NISSAN X-TRAIL 2005 Service Repair Manual

SIDE OIL SEAL
RFD-11
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RFD

SIDE OIL SEALPFP:38343
Removal and InstallationEDS001Z3
REMOVAL
1. Remove rear drive shaft with power tool. Refer to RAX-14, "REAR DRIVE SHAFT" .
2. Remove side oil seal, using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage carrier case and rear cover.
INSTALLATION
1. Apply multi-purpose grease to side oil seal lips.
2. Install side oil seal until it becomes flush with the case end,
using the drift.
CAUTION:

Do not reuse oil seal.

When installing, do not incline oil seal.
3. Install rear drive shaft. Refer to RAX-14, "
REAR DRIVE
SHAFT" .
PDIA0431E
Tool number : KV38100200
PDIA0432E

RFD-12
ELECTRIC CONTROLLED COUPLING

ELECTRIC CONTROLLED COUPLINGPFP:38760
Removal and InstallationEDS0027J
REMOVAL
1. Remove propeller shaft. Refer to PR-4, "Removal and Installation" .
2. Put matching mark on the thread edge of electric controlled cou-
pling. The matching mark should be in line with the matching
mark on the companion flange.
CAUTION:
For matching mark, use paint. Do not damage electric con-
trolled coupling.
NOTE:
When replacing electric controlled coupling, matching mark is
not necessary.
3. Remove companion flange lock nut, using a flange wrench.
4. Remove companion flange.
5. Disconnect 4WD solenoid harness connector and remove con-
nector bracket.
6. Remove electric controlled coupling breather hose from cou-
pling cover.
7. Remove coupling cover with electric controlled coupling from
carrier case.
8. Remove electric controlled coupling from coupling cover.
PDIA0455E
PDIA0456E
PDIA0458E

ELECTRIC CONTROLLED COUPLING
RFD-13
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INSTALLATION
1. Install electric controlled coupling to spline of drive pinion inside
carrier case.
CAUTION:

Align the pin on electric controlled coupling with the
groove of carrier case.

Be careful not to damage center oil seal.
2. Set 4WD solenoid harness guide to carrier case.
3. Apply liquid gasket to mating surface of coupling cover. Overlap
both ends of the bead for at least 3 mm (0.12 in).

Use sealant (Three bound 1217 or equivalent).
CAUTION:
Remove old sealant adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering
to the mounting surfaces.
4. Install coupling cover to carrier case with arrow facing upward,
temporarily tighten reamer bolts to the positions shown in the
figure.
5. Tighten reamer bolts and coupling cover mounting bolts to the
specified torque. Refer to RFD-16, "
Components" .
6. Install electric controlled coupling breather hose to coupling
cover.
7. Install connector bracket and connect 4WD solenoid harness
connector.
8. Install companion flange.
NOTE:
When reusing electric controlled coupling, align the matching
mark of electric controlled coupling with the matching mark of
companion flange, then install companion flange.
9. Install companion flange lock nut with flange wrench, tighten to
the specified torque. Refer to RFD-16, "
Components" .
CAUTION:
Do not reuse companion flange lock nut.
10. Install propeller shaft. Refer to PR-4, "
Removal and Installation"
.
PDIA0912E
PDIA0451E
SDIA0587E
PDIA0455E

RFD-14
REAR FINAL DRIVE ASSEMBLY

REAR FINAL DRIVE ASSEMBLYPFP:38300
Removal and InstallationEDS001ZA
REMOVAL
1. Remove propeller shaft. Refer to PR-4, "Removal and Installation" .
2. Remove drive shaft with power tool. Refer to RAX-14, "
Removal and Installation" .
3. Disconnect 4WD solenoid harness connector.
4. Remove rear final drive breather hose and electric controlled coupling breather hose.
5. Support rear final drive assembly with a suitable jack.
6. Remove rear final drive mounting nut at rear suspension mem-
ber.
7. Remove rear final drive mounting bolts at final drive mounting
bracket, and then remove rear final drive assembly.
If necessary, remove final drive mounting bracket.
CAUTION:
Secure rear final drive assembly to a suitable jack while
removing it.
1. Rear suspension member 2. Final drive mounting bracket 3. Harness bracket
4. Drive shaft 5. Propeller shaft 6. Rear final drive assembly
PDIA0433E
PDIA0434E
PDIA0435E

REAR FINAL DRIVE ASSEMBLY
RFD-15
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INSTALLATION
Note the following, and install in the reverse order of removal.

