check oil NISSAN X-TRAIL 2003 Electronic Repair Manual

TRANSFER ASSEMBLY
TF-13
C
E
F
G
H
I
J
K
L
MA
B
TF
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-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
TF-23
C
E
F
G
H
I
J
K
L
MA
B
TF
8. Using a puller, remove the oil seal from the gear ring.
Transfer case
1. Remove the pinion sleeve assembly.
2. Remove the adapter case.
3. Remove the drive gear assembly from the transfer case.
4. Using a flat-bladed screwdriver, remove the oil seal.
CAUTION:
Be careful not to damage the transfer case.
5. Remove the oil defense.
6. Using a brass rod, tap the adjusting shim evenly from the 2 cut-
outs on the transfer case to remove the adjusting shim and gear
ring bearing outer race.
7. Remove the filler plug, and breather tube.
INSPECTION AFTER DISASSEMBLY
Gears
lCheck the gear faces and shaft for wear, cracks, damage, and seizure.
SDIA0534E
TFB0297D
SDIA0535E
SDIA0536E

TF-24
TRANSFER ASSEMBLY
CAUTION:
If a malfunction is detected on the drive gear or drive pinion gear, replace the drive gear and drive pin-
ion gear as a set.
Bearings
lCheck for seizure, peeling, wear, corrosion, sticking/abnormal noise/roughness in hand turning, and other
damage.
CAUTION:
When replacing the bearing, always replace the inner race and outer race as a pair.
Washers and shims
lCheck for seizure, damage, and abnormal wear.
Oil seals
lDiscard old oil seals; replace with new ones.
lIf wear, deterioration of adherence (sealing force of lips), or damage is detected on the lips, replace them.
SELECTIONG ADJUSTING SHIMS
Measuring point
At gear ring bearing on transfer case
1. Measure the points F, H, I, R, and U shown in the measurement points.
2. Convert the values F, H, I, R, and U according to the standards below.
3. Check dimension Z on the drive gear side face.
NOTE:
Dimension Z indicates the difference between the optimum engagement and the standard dimensions in
increments of 0.01 mm (0.0004 in) written on the drive gear side face.
SDIA0537E
F : Value obtained by subtracting 163.00 mm (6.42 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
H : Value obtained by subtracting 83.00 mm (3.27 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
I : Value obtained by subtracting 131.90 mm (5.19 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
R : Value obtained by subtracting 17.00 mm (0.67 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
U : Value obtained by subtracting 89.50 mm (3.524 in) from
the reading [in increments of 0.01 mm (0.0004 in)].

TF-26
TRANSFER ASSEMBLY
ASSMBLY
Transfer case
1. Select the adjusting shim on the gear ring bearing.
lTF-24, "SELECTIONG ADJUSTING SHIMS".
2. Using a drift, install the selected adjusting shim and gear ring
bearing outer race.
3. Install the oil defense, and tighten the mounting bolts to the
specified torque. The clearance between the oil defense and
transfer case (dimension A) should be the following.
CAUTION:
Do not reuse the mounting bolts.
4. Install the magnet.
5. Using a drift, drive the oil seal until it becomes flush with the
case end.
CAUTION:
lWhen checking the overall preload torque, measure it
without the oil seal, then install the oil seal.
lDiscard old oil seals; replace with new ones.
lApply onto oil seal lips, and gear oil onto the circumfer-
ence of the oil seal.
6. Apply recommended sealant to filler plug and its threads before
installing it to the transfer case.
7. Apply recommended sealant to breather tube and install it to the transfer case.
8. Install the drive gear assembly.
9. Install the adapter case.
10. Install the pinion sleeve assembly.
11. Check backlash, preload torque, tooth contact, and companion flange runout.
lTF-15, "Assembly Inspection"
CAUTION:
Measure the overall preload torque without the oil seal.
SDIA0538E
Tightening torque
: 6.9 - 8.8 N·m (0.7 - 0.9 kg·m, 61-78 in-lb)
Clearance between oil defense and transfer case
Dimension A : 1.0 - 3.5 mm (0.04 - 0.138 in)
Filler plug tightening torque : 10 - 19 N·m (1.0 - 2.0 kg·m, 8 - 14ft-lb)
Plug tightening torque : 15 - 19 N·m (1.5 - 2.0 kg·m, 11 - 14 ft-lb)
TFB0283D
SDIA0539E

