NISSAN X-TRAIL 2001 Service Repair Manual

TRANSAXLE ASSEMBLY
MT-35
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28. Using a drift, install welch plug.
CAUTION:
Do not reuse welch plug.
29. Install 2 check balls, 2 check springs and 2 check ball plugs.
CAUTION:
Do not reuse check ball plug.
30. Apply recommended sealant to threads of neutral switch and
reverse lamp switch. Then install them into transaxle case.
31. Install gaskets onto drain plug and filler plug, and then install
them into transaxle case.
CAUTION:
●Do not reuse gasket.
●After oil is filled, tighten filler plug to specified torque.
Disassembly and Assembly (RS6F51A)ECS008C1
DISASSEMBLY
1. Remove drain plug and filler plug.
2. Remove park/neutral position switch and back-up lamp switch.
3. After removing shift check and stopper bolt, remove control
assembly.
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MT-36
TRANSAXLE ASSEMBLY
4. Remove check plugs (4 pieces), check springs (4 pieces), check
balls (4 pieces) and shift check sleeve (2 pieces).
5. Remove transaxle case fixing bolts.
6. Remove bore plug.
CAUTION:
Be careful not to damage transaxle case.
7. While spreading the snap ring of mainshaft rear bearing located
at bore plug hole, remove transaxle case.
8. Remove oil gutter, baffle plate.
9. Remove snap ring, mainshaft rear bearing adjusting shim and
input shaft rear bearing adjusting shim from transaxle case.
10. Remove differential side bearing outer race (transaxle case
side) and then adjusting shim.
11. Remove welch plug.
12. Remove differential oil seal (transaxle case side).
13. Remove magnet from clutch housing.
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TRANSAXLE ASSEMBLY
MT-37
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14. With shift lever in 5th position, remove bracket bolts from
reverse lever assembly. Lift reverse lever assembly to remove.
CAUTION:
Be careful not to lose shifter cap.
15. Pull out reverse fork rod then remove reverse shift fork.
16. Remove retaining pin of reverse bracket.
17. Pull out reverse bracket and reverse bracket fork rod.
18. Remove check ball (2 pieces) and inter lock pin.
19. Shift 3rd & 4th fork rod to 3rd position. Remove retaining pin of
5th & 6th shift fork using pin punch.
20. Remove stopper rings for 5th & 6th bracket.
21. Pull out 5th & 6th fork rod and remove 5th & 6th shift fork and
5th & 6th bracket.
22. Remove check balls (2 pieces) and inter lock pin.
23. Remove retaining pin of 3rd & 4th bracket using pin punch.
24. Remove stopper rings for 3rd & 4th shift fork.
25. Pull out 3rd & 4th fork rod and remove 3rd & 4th shift fork and
bracket.
26. Remove shift check sleeve from clutch housing.
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MT-38
TRANSAXLE ASSEMBLY
27. Remove retaining pin of 1st & 2nd shift fork using pin punch.
28. Pull out 1st & 2nd fork rod with bracket.
29. Remove 1st & 2nd shift fork.
30. Remove retaining pin of 1st & 2nd bracket using pin punch and
separate fork rod and bracket.
31. Remove gear components from clutch housing in the following
procedure.
a. While tapping input shaft with plastic hammer, remove input
shaft assembly, mainshaft assembly and reverse idler gear
assembly as a set.
CAUTION:
Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
b. Remove final drive assembly.
32. Remove main bearing retainer and then mainshaft front bearing.
33. Remove oil channel on mainshaft side.
34. Remove differential oil seal (clutch housing side).
35. Remove differential side bearing outer race (clutch housing
side).
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TRANSAXLE ASSEMBLY
MT-39
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36. Remove input shaft oil seal.
CAUTION:
Be careful not to damage clutch housing.
ASSEMBLY
1. Using a drift, install input shaft oil seal from clutch housing end
of side to the depth of 1.8 to 2.8 mm (0.071 to 0.110 in).
CAUTION:
Do not reuse oil seals.
2. Using a drift, install differential oil seal until the face is flush with
clutch housing.
CAUTION:
Do not reuse oil seals.
3. Install oil channel on mainshaft side.
CAUTION:
Be careful with orientation of installation.
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MT-40
TRANSAXLE ASSEMBLY
4. Using a drift, install mainshaft front bearing.
CAUTION:
Be careful with orientation of installation.
5. Install bearing retainer.
CAUTION:
Install with punched surface facing up.