Refer to RFD-16, "Components" about each tightening torque.

When installing breather hoses, refer to the figure and following.
CAUTION:
Make sure there are no pinched or restricted areas on the
breather hose caused by bending or winding when install-
ing it.
–For installation of rear final drive breather hose, the vehicle side
end shall be inserted to cross member. Install metal connector
side of this hose to rear cover by inserting it with aiming painted
marking to the front of vehicle.
–For installation of electric controlled coupling breather hose, the
vehicle side end shall be inserted to cross member. Install its
metal tube to rear final drive assembly and direct the metal tube
hose side end to the front of vehicle.

When oil leaks while removing final drive assembly, check oil
level after the installation. Refer to RFD-8, "
Checking Differential
Gear Oil" .
PDIA0436E
PDIA0437E

RFD-16
REAR FINAL DRIVE ASSEMBLY

ComponentsEDS001ZB
PDIA0932E
1. Companion flange lock nut 2. Companion flange 3. Front oil seal
4. Coupling cover 5. Connector bracket 6. Reamer bolt
7. Coupling front bearing 8. Bearing shim 9. Electric controlled coupling
10. 4WD solenoid harness 11. Center oil seal 12. Drive pinion nut
13. Pinion front bearing 14. Carrier case 15. Collapsible spacer
16. Drive pinion adjusting shim 17. Pinion rear bearing 18. Drive pinion
19. Side oil seal 20. Side bearing adjusting shim 21. Side bearing
22. Drive gear 23. Differential case 24. Side gear thrust washer
25. Side gear 26. Pinion mate thrust washer 27. Pinion mate gear
28. Pinion mate shaft 29. Lock pin 30. Rear cover
31. Filler plug 32. Drain plug 33. Gasket

REAR FINAL DRIVE ASSEMBLY
RFD-17
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Pre-InspectionEDS001ZC
TOTAL PRELOAD
1. Drain the oil.
2. Remove electric controlled coupling assembly. Refer to RFD-22, "
Removal of Electric Controlled Coupling
Assembly" .
3. Rotate the drive pinion back and forth in 2 to 3 times to check for unusual noise and rotation malfunction.
4. Rotate the drive pinion at least 20 times to check for smooth
operation of the bearing.
5. Fit the drive pinion socket onto the drive pinion spline. Using the
preload gauge below, measure the total preload.

If outside the standard, disassemble, check, and adjust each
part. Adjust the pinion bearing and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bearing preload.
Side bearing adjusting shims
*: Always check with the Parts Department for the latest parts information.
Tool number A: ST3127S000
B: KV38108500
Total preload
:1.33 - 2.15 N·m (0.14 - 0.21 kg-m, 12 - 19 in-lb)
Side bearing preload
: 0.64-0.98 N·m (0.07 - 0.09 kg-m, 6 - 8 in-lb)
When the preload torque is large
On pinion bearings : Replace the collapsible spacer.
On side bearings : Use thinner side bearing adjusting shims.
When the preload is small
On pinion bearings : Tighten the pinion nut.
On side bearings : Use thicker side bearing adjusting shims.
PDIA0048E
Thickness Part number* Thickness Part number*
1.85 mm (0.0728 in)
1.90 mm (0.0748 in)
1.95 mm (0.0768 in)
2.00 mm (0.0787 in)38453 4N200
38453 4N201
38453 4N202
38453 4N2032.05 mm (0.0807 in)
2.10 mm (0.0827 in)
2.15 mm (0.0854 in)
2.20 mm (0.0866 in)38453 4N204
38453 4N205
38453 4N206
38453 4N207

RFD-18
REAR FINAL DRIVE ASSEMBLY

DRIVE GEAR TO DRIVE PINION BACKLASH
1. Drain the oil.
2. Remove the rear cover. Refer to RFD-22, "
Removal of Differential Assembly" .
3. Following the procedure below, install a dummy cover set to the
carrier case.
a. Fit dummy cover shims to the right and left side bearing adjust-
ing shims.
b. Temporarily tighten a dummy cover to the carrier case.
c. Position a dummy cover spacer to the dummy cover.
d. Tighten rear cover mounting bolts to the specified torque. Refer to RFD-16, "
Components" .
e. Tighten dummy cover spacer mounting bolts evenly to the specified torque.
4. Fit a dial indicator to the drive gear face to measure the back-
lash.

