NISSAN X-TRAIL 2003 Service Repair Manual

TRANSFER ASSEMBLY
TF-65
C
E
F
G
H
I
J
K
L
MA
B
TF

3. Using a drift and replacer, remove the gear ring bearing inner
race (adapter case side) on the gear ring.
4. Using a drift and puller, remove the gear ring bearing inner race
(transfer case side) on the gear ring.
5. Remove the drive gear mounting bolts.
6. Using a plastic hammer, tap the drive gear to remove the drive
gear from the gear ring.
7. Using a puller, remove the gear ring oil seal from the gear ring.
Transfer Case
1. Remove the pinion sleeve assembly. Refer to TF-62, "Pinion Sleeve Assembly" .
2. Remove the adapter case. Refer to TF-63, "
Adapter Case" .
3. Remove the drive gear assembly from the transfer case. Refer to TF-64, "
Drive Gear Assembly" . Tool number : ST33200000
SDIA1560E
Tool number : ST33061000
SDIA1561E
SDIA1807J
Tool number : KV381054S0
SDIA1808E

TF-66
TRANSFER ASSEMBLY

4. Using a flat-bladed screwdriver, remove the transfer case oil
seal.
CAUTION:
Be careful not to damage the transfer case.
5. Remove the oil defense.
6. Using a brass rod, tap the gear ring bearing adjusting shim
evenly from the 2 cutouts on the transfer case to remove the
gear ring bearing adjusting shim and gear ring bearing outer
race.
7. Remove the filler plug, plug and breather tube.
INSPECTION AFTER DISASSEMBLY
Gears

Check the gear faces and shaft for wear, cracks, damage, and seizure.
CAUTION:
If a malfunction is detected on the drive gear or drive pinion, replace the drive gear and drive pinion as
a set.
Bearings

Check for seizure, peeling, wear, corrosion, sticking/abnormal noise/roughness in hand turning, and other
damage.
CAUTION:
When replacing the bearing, always replace the inner race and outer race as a pair.
Washers and Shims

Check for seizure, damage, and unusual wear.
Oil Seals

Discard old oil seals, replace with new ones.

If wear, deterioration of adherence (sealing force of lips), or damage is detected on the lips, replace them.
TFB0297D
SDIA1533E
SDIA0536E

TRANSFER ASSEMBLY
TF-67
C
E
F
G
H
I
J
K
L
MA
B
TF

SELECTING ADJUSTING SHIMS
Measurement points
Gear Ring Bearing Adjusting Shim (Transfer Case Side)
1. Measure the points F, H, I, R and U shown in the measurement points.
2. Convert the values F, H, I, R and U according to the standards below.
3. Check dimension Z on the drive gear side face.
NOTE:
Dimension Z indicates the difference between the optimum engagement and the standard dimensions in
increments of 0.01mm (0.0004 in) written on the drive gear side face.
4. Use the formula below to calculate gear ring bearing adjusting shim (transfer case side) thickness T
1 .
5. Select the gear ring bearing adjusting shim (transfer case side).

For information on selecting an adjusting shim, refer to TF-74, "Gear ring Bearing Adjusting Shim
(Transfer Case Side)" .
CAUTION:

Only one adjusting shim can be selected.

If no adjusting shim with the calculated value is available, select the thicker and closest one.
Gear Ring Bearing Adjusting Shim (Adapter Case Side)
1. Measure the points F, H, J, K, U and V shown in the measurement points.
2. Convert the values F, H, J, K, U and V according to the standards below.
SDIA1179E
F: Value obtained by subtracting 163.00 mm (6.42 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
H: Value obtained by subtracting 83.00 mm (3.27 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
I: Value obtained by subtracting 131.90 mm (5.19 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
R: Value obtained by subtracting 17.00 mm (0.67 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
U: Value obtained by subtracting 89.50 mm (3.524 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
T
1 = (I - F + H + Z - U - R) × 0.01 mm (0.0004 in) + 1.49 mm (0.0587 in)

TF-68
TRANSFER ASSEMBLY

3. Check dimension Z on the drive gear side face.
NOTE:
Dimension Z indicates the difference between the optimum engagement and the standard dimensions in
increments of 0.01mm (0.0004 in) written on the drive gear side face.
4. Use the formula below to calculate gear ring bearing adjusting shim (adapter case side) thickness T
2 .
5. Select the gear ring bearing adjusting shim (adapter case side).

