NISSAN X-TRAIL 2001 Service Repair Manual

TRANSFER ASSEMBLY
TF-21
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 on the adapter case.
4. Using a drift and puller, remove the gear ring bearing inner race
on the transfer case.
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 oil seal from the gear ring.
Transfer case
1. Remove the pinion sleeve assembly.
2. Remove the adapter case.
3. Remove the drive gear assembly from the transfer case.
SDIA0531E
SDIA1157E
TFB0295D
SDIA0534E

TF-22
TRANSFER ASSEMBLY
4. Using a flat-bladed screwdriver, remove the oil seal.
CAUTION:
Be careful not to damage the transfer case.
5. Remove the oil defense.
6. Using a brass rod, tap the adjusting shim evenly from the 2 cut-
outs on the transfer case to remove the adjusting shim and gear
ring bearing outer race.
7. Remove the filler 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 gear, replace the drive gear and drive pin-
ion gear 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 abnormal 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
SDIA0535E
SDIA0536E

TRANSFER ASSEMBLY
TF-23
C
E
F
G
H
I
J
K
L
MA
B
TF
SELECTIONG ADJUSTING SHIMS
Measuring point
At gear ring bearing on transfer case
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 0.01 mm (0.0004 in) written on the drive gear side face.
4. Use the formula below to calculate adjusting shim thickness T
1 at the ring gear bearing on the transfer
case.
5. Select the adjusting shim.
●For information on selecting an adjusting shim, refer to TF-59, "SELECTIVE PARTS" .
CAUTION:
●Only one adjusting shim can be selected.
●If no adjusting shim with the calculated value is available, select the thicker and closest one.
At the gear bearing on the adapter case
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-24
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 the thickness of adjusting shim T
2 at the ring gear bearing on the
adapter case.
5. Select the adjusting shim.
●For information on selecting an adjusting shim, refer to TF-59, "SELECTIVE PARTS" .
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 gear.
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 gear.
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 toTF-59, "SELECTIVE PARTS" .
CAUTION:
Only one pinion sleeve shim can be selected.
ASSEMBLY
Transfer case
1. Select the adjusting shim on the gear ring bearing.
●TF-23, "SELECTIONG ADJUSTING 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 ([n 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-25
C
E
F
G
H
I
J
K
L
MA
B
TF
2. Using a drift, install the selected adjusting shim and gear ring
bearing outer race.
3. Install the oil defense, and tighten the mounting bolts to the
specified torque. The clearance between the oil defense and
transfer case (dimension A) should be the following.
CAUTION:
Do not reuse the mounting bolts.
4. Install the magnet.
5. Using a drift, drive the oil seal until it becomes flush with the
case end.
CAUTION:
●When checking the overall preload torque, measure it
without the oil seal, then install the oil seal.
●Discard old oil seals; replace with new ones.
●Apply onto oil seal lips, and gear oil onto the circumfer-
ence of the oil seal.
6. Apply recommended sealant to filler plug and its threads before
installing it to the transfer case.
7. Apply recommended sealant to breather tube and install it to the transfer case.
8. Install the drive gear assembly.
9. Install the adapter case.
10. Install the pinion sleeve assembly.
11. Check backlash, preload torque, tooth contact, and companion flange runout.
●TF-14, "Assembly Inspection"
CAUTION:
Measure the overall preload torque without the oil seal.
SDIA0538E
Tightening torque
: 6.9 - 8.8 N·m (0.7 - 0.9 kg-m, 61 - 78 in-lb)
Clearance between oil defense and transfer case
Dimension A : 1.0 - 3.5 mm (0.04 - 0.138 in)
Filler plug tightening torque : 9.8 - 19.6 N·m (1.0 - 1.9 kg-m, 87 - 173 in-lb)
Plug tightening torque : 15 - 19 N·m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
TFB0283D
SDIA0539E

TF-26
TRANSFER ASSEMBLY
Drive gear assembly
1. Using a drift, drive the oil seal into the gear ring.
CAUTION:
●When checking the overall preload torque, measure it
without the oil seal, then install the oil seal.
●Discard old oil seals; replace with new ones.
●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.
2. Apply a thread locking adhesive into the thread hole for the drive
gear.
a. Completely clean and de grease the drive gear back face,
thread holes, and drive gear mounting bolts. (Use a gasket
remover to remove the thread locking adhesive.)
b. Apply a thread locking adhesive 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.
CAUTION:
●Temporary installation before tightening the bolts through the completion of the tightening
should be within 90 seconds.
●If the thread locking adhesive is applied aside, quickly wipe it off.
4. Apply gear oil to ring gear bearing inner race on the transfer
case. Using a drift, install gear bearing inner race.
5. Apply gear oil to ring gear bearing inner race on the adapter
case. Using a drift, install ring gear bearing inner race.
6. Assemble the drive gear assembly to the transfer case.
7. Install the adapter case.
8. Check backlash, preload torque, tooth contact, and companion
flange runout.
●TF-14, "Assembly Inspection".
CAUTION:
Measure the overall preload torque without the oil seal.
SDIA0540E
Tightening torque
First (temporary tightening) : 25 - 29 N·m (2.5 - 3.0 kg-m, 18 - 21 ft-lb)
Second (final tightening) : 82 - 115 N·m (8.3 - 11.7 kg-m,60 - 84 ft-lb)
SDIA0541E
SDIA0543E
SDIA0544E

