NISSAN X-TRAIL 2001 Service Repair Manual

TRANSFER ASSEMBLY
TF-11
C
E
F
G
H
I
J
K
L
MA
B
TF
TRANSFER ASSEMBLYPFP:33100
Removal and Installation from VehicleEDS0004U
REMOVAL
1. Remove the exhaust front tube, propeller shaft, and RH drive shaft.
2. Remove the side shaft.
3. Remove the air breather hose.
4. Remove transfer gusset (vehicle with YD22ET engine only).
5. Place a transmission jack onto the transaxle.
6. Remove the center member.
7. Remove suspension members.
●Refer to FSU-12, "Removal and Installation" in FUS Front Suspension.
8. Remove rear engine mounting bracket.
9. Place a transmission jack onto the transfer unit.
10. Remove the mounting bolts fastening the transaxle and transfer unit.
11. Remove the transfer unit from the vehicle.
INSTALLATION
Paying attention to the following items, install in the reverse order of removal.
SDIA1177E

TF-12
TRANSFER ASSEMBLY
●When installing the transfer to the transaxle, install the mounting
bolts following the standard below.
CAUTION:
When installing the transfer to the transaxle, be careful not
to damage the oil seals.
●When installing transfer gusset, tighten mounting bolts to the following torque (vehicles with YD22ET
engine only):
●After the installation, check the oil level and oil leakage.
Bolt No. 1 2
Quantity 4 2
Nominal length mm (in) 65 (2.56) 40 (1.57)
Tightening torque [N·m
(kg·mfg.-lb.)]30 - 39 (3.0 - 4.0,22-28)
SDIA1178E
Tightening torque : 31 - 40 N·m (3.1 - 4.1 kg-m, 23 - 29 ft.-lb.)

TRANSFER ASSEMBLY
TF-13
C
E
F
G
H
I
J
K
L
MA
B
TF
Component Parts DrawingEDS0004V
SDIA1149E

TF-14
TRANSFER ASSEMBLY
Assembly Inspection
EDS0004W
BACKLASH
1. Install a bolt to the companion flange.
2. Fit a dial gauge onto the bolt.
3. Measure the circumference backlash of the companion flange,
and check that it satisfies the standard below.
●If outside the standard, disassemble it to check and adjust
each part.
TOOTH CONTACT
1. Remove the pinion sleeve assembly, and apply red lead to the
drive gear.
CAUTION:
Apply red lead to the both faces of 3 to 4 gears at 4 loca-
tions evenly spaced on the drive gear.
2. Install the pinion sleeve shims and pinion sleeve assembly.
3. Remove the plug on the upper side of the transfer case.
4. Rotate the companion flange back and forth several times, and
check the drive pinion gear to drive gear tooth contact by view-
ing from the plug hole.Backlash : 0.13 - 0.19 mm (0.0051 - 0.0075 in)
TFB0280D
TFB0212D
SDIA0516E

TRANSFER ASSEMBLY
TF-15
C
E
F
G
H
I
J
K
L
MA
B
TF
5. If tooth contact is poorly adjusted, adjust pinion height (dimen-
sion X) in the following manner:
SDIA0520E
SDIA0517E

TF-16
TRANSFER ASSEMBLY
●If the tooth contact is near the face (face contact), or near the
heal (heal contact), thin the pinion sleeve shims to move the
drive pinion gear closer to the drive gear.
●If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thicken the pinion sleeve shims to move the
drive pinion gear farther from the drive gear.
PRELOAD TORQUE
Pinion bearing preload torque
1. Remove the pinion sleeve assembly, and rotate the companion flange back and forth in 2 to 3 times.
Check for abnormal noise, rotation malfunction, and other malfunctions.
2. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
SDIA0518E
SDIA0519E

TRANSFER ASSEMBLY
TF-17
C
E
F
G
H
I
J
K
L
MA
B
TF
3. Using a preload gauge, measure the preload torque of the pin-
ion bearing.
CAUTION:
Every rotational part shall rotate smoothly with the speci-
fied gear oil.
●If outside the standard, disassemble the pinion sleeve assem-
bly to check and adjust each part.
Overall preload torque
1. Measure pinion bearing preload torque (P1 ).
2. Install the pinion sleeve shims and pinion sleeve assembly.
3. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
4. Using a preload gauge, measure the overall preload torque.
●If outside of the standard, disassemble it to check and adjust
each part. If measuring the overall preload torque after the disassembly, measure it with the transfer
case oil seals and gear ring oil seals removed, then install the oil seals.
COMPANION FLANGE RUNOUT
1. Fit a dial gauge 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. While changing the phase between companion flange and drive pinion gear by 90° at a time, check runout
and determine which phase angle minimizes the runout.
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 is outside the standard after the companion flange is replaced, adjust the assembly status of
the pinion bearings and drive pinion gear, or replace the pinion bearings. Preload torque
: 0.10 - 0.39 N·m (0.01 - 0.04 kg-m,1 - 3 in-lb)
SDIA0522E
Pinion bearing preload torque (P1)
: 0.10 - 0.39 N·m (0.01 - 0.04 kg-m, 1 - 3 in-lb)
Overall preload torque
When all oil seals are installed:
: P
1 +0.16 - 0.22 N·m (0.016 - 0.023 kg-m, 1.4 - 1.9
in-lb)
Transfer case oil seals and
When no gear ring oil seal:
: P
1 +0.06 - 0.12 N·m (0.006 - 0.013 kg-m, 0.6 - 1.1
in-lb)
SDIA0523E
Runout limit : 0.08 mm (0.0031 in)
Runout limit : 0.08 mm (0.0031 in)
SDIA0524E

TF-18
TRANSFER ASSEMBLY
Disassembly and Assembly
EDS0004X
DISASSEMBLY
Pinion sleeve assembly
1. Remove 7 pinion sleeve mounting bolts.
2. Temporarily tighten 2 bolts. Using a plastic hammer, tap com-
panion flange to remove pinion sleeve assembly.
3. Remove the pinion sleeve shim.
4. Remove the pinion nut.
5. Using a drift, remove drive pinion from pinion sleeve with a
press.
6. Remove the drive pinion gear assembly.
7. Remove the O-ring.
8. Using a flat-bladed screwdriver, remove the oil seal.
CAUTION:
Be careful not to damage the pinion sleeve.
9. Remove the pinion rear bearing inner race.
TFB0302D
TFB0284D
SDIA0525E
TFB0286D

TRANSFER ASSEMBLY
TF-19
C
E
F
G
H
I
J
K
L
MA
B
TF
10. Using a puller, remove the pinion rear bearing outer race.
11. Using a puller, remove the pinion front bearing outer race.
12. Remove the collapsible spacer from the drive pinion gear.
13. Using a replacer, press the pinion front bearing inner race out of
the drive pinion gear.
Adapter case
1. Remove the adapter case mounting bolts.
SDIA0526E
SDIA0527E
SDIA0528E
TFB0289D

TF-20
TRANSFER ASSEMBLY
2. Using a plastic hammer, tap the adapter case to remove.
3. Remove the O-ring.
4. Using a flat-bladed screwdriver, remove the oil seal.
CAUTION:
Be careful not to damage the adapter case.
5. Using a brass rod, tap the adjusting shim from the cutout on the
adapter case to remove the adjusting shim and gear ring bear-
ing outer race.
6. Remove the oil gutter.
7. Remove the drain plug.
Drive gear assembly
1. Remove the adapter case.
2. Remove the drive gear assembly from the transfer case.
TFB0290D
TFB0291D
SDIA0529E
SDIA0530E