For information on selecting an adjusting shim, refer to TF-75, "Gear ring Bearing Adjusting Shim
(Adapter Case Side)" .
CAUTION:

Only one adjusting shim can be selected.

If no adjusting shim with the calculated value is available, select the thicker and closest one.
Pinion Sleeve Shim
1. Measure the points L, N and Q shown in the measurement points.
2. Check the dimension S written on the gear end of the drive pinion.
NOTE:
The dimension S indicates the difference between the optimum engagement and the standard dimensions
in increments of 0.01 mm (0.0004 in) written on the gear end of the drive pinion.
3. Use the formula below to calculate pinion sleeve shim thickness T
3 .
4. Select the pinion sleeve shim.

For information on selecting a pinion sleeve shim, refer to TF-75, "Pinion Sleeve Shim" .
CAUTION:
Only one pinion sleeve shim can be selected.
ASSEMBLY
Transfer Case
1. Select the gear ring bearing adjusting shim (transfer case side). Refer to TF-67, "SELECTING ADJUST-
ING SHIMS" . F: Value obtained by subtracting 163.00 mm (6.42 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
H: Value obtained by subtracting 83.00 mm (3.27 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
J: Value obtained by subtracting 109.50 mm (4.31 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
K: Value obtained by subtracting 14.40 mm (0.5669 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
U: Value obtained by subtracting 89.50 mm (3.524 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
V: Value obtained by subtracting 17.00 mm (0.67 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
T
2 = (K + F - H - Z + U - J - V) × 0.01 mm (0.0004 in) + 1.49 mm (0.0587 in)
T
3 = [74.6 mm (2.937 in) + S] + N + Q - L

TRANSFER ASSEMBLY
TF-69
C
E
F
G
H
I
J
K
L
MA
B
TF

2. Using a drift, install the selected gear ring bearing adjusting
shim (transfer case side) and gear ring bearing outer race
(transfer case side).
3. Install the oil defense, and tighten the mounting bolts to the
specified torque. Refer to TF-57, "
COMPONENTS" . The clear-
ance between the oil defense and transfer case (dimension A)
should be the following.
CAUTION:
Do not reuse the mounting bolts.
4. Using a drift, drive the transfer case oil seal until it becomes
flush with the case end.
CAUTION:

When checking the total preload torque, measure it with-
out the oil seal, then install the oil seal.

Do not reuse the oil seal.

Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of the oil seal.
5. Apply recommended sealant to filler plug and plug before install-
ing them to the transfer case. Refer to TF-57, "
COMPONENTS"
.
6. Apply recommended sealant to breather tube and install it to the transfer case.
7. Install the drive gear assembly. Refer to TF-69, "
Drive Gear Assembly" .
8. Install the adapter case. Refer to TF-70, "
Adapter Case" .
9. Install the pinion sleeve assembly. Refer to TF-72, "
Pinion Sleeve Assembly" .
10. Check backlash, preload torque, tooth contact, and companion flange runout. Refer to TF-58, "
ASSEM-
BLY INSPECTION" .
CAUTION:
Measure the total preload torque without the oil seal.
Drive Gear Assembly
1. Using a drift, drive the gear ring oil seal into the gear ring.
CAUTION:

Do not reuse the oil seal.

Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of the oil seal.

The oil seal back position after the installation shall be
56.5 mm (2.22 in) from the gear ring end.Tool number A: ST30720000
B: KV40101840
SDIA1563E
Clearance between oil defense and transfer case
Dimension A : 1.0 - 3.5 mm (0.04 - 0.138 in)
TFB0283D
Tool number : ST30720000
SDIA1564E
Tool number : ST33230000
SDIA1809E

TF-70
TRANSFER ASSEMBLY

2. Apply recommended thread locking sealant into the thread hole
for the drive gear.
a. Completely clean and degrease the drive gear back face, thread
holes, and drive gear mounting bolts.
b. Apply recommended thread locking sealant onto the first and
second threads under the thread hole chamfering of the drive
gear on 3 or more different points.
3. Install the drive gear to gear ring, and apply anti-corrosive oil
onto threads and seats on the mounting bolts, and then tighten
to the specified torque. Refer to TF-57, "
COMPONENTS" .
CAUTION:

Temporary installation before tightening the bolts through to the completion of the tightening
should be within 90 seconds.

