NISSAN X-TRAIL 2003 Electronic Repair Manual

SUNROOF
RF-9
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MA
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RF
Installation
1. After bringing sunroof unit into the passenger compartment,
tighten mounting nuts on the side rails (2 each on left/right) Start
from the one at the front reference point.
2. Tighten mounting nuts (4) on the front end.
3. Align the front sunroof bracket to lower face of the rail and roof
side mounting face, and tighten bolts. Then tighten bolts on the
roof side.
4. Align the center and rear sunroof brackets to lower face of the
rail and roof side mounting face, and tighten bolts. Then tighten
bolts on the roof side.
NOTE:
Install the sunroof bracket evenly so that the roof surface has no
distortion.
5. Tighten bolts on motor bracket.
6. Connect the interior lamp harness.
GLASS LID
Removal
1. Tilt up glass lid.
2. Remove side trim.
3. Confirm the number of shims between glass lid and link, and
remove mounting nut to remove glass lid.
Installation
1. Tighten nuts on glass lid diagonally.
2. After installation, adjust the fit.
SUNSHADE
Removal and installation
1. Remove glass lid.
2. Remove rear drain.
3. Move link assembly to the fully open position.
4. Loosen the mounting screws (2) on the front LH shade slider.
SIIA0122E
SIIA0131E
SIIA0124E

RF-10
SUNROOF
5. As shown in the figure, slide shade slider to remove it from the
aluminum rail.
6. Swivel shade toward the left, and remove RH shade from the
aluminum rail.
7. Slide shade forward, and remove rear shade sliders as well.
8. Install in the reverse order of removal.
WIND DEFLECTOR
Removal and installation
1. Remove deflector arm mounting screws (2 for each side).
2. Using a pointed tool, pull up the tabs (2 each on left/right) on the
bushing.
NOTE:
Do not reuse the bushing after its tabs are pulled up.
3. Press and pull off the shaft.
4. Install in the reverse order of removal.
SUNROOF MOTOR
Removal
1. Remove headliner.
2. Remove motor mounting screw and mounting nut.
3. Remove the harness connector, and remove the sunroof motor.
NOTE:
lRemove the sunroof motor when the sunroof is in the fully-
closed position.
lNever rotate the removed motor as a single unit.
Installation
1. Move motor laterally little by little until the gear is completely engaged onto the wire on sunroof unit and
the mounting surface becomes parallel. Then secure motor with screws and nuts.
NOTE:
Before installing motor, be sure to place the link and wire assembly in the symmetrical and fully closed posi-
tion.
SIIA0126E
SIIA0127E
SIIA0128E

RFD-1
REAR FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
C
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SECTION
A
B
RFD
REAR FINAL DRIVE
PRECAUTIONS .......................................................... 2
Caution ..................................................................... 2
Precautions for Brake System .................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 5
OIL .............................................................................. 6
Inspection ................................................................. 6
FLUID LEAKAGE AND OIL LEVEL ...................... 6
REAR FINAL DRIVE SYSTEM ................................... 7
Sectional View .......................................................... 7
FRONT OIL SEAL ...................................................... 8
Removal and Installation .......................................... 8
REMOVAL ............................................................. 8
INSTALLATION ..................................................... 8
SIDE OIL SEAL .......................................................... 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9
REAR COVER GASKET .......................................... 10
Replacement .......................................................... 10
REAR FINAL DRIVE ASSEMBLY .............................11
Removal and Installation .........................................11
REMOVAL ............................................................11
INSTALLATION ....................................................11Electronically Controlled Coupling Breather Hose... 12
Rear Final Drive Breather Hose ............................. 13
Components ........................................................... 14
Inspection Before Disassembly .............................. 15
OVERALL PRELOAD TORQUE ......................... 15
HYPOID GEAR BACKLASH ............................... 15
DRIVE GEAR BACK RUNOUT ........................... 16
COMPANION FLANGE RUNOUT ....................... 16
TOOTH CONTACT .............................................. 17
Disassembly and Assembly .................................... 19
DISASSEMBLY ................................................... 19
ASSEMBLY ......................................................... 22
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 28
General Specification ............................................. 28
Ring Gear Vibration ................................................ 28
Side Gear Clearance Adjustment ........................... 28
THRUST WASHER FOR ADJUSTMENT OF
SIDE GEAR BACK CLEARANCE ....................... 28
Drive Pinion Gear Preload Adjustment ................... 28
DRIVE PINION GEAR PRELOAD ADJUSTING
SHIM ................................................................... 28
Side Bearing Preload Adjustment ........................... 28
ADJUSTING SHIM FOR SIDE BEARING PRE-
LOAD ................................................................... 29
Overall Preload ....................................................... 29

RFD-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
CautionEDS00056
lBefore starting diagnosis of the vehicle, understand symptoms well. Perform correct and systematic oper-
ations.
lCheck for the correct installation status prior to removal or disassembly. When mating marks are required,
be sure they do not interfere with the function of the parts they are applied to.
lCarry out an overhaul in a clean work place. Using a dust proof room is recommended.
lBefore disassembly, using steam or white gasoline, completely remove sand and mud from the exterior of
the unit, preventing them from entering into the unit during disassembly or assembly.
lCheck appearance of the disassembled parts for damage, deformation, and abnormal wear. If a malfunc-
tion is detected, replace it with a new one.
lNormally replace lock pins, oil seals, and bearings with new ones every time they are removed.
lIn principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
lClean and flush the parts sufficiently and blow them dry.
lBe careful not to damage the sliding surfaces and mating surfaces.
lWhen applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.
lAlways use shop paper for cleaning the inside of components.
lAvoid using cotton gloves or a shop cloth to prevent entering of lint.
lDuring assembly, observe the specified tightening torque, and apply new differential oil, Vaseline, or Nis-
san MP Special Grease No. 2, as specified for each vehicle, when necessary.
lDo not reuse drained oil. Discard waste oil after oil changes or part treatment in accordance with local
laws and regulations.
Precautions for Brake SystemEDS000HX
lWhen installing rubber parts, final tightening must be carried out
under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
lAfter installing removed suspension parts, check wheel align-
ment and adjust if necessary.
lUse flare nut wrench when removing or installing brake tubes.
lAlways torque brake lines when installing.
SBR686C

