK ....................................................... 95
Inspection (RS6F51A) ............................................ 96
SHIFT FORK ....................................................... 96SERVICE DATA AND SPECIFICATIONS (SDS) ...... 97
General Specifications ......................................... ... 97
TRANSAXLE ........................................................ 97
FINAL GEAR ........................................................ 98
Gear End Play ......................................................... 98
Clearance Between Baulk Ring and Gear .............. 98
3RD,4TH,5TH,6TH & REVERSE BAULK RING ... 98
1ST AND 2ND DOUBLE BAULK RING ............... 98
Available Snap Rings ........................................... ... 99
INPUT SHAFT SPACER ...................................... 99
6TH BUSHING ..................................................... 99
5TH MAIN GEAR ................................................. 99
Available C-Rings ................................................... 99
MAINSHAFT C-RING .......................................... 99
Available Thrust Washer .......................................100
INPUT SHAFT THRUST WASHER ...................100
DIFFERENTIAL SIDE GEAR THRUST WASHER
.100
Available Adjusting Shims .....................................100
MAINSHAFT ADJUSTING SHIM .......................100
INPUT SHAFT REAR BEARING ADJUSTING
SHIM ..................................................................101
MAINSHAFT REAR BEARING ADJUSTING
SHIM ..................................................................101
REVERSE IDLER GEAR ADJUSTING SHIM ....101
6TH MAIN GEAR ADJUSTING SHIM ................101
Available Shims ....................................................102
BEARING PRELOAD .........................................102
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM(S) .............................................................102

PRECAUTIONS
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PRECAUTIONSPFP:00001
CautionECS008BM
●Do not reuse transaxle oil, once it has been drained.
●Check oil level or replace oil with vehicle on level ground.
●During removal or installation, keep inside of transaxle clear of dust or dirt.
●Check for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to.
●In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
●Be careful not to damage sliding surfaces and mating surfaces.

MT-4
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsECS008BN
Tool name
Tool numberDescription
Puller
KV381054S0
●Side bearing outer race removal
●Mainshaft front bearing removal
Drift
ST35321000
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
●Input shaft oil seal installation
●Reverse main gear installation
●1st bushing installation
●1st-2nd synchronizer hub installation
●2nd bushing installation
●3rd main gear installation
●Differential side bearing removal
Drift
ST30720000
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
●Differential oil seal installation
●Differential side bearing outer race
installation
●Mainshaft rear bearing installation
●Differential side bearing installation
Drift
ST33200000
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
●Mainshaft front bearing installation
●6th bushing installation (RS6F51A)
●4th main gear installation
●5th main gear installation
●6th main gear installation (RS6F51A)
Drift
KV40105320
a: 88 mm (3.46 in) dia.
●Differential side bearing outer race
installation
Drift
ST33061000
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
●Bore plug installation
●Differential side bearing removal
ZZA0601D
ZZA1000D
ZZA0811D
ZZA1002D
ZZA0898D
ZZA1000D