NISSAN X-TRAIL 2003 Electronic Repair Manual

TRANSAXLE ASSEMBLY
MT-25
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1. Mainshaft front bearing 2. Mainshaft bearing retainer 3. Mainshaft
4. Reverse main gear 5. 1st main gear 6. Bushing
7. Needle bearing 8. 1st inner baulk ring 9. 1st gear synchronizer cone
10. 1st outer baulk ring 11. Spread spring 12. 1st & 2nd shifting insert
13. 1st & 2nd synchronizer hub 14. 2nd outer baulk ring 15. 2nd gear synchronizer cone
16. 2nd inner baulk ring 17. 1st & 2nd coupling sleeve 18. Bushing
19. 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
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MT-26
TRANSAXLE ASSEMBLY
SHIFT CONTROL COMPONENTS
1. Reverse shift fork 2. Shifter cap 3. Reverse shift fork rod
4. Reverse lever assembly 5. 5th & 6th bracket 6. 5th & 6th fork rod
7. 5th & 6th shift fork 8. Retaining pin 9. 3rd & 4th bracket
10. 3rd & 4th shift fork 11. 3rd & 4th fork rod 12. 1st & 2nd shift fork
13. 1st & 2nd fork rod bracket 14. 1st & 2nd fork rod 15. Shift check sleeve
16. Inter lock pin 17. Check ball 18. Shift check sleeve
19. Check spring 20. Check plug 21. Control assembly
22. O ring 23. Shift check 24. Stopper bolt
25. Stopper ring 26. Reverse bracket fork rod 27. Reverse bracket
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TRANSAXLE ASSEMBLY
MT-27
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FINAL DRIVE COMPONENTS
Disassembly and Assembly (RS5F51A)ECS00469
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.
1. Differential side bearing outer race 2. Differential side bearing 3. Differential case
4. Final gear 5. Differential side bearing 6. Differential side bearing outer race
7. Differential side bearing adjusting shim 8. Pinion mate shaft 9. Side gear
10. Side gear thrust washer 11. Pinion mate gear 12. Pinion mate gear washer
13. Retaining pin
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MT-28
TRANSAXLE ASSEMBLY
4. Remove check plugs (3 pieces), check springs (3 pieces), check
balls (3 pieces) and shift check sleeve (1 piece).
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 adjust shim.
11. Remove differential oil seal.
12. Remove magnet from clutch housing.
13. 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.
14. Pull out reverse fork rod then remove reverse shift fork.
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TRANSAXLE ASSEMBLY
MT-29
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15. Shift 3rd & 4th fork rod to 3rd position. Remove retaining pin of
5th shift fork using pin punch.
16. Remove stopper rings for 5th & reverse bracket.
17. Pull out 5th & reverse fork rod and remove 5th shift fork and 5th
& reverse bracket.
18. Remove check balls (2 pieces) and inter lock pin.
19. Remove retaining pin of 3rd & 4th bracket using pin punch.
20. Remove stopper rings for 3rd & 4th shift fork.
21. Pull out 3rd & 4th fork rod and remove 3rd & 4th shift fork and
bracket.
22. Remove shift check sleeve from clutch housing.
23. Remove retaining pin of 1st & 2nd shift fork using pin punch.
24. Pull out 1st & 2nd with bracket.
25. Remove 1st & 2nd shift fork.
26. Remove retaining pin of 1st & 2nd bracket using pin punch and
separate 1st & 2nd fork rod and bracket.
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MT-30
TRANSAXLE ASSEMBLY
27. 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.
28. Remove bearing retainer and then mainshaft front bearing.
29. Remove oil channel on mainshaft side.
30. Remove differential oil seal.
31. Remove differential side bearing outer race (clutch housing
side).
32. Remove input shaft oil seal.
CAUTION:
Be careful not to damage clutch housing.
ASSEMBLY
1. Using a drift, install input shaft oil seal.
CAUTION:
Oil seals are not reusable. Never reuse them.
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TRANSAXLE ASSEMBLY
MT-31
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2. Using a drift, install differential oil seal.
CAUTION:
Oil seals are not reusable. Never reuse them.
3. Install oil channel on mainshaft side.
CAUTION:
Be careful with orientation of installation.
4. Using a drift, install mainshaft front bearing.
5. Install bearing retainer.
6. Install differential side bearing outer race.
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MT-32
TRANSAXLE ASSEMBLY
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.
9. Install 1st-2nd fork rod bracket onto 1st-2nd fork rod, and then
install retaining pin.
CAUTION:
Retaining pins are not reusable. Never reuse them.
10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install
retaining pin.
CAUTION:
Retaining pins are not reusable. Never reuse them.
11. Install shift check sleeve.
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TRANSAXLE ASSEMBLY
MT-33
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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:
Stopper rings are not reusable. Never reuse them.
14. Install retaining pin onto 3rd-4th bracket.
CAUTION:
Retaining pins are not reusable. Never reuse them.
15. Install 2 check balls.
16. Install 5th-reverse bracket, 5th shift fork, and 5th-reverse fork
rod.
17. Install stopper ring onto 5th-reverse bracket.
CAUTION:
Stopper rings are not reusable. Never reuse them.
18. Install retaining pin onto 5th shift fork.
CAUTION:
Retaining pins are not reusable. Never reuse them.
19. Install reverse shift fork and reverse fork rod.
20. 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 5th-reverse
bracket.
c. Tighten mounting bolts to specified torque, and then install
reverse lever assembly.
d. Install snap ring.
21. Install the magnet onto clutch housing.
22. Install selected input shaft adjusting shim onto input shaft.
lFor selection of adjusting shims, refer toMT-44, "INPUT-
SHAFT END PLAY".
23. Install baffle plate and oil gutter.
24. Install transaxle case following procedures below.
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MT-34
TRANSAXLE ASSEMBLY
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
lFor selection of adjusting shims, refer toMT-46, "MAINSHAFT END PLAY".
b. Temporarily install snap ring of mainshaft rear bearing into transaxle case.
CAUTION:
Do not reuse the snap ring.
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. Install control assembly.
CAUTION:
Do not reuse the O-ring.
f. Install shift check and stopper bolt.
CAUTION:
Shift check and stopper bolt are not reusable. Never reuse
them.
g. Through bore plug mounting hole, with snap ring stretched,
move shift lever of striking rod assembly to 2nd speed, and lift
up mainshaft assembly.
h. Securely install snap ring onto mainshaft rear bearing.
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