If the thread locking sealant is applied aside, quickly wipe it off.
4. Apply gear oil to gear ring bearing inner race (transfer case
side). Using a drift, install gear ring bearing inner race.
5. Apply gear oil to gear ring bearing inner race (adapter case
side). Using a drift, install gear ring bearing inner race.
6. Install the drive gear assembly to the transfer case.
7. Install the adapter case.
8. Check backlash, preload torque, tooth contact, and companion
flange runout. Refer to TF-58, "
ASSEMBLY INSPECTION" .
CAUTION:
Measure the total preload torque without the oil seal.
Adapter Case
1. Select the gear ring bearing adjusting shim (adapter case side). Refer to TF-67, "SELECTING ADJUST-
ING SHIMS" .
2. Install the oil gutter.
3. Using a drift, install the selected gear ring bearing adjusting
shim (adapter case side) and gear ring bearing outer race
(adapter case side).
SDIA0541E
Tool number A: ST30720000
B: ST27863000
C: KV40101630
SDIA1566E
Tool number A: ST30720000
B: KV38102510
SDIA1810E
Tool number A: ST30720000
B: KV40105230
SDIA1535E

TRANSFER ASSEMBLY
TF-71
C
E
F
G
H
I
J
K
L
MA
B
TF

4. Using a drift, drive the adapter case oil seal until it becomes
flush with the case end.
CAUTION:

When checking the total preload torque, measure it with-
out the oil seal, then install the oil seal.

Do not reuse the oil seal.

Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of the oil seal.
5. Apply recommended sealant on drain plug and install it to the
adapter case. Refer to TF-57, "
COMPONENTS" .
6. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the adapter case.
CAUTION:
Do not reuse the O-ring.
7. Install the adapter case to the transfer case, and apply anti-cor-
rosive oil onto threads and seats on the mounting bolts. Tighten
to the specified torque.
8. Check backlash, preload torque, tooth contact, and companion
flange runout. Refer to TF-58, "
ASSEMBLY INSPECTION" .
CAUTION:
Measure the total preload torque without the oil seal.Tool number : KV38101700
Bolt symbol
Bolt length “ ” mm (in)Tightening torque
N·m (kg-m, ft-lb)
A 35 (1.38)
15.2 (1.6, 11)
B 30 (1.18)
SDIA1568E
SDIA2318E

TF-72
TRANSFER ASSEMBLY

Pinion Sleeve Assembly
1. Select the pinion sleeve shim. Refer to TF-67, "SELECTING ADJUSTING SHIMS" .
2. Install dust cover.
3. Using a drift, install the pinion rear bearing outer race.
4. Using a drift, install the pinion front bearing outer race.
5. Apply gear oil to pinion front bearing inner race and mating posi-
tion on the drive pinion. Using a drift, install pinion front bearing
inner race to the drive pinion.
6. Install a collapsible spacer to the drive pinion.
CAUTION:
Do not reuse the collapsible spacer.
7. Apply gear oil to pinion rear bearing inner race and install it to
the pinion sleeve.
8. Using a drift, install pinion sleeve oil seal to the pinion sleeve.
CAUTION:

Do not reuse the oil seal.

Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of the oil seal.Tool number : KV38100300
SDIA1569E
Tool number A: ST33400001
B: ST30901000
SDIA1570E
Tool number : ST30901000
SDIA1571E
Tool number : ST33400001
SDIA1572E

TRANSFER ASSEMBLY
TF-73
C
E
F
G
H
I
J
K
L
MA
B
TF

9. Using a drift and press in the companion flange.
10. Apply anti-corrosion oil onto threads and seat of the pinion lock
nut and adjust the pinion lock nut tightening torque and pinion
bearing preload torque (P’
1 ), using a preload gauge.
CAUTION:

Do not reuse the pinion lock nut.

Adjust the lower limit of the pinion lock nut tightening torque first.

While confirming the preload torque, tighten pinion lock nut by 5° to 10°. Because preload will
increase suddenly.

If specified preload torque is exceeded, replace the collapsible spacer and tighten again. Never
loosen the pinion lock nut for further preload torque adjustment.