6. Install differential side bearing outer race.
7. Install final drive assembly into clutch housing.
8. Install input shaft assembly, mainshaft assembly, and reverse
idler gear assembly into clutch housing.
CAUTION:
Be sure not to damage input shaft oil seal.
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TRANSAXLE ASSEMBLY
MT-41
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9. Install 1st-2nd fork rod bracket onto 1st-2nd fork rod, and then
install retaining pin.
CAUTION:
Do not reuse retaining pin.
10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install
retaining pin.
CAUTION:
Do not reuse retaining pin.
11. Install shift check sleeve.
12. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod
with inter lock pin.
13. Install stopper ring onto 3rd-4th shift fork.
CAUTION:
Do not stopper ring.
14. Install retaining pin onto 3rd-4th bracket.
CAUTION:
Do not reuse retaining pin.
15. Install 2 check balls.
16. Install 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod
with inter lock pin.
17. Install stopper ring onto 5th-6th bracket.
CAUTION:
Do not stopper ring.
18. Install retaining pin onto 5th-6th shift fork.
CAUTION:
Do not reuse retaining pin.
19. Install 2 check balls.
20. Install check ball, 5th-6th shift check sleeve, 5th-6th check
spring and 5th-6th check ball plug.
CAUTION:
●Do not reuse check ball plug.
●Do not drop check ball.
21. Install reverse bracket fork rod and reverse lever bracket.
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MT-42
TRANSAXLE ASSEMBLY
22. Install retaining pin onto reverse bracket.
CAUTION:
Do not reuse retaining pin.
23. Install reverse shift fork and reverse fork rod.
24. Install reverse lever assembly following procedures below.
a. Install shifter cap onto reverse lever assembly cam, and then
install them onto reverse shift fork.
CAUTION:
Do not drop shifter cap.
b. While lifting reverse shift fork, align cam with reverse bracket.
c. Tighten mounting bolts to specified torque, and then install
reverse lever assembly.
25. Install check ball, reverse shift check sleeve, reverse check
spring and reverse check ball plug.
CAUTION:
●Do not reuse check ball plug.
●Do not drop check ball.
26. Install the magnet onto clutch housing.
27. Using a drift, install differential oil seal until it is flush with end
face of transaxle case.
CAUTION:
Do not reuse oil seals.
28. Install selected input shaft adjusting shim onto input shaft.
●For selection of adjusting shims, refer toMT-49, "INPUT
SHAFT END PLAY" .
29. Install baffle plate and oil gutter.
30. Install transaxle case following procedures below.
a. Install selected mainshaft rear bearing adjusting shim into tran-
saxle case.
●For selection of adjusting shims, refer toMT-50, "MAINSHAFT END PLAY" .
b. Temporarily install snap ring of mainshaft rear bearing into transaxle case.
CAUTION:
Do not reuse the snap ring.
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TRANSAXLE ASSEMBLY
MT-43
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c. Apply recommended sealant to mating surfaces of transaxle
case and clutch housing.
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
d. With snap ring of mainshaft rear bearing temporarily installed,
place transaxle case over clutch housing.
e. Through bore plug mounting hole, with snap ring stretched, and
lift up mainshaft assembly from the control assembly mounting
hole.
f. Securely install snap ring onto mainshaft rear bearing.
g. Tighten mounting bolts.
CAUTION:
Always replace bolts B as they are self-sealing bolts.
h. Install control assembly.
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Bolt A:
: 50.0 - 53.9 N·m (5.1 - 5.4 kg-m, 37 - 39 ft-lb)
Bolt B:
: 63.0 - 66.9 N·m (6.5 - 6.8 kg-m, 47 - 49 ft-lb)
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MT-44
TRANSAXLE ASSEMBLY
CAUTION:
Do not reuse the O-ring.
i. Install shift check and stopper bolt.
CAUTION:
Does not reuse shift check and stopper bolt.
31. Using a drift, install bore plug.
CAUTION:
Do not reuse bore plug.
32. Using a drift, install welch plug.
CAUTION:
Do not reuse welch plug.
33. Install 2 check balls, 2 check springs and 2 check ball plugs.
CAUTION:
Do not reuse check ball plug.
34. Apply recommended sealant to threads of neutral switch and
reverse lamp switch. Then install them into transaxle case.
35. Install gaskets onto drain plug and filler plug, and then install
them into transaxle case.
CAUTION:
●Do not reuse gasket.
●After oil is filled, tighten filler plug to specified torque.
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