NISSAN X-TRAIL 2003 Service Repair Manual

SERVICE DATA AND SPECIFICATIONS (SDS)CL-17
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Clutch Control SystemECS008BH
Clutch Master CylinderECS008BI
Clutch Operating CylinderECS008BJ
Clutch DiscECS008BK
Clutch CoverECS008BL
Type of clutch control Hydraulic
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) 7.70 - 8.10 mm (0.303 -
0.319 in) with 7,845N (800
kg, 1,764 lb)
Wear limit of facing surface to rivet head 0.3 mm (0.012 in)
Runout limit/diameter of the area to be
measured 1.0 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 \
240 250
Set-load
4,903 N (500 kg, 1,103 lb) 5,884 N (600 kg, 1,323 lb) 7,600 N (755 kg, 1,708 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

CL-18
SERVICE DATA AND SPECIFICATIONS (SDS)

MT-1
MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
CONTENTS
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SECTION
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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 ................................................ 8
NVH Troubleshooting Chart ..................................... 8
MANUAL TRANSAXLE ......................................... 8
DESCRIPTION ............................................................ 9
Cross-Sectional View ............................................... 9
DOUBLE-CONE SYNCHRONIZER .................... 10
TRIPLE-CONE SYNCHRONIZER ...................... 10
REVERSE GEAR NOISE PREVENTION FUNC-
TION (SYNCHRONIZING METHOD) ................. 10
M/T OIL ......................................................................11
Changing M/T Oil .................................................... 11
DRAINING ............................................................ 11
FILLING ................................................................ 11
Checking M/T Oil ..................................................... 11
OIL LEAKAGE AND OIL LEVEL .......................... 11
SIDE OIL SEAL ........................................................ 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
POSITION SWITCH .................................................. 13
Checking ................................................................ 13
BACK-UP LAMP SWITCH .................................. 13
PARK/NEUTRAL POSITION SWITCH ............... 13
CONTROL LINKAGE ............................................... 14
Components of Control Device and Cable ............. 14
Removal and Installation ........................................ 15
AIR BREATHER HOSE ............................................ 16
Removal and Installation ........................................ 16
TRANSAXLE ASSEMBLY ........................................ 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 18
Component Parts (RS5F51A) ................................ 19CASE AND HOUSING COMPONENTS .............. 19
GEAR COMPONENTS ....................................... 20
SHIFT CONTROL COMPONENTS ..................... 22
FINAL DRIVE COMPONENTS ........................... 23
Component Parts (RS6F51A) ................................. 24
CASE AND HOUSING COMPONENTS .............. 24
GEAR COMPONENTS ....................................... 25
SHIFT CONTROL COMPONENTS ..................... 27
FINAL DRIVE COMPONENTS ........................... 28
Disassembly and Assembly (RS5F51A) ................. 28
DISASSEMBLY ................................................... 28
ASSEMBLY ......................................................... 32
Disassembly and Assembly (RS6F51A) ................. 37
DISASSEMBLY ................................................... 37
ASSEMBLY ......................................................... 41
Adjustment (RS5F51A) ........................................... 47
INPUT SHAFT END PLAY .................................. 47
MAINSHAFT END PLAY ..................................... 48
DIFFERENTIAL SIDE BEARING PRELOAD ...... 48
REVERSE IDLER GEAR END PLAY .................. 49
Adjustment (RS6F51A) ........................................... 50
INPUT SHAFT END PLAY .................................. 50
MAINSHAFT END PLAY ..................................... 51
DIFFERENTIAL SIDE BEARING PRELOAD ...... 52
REVERSE IDLER GEAR END PLAY .................. 53
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 ......................................................... 72
Assembly and Disassembly (RS6F51A) ................. 76
DISASSEMBLY ................................................... 76
INSPECTION AFTER DISASSEMBLY ................ 77
ASSEMBLY ......................................................... 80
REVERSE IDLER SHAFT AND GEARS .................. 85
Assembly and Disassembly (RS5F51A) ................. 85
DISASSEMBLY ................................................... 85
INSPECTION AFTER DISASSEMBLY ................ 85
ASSEMBLY ......................................................... 86
Assembly and Disassembly (RS6F51A) ................. 86
DISASSEMBLY ................................................... 86
INSPECTION AFTER DISASSEMBLY ................ 87
ASSEMBLY ......................................................... 87
FINAL DRIVE ............................................................ 89
Assembly and Disassembly (RS5F51A) ................. 89
PRE-INSPECTION .............................................. 89
DISASSEMBLY ................................................... 89
INSPECTION AFTER DISASSEMBLY ................ 90
ASSEMBLY ......................................................... 90
Assembly and Disassembly (RS6F51A) ................. 92
PRE-INSPECTION .............................................. 92
DISASSEMBLY ................................................... 92
INSPECTION AFTER DISASSEMBLY ................ 93
ASSEMBLY ......................................................... 94
SHIFT CONTROL ...................................................... 96
Inspection (RS5F51A) ............................................ 96
SHIFT FORK ....................................................... 96
Inspection (RS6F51A) ............................................ 97
SHIFT FORK ....................................................... 97SERVICE DATA AND SPECIFICATIONS (SDS) ...... 98
General Specifications ............................................ 98
TRANSAXLE ........................................................ 98
FINAL GEAR ........................................................ 99
End Play .................................................................. 99
Baulk Ring Clearance ............................................. 99
Available Snap Rings ............................................100
INPUT SHAFT BEARING SPACER ...................100
6TH INPUT GEAR BUSHING ............................100
5TH MAIN GEAR ...............................................100
Available C-Rings .................................................100
MAINSHAFT C-RING ........................................100
Available Thrust Washer .......................................101
INPUT SHAFT THRUST WASHER ...................101
DIFFERENTIAL SIDE GEAR THRUST WASHER
.101
Available Adjusting Shims .....................................101
4TH MAIN GEAR ADJUSTING SHIM ................101
INPUT SHAFT REAR BEARING ADJUSTING
SHIM ..................................................................102
MAINSHAFT REAR BEARING ADJUSTING
SHIM ..................................................................102
REVERSE IDLER GEAR ADJUSTING SHIM ....102
6TH MAIN GEAR ADJUSTING SHIM ................102
Available Shims ....................................................103
BEARING PRELOAD .........................................103
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM(S) .............................................................103

