NISSAN X-TRAIL 2003 Electronic Repair Manual

AIR BREATHER HOSE
TF-11
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lRefer to the figure for air breather hose removal and installation information.
CAUTION:
lBe sure to insert air breather hose into transfer tube (metal connector) until hose end reaches the
tube's base.
lMake sure there are no pinched or restricted areas on the air breather hose caused by bending or
winding when installing it.

TF-12
TRANSFER ASSEMBLY
TRANSFER ASSEMBLY
PFP:33100
Removal and Installation from VehicleEDS0004U
REMOVAL
1. Remove the exhaust front tube, propeller shaft, and RH drive shaft.
2. Remove the side shaft.
3. Remove the air breather hose.
4. Remove transfer gusset (vehicle with YD22ET engine only).
5. Place a transmission jack onto the transaxle.
6. Remove the center member.
7. Remove suspension members.
lRefer toFSU-12, "Removal and Installation"in FUS Front Suspension.
8. Remove rear engine mounting bracket.
9. Place a transmission jack onto the transfer unit.
10. Remove the mounting bolts fastening the transaxle and transfer unit.
11. Remove the transfer unit from the vehicle.
INSTALLATION
Paying attention to the following items, install in the reverse order of removal.
SDIA0492E

TRANSFER ASSEMBLY
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lWhen installing the transfer to the transaxle, install the mounting
bolts following the standard below.
CAUTION:
When installing the transfer to the transaxle, be careful not
to damage the oil seals.
lWhen installing transfer gusset, tighten mounting bolts to the following torque (vehicles with YD22ET
engine only):
lAfter the installation, check the oil level and oil leakage.
Bolt No. 1 2
Quantity 4 2
Nominal length mm (in) 65 (2.56) 40 (1.57)
Tightening torque [N·m
(kg·mfg.-lb.)]30 - 39 (3.0 - 4.0,22-28)
SDIA0514E
Tightening torque : 31 - 40 N·m (3.1 - 4.1 kg·m, 23-29 ft.-lb.)

TF-14
TRANSFER ASSEMBLY
Component Parts Drawing
EDS0004V
SDIA0521E

TRANSFER ASSEMBLY
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Assembly InspectionEDS0004W
BACKLASH
1. Install a bolt to the companion flange.
2. Fit a dial gauge onto the bolt.
3. Measure the circumference backlash of the companion flange,
and check that it satisfies the standard below.
lIf outside the standard, disassemble it to check and adjust
each part.
TOOTH CONTACT
1. Remove the pinion sleeve assembly, and apply red lead to the
drive gear.
CAUTION:
Apply red lead to the both faces of 3 to 4 gears at 4 loca-
tions evenly spaced on the drive gear.
2. Install the pinion sleeve shims and pinion sleeve assembly.
3. Remove the plug on the upper side of the transfer case.
4. Rotate the companion flange back and forth several times, and
check the drive pinion gear to drive gear tooth contact by view-
ing from the plug hole.Backlash : 0.13 - 0.19 mm (0.0051 - 0.0075 in)
TFB0280D
TFB0212D
SDIA0516E

TF-16
TRANSFER ASSEMBLY
5. If tooth contact is poorly adjusted, adjust pinion height (dimen-
sion X) in the following manner:
SDIA0520E
SDIA0517E

TRANSFER ASSEMBLY
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lIf the tooth contact is near the face (face contact), or near the
heal (heal contact), thin the pinion sleeve shims to move the
drive pinion gear closer to the drive gear.
lIf the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thicken the pinion sleeve shims to move the
drive pinion gear farther from the drive gear.
PRELOAD TORQUE
Pinion bearing preload torque
1. Remove the pinion sleeve assembly, and rotate the companion flange back and forth in 2 to 3 times.
Check for abnormal noise, rotation malfunction, and other malfunctions.
2. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
SDIA0518E
SDIA0519E

TF-18
TRANSFER ASSEMBLY
3. Using a preload gauge, measure the preload torque of the pin-
ion bearing.
CAUTION:
Every rotational part shall rotate smoothly with the speci-
fied gear oil.
lIf outside the standard, disassemble the pinion sleeve assem-
bly to check and adjust each part.
Overall preload torque
1. Measure pinion bearing preload torque (P1).
2. Install the pinion sleeve shims and pinion sleeve assembly.
3. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
4. Using a preload gauge, measure the overall preload torque.
lIf outside of the standard, disassemble it to check and adjust
each part. If measuring the overall preload torque after the disassembly, measure it with the transfer
case oil seals and gear ring oil seals removed, then install the oil seals.
COMPANION FLANGE RUNOUT
1. Fit a dial gauge onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
2. Rotate the companion flange to check for runout.
3. Fit a test indicator to the inner side of the companion flange
(socket diameter).
4. Rotate the companion flange to check for runout.
5. If the runout value is outside the repair limit, follow the procedure
below to adjust.
a. While changing the phase between companion flange and drive pinion gear by 90°at a time, check runout
and determine which phase angle minimizes the runout.
b. If the runout value is still outside of the limit after the phase has been changed, replace the companion
flange.
c. If the runout is outside the standard after the companion flange is replaced, adjust the assembly status of
the pinion bearings and drive pinion gear, or replace the pinion bearings.Preload torque
: 0.10 - 0.39 N·m (0.01 - 0.04kg·m,1 - 3 ft-lb)
SDIA0522E
Overall preload torque
When all oil seals are installed:
:P
1+0.16 - 0.22 N·m (0.016 - 0.023 kg·m, 1.4-1.9 ft-
lb)
Transfer case oil seals and
When no gear ring oil seal:
:P
1+0.06 - 0.12 N·m (0.006 - 0.013 kg·m, 0.6-1.1
in-lb)
SDIA0523E
Runout limit : 0.08 mm (0.0031 in)
Runout limit : 0.08 mm (0.0031 in)
SDIA0524E

TRANSFER ASSEMBLY
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Disassembly and AssemblyEDS0004X
DISASSEMBLY
Pinion sleeve assembly
1. Remove 7 pinion sleeve mounting bolts.
2. Temporarily tighten 2 bolts. Using a plastic hammer, tap com-
panion flange to remove pinion sleeve assembly.
3. Remove the pinion sleeve shim.
4. Remove the pinion nut.
5. Using a drift, remove drive pinion from pinion sleeve with a
press.
6. Remove the drive pinion gear assembly.
7. Remove the O-ring.
8. Using a flat-bladed screwdriver, remove the oil seal.
CAUTION:
Be careful not to damage the pinion sleeve.
9. Remove the pinion rear bearing inner race.
TFB0302D
TFB0284D
SDIA0525E
TFB0286D

TF-20
TRANSFER ASSEMBLY
10. Using a puller, remove the pinion rear bearing outer race.
11. Using a puller, remove the pinion front bearing outer race.
12. Remove the collapsible spacer from the drive pinion gear.
13. Using a replacer, press the pinion front bearing inner race out of
the drive pinion gear.
Adapter case
1. Remove the adapter case mounting bolts.
SDIA0526E
SDIA0527E
SDIA0528E
TFB0289D