NISSAN X-TRAIL 2003 Electronic Repair Manual
Manufacturer: NISSAN, Model Year: 2003, Model line: X-TRAIL, Model: NISSAN X-TRAIL 2003Pages: 3066, PDF Size: 51.47 MB
Page 2601 of 3066

INPUT SHAFT AND GEARS
MT-65
D
E
F
G
H
I
J
K
L
MA
B
MT
CAUTION:
lBe careful with orientation of synchronizer hub.
lBe sure not to hook ends of 2 spread springs (front ·
back: 2 each) on same shifting insert.
13. Install 5th-6th synchronizer hub assembly.
CAUTION:
Align grooves of 5th-6th shifting insert and 5th-6th baulk
ring.
14. Install needle bearing, 6th input gear and then 6th bushing.
SCIA0921E
SMT761B
SCIA0928E
SCIA0969E
Page 2602 of 3066

MT-66
INPUT SHAFT AND GEARS
15. Install snap ring onto input shaft, and check that end play (gap
between snap ring and groove) of 6th bushing satisfies stan-
dard.
lIf measurement is outside the standard range, select snap
ring.
Snap Rings
16. Install input shaft rear bearing.
CAUTION:
Install input shaft rear bearing with its brown surface facing
the input gear side.
17. Install input shaft front bearing.
18. Install oil channel onto input shaft.
19. Check end play of 3rd, 4th, and 5th input gears.End play standard value : 0 - 0.1 mm (0 - 0.004 in)
SCIA0970E
Thickness Part number Thickness Part number
1.76mm (0.0693 in)
1.81mm (0.0713 in)
1.86mm (0.0732 in)
1.91mm (0.0752 in)
1.96mm (0.0772 in)32204 8H511
32204 8H512
32204 8H513
32204 8H514
32204 8H5152.01mm (0.0791 in)
2.06mm (0.0811 in)
2.11mm (0.0831 in)
2.16mm (0.0850 in)
2.21mm (0.0871 in)32204 8H516
32204 8H517
32204 8H518
32204 8H519
32204 8H520
SCIA0971E
SCIA0972E
Endplaystandardvalue
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)
6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0966E
Page 2603 of 3066

MAINSHAFT AND GEARS
MT-67
D
E
F
G
H
I
J
K
L
MA
B
MT
MAINSHAFT AND GEARSPFP:32241
Assembly and Disassembly (RS5F51A)ECS004UP
DISASSEMBLY
1. Before disassembling, measure end play of 1st and 2nd main
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. Removethesnapring.
3. Remove C-ring holder, and then mainshaft C-ring.
4. Remove mainshaft rear bearing.
5. Removethesnapring.End play standard value
1st gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0933E
SCIA0934E
SCIA0935E
SCIA0936E
Page 2604 of 3066

MT-68
MAINSHAFT AND GEARS
6. Remove 4th main gear and 5th main gear simultaneously.
7. Remove adjusting shim.
8. Remove 3rd-4th mainshaft spacer.
9. Remove 3rd main gear, 2nd main gear, 2nd needle bearing, 2nd
bushing, 1st-2nd synchronizer hub assembly, 1st main gear,
reverse main gear, 1st needle bearing, and 1st bushing simulta-
neously.
INSPECTION AFTER DISASSEMBLY
MainShaft and Gears
Check items below. If necessary, replace them with new ones.
lDamage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the shaft.
lExcessive wear, damage, peeling, and other non-standard con-
ditions of the gears.
Synchronizer
Check items below. If necessary, replace them with new ones.
lDamage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub, and shifting insert.
lCoupling sleeve and synchronizer hub must move smoothly.
SCIA0937E
SCIA0938E
SMT640A
SMT387A
Page 2605 of 3066

MAINSHAFT AND GEARS
MT-69
D
E
F
G
H
I
J
K
L
MA
B
MT
lIf any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
Baulk ring clearance
lDouble cone synchronizer (1st and 2nd)
Check clearance of outer baulk ring, synchronizer cone, and
inner baulk ring of 1st and 2nd double cone synchronizers, fol-
lowing procedure below.
CAUTION:
Outer baulk ring, synchronizer cone, and inner baulk ring
as a set control clearance A and B. If measurement exceeds
service limit value, replace all of them as a set.
1. Using a dial gauge, measure clearance A at 2 or more points
diagonally opposite, and calculate mean value.
2. Using a dial gauge, measure clearance B at 2 or more points
diagonally opposite, and calculate mean value.
SMT867D
SCIA0950E
Clearance A
Standard : 0.6 - 0.8 mm (0.024 - 0.031 in)
Limit value : 0.2 mm (0.008 in) or less
SCIA0951E
Clearance B
Standard : 1.3 - 1.5 mm (0.051 - 0.059 in)
Limit value : 0.2 mm (0.008 in) or less
SCIA0952E
Page 2606 of 3066