If outside the standard, change the thickness of the side bearing
adjusting shims.
Side bearing adjusting shims
*: Always check with the Parts Department for the latest parts information.
Tool Number : KV389L0010
PDIA0474E
: 5.9 N·m (0.6 kg-m, 52 in-lb)
Backlash : 0.10 - 0.15 mm (0.0039 - 0.0059 in)
Tool number : KV389L0010
PDIA0049E
When the backlash is large:
Make the drive gear back adjusting shims thicker, and the drive gear front adjusting
shims thinner.
When the backlash is small:
Make the drive gear back adjusting shims thinner, and the drive gear front adjusting
shims thicker.
Thickness Part number* Thickness Part number*
1.85 mm (0.0728 in)
1.90 mm (0.0748 in)
1.95 mm (0.0768 in)
2.00 mm (0.0787 in)38453 4N200
38453 4N201
38453 4N202
38453 4N2032.05 mm (0.0807 in)
2.10 mm (0.0827 in)
2.15 mm (0.0854 in)
2.20 mm (0.0866 in)38453 4N204
38453 4N205
38453 4N206
38453 4N207

REAR FINAL DRIVE ASSEMBLY
RFD-19
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DRIVE GEAR RUNOUT
1. Drain the oil.
2. Remove the rear cover.Refer to RFD-22, "
Removal of Differential Assembly" .
3. Attach dummy cover set. Refer to RFD-18, "
DRIVE GEAR TO
DRIVE PINION BACKLASH" .
4. Fit a dial indicator to the drive gear back face.
5. Rotate the drive gear to measure runout.

If outside the repair limit, check drive gear assembly condition;
foreign material may be caught between drive gear and differen-
tial case, or differential case or drive gear may be deformed, etc.
CAUTION:
Replace the drive gear and drive pinion gear as a set.
COMPANION FLANGE RUNOUT
1. Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
2. Rotate the companion flange to check for runout.
3. Fit a test indicator to the inner side of the companion flange
(socket diameter).
4. Rotate the companion flange to check for runout.
5. If the runout value is outside the repair limit, follow the procedure
below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion gear by 90° step,
and search for the point where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, replace the companion
flange.
c. If the runout value is still outside of the limit after the companion flange has been replaced, possible cause
will be an assembly malfunction of the drive pinion gear and the electronically controlled coupling, mal-
functioning coupling bearing, or malfunctioning of electronically controlled coupling.
TOOTH CONTACT
1. Drain the oil.
2. Remove the rear cover. Refer to RFD-22, "
Removal of Differential Assembly" .
3. Attach dummy cover set. Refer to RFD-18, "
DRIVE GEAR TO
DRIVE PINION BACKLASH" .
4. Thoroughly clean drive gear and drive pinion teeth.
5. Lightly apply a mixture of powdered ferric oxide and oil or the
equivalent. Apply it to 3 to 4 teeth of drive gear drive side.Tool Number : KV389L0010
Runout limit : 0.05 mm (0.0020 in)
PDIA0050E
Runout limit : 0.13 mm (0.0051 in)
Runout limit : 0.19 mm (0.0075 in)
PDIA0439E
Tool Number : KV389L0010
PDIA0051E

RFD-20
REAR FINAL DRIVE ASSEMBLY

6. Rotate the drive gear back and forth in several times, check
drive pinion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side and reverse side.
7. If the tooth contact is improperly adjusted, follow the procedure
below to adjust the pinion height (dimension X in the figure).
SDIA0570E
SDIA2549E
SDIA0517E