PREPARATION
RFD-3
C
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RFD
PREPARATIONPFP:00002
Special Service ToolsEDS00057
To o l n a m e
Tool numberDescription
Drift
ST27861000
a: 62 mm (2.44 in) dia.
b: 52 mm (2.05 in) dia.Installing final drive front oil seal
Drift
KV38100200
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.
lInstalling final drive front oil seal
lInstalling final drive side oil seal
Preload gauge
ST3127S000Measuring preload torque
Drift
ST33052000
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.
lRemoving side bearing inner
Drift
KV40100610
a: 63 mm (2.48 in) dia.
b: 54.3 mm (2.138 in) dia.
lRemoving and installing carrier
case and rear cover (2 pieces are
used)
lInstalling pinion front bearing inner
race
Pin punch
ST23550000
Tip diameter: 4.5 mm (0.177 in) dia.Removing and installing lock pin
Drift
ST17130000
a: 31.8 mm (1.252 in) dia.
b: 58 mm (2.28 in) dia.Installing pinion rear bearing outer
race
ZZA0832D
ZZA1143D
ZZA0503D
ZZA1023D
ZZA0810D
ZZA0815D
ZZA0836D

RFD-4
PREPARATION
Drift
ST33230000
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.
c: 28.5 mm (1.122 in) dia.Installing pinion front bearing outer
race
Drift
ST23860000
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
lInstalling pinion rear bearing inner
race
lInstalling pinion front bearing inner
race
Press stand
ST38220000
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in)Installing pinion front bearing inner
race
Drift
KV40105020
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in)Installing side bearing inner race
Drift
ST22350000
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.Installing coupling front bearing
Drift
ST33400001
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.Installing coupling cover oil seal
Dummy cover set
KV381086S0
1. Dummy cover
KV38108610
2. Dummy cover spacer
KV38108620 (with bolt)
a: KV38108620-1
3. Dummy cover shim
KV38108630
b: KV38108630-1
lChecking backlash
lChecking drive gear back runout
lChecking tooth contact Tool name
Tool numberDescription
ZZA1046D
ZZA0534D
ZZA1058D
ZZA1133D
ZZA0534D
ZZA0814D
ZZA1204D

PREPARATION
RFD-5
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RFD
Commercial Service ToolsEDS000HY
drive pinion gear socket
KV38108500lMeasuring preload torque
lRemoving and installing pinion nut
Pinion nut wrench
KV38108400Removing and installing pinion nut
Oilsealdrift
ST15310000
a: 96 mm (3.78 in) dia.
b: 84 mm (3.31 in) dia.Center oil seal installation
Support ring
KV40104710
a: 76.3 mm (3.004 in) dia.
b: 67.9 mm (2.673 in) dia.Center oil seal installation To o l n a m e
Tool numberDescription
ZZA1205D
ZZA1206D
ZZA0908D
ZZA0832D
Tool nameDescription
1. Flare nut crowfoot
2. Torque wrench
a: 10 mm (0.39 in)Removing and installing brake piping
S-NT360

RFD-6
OIL
OIL
PFP:00024
InspectionEDS00059
FLUID LEAKAGE AND OIL LEVEL
1. Check for fluid leakage and for proper oil level.
2. Install the filler plug to the final drive, and tighten to the specified
torque.
CAUTION:
Do not reuse the filler plug gasket.
: 30 - 39 N-m (3.0 - 4.0 kg-m,22 - 28 ft-lb)
SDIA0567E

REAR FINAL DRIVE SYSTEM
RFD-7
C
E
F
G
H
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MA
B
RFD
REAR FINAL DRIVE SYSTEMPFP:38300
Sectional ViewEDS0005A
SDIA0141E

RFD-8
FRONT OIL SEAL
FRONT OIL SEAL
PFP:38189
Removal and InstallationEDS0005B
REMOVAL
1. Remove propeller shaft. Refer toPR-3, "REMOVAL".
2. Paint mating marks on the final drive companion flange and the thread edge of the electronically con-
trolled coupling.
CAUTION:
Use paint to avoid scratching the surface.
3. Using a differential flange tool, remove companion flange nut to remove companion flange.
4. Using a screwdriver or similar tool, remove oil seal.
INSTALLATION
1. Apply multi-purpose grease to oil seal lips. Using a drift as
shown, install oil seal. It should become flush with case end sur-
face.
CAUTION:
lWhen installing, do not incline the oil seal.
lOil seals are not reusable. Never reuse them.
2. Align the mating marks on the companion flange and on the electronically controlled coupling, and install
the companion flange.
3. Install a companion flange nut. Using a differential flange tool, tighten the nut to the specified torque.
CAUTION:
Do not reuse the companion flange nut.
4. Connect propeller shaft. Refer toPR-3, "
Removal and Installation".
SDIA0142J
: 100 - 122 N-m (11 - 12 kg-m,74 - 89 ft-lb)