MT-70
MAINSHAFT AND GEARS
Bearing
Check items below. If necessary, replace them with new ones.
lDamage and rough rotation of bearing
ASSEMBLY
1. Install reverse main gear.
CAUTION:
Be careful with orientation of reverse main gear.
2. Install 1st bushing.
3. Install needle bearing, and then 1st main gear.
4. Install spread spring, shifting insert and 1st-2nd synchronizer hub onto 1st-2nd coupling sleeve.
MTF0041D
SCIA0939E
SCIA0992E
SCIA0940E
Page 2607 of 3066

MAINSHAFT AND GEARS
MT-71
D
E
F
G
H
I
J
K
L
MA
B
MT
CAUTION:
lBe careful with orientation of synchronizer hub.
lBe careful with orientation of coupling sleeve.
lBe sure not to hook ends of 2 spread springs (front ·
back: 2 each) on same shifting insert.
5. Install 1st gear synchronizer assembly onto mainshaft, and syn-
chronizer hub assembly onto mainshaft.
CAUTION:
lOuter baulk ring, synchronizer cone, and inner baulk ring
on 2nd gear-side must have been removed.
lBe careful with orientation of coupling sleeve.
SCIA0921E
SCIA0989E
SMT761B
SCIA0941E
Page 2608 of 3066

MT-72
MAINSHAFT AND GEARS
6. Install 2nd bushing.
7. Install outer baulk ring, synchronizer cone, and inner baulk ring
on 2nd gear-side.
8. Install 2nd needle bearing and 2nd gear.
9. Install 3rd main gear.
CAUTION:
Be careful with orientation of 3rd main gear.
10. Install 3rd-4th mainshaft spacer.
11. Select suitable adjusting shim so that dimension “C1” satisfies
standard value below, and install it onto mainshaft.
Adjusting Shim
CAUTION:
Only one adjusting shim can be selected.
SCIA0942E
SCIA0943E
Standard for dimension C1
: 173.85 - 173.95 mm (6.844 - 6.848 in)
SCIA0944E
Thickness Part number Thickness Part number
0.52mm (0.0205 in)
0.60mm (0.0236 in)
0.68mm (0.0268 in)
0.76mm (0.0299 in)32238 8H500
32238 8H501
32238 8H502
32238 8H5030.84mm (0.0331 in)
0.92mm (0.0362 in)
1.00mm (0.0394 in)
1.08mm (0.0425 in)32238 8H504
32238 8H505
32238 8H506
32238 8H507
Page 2609 of 3066

MAINSHAFT AND GEARS
MT-73
D
E
F
G
H
I
J
K
L
MA
B
MT
12. Install 4th main gear.
CAUTION:
Be careful with orientation of 4th main gear.
13. Install 5th main gear.
CAUTION:
Be careful with orientation of 5th main gear.
14. Install snap ring onto mainshaft, and check that end play of 5th
main gear satisfies standard value.
lIf measurement is outside the standard range, reselect snap
ring.
Snap Rings
15. Install mainshaft rear bearing.
SCIA0945E
SCIA0946E
Endplaystandardvalue :0-0.1mm(0-0.004in)
SCIA0947E
Thickness Part number Thickness Part number
1.85mm (0.0728 in)
1.90mm (0.0748 in)
1.95mm (0.0768 in)
2.00mm (0.0787 in)32204 8H500
32204 8H501
32204 8H502
32204 8H5032.05mm (0.0807 in)
2.10mm (0.0827 in)
2.15mm (0.0846 in)
2.20mm (0.0866 in)32204 8H504
32204 8H505
32204 8H506
32204 8H507
SCIA0948E
Page 2610 of 3066

MT-74
MAINSHAFT AND GEARS
16. Install C-ring onto mainshaft, and check that end play of main-
shaft rear bearing satisfies standard value.
lIf measurement is outside the standard range, reselect C-ring.
C-ring
17. Fit C-ring holder, and install snap ring.
18. Check end play of 1st and 2nd main gears.
Assembly and Disassembly (RS6F51A)ECS004UU
DISASSEMBLY
1. Before disassembling, measure end play of 1st and 2nd main
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.End play standard value : 0 - 0.06 mm (0 - 0.0024 in)
SCIA0949E
Thickness Part number Thickness Part number
2.535mm (0.0866 in)
2.565mm (0.1010 in)
2.595mm (0.1022 in)
2.625mm (0.1033 in)
2.655mm (0.1045 in)
2.685mm (0.1057 in)
2.715mm (0.1069 in)
2.745mm (0.1081 in)
2.775mm (0.1093 in)
2.805mm (0.1104 in)32348 8H800
32348 8H801
32348 8H802
32348 8H803
32348 8H804
32348 8H805
32348 8H806
32348 8H807
32348 8H808
32348 8H8092.835mm (0.1116 in)
2.865mm (0.1128 in)
2.895mm (0.1140 in)
2.925mm (0.1152 in)
2.955mm (0.1163 in)
2.985mm (0.1175 in)
3.015mm (0.1187 in)
3.045mm (0.1199 in)
3.075mm (0.1211 in)32348 8H810
32348 8H811
32348 8H812
32348 8H813
32348 8H814
32348 8H815
32348 8H816
32348 8H817
32348 8H818
Endplaystandardvalue
1st gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0934E
Endplaystandardvalue
1st gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0973E