NISSAN X-TRAIL 2005 Service Repair Manual

TRANSAXLE ASSEMBLY
MT-35
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30. Install bore plug to transaxle case using the drift.
CAUTION:
Do not reuse bore plug.
31. Install welch plug to transaxle case using the drift.
CAUTION:
Do not reuse welch plug.
32. Install 2 check balls, 2 check springs and 2 check plugs to tran-
saxle case, and then tighten check plug to the specified torque.
Refer to MT-25, "
Shift Control Components" .
CAUTION:
Do not reuse check plug.
33. Apply recommended sealant to threads of park/neutral position
switch and back-up lamp switch. Then install them to transaxle
case and tighten to the specified torque. Refer to MT-22, "
Case
and Housing Components" .
34. Install gaskets onto drain plug and plug, and then install them
into transaxle case. Tighten drain plug and plug to the specified
torque. Refer to MT-22, "
Case and Housing Components" .
CAUTION:
Do not reuse gasket.
35. Install O-ring onto plug (for 2WD models) or gasket onto filler
plug (for 4WD models), and then install it into clutch housing.
Tighten plug mounting bolt or filler plug to the specified torque.
Refer to MT-22, "
Case and Housing Components" .
CAUTION:

Do not reuse O-ring or gasket.

After oil is filled, tighten plug mounting bolt or filler plug to specified torque.
SCIA0894E
SCIA0403E
SCIA1668J
SCIA0895E

MT-36
TRANSAXLE ASSEMBLY

ADJUSTMENT
Differential Side Bearing Preload

When adjusting differential side bearing preload, select adjust-
ing shim for differential side bearing. To select adjusting shim,
measure clearance “L” between transaxle case and differential
side bearing outer race. Refer to MT-108, "
DIFFERENTIAL
SIDE BEARING ADJUSTING SHIM(S)" .
CAUTION:
Up to 2 adjusting shims can be selected.

Calculate dimension “L” (thickness of adjusting shim) using the
following procedure to satisfy specification of preload for differ-
ential side bearing.
1. Using depth micrometer and straightedge, measure dimension
“L
1 ” between transaxle case end face and mounting face of
adjusting shim.
2. Install differential side bearing outer race onto differential side
bearing on final gear side. Holding lightly differential side bear-
ing outer race horizontally by hand, rotate final gear five times or
more (for smooth movement of bearing roller).
3. Using depth micrometer and straightedge as shown in the fig-
ure, measure dimension “L
2” between differential side bearing
outer race and clutch housing end face.
4. Install selected differential side bearing adjusting shim, and then
install differential side bearing outer race using the drift.Preload: 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension“L” = (L
1 - L2 ) + Preload
L: Thickness of adjusting shim
L
1 : Distance between transaxle case end face and
mounting face of adjusting shim
L
2 : Distance between differential side bearing
outer race and clutch housing end face
PCIB0795E
SCIA1078E
SCIA1079E
SCIA0898E

TRANSAXLE ASSEMBLY
MT-37
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Reverse Idler Gear End Play

When adjusting reverse idler gear end play, select adjusting
shim for reverse idler gear. To select adjusting shim, measure
clearance between transaxle case and reverse idler gear. Refer
to MT-107, "
REVERSE IDLER GEAR ADJUSTING SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.

Calculate dimension “Q” (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for
reverse idler gear.
1. Using depth micrometer and straightedge, measure dimension
“Q
1” between transaxle case end face and mounting face of
adjusting shim.
2. Using depth micrometer and straightedge as shown in the fig-
ure, measure dimension “Q
2” between clutch housing end face
and end face of reverse idler gear (Rear).
3. Install selected reverse idler gear adjusting shim onto reverse
idler gear assembly.
Input Shaft End Play

When adjusting input shaft end play, select adjusting shim for
input shaft rear bearing. To select adjusting shim, measure
clearance between transaxle case and input shaft rear bearing.
Refer to MT-107, "
INPUT SHAFT REAR BEARING ADJUSTING
SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.

Calculate dimension “O” (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for input
shaft rear bearing.End play: 0.04 - 0.10 mm (0.0016 - 0.0039 in)
Dimension“Q” = (Q
1 - Q2 ) - End play
Q: Thickness of adjusting shim
Q
1 : Distance between transaxle case end face and
mounting face of adjusting shim
Q
2 : Distance between clutch housing end face
and end face of reverse idler gear (Rear)
PCIB0796E
SCIA1003E
PCIB0797E
End play: 0 - 0.06 mm (0 - 0.0024 in)
Dimension“O” = (O
1 - O2 ) - End play
SCIA1006E

MT-38
TRANSAXLE ASSEMBLY

1. Using depth micrometer and straightedge, measure dimension
“O
1 ” between transaxle case end face and mounting face of
adjusting shim.
2. Using depth micrometer and straightedge as shown in the fig-
ure, measure dimension “O
2 ” between clutch housing end face
and end face of input shaft rear bearing.
3. Install selected input shaft rear bearing adjusting shim onto input
shaft.
Mainshaft End Play

When adjusting mainshaft end play, select adjusting shim for
mainshaft rear bearing. To select adjusting shim, measure clear-
ance “M” between transaxle case and mainshaft rear bearing.
Refer to MT-107, "
MAINSHAFT REAR BEARING ADJUSTING
SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.

