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 2611 of 3066

MAINSHAFT AND GEARS
MT-75
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B
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2. Removethesnapring.
3. Remove C-ring holder, and then mainshaft C-ring.
4. Remove mainshaft rear bearing, adjust shim and 6th main gear.
5. Remove 5th-6th mainshaft spacer.
6. Remove 4th main gear and 5th main gear simultaneously.
7. Remove adjusting shim.
8. Remove spacer.
9. Remove 3rd main gear, 2nd main gear, 2nd gear needle bear-
ing, 2nd bushing, 1st-2nd synchronizer assembly, 1st main gear,
reverse main gear, 1st gear needle bearing, and 1st bushing
simultaneously.
SCIA0974E
SCIA0976E
SCIA0937E
SCIA0938E
Page 2612 of 3066

MT-76
MAINSHAFT AND GEARS
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.
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.
SMT640A
SMT387A
SMT867D
SCIA0950E
Page 2613 of 3066

MAINSHAFT AND GEARS
MT-77
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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.
Bearing
Check items below. If necessary, replace them with new ones.
lDamage and rough rotation of bearing
ASSEMBLY
1. Install reverse main gear.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
MTF0041D
SCIA0939E
Page 2614 of 3066

MT-78
MAINSHAFT AND GEARS
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.
CAUTION:
lBe careful with orientation of synchronizer hub.
lBe careful with orientation of coupling sleeve.
SCIA0992E
SCIA0940E
SCIA0921E
SCIA0989E
Page 2615 of 3066

MAINSHAFT AND GEARS
MT-79
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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.
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.
SMT761B
SCIA0941E
SCIA0942E
SCIA0943E
Page 2616 of 3066

MT-80
MAINSHAFT AND GEARS
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.
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 5th-6th mainshaft spacer.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
SCIA0945E
SCIA0946E
Page 2617 of 3066

MAINSHAFT AND GEARS
MT-81
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15. Install 6th main gear.
16. Adjustment between 6th main gear and 6th main adjusting shim.
lCalculate thickness “Q” of 6th main adjusting shim by proce-
dure below so that end play dimension between 6th main
gear and mainshaft rear bearing becomes the dimension
shown below.
Adjusting Shim
CAUTION:
Only one adjusting shim can be selected.
a. Using height gauge, measure dimension “Q1”and“Q2”.
b. Install selected 6th main adjusting shim to mainshaft.
17. Install mainshaft rear bearing.
SCIA0977E
Endplay :0-0.1mm(0-0.004in)
Dimension“Q” = (Q
1-Q2)+Endplay
Q : Thickness of adjusting shim
Q
1: Dimension from mainshaft reference face to
mainshaft rear bearing press-fit end face
Q
2: Dimension from mainshaft reference face to
6th main gear end face
SCIA0995E
Thickness Part number Thickness Part number
0.88mm (0.0346 in)
0.96mm (0.0378 in)
1.04mm (0.0409 in)
1.12mm (0.0441 in)32237 8H560
32237 8H561
32237 8H562
32237 8H5631.20mm (0.0472 in)
1.28mm (0.0504 in)
1.36mm (0.0535 in)32237 8H564
32237 8H565
32237 8H566
SCIA0978E
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MT-82
MAINSHAFT AND GEARS
18. 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
19. Fit C-ring holder, and install snap ring.
20. Check end play of 1st and 2nd main gears.End play standard value : 0 - 0.06 mm (0 - 0.0024 in)
SCIA0979E
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
SCIA0974E
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
Page 2619 of 3066

REVERSE IDLER SHAFT AND GEARS
MT-83
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REVERSE IDLER SHAFT AND GEARSPFP:32281
Assembly and Disassembly (RS5F51A)ECS004UQ
DISASSEMBLY
1. Remove reverse idler gear adjusting shim.
2. Remove reverse idler gear (rear), reverse coupling sleeve and insert spring simultaneously.
3. Remove reverse idler gear needle bearing.
4. Remove thrust needle bearing.
5. Remove reverse baulk ring.
6. Remove reverse idler gear (front).
7. Remove reverse idler gear needle bearing.
8. Remove thrust needle bearing.
9. Pull off locking pin from reverse idler shaft.
INSPECTION AFTER DISASSEMBLY
Reverse Idler Shaft 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 insert spring.
lCoupling sleeve and synchronizer hub must move smoothly.
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
SCIA0953E
SMT637A
SMT867D
Page 2620 of 3066

MT-84
REVERSE IDLER SHAFT AND GEARS
lPress baulk ring against cone, and measure clearance between
baulk ring and cone. If measurement is below limit, replace it
with a new one.
Bearing
Check items below. If necessary, replace them with new ones.
lDamage and rough rotation of bearing.
ASSEMBLY
Paying attention to following work, assemble in reverse order of disassembly.
CAUTION:
lBe careful with orientation of insert spring.
Assembly and Disassembly (RS6F51A)ECS004UV
DISASSEMBLY
1. Remove reverse idler gear adjusting shim.
2. Remove reverse idler gear (rear), reverse coupling sleeve and insert spring simultaneously.
3. Remove reverse idler gear needle bearing.
4. Remove thrust needle bearing.
5. Remove reverse baulk ring.
6. Remove reverse idler gear (front).
7. Remove reverse idler gear needle bearing.
8. Remove thrust needle bearing.
9. Pull off locking pin from reverse idler shaft.
INSPECTION AFTER DISASSEMBLY
Reverse Idler Shaft 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.Clearance
Standard : 0.95 - 1.4 mm (0.0374 - 0.055 in)
Limit value : 0.7 mm (0.028 in)
SMT140
SCIA0954E
SCIA0953E