PRECAUTIONS
MT-3
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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

PREPARATIONPFP:00002
Special Service ToolsECS008BN
Tool number
Tool nameDescription
KV381054S0
Puller

Differential side bearing outer race removal

Mainshaft front bearing removal
ST35321000
Drift
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.

Input shaft oil seal installation

Reverse main gear installation

1st main gear bushing installation

1st-2nd synchronizer hub assembly
installation

2nd main gear bushing installation

3rd main gear installation

Differential side bearing (clutch housing
side) removal
ST30720000
Drift
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
ST33200000
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.

Mainshaft front bearing installation

6th input gear bushing installation
(RS6F51A)

4th main gear installation

5th main gear installation

6th main gear installation (RS6F51A)
KV40105320
Drift
a: 88 mm (3.46 in) dia.Differential side bearing outer race installation
ST33061000
Drift
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.

Bore plug installation

Differential side bearing (transaxle case
side) removal
ZZA0601D
ZZA1000D
ZZA0811D
ZZA1002D
ZZA0898D
ZZA1000D

PREPARATION
MT-5
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ST33052000
Drift
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.
Welch plug installation

Input shaft rear bearing removal

Input shaft bearing spacer and 5th stopper
removal (RS5F51A)

5th input gear bushing, thrust washer, 4th
input gear, 4th gear bushing, 3rd-4th
synchronizer hub assembly and 3rd input
gear removal

Input shaft front bearing installation

6th input gear and 6th input gear bushing
removal (RS6F51A)

