differential NISSAN X-TRAIL 2003 Electronic Service Manual

PREPARATION
MT-5
D
E
F
G
H
I
J
K
L
MA
B
MT
Drift
ST33061000
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.lBore plug installation
lDifferential side bearing removal
Drift
ST33052000
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.
lInput shaft rear bearing removal and
installation
lInput shaft bearing spacer and 5th stopper
removal
l5th bushing, thrust washer, 4th input gear,
4th gear bushing, 3rd-4th synchronizer
hub and 3rd input gear removal
lInput shaft front bearing installation
l6th input gear and 6th bushing removal
(RS6F51A)
lMainshaft rear bearing removal
l4th main gear and 5th main gear removal
Drift
KV40105020
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in).
l5th input gear and synchronizer hub
removal
l3rd main gear, 2nd main gear, 2nd
bushing, 1st-2nd synchronizer hub, 1st
main gear, reverse main gear and 1st
bushing removal
Press stand
KV40105710
a: 46 mm (1.81 in) dia.
b: 41 mm (1.61 in).
l3rd-4th synchronizer hub installation
l4th bushing installation
l5th bushing installation (RS5F51A)
l5th synchronizer hub installation
(RS5F51A)
l5th-6th synchronizer hub installation
(RS6F51A)
l2nd bushing installation
l3rd main gear installation
Press stand
ST38220000
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in).
lReverse main gear installation
l1st bushing installation
Drift
ST30032000
a: 80 mm (3.15 in) dia.
b: 38 mm (1.50 in) dia.
c: 31 mm (1.22 in) dia.
l5th stopper and input shaft bearing spacer
installation
lInput shaft front bearing installation
l1st-2nd synchronizer hub installation To o l n a m e
Tool numberDescription
ZZA1000D
ZZA1023D
ZZA1133D
ZZA1058D
ZZA1058D
ZZA0978D

MT-6
PREPARATION
Commercial Service Tools
ECS004NA
Drift
ST30901000
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.lInput shaft rear bearing installation
l4th main gear installation
l5th main gear installation
lMainshaft rear bearing installation
Puller
ST30031000
lMeasuring wear of 1st and 2nd baulk ring
Drift
KV40101630
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.
lReverse main gear installation
Drift
KV38102510
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.
l1st bushing installation
l1st-2nd synchronizer hub installation
lDifferential side bearing installation
Drift
KV40104830
a: 70 mm (2.76 in) dia.
b: 63.5 mm (2.500 in) dia.
lDifferential side bearing installation Tool name
Tool numberDescription
ZZA0978D
ZZA0537D
ZZA1003D
ZZA0838D
ZZA0936D
Tool nameDescription
PullerEach bearing gear and bushing removal
ZZA0537D

MT-18
TRANSAXLE ASSEMBLY
Component Parts (RS5F51A)
ECS00468
CASE AND HOUSING COMPONENTS
1. Clutch housing 2. Input shaft oil seal 3. Oil channel
4. Magnet 5. Differential oil seal 6. Ball pin
7. Washer 8. Transaxle case 9. Welch plug
10. Bore plug 11. Differential oil seal 12. Park/Neutral position switch
13. Oil gutter 14. Back-up lamp switch 15. Air breather tube
16. Baffle plate 17. Filler plug 18. Gasket
19. Drain plug 20. Gasket
SCIA0384E

MT-22
TRANSAXLE ASSEMBLY
FINAL DRIVE COMPONENTS
1. Differential side bearing outer race 2. Differential side bearing 3. Differential case
4. Final gear 5. Differential side bearing 6. Differential side bearing outer race
7. Differential side bearing adjusting shim 8. Pinion mate shaft 9. Side gear
10. Side gear thrust washer 11. Pinion mate gear 12. Pinion mate gear washer
13. Retaining pin
SCIA0388E