After the adjustment, rotate the companion flange back and forth 2 to 3 times to check for
unusual noise, rotation malfunction, and other malfunctions.
11. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the pinion sleeve.
CAUTION:
Do not reuse the old O-ring.
12. Assemble the selected pinion sleeve shim.
13. Install the pinion sleeve assembly, and apply anti-corrosive oil onto threads and seats on the mounting
bolts. Tighten to the specified torque. Refer to TF-57, "
COMPONENTS" .
14. Check backlash, preload torque, tooth contact and companion flange runout. Refer to TF-58, "
ASSEMBLY
INSPECTION" .
The total preload torque is as follows:Tool number : ST33200000
Pinion lock nut tightening torque
: 128 - 294 N·m (13 - 29 kg-m, 95 - 216 ft-lb)
Pinion bearing preload torque (P’
1 )
: 0.40 - 0.78 N·m (0.04 - 0.08 kg-m, 4 - 6 in-lb)
Total preload torque
With all oil seals installed : P’
1 + 0.45 - 0.47 N·m (0.045 - 0.048 kg-m, 3.9 - 4.1 in-lb)
Without transfer case oil seal and adapter case oil seal
: P’
1 + 0.35 - 0.37 N·m (0.035 - 0.038 kg-m, 3.1 - 3.2 in-lb)
SDIA1811E

TF-74
SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsEDS000I6
Inspection and AdjustmentEDS0004Y
PRELOAD TORQUE BEFORE DISASSEMBLY
PRELOAD TORQUE AFTER DISASSEMBLY AND REASSEMBLY
BACKLASH
Unit: mm (in)
COMPANION FLANGE RUNOUT
Unit: mm (in)
SELECTIVE PARTS
Gear ring Bearing Adjusting Shim (Transfer Case Side)
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.Applied model QR20DE QR25DE YD22DDTi
Transfer model TY20A
Oil capacity (Approx.) (lmp pt)0.31 (1/2)
Gear ratio0.404
Number of teeth Drive pinion 17
Drive gear 42
Item Specification [N·m (kg-m, in-lb)]
Pinion bearing (P
1 )0.10 - 0.39 (0.01 - 0.04, 1 - 3)
Gear ring bearing to pinion
bearing (Total preload)With all oil seals P
1 + 0.16 - 0.22 (0.016 - 0.023, 1.4 - 1.9)
Without transfer case oil seal and adapter case oil seal P
1 + 0.06 - 0.12 (0.006 - 0.013, 0.6 - 1.1)
Item Specification [N·m (kg-m, in-lb)]
Pinion bearing (P’
1 )0.40 - 0.78 (0.04 - 0.08, 4 - 6)
Gear ring bearing to pinion
bearing (Total preload)With all oil seals P’
1 + 0.45 - 0.47 (0.045 - 0.048, 3.9 - 4.1)
Without transfer case oil seal and adapter case oil seal P’
1 + 0.35 - 0.37 (0.035 - 0.038, 3.1 - 3.2)
Item Standard
Drive gear to drive pinion gear 0.13 - 0.19 (0.0051 - 0.0075)
Item Runout limit
Companion flange face 0.1 (0.004)
Inner side of the companion flange 0.1 (0.004)
Thickness Part number* Thickness Part number* Thickness Part number*
0.80 (0.0315)
0.83 (0.0327)
0.86 (0.0339)
0.89 (0.0350)
0.92 (0.0362)
0.95 (0.0374)
0.98 (0.0386)
1.01 (0.0398)
1.04 (0.0409)
1.07 (0.0421)
1.10 (0.0433)
1.13 (0.0445)
1.16 (0.0457)
1.19 (0.0469)33147 AD300
33147 AD301
33147 AD302
33147 AD303
33147 AD304
33147 AD305
33147 AD306
33147 AD307
33147 AD308
33147 AD309
33147 AD310
33147 AD311
33147 AD312
33147 AD3131.22 (0.0480)
1.25 (0.0492)
1.28 (0.0504)
1.31 (0.0516)
1.34 (0.0528)
1.37 (0.0539)
1.40 (0.0551)
1.43 (0.0563)
1.46 (0.0575)
1.49 (0.0587)
1.52 (0.0598)
1.55 (0.0610)
1.58 (0.0622)
1.61 (0.0634)33147 AD314
33147 AD315
33147 AD316
33147 AD317
33147 AD318
33147 AD319
33147 AD320
33147 AD321
33147 AD322
33147 AD323
33147 AD324
33147 AD360
33147 AD361
33147 AD3621.64 (0.0646)
1.67 (0.0657)
1.70 (0.0669)
1.73 (0.0681)
1.76 (0.0693)
1.79 (0.0705)
1.82 (0.0717)
1.85 (0.0728)
1.88 (0.0740)
1.91 (0.0752)
1.94 (0.0764)
1.97 (0.0776)
2.00 (0.0787)
2.03 (0.0799)33147 AD363
33147 AD364
33147 AD365
33147 AD366
33147 AD367
33147 AD368
33147 AD369
33147 AD370
33147 AD371
33147 AD372
33147 AD373
33147 AD374
33147 AD375
33147 AD376