Mainshaft rear bearing removal

4th main gear and 5th main gear removal

6th main gear removal (RS6F51A)
KV40105020
Drift
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in)

5th input gear and 5th synchronizer hub
assembly removal

3rd main gear, 2nd main gear, 2nd main
gear bushing, 1st-2nd synchronizer hub
assembly, 1st main gear, reverse main gear
and 1st main gear bushing removal
KV40105710
Press stand
a: 46 mm (1.81 in) dia.
b: 41 mm (1.61 in)

3rd-4th synchronizer hub assembly
installation

4th input gear bushing installation

5th input gear bushing installation

5th synchronizer hub assembly installation
(RS5F51A)

5th-6th synchronizer hub assembly
installation (RS6F51A)

2nd main gear bushing installation

3rd main gear installation
ST38220000
Press stand
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in)

Reverse main gear installation

1st main gear bushing installation

1st-2nd synchronizer hub assembly
installation
ST30032000
Drift
a: 80 mm (3.15 in) dia.
b: 38 mm (1.50 in) dia.
c: 31 mm (1.22 in) dia.

5th stopper and input shaft bearing spacer
installation (RS5F51A)

Input shaft front bearing installation
ST30901000
Drift
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.

Input shaft rear bearing installation

4th main gear installation

5th main gear installation

6th main gear installation (RS6F51A)

Mainshaft rear bearing installation Tool number
Tool nameDescription
ZZA1023D
ZZA1133D
ZZA1058D
ZZA1058D
ZZA0978D
ZZA0978D

MT-6
PREPARATION

Commercial Service ToolsECS008BO
ST30031000
PullerMeasuring wear of inner baulk ring
KV40101630
Drift
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.Reverse main gear installation
KV38102510
Drift
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.

1st main gear bushing installation

1st-2nd synchronizer hub assembly
installation

Differential side bearing (transaxle case
side) installation
KV40104830
Drift
a: 70 mm (2.76 in) dia.
b: 63.5 mm (2.500 in) dia.Differential side bearing (clutch housing side)
installation
ST15243000
Drift
a: φ 30mmMeasuring end play of side gear Tool number
Tool nameDescription
ZZA0537D
ZZA1003D
ZZA0838D
ZZA0936D
SCIA1088J
Tool nameDescription
PullerEach bearing, gear and bushing removal
ZZA0537D

PREPARATION
MT-7
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PullerEach bearing, gear and bushing removal
Pin punch
Tip diameter: 4.5 mm (0.177 in) dia.Each retaining pin removal and installation Tool nameDescription
NT077
ZZA0815D

MT-8
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartECS008BP
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
MANUAL TRANSAXLE
Reference pageMA-37
MT-19
(RS5F51A), MT-24
(RS6F51A)
MT-19
(RS5F51A), MT-24
(RS6F51A)
MT-19
(RS5F51A), MT-24
(RS6F51A)
MT-14
MT-22
(RS5F51A), MT-27
(RS6F51A)
MT-22
(RS5F51A), MT-27
(RS6F51A)
MT-20
(RS5F51A), MT-25
(RS6F51A)
MT-20
(RS5F51A), MT-25
(RS6F51A)
MT-20
(RS5F51A), MT-25
(RS6F51A)
MT-20
(RS5F51A), MT-25
(RS6F51A)
SUSPECTED PARTS
(Possible cause)
OIL (Oil level is low.)
OIL (Wrong oil.)
OIL (Oil level is high.)
GASKET (Damaged)
OIL SEAL (Worn or damaged)
O-RING (Worn or damaged)
SHIFT CONTROL LINKAGE (Worn)
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
SHIFT FORK (Worn)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
BAULK RING (Worn or damaged)
INSERT SPRING (Damaged)
SymptomsNoise 1 2 3 3
Oil leakage 31222
Hard to shift or will not shift 1 1 2 3 3
Jumps out of gear 1 2 3 3