TRANSAXLE ASSEMBLY
MT-23
D
E
F
G
H
I
J
K
L
MA
B
MT
Component Parts (RS6F51A)ECS004PX
CASE AND HOUSING COMPONENTS
1. Clutch housing 2. Input shaft oil seal 3. Oil channel
4. Magnet 5. Differential oil seal 6. Ball pin
7. Washer 8. Transaxle case 9. Welch plug
10. Bore plug 11. Differential oil seal 12. Park/Neutral position switch
13. Oil gutter 14. Back-up lamp switch 15. Air breather tube
16. Baffle plate 17. Filler plug 18. Gasket
19. Drain plug 20. Gasket
SCIA0384E

TRANSAXLE ASSEMBLY
MT-27
D
E
F
G
H
I
J
K
L
MA
B
MT
FINAL DRIVE COMPONENTS
Disassembly and Assembly (RS5F51A)ECS00469
DISASSEMBLY
1. Remove drain plug and filler plug.
2. Remove park/neutral position switch and back-up lamp switch.
3. After removing shift check and stopper bolt, remove control
assembly.
1. Differential side bearing outer race 2. Differential side bearing 3. Differential case
4. Final gear 5. Differential side bearing 6. Differential side bearing outer race
7. Differential side bearing adjusting shim 8. Pinion mate shaft 9. Side gear
10. Side gear thrust washer 11. Pinion mate gear 12. Pinion mate gear washer
13. Retaining pin
SCIA0388E
SCIA0389E

MT-28
TRANSAXLE ASSEMBLY
4. Remove check plugs (3 pieces), check springs (3 pieces), check
balls (3 pieces) and shift check sleeve (1 piece).
5. Remove transaxle case fixing bolts.
6. Remove bore plug.
CAUTION:
Be careful not to damage transaxle case.
7. While spreading the snap ring of mainshaft rear bearing located
at bore plug hole, remove transaxle case.
8. Remove oil gutter, baffle plate.
9. Remove snap ring, mainshaft rear bearing adjusting shim and
input shaft rear bearing adjusting shim from transaxle case.
10. Remove differential side bearing outer race (transaxle case
side) and then adjust shim.
11. Remove differential oil seal.
12. Remove magnet from clutch housing.
13. With shift lever in 5th position, remove bracket bolts from
reverse lever assembly. Lift reverse lever assembly to remove.
CAUTION:
Be careful not to lose shifter cap.
14. Pull out reverse fork rod then remove reverse shift fork.
SCIA0396E
SCIA0983E
SCIA0897E
SCIA0397E
SCIA0390E

MT-30
TRANSAXLE ASSEMBLY
27. Remove gear components from clutch housing in the following
procedure.
a. While tapping input shaft with plastic hammer, remove input
shaft assembly, mainshaft assembly and reverse idler gear
assembly as a set.
CAUTION:
Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
b. Remove final drive assembly.
28. Remove bearing retainer and then mainshaft front bearing.
29. Remove oil channel on mainshaft side.
30. Remove differential oil seal.
31. Remove differential side bearing outer race (clutch housing
side).
32. Remove input shaft oil seal.
CAUTION:
Be careful not to damage clutch housing.
ASSEMBLY
1. Using a drift, install input shaft oil seal.
CAUTION:
Oil seals are not reusable. Never reuse them.
SCIA0395E
SCIA0400E
SCIA0398E
SCIA0399E

TRANSAXLE ASSEMBLY
MT-31
D
E
F
G
H
I
J
K
L
MA
B
MT
2. Using a drift, install differential oil seal.
CAUTION:
Oil seals are not reusable. Never reuse them.
3. Install oil channel on mainshaft side.
CAUTION:
Be careful with orientation of installation.
4. Using a drift, install mainshaft front bearing.
5. Install bearing retainer.
6. Install differential side bearing outer race.
SCIA0887E
SCIA0986E
SCIA0401E
SCIA0400E
SCIA0987E

MT-36
TRANSAXLE ASSEMBLY
2. Remove park/neutral position switch and back-up lamp switch.
3. After removing shift check and stopper bolt, remove control
assembly.
4. Remove check plugs (4 pieces), check springs (4 pieces), check
balls (4 pieces) and shift check sleeve (2 pieces).
5. Remove transaