NISSAN X-TRAIL 2003 Electronic Repair Manual

TRANSAXLE ASSEMBLY
MT-45
D
E
F
G
H
I
J
K
L
MA
B
MT
1. Using depth micrometer and straight edge, measure dimension
"O
1" between transaxle case end face and mounting face of
adjusting shim.
2. Using depth micrometer and straight edge as shown in the fig-
ure, measure dimension "O
2" between clutch housing case end
face and end face of input shaft rear bearing.
3. Install selected input shaft rear bearing adjusting shim onto input
shaft.
DIFFERENTIAL SIDE BEARING PRELOAD
lWhen adjusting differential side bearing preload, select adjust-
ing shim for differential side bearing. To select adjusting shim,
measure clearance “L” between transaxle case and differential
side bearing outer race.
lCalculate dimension “L” (thickness of adjusting shim) using the
following procedure to satisfy specification of preload for differ-
ential side bearing.
Adjusting Shim
CAUTION:
Up to 2 adjusting shims can be selected.
SCIA1002E
SCIA1004E
Preload : 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension“L” = (L
1-L2)+Preload
L : Thickness of adjusting shim
L
1: Distance between clutch housing case end
face and mounting face of adjusting shim
L
2: Distance between differential side bearing
and transaxle case
SCIA0896E
Shim thickness Part number
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)
0.88 mm (0.0346 in)
0.92 mm (0.0362 in)31438 80X00
31438 80X01
31438 80X02
31438 80X03
31438 80X04
31438 80X05
31438 80X06
31438 80X07
31438 80X08
31438 80X09
31438 80X10
31438 80X11

MT-46
TRANSAXLE ASSEMBLY
1. Using dial gauge and scale, measure dimension "L1" between
clutch housing case end face and mounting face of adjusting
shim.
2. Install outer race onto differential side bearing on final gear side.
Holding lightly the outer race horizontally by hand, rotate final
gear five times or more (for smooth movement of bearing roller).
3. Using dial gauge and scale as shown in the figure, measure
dimension "L
2" between differential side bearing outer race and
transaxle case end face.
4. Install selected adjusting shim and then differential side bearing
outer race.
MAINSHAFT END PLAY
lWhen adjusting mainshaft end play, select adjusting shim for
mainshaft rear bearing. To select adjusting shim, measure clear-
ance “M” between transaxle case and mainshaft rear bearing.
lCalculate dimension "P" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for main-
shaft rear bearing.
SCIA1015E
SCIA1016E
SCIA0898E
End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension“P” = "M" + End play
P : Thickness of adjusting shim
M : Distance between mainshaft rear bearing and
transaxle case
SCIA0904E

TRANSAXLE ASSEMBLY
MT-47
D
E
F
G
H
I
J
K
L
MA
B
MT
Adjusting Shim
CAUTION:
Only 1 adjusting shim can be selected.
1. Install mainshaft assembly to clutch housing.
2. Install snap ring to transaxle case.
3. Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install tempo-
rarily snap ring to mainshaft rear bearing.
4. Install dial gauge to snap ring access hole, and expand snap
ring. Lift mainshaft assembly through control assembly installa-
tion hole, and push it against transaxle case. This state shall be
defined as base. Moving distance of mainshaft assembly, with
snap ring fit on main bearing, becomes “L”.
REVERSE IDLER GEAR END PLAY
lWhen adjusting reverse idler gear end play, select adjusting
shim for reverse idler gear. To select adjusting shim, measure
clearance between transaxle case and reverse idler gear.
lCalculate dimension "Q" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for
reverse idler gear.
Shim thickness Part number
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)
0.88 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)32238 8H510
32238 8H511
32238 8H512
32238 8H513
32238 8H514
32238 8H515
32238 8H516
32238 8H517
32238 8H518
32238 8H519
32238 8H520
32238 8H521
32238 8H522
32238 8H523
32238 8H524
32238 8H560
32238 8H561
SCIA1017E
End play : 0.04 - 0.14 mm (0.0016 - 0.0055 in)
Dimension“Q” = (Q
1-Q2)+Endplay
Q : Thickness of adjusting shim
Q
1: Distance between transaxle case end face
and mounting face of adjusting shim
Q
2: Distance between clutch housing case end
face and end face of reverse idler gear
SCIA1007E

MT-48
TRANSAXLE ASSEMBLY
Adjusting Shim
CAUTION:
Only 1 adjusting shim can be selected.
1. Using depth micrometer and straight edge, measure dimension
"Q
1" between transaxle case end face and mounting face of
adjusting shim.
2. Using depth micrometer and straight edge as shown in the fig-
ure, measure dimension "Q
2" between clutch housing case end
face and end face of reverse idler gear.
3. Install selected reverse idler gear adjusting shim onto reverse
idler gear.
Adjustment (RS6F51A)ECS004PZ
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.
Shim thickness Part number
1.76 mm (0.0693 in)
1.84 mm (0.0724 in)
1.92 mm (0.0756 in)
2.00 mm (0.0787 in)
2.08 mm (0.0819 in)
2.16 mm (0.0850 in)
2.24 mm (0.0882 in)
2.32 mm (0.0913 in)
2.40 mm (0.0945 in)
2.48 mm (0.0976 in)
2.56 mm (0.1008 in)
2.64 mm (0.1039 in)32237 8H500
32237 8H501
32237 8H502
32237 8H503
32237 8H504
32237 8H505
32237 8H506
32237 8H507
32237 8H508
32237 8H509
32237 8H510
32237 8H511
SCIA1003E
SCIA1005E
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
SCIA1001E

TRANSAXLE ASSEMBLY
MT-49
D
E
F
G
H
I
J
K
L
MA
B
MT
Adjusting Shim
CAUTION:
Only 1 adjusting shim can be selected.
1. Using depth micrometer and straight edge, measure dimension
"O
1" between transaxle case end face and mounting face of
adjusting shim.
2. Using depth micrometer and straight edge as shown in the fig-
ure, measure dimension "O
2" between clutch housing case end
face and end face of input shaft rear bearing.
3. Install selected input shaft rear bearing adjusting shim onto input
shaft.
DIFFERENTIAL SIDE BEARING PRELOAD
lWhen adjusting differential side bearing preload, select adjust-
ing shim for differential side bearing. To select adjusting shim,
measure clearance “L” between transaxle case and differential
side bearing outer race.
lCalculate dimension “L” (thickness of adjusting shim) using the
following procedure to satisfy specification of preload for differ-
ential side bearing.
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
SCIA1002E
SCIA1004E
Preload : 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension“L” = (L
1-L2)+Preload
L : Thickness of adjusting shim
L
1: Distance between clutch housing case end
face and mounting face of adjusting shim
L
2: Distance between differential side bearing
and transaxle case
SCIA0896E

MT-50
TRANSAXLE ASSEMBLY
Adjusting Shim
CAUTION:
Up to 2 adjusting shims can be selected.
1. Using dial gauge and scale, measure dimension "L1" between
clutch housing case end face and mounting face of adjusting
shim.
2. Install outer race onto differential side bearing on final gear side.
Holding lightly the outer race horizontally by hand, rotate final
gear five times or more (for smooth movement of bearing roller).
3. Using dial gauge and scale as shown in the figure, measure
dimension "L
2" between differential side bearing outer race and
transaxle case end face.
4. Install selected adjusting shim and then differential side bearing
outer race.
Shim thickness Part number
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)
0.88 mm (0.0346 in)
0.92 mm (0.0362 in)31438 80X00
31438 80X01
31438 80X02
31438 80X03
31438 80X04
31438 80X05
31438 80X06
31438 80X07
31438 80X08
31438 80X09
31438 80X10
31438 80X11
SCIA1015E
SCIA1016E
SCIA0898E

TRANSAXLE ASSEMBLY
MT-51
D
E
F
G
H
I
J
K
L
MA
B
MT
MAINSHAFT END PLAY
lWhen adjusting mainshaft end play, select adjusting shim for
mainshaft rear bearing. To select adjusting shim, measure clear-
ance “M” between transaxle case and mainshaft rear bearing.
lCalculate dimension "P" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for main-
shaft rear bearing.
Adjusting Shim
CAUTION:
Only 1 adjusting shim can be selected.
1. Install mainshaft assembly to clutch housing.
2. Install snap ring to transaxle case.
3. Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install tempo-
rarily snap ring to mainshaft rear bearing.
4. Install dial gauge to snap ring access hole, and expand snap
ring. Lift mainshaft assembly through control assembly installa-
tion hole, and push it against transaxle case. This state shall be
defined as base. Moving distance of mainshaft assembly, with
snap ring fit on main bearing, becomes “L”.End play : 0 - 0.06 mm (0 - 0.0024 in)
Dimension“P” = "M" + End play
P : Thickness of adjusting shim
M : Distance between mainshaft rear bearing and
transaxle case
SCIA0904E
Shim thickness Part number
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)
0.88 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)32238 8H510
32238 8H511
32238 8H512
32238 8H513
32238 8H514
32238 8H515
32238 8H516
32238 8H517
32238 8H518
32238 8H519
32238 8H520
32238 8H521
32238 8H522
32238 8H523
32238 8H524
32238 8H560
32238 8H561
SCIA1017E

MT-52
TRANSAXLE ASSEMBLY
REVERSE IDLER GEAR END PLAY
lWhen adjusting reverse idler gear end play, select adjusting
shim for reverse idler gear. To select adjusting shim, measure
clearance between transaxle case and reverse idler gear.
lCalculate dimension "Q" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for
reverse idler gear.
Adjusting Shim
CAUTION:
Only 1 adjusting shim can be selected.
1. Using depth micrometer and straight edge, measure dimension
"Q
1" between transaxle case end face and mounting face of
adjusting shim.
2. Using depth micrometer and straight edge as shown in the fig-
ure, measure dimension "Q
2" between clutch housing case end
face and end face of reverse idler gear.
3. Install selected reverse idler gear adjusting shim onto reverse
idler gear.End play : 0.04 - 0.14 mm (0.0016 - 0.0055 in)
Dimension“Q” = (Q
1-Q2)+Endplay
Q : Thickness of adjusting shim
Q
1: Distance between transaxle case end face
and mounting face of adjusting shim
Q
2: Distance between clutch housing case end
face and end face of reverse idler gear
SCIA1007E
Shim thickness Part number
1.76 mm (0.0693 in)
1.84 mm (0.0724 in)
1.92 mm (0.0756 in)
2.00 mm (0.0787 in)
2.08 mm (0.0819 in)
2.16 mm (0.0850 in)
2.24 mm (0.0882 in)
2.32 mm (0.0913 in)
2.40 mm (0.0945 in)
2.48 mm (0.0976 in)
2.56 mm (0.1008 in)
2.64 mm (0.1039 in)32237 8H500
32237 8H501
32237 8H502
32237 8H503
32237 8H504
32237 8H505
32237 8H506
32237 8H507
32237 8H508
32237 8H509
32237 8H510
32237 8H511
SCIA1003E
SCIA1005E

INPUT SHAFT AND GEARS
MT-53
D
E
F
G
H
I
J
K
L
MA
B
MT
INPUT SHAFT AND GEARSPFP:32200
Assembly and Disassembly (RS5F51A)ECS004UO
DISASSEMBLY
1. Before disassembling, measure end play for 3rd, 4th, and 5th
input gears.
CAUTION:
If measurement is outside the standard range, disassemble
to check contact surfaces of gear, shaft, and hub. Adjust
with snap ring at assembly.
2. Remove oil channel.
3. Remove input shaft rear bearing.
4. Removethesnapring.
5. Remove input shaft bearing spacer and 5th stopper simulta-
neously.End play standard value
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0914E
SCIA0915E
SCIA0916E
SCIA0917E

MT-54
INPUT SHAFT AND GEARS
6. Remove 5th input gear and synchronizer hub assembly simulta-
neously.
7. Remove 5th needle bearing.
8. Remove 5th bushing, thrust washer, 4th input gear, 4th needle
bearing, 4th gear bushing, 3rd-4th synchronizer hub assembly,
3rd-4th baulk ring and 3rd input gear simultaneously.
9. Remove 3rd needle bearing.
10. Remove input shaft front bearing.
INSPECTION AFTER DISASSEMBLY
Input Shaft and Gear
Check items below. If necessary, replace them with new ones.
lDamage, peeling, dent, uneven wear, bending, etc. of shaft
lExcessive wear, damage, peeling, etc. of gears
SCIA0918E
SCIA0919E
SCIA0920E
SMT636A