TRANSFER ASSEMBLY
TF-27
C
E
F
G
H
I
J
K
L
MA
B
TF
Drive gear assembly
1. Using a drift, drive the oil seal into the gear ring.
CAUTION:
lWhen checking the overall preload torque, measure it
without the oil seal, then install the oil seal.
lDiscard old oil seals; replace with new ones.
lApply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of the oil seal.
lThe oil seal back position after the installation shall be
56.5 mm from the gear ring end.
2. Apply a thread locking adhesive into the thread hole for the drive
gear.
a. Completely clean and degrease the drive gear back face, thread
holes, and drive gear mounting bolts. (Use a gasket remover to
remove the thread locking adhesive.)
b. Apply a thread locking adhesive onto the first and second
threads under the thread hole chamfering of the drive gear, on 3
or more different points.
3. Install the drive gear to gear ring, and apply anti-corrosive oil
onto threads and seats on the mounting bolts, and then tighten
to the specified torque.
CAUTION:
lTemporary installation before tightening the bolts through the completion of the tightening
should be within 90 seconds.
lIf the thread locking adhesive is applied aside, quickly wipe it off.
4. Using a drift, install the speedometer drive gear.
CAUTION:
The gear ring cutout and the lug on the speedometer drive
gear should be mated to assemble.
5. Apply gear oil to ring gear bearing inner race on the transfer
case. Using a drift, install gear bearing inner race.
SDIA0540E
Tightening torque
First (temporary tightening) : 25 - 29 N·m (2.5 - 3.0 kg·m, 18-21 ft-lb)
Second (final tightening) : 82 - 115 N·m (8.3 - 11.7 kg·m,60-84 ft-lb)
SDIA0541E
SDIA0542E
SDIA0543E

TF-28
TRANSFER ASSEMBLY
6. Apply gear oil to ring gear bearing inner race on the adapter
case. Using a drift, install ring gear bearing inner race.
7. Assemble the drive gear assembly to the transfer case.
8. Install the adapter case.
9. Check backlash, preload torque, tooth contact, and companion
flange runout.
lTF-15, "Assembly Inspection".
CAUTION:
Measure the overall preload torque without the oil seal.
Adapter case
1. Select the adjusting shim on the gear ring bearing.
lTF-24, "SELECTIONG ADJUSTING SHIMS".
2. Install the oil gutter.
3. Using a drift, install the selected adjusting shim and gear ring
bearing outer race to the adapter case.
4. Using a drift, drive the oil seal until it becomes flush with the
case end.
CAUTION:
lWhen checking the overall preload torque, measure it
without the oil seal, then install the oil seal.
lDiscard old oil seals; replace with new ones.
lApply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of the oil seal.
5. Apply recommended sealant on drain plug and install it to the
adapter case.
6. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the adapter case.
CAUTION:
Do not reuse the O-ring.
7. Install the adapter case to the transfer case, and apply anti-cor-
rosive oil onto threads and seats on the mounting bolts. Tighten
to the specified torque.
8. Check backlash, preload torque, tooth contact, and companion
flange runout.
lTF-15, "Assembly Inspection".
CAUTION:
Measure the overall preload torque without the oil seal.
SDIA0544E
SDIA0545E
Drain plug tightening torque
: 10 - 19 N·m (1.0 - 2.0 kg·m, 8-14 ft-lb)
Tightening torque
: 14 - 16 N·m (1.4 - 1.7 kg·m, 11-12 ft-lb)
SDIA0546E
SDIA0547E