Calculate dimension “P” (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for main-
shaft rear bearing.
1. Install mainshaft assembly to clutch housing.
2. Install snap ring to transaxle case.
3. Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install tempo-
rarily snap ring to mainshaft rear bearing.O: Thickness of adjusting shim
O
1 : Distance between transaxle case end face and
mounting face of adjusting shim
O
2 : Distance between clutch housing end face
and end face of input shaft rear bearing
SCIA1002E
PCIB0792E
End play: 0 - 0.06 mm (0 - 0.0024 in)
Dimension“P” = “M” - End play
P: Thickness of adjusting shim
M: Distance between mainshaft rear bearing end
face and transaxle case end facePCIB0793E

TRANSAXLE ASSEMBLY
MT-39
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4. Install dial indicator to bore plug mounting hole, and expand
snap ring. Lift mainshaft assembly through control assembly
installation hole, and push it against transaxle case. This state
shall be defined as base. Moving distance of mainshaft assem-
bly, with snap ring fit on main rear bearing, becomes “M”.
PCIB0874E

MT-40
TRANSAXLE ASSEMBLY

Disassembly and Assembly (RS6F51A)ECS008C1
COMPONENTS
Case and Housing Components
1. Clutch housing 2. Differential side oil seal 3. Ball pin
4. Washer 5. Input shaft oil seal 6. Oil channel
7. Magnet 8. Gasket 9. Filler plug
10. O-ring 11. Plug 12. Air breather tube
13. Back-up lamp switch 14. Oil gutter 15. Baffle plate
16. Transaxle case 17. Plug 18. Welch plug
19. Bore plug 20. Drain plug 21. Differential side oil seal
22. Park/Neutral position (PNP) switch
PCIB1457E

TRANSAXLE ASSEMBLY
MT-41
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Gear Components
1. Input shaft front bearing 2. Input shaft 3. 3rd needle bearing
4. 3rd input gear 5. 3rd inner baulk ring 6. 3rd synchronizer cone
7. 3rd outer baulk ring 8. 3rd-4th spread spring 9. 3rd-4th shifting insert
10. 3rd-4th synchronizer hub 11. 4th baulk ring 12. 3rd-4th coupling sleeve
13. 4th input gear bushing 14. 4th needle bearing 15. 4th input gear
16. Thrust washer 17. 5th input gear bushing 18. 5th needle bearing
19. 5th input gear 20. 5th baulk ring 21. 5th-6th spread spring
22. 5th-6th shifting insert 23. 5th-6th synchronizer hub 24. 5th-6th coupling sleeve
25. 6th baulk ring 26. 6th input gear 27. 6th needle bearing
28. 6th input gear bushing 29. Snap ring 30. Input shaft rear bearing
31. Oil channel 32. Input shaft rear bearing adjusting
shim33. Retaining pin
34. Reverse idler shaft 35. Thrust needle bearing 36. Reverse idler gear needle bearing
37. Reverse insert spring 38. Reverse idler gear (Front) 39. Reverse balk ring
40. Reverse coupling sleeve 41. Reverse idler gear (Rear) 42. Reverse idler gear adjusting shim
PCIB1460E

MT-42
TRANSAXLE ASSEMBLY

1. Mainshaft front bearing 2. Mainshaft bearing retainer 3. Mainshaft
4. Reverse main gear 5. 1st main gear 6. 1st main gear bushing
7. 1st needle bearing 8. 1st inner baulk ring 9. 1st synchronizer cone
10. 1st outer baulk ring 11. 1st-2nd spread spring 12. 1st-2nd shifting insert
13. 1st-2nd synchronizer hub 14. 2nd outer baulk ring 15. 2nd synchronizer cone
16. 2nd inner baulk ring 17. 1st-2nd coupling sleeve 18. 2nd main gear bushing
19. 2nd needle bearing 20. 2nd main gear 21. 3rd main gear
22. 3rd-4th mainshaft spacer 23. 4th main adjusting shim 24. 4th main gear
25. 5th main gear 26. 6th main gear 27. Mainshaft rear bearing
28. Mainshaft C-ring 29. C-ring holder 30. Snap ring
31. Snap ring 32. Mainshaft rear bearing adjusting shim 33. 5th-6th mainshaft spacer
34. 6th main adjusting shim
PCIB0787E

TRANSAXLE ASSEMBLY
MT-43
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Shift Control Components
1. 3rd-4th bracket 2. Retaining pin 3. Check plug
4. 5th-6th bracket 5. Stopper ring 6. Reverse bracket
7. Reverse lever assembly 8. Shifter cap 9. Reverse shift fork
10. Reverse fork rod 11. Check spring 12. Shift check sleeve
13. Check ball 14. Reverse bracket fork rod 15. 5th-6th shift fork
16. 5th-6th fork rod 17. Interlock pin 18. Shift check sleeve
19. Check spring 20. Check spring 21. 3rd-4th fork rod
22. 3rd-4th shift fork 23. 1st-2nd fork rod 24. 1st-2nd fork rod bracket
25. 1st-2nd shift fork 26. Transaxle case 27. Stopper bolt
28. Shift check 29. O-ring 30. Control assembly
PCIB0871E

MT-44
TRANSAXLE ASSEMBLY

Final Drive Components
DISASSEMBLY
1. Remove plug (for 2WD models) or filler plug (for 4WD models) from clutch housing.
2. Remove drain plug and plug from transaxle case.
3. Remove park/neutral position switch and back-up lamp switch
from transaxle case.
4. Remove shift check and stopper bolt from transaxle case, and
then remove control assembly from transaxle case.
1. Differential side bearing outer race
(clutch housing side)2. Differential side bearing (clutch
housing side)3. Speedometer drive gear (for 2WD
models)
4. Differential case 5. Final gear 6. Differential side bearing (transaxle
case side)
7. Differential side bearing outer race
(transaxle case side)8. Differential side bearing adjusting
shim9. Pinion mate shaft
10. Side gear 11. Side gear thrust washer 12. Pinion mate gear
13. Pinion mate thrust washer 14. Retaining pin
PCIB0869E
SCIA0389E