TRANSFER ASSEMBLY
TF-27
C
E
F
G
H
I
J
K
L
MA
B
TF
Adapter case
1. Select the adjusting shim on the gear ring bearing.
●TF-23, "SELECTIONG ADJUSTING SHIMS".
2. Install the oil gutter.
3. Using a drift, install the selected adjusting shim and gear ring
bearing outer race to the adapter case.
4. Using a drift, drive the oil seal until it becomes flush with the
case end.
CAUTION:
●When checking the overall preload torque, measure it
without the oil seal, then install the oil seal.
●Discard old oil seals; replace with new ones.
●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.
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.
●TF-14, "Assembly Inspection".
CAUTION:
Measure the overall preload torque without the oil seal.
Pinion sleeve assembly
1. Select the pinion sleeve shim.
●TF-23, "SELECTIONG ADJUSTING SHIMS".
SDIA0545E
Drain plug tightening torque
: 9.8 - 19.6 N·m (1.0 -1.9 kg-m, 87 - 173 in-lb)
Tightening torque
: 14 - 16 N·m (1.4 -1.7 kg-m, 11 - 12 ft-lb)
SDIA0546E
SDIA0547E

TF-28
TRANSFER ASSEMBLY
2. Using a drift, install the pinion rear bearing outer race.
3. Using a drift, install the pinion front bearing outer race.
4. Apply gear oil to pinion front bearing inner race and mating posi-
tion on the drive pinion gear. Using a drift, install pinion front
bearing inner race to the drive pinion gear.
5. Install a collapsible spacer to the drive pinion gear.
CAUTION:
Do not reuse the collapsible spacer.
6. Apply gear oil to pinion rear bearing inner race and install it to
the pinion sleeve.
7. Using a drift, install an oil seal to the pinion sleeve.
CAUTION:
●Discard old oil seals; replace with new ones.
●Apply multi purpose grease onto oil seal lips, and gear oil
onto the circumference of the oil seal.
SDIA0548E
SDIA0549E
SDIA0550E
SDIA0551E

TRANSFER ASSEMBLY
TF-29
C
E
F
G
H
I
J
K
L
MA
B
TF
8. Using a drift and press, press in the companion flange.
9. Apply anti-corrosion oil onto threads and seat of the pinion nut
and adjust the pinion nut tightening torque and pinion bearing
preload torque (P’
1 ).
CAUTION:
●Discard the old pinion nut; replace with new ones.
●Adjust the lower limit of the pinion nut tightening torque first.
●If specified preload torque is exceeded, replace the collapsible spacer and tighten again. Never
loosen the pinion nut for further preload torque adjustment.
●After the adjustment, rotate the companion flange back and forth in 2 to 3 times to check for
abnormal noise, rotation malfunction, and other malfunctions.
10. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the pinion sleeve.
CAUTION:
Discard the old O-ring; replace with new one.
11. Assemble the selected pinion sleeve shim.
12. Install the pinion sleeve assembly, and apply anti-corrosive oil onto threads and seats on the mounting
bolts. Tighten to the specified torque.
13. Check backlash, preload torque, tooth contact, and companion flange runout.
●TF-14, "Assembly Inspection".
The overall preload torque is as follows:Pinion nut tightening torque
: 128 - 294 N·m (13 - 30 kg-m, 94 - 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)
Tightening torque : 26 - 33 N·m (2.6 - 3.4 kg-m, 19 - 24 ft-lb)
Overall 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 ring gear oil seal
: P’
1 + 0 . 3 5 - 0 . 3 7 N · m ( 0 . 0 3 5 - 0 . 0 3 8 k g - m , 3 . 1 - 3 . 2 i n - l b )
SDIA0552E

TF-30
ALL MODE 4X4 SYSTEM
ALL MODE 4X4 SYSTEM
PFP:47850
PrecautionsEDS000IV
●This section describes ESP/TCS/ABS model.
●Refer to the BRC section for model without ESP/TCS/ABS.Refer toBRC-6, "ALL MODE 4X4 SYSTEM"
System ComponentEDS000IJ
System DescriptionEDS000IK
ELECTRONIC COUPLING
●In response to command current from 4WD control unit, control
clutch pull-in force is generated at the electromagnet and torque
is generated at the control clutch.
●The cam operates in response to control clutch torque and
applies pressure to main clutch.
● Main clutch transmits torque from input shaft to output shaft,
according to the amount of pressure.
●The actual amount of torque transfer is determined by control
current as shown in figure below (I-T characteristics figure).
4WD CONTROL UNIT
●Controls distribution of drive power between front-wheel drive
(100:0) and 4WD (50:50) conditions circuit according to signals
from sensors.
●If malfunction occurs in 4WD system, 4WD warning lamp turns
ON and vehicle changes to front-wheel drive.
● Self-diagnosis can be done with CONSULT-II.
SFIA0283E
SFIA0284E
SFIA0285E
SFIA0286E