TF-30
TRANSFER ASSEMBLY
8. Using a drift and press, press in the companion flange.
9. Apply anti-corrosion oil onto threads and seat of the pinion nut
and adjust the pinion nut tightening torque and pinion bearing
preload torque (P’
1).
CAUTION:
lDiscard the old pinion nut; replace with new ones.
lAdjust the lower limit of the pinion nut tightening torque first.
lIf specified preload torque is exceeded, replace the collapsible spacer and tighten again. Never
loosen the pinion nut for further preload torque adjustment.
lAfter the adjustment, rotate the companion flange back and forth in 2 to 3 times to check for
abnormal noise, rotation malfunction, and other malfunctions.
10. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the pinion sleeve.
CAUTION:
Discard the old O-ring; replace with new one.
11. Assemble the selected pinion sleeve shim.
12. Install the pinion sleeve assembly, and apply anti-corrosive oil onto threads and seats on the mounting
bolts. Tighten to the specified torque.
13. Check backlash, preload torque, tooth contact, and companion flange runout.
lTF-15, "Assembly Inspection".
The overall preload torque is as follows:Pinion nut tightening torque
: 128 - 294 N·m (13 - 30 kg·m, 94-216 ft-lb)
Pinion bearing preload torque (P’
1)
: 0.40 - 0.78 N·m (0.04 - 0.08 kg·m, 4-6 in-lb)
Tightening torque : 26 - 33 N·m (2.6 - 3.4 kg·m, 19-24 ft-lb)
Overall preload torque
With all oil seals installed : P’
1+0.45 - 0.47 N·m (0.045 - 0.048 kg·m, 3.9-4.1 in-lb)
Without transfer case oil seal and ring gear oil seal
:P’
1+0.35 - 0.37 N·m (0.035 - 0.038 kg·m, 3.1-3.2 in-lb)
SDIA0552E

TF-32
ALL MODE 4X4 SYSTEM
4WD MODE SWITCT
AUTO mode (AUTO indicator lamp ON)
lElectronic control allows optimal distribution of torque to front/rear wheels to match road conditions.
lMakes possible stable driving, with no wheel spin, on snowy roads or other slippery surfaces.
lOn roads which do not require 4WD, it contributes to improved fuel economy by driving in conditions close
to front-wheel drive.
lSensors determine the vehicle's turning condition, and in response tight cornering/braking are controlled
by distributing optimum torque to rear wheels.
NOTE:
lWhen driving in AUTO mode or LOCK mode, if there is a large difference between front and rear wheel
speed which continues for a long time, oil temperature of drive system parts becomes too high and 4WD
warning lamp flashes rapidly. (When 4WD warning lamp flashes, vehicle changes to front-wheel drive
conditions.)
lWhen driving in AUTO mode, 4WD warning lamp may flash slowly if there is a significant difference in
pressure or wear between tires. At this time, vehicle performance is not fully available and cautious driving
is required. (Continues until engine is turned OFF.)
lIf 4WD warning lamp is flashing rapidly, stop vehicle and allow it to idle for some time. Flashing will stop
and AUTO mode will be restored.
lIf the warning lamp flashes slowly during driving but remains OFF after engine is restarted, the system is
normal. If it again flashes slowly after driving for some time, vehicle must be inspected.
lWhen the difference of revolution speed between the front and rear wheel with AUTO mode the shift
switch occasionally changes to LOCK mode automatically. This is not malfunction.
LOCK mode (LOCK indicator lamp and AUTO indicator lamp ON)
lFront/rear wheel torque distribution is fixed, ensuring stable driving when climbing slopes.
lWhen LOCK mode is selected, vehicle will switch automatically to AUTO mode if vehicle speed increases.
If vehicle speed then decreases, the vehicle automatically returns to direct 4-wheel driving conditions.
NOTE:
If there is a significant difference in pressure or wear between tires, full vehicle performance is not available.
Tire conditions are detected, and LOCK mode may be prohibited, or else speeds at which LOCK mode is
enabled may be restricted.
2WD mode (indicator lamps OFF)
Vehicle is in front-wheel drive.
NOTE:
lIf front wheels are slipping in 2WD mode, do not switch to AUTO or LOCK. This can cause difficulties for
the system.
lThe shift switch even if the shift switch is in 2WD mode, the sift switch occasionally automatically change
to 4WD mode depending on the driving condition (For example; Depressing the acceleration firmly). this is
not malfunction. How ever, 4WD mode indicator lamp dose not illuminate.
4WD WARNING LAMP
Turns ON when there is a malfunction in 4WD system. It indicates that fail-safe mode is engaged and vehicle
is in 2WD.
Also turns ON when ignition switch is turned ON, for purpose of bulb check. Turns OFF approximately for 3
seconds after the engine starts if system is normal.
4WD waning lamp indiction
Condition Display 4WD warning lamp
Self-diagnosisWhen self-diagnosis is performed, indicates location of
malfunction by number of flashes.-
Lamp checkTurns ON when engine is started to check for burned-out
lamps.Turns ON when ignition switch
is turned ON. Turns OFF
approximately 3 seconds after
engine start.
4WD system malfunction Turns ON if there is malfunction in 4WD system. ON