NISSAN X-TRAIL 2003 Electronic Repair Manual

TRANSAXLE ASSEMBLY
MT-35
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B
MT
i. Tighten mounting bolts.
CAUTION:
Always replace bolts B as they are self-sealing bolts.
25. Using a drift, install bore plug.
CAUTION:
Bore plugs are not reusable. Never reuse them.
26. Install 1 shift check sleeve, 3 check balls, 3 check springs, and 3
check ball plugs.
CAUTION:
Check ball plugs are not reusable. Never reuse them.
27. Apply recommended sealant to threads of neutral switch and
reverse lamp switch. Then install them into transaxle case.
28. Install gaskets onto drain plug and filler plug, and then install
them into transaxle case.
CAUTION:
lGaskets are not reusable. Never reuse them.
lAfter oil is filled, tighten filler plug to specified torque.
Disassembly and Assembly (RS6F51A)ECS004PY
DISASSEMBLY
1. Remove drain plug and filler plug.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-36
TRANSAXLE ASSEMBLY
2. Remove park/neutral position switch and back-up lamp switch.
3. After removing shift check and stopper bolt, remove control
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 differential oil seal.
12. Remove magnet from clutch housing.
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TRANSAXLE ASSEMBLY
MT-37
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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.
15. Remove retaining pin of reverse bracket.
16. Pull out reverse lever and reverse bracket fork rod.
17. Remove check ball (2 pieces) and inter lock pin.
18. Shift 3rd & 4th fork rod to 3rd position. Remove retaining pin of
5th & 6th shift fork using pin punch.
19. Remove stopper rings for 5th & 6th bracket.
20. Pull out 5th & 6th fork rod and remove 5th & 6th shift fork and
5th & 6th bracket.
21. Remove check balls (2 pieces) and inter lock pin.
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MT-38
TRANSAXLE ASSEMBLY
22. Remove retaining pin of 3rd & 4th bracket using pin punch.
23. Remove stopper rings for 3rd & 4th shift fork.
24. Pull out 3rd & 4th fork rod and remove 3rd & 4th shift fork and
bracket.
25. Remove shift check sleeve from clutch housing.
26. Remove retaining pin of 1st & 2nd shift fork using pin punch.
27. Pull out 1st & 2nd fork rod with bracket.
28. Remove 1st & 2nd shift fork.
29. Remove retaining pin of 1st & 2nd bracket using pin punch and
separate fork rod and bracket.
30. 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.
31. Remove bearing retainer and then mainshaft front bearing.
32. Remove oil channel on mainshaft side.
33. Remove differential oil seal.
34. Remove differential side bearing outer race (clutch housing
side).
35. Remove input shaft oil seal.
CAUTION:
Be careful not to damage clutch housing.
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TRANSAXLE ASSEMBLY
MT-39
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ASSEMBLY
1. Using a drift, install input shaft oil seal.
CAUTION:
Oil seals are not reusable. Never reuse them.
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.
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MT-40
TRANSAXLE ASSEMBLY
5. Install bearing retainer.
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.
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.
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TRANSAXLE ASSEMBLY
MT-41
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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.
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-6th bracket, 5th-6th shift fork, and 5th-6th fork rod.
17. Install stopper ring onto 5th-6th fork rod bracket with inter lock
pin.
CAUTION:
Stopper rings are not reusable. Never reuse them.
18. Install retaining pin onto 5th-6th shift fork.
CAUTION:
Retaining pins are not reusable. Never reuse them.
19. Install 2 check balls.
20. Install reverse bracket fork rod and reverse lever bracket.
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MT-42
TRANSAXLE ASSEMBLY
21. Install retaining pin onto reverse bracket.
CAUTION:
Retaining pins are not reusable. Never reuse them.
22. Install reverse shift fork and reverse fork rod.
23. 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.
24. Install the magnet onto clutch housing.
25. Install selected input shaft adjusting shim onto input shaft.
lFor selection of adjusting shims, refer toMT-48, "INPUT-
SHAFT END PLAY".
26. Install baffle plate and oil gutter.
27. Install transaxle case following procedures below.
a. Install selected mainshaft rear bearing adjusting shim into tran-
saxle case.
lFor selection of adjusting shims, refer toMT-51, "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.
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TRANSAXLE ASSEMBLY
MT-43
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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.
i. Tighten mounting bolts.
CAUTION:
Always replace bolts B as they are self-sealing bolts.
28. Using a drift, install bore plug.
CAUTION:
Bore plugs are not reusable. Never reuse them.
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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
29. Install 2 shift check sleeves, 4 check balls, 4 check springs, and
4 check ball plugs.
CAUTION:
Check ball plugs are not reusable. Never reuse them.
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:
lGaskets are not reusable. Never reuse them.
lAfter oil is filled, tighten filler plug to specified torque.
Adjustment (RS5F51A)ECS0046A
INPUTSHAFT END PLAY
lWhen adjusting input shaft end play, select adjusting shim for
input shaft bearing. To select adjusting shim, measure clearance
between transaxle case and input shaft rear bearing.
lCalculate dimension "O" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for input
shaft rear bearing.
Adjusting Shim
CAUTION:
Only 1 adjusting shim can be selected.
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End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension“O” = (O
1-O2)+Endplay
O : Thickness of adjusting shim
O
1: Distance between transaxle case end face
and mounting face of adjusting shim
O
2: Distance between clutch housing case end
face and end face of input shaft rear bearing
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Shim thickness Part number Shim thickness Part number Shim thickness Part number
0.40 mm (0.0157 in)
0.44 mm (0.0173 in)
0.48 mm (0.0189 in)
0.52 mm (0.0205 in)
0.56 mm (0.0220 in)
0.60 mm (0.0236 in)
0.64 mm (0.0252 in)
0.68 mm (0.0268 in)
0.72 mm (0.0283 in)
0.76 mm (0.0299 in)
0.80 mm (0.0315 in)
0.84 mm (0.0331 in)32225 8H500
32225 8H501
32225 8H502
32225 8H503
32225 8H504
32225 8H505
32225 8H506
32225 8H507
32225 8H508
32225 8H509
32225 8H510
32225 8H5110.88 mm (0.0346 in)
0.92 mm (0.0362 in)
0.96 mm (0.0378 in)
1.00 mm (0.0396 in)
1.04 mm (0.0409 in)
1.08 mm (0.0425 in)
1.12 mm (0.0441 in)
1.16 mm (0.0457 in)
1.20 mm (0.0472 in)
1.24 mm (0.0488 in)
1.28 mm (0.0504 in)
1.32 mm (0.0520 in)32225 8H512
32225 8H513
32225 8H514
32225 8H515
32225 8H516
32225 8H517
32225 8H518
32225 8H519
32225 8H520
32225 8H521
32225 8H522
32225 8H5231.36 mm (0.0520 in)
1.40 mm (0.0551 in)
1.44 mm (0.0567 in)
1.48 mm (0.0583 in)
1.52 mm (0.0598 in)
1.56 mm (0.0614 in)
1.60 mm (0.0630 in)
1.64 mm (0.0646 in)
1.68 mm (0.0661 in)
1.72 mm (0.0677 in)32225 8H524
32225 8H560
32225 8H561
32225 8H562
32225 8H563
32225 8H564
32225 8H565
32225 8H566
32225 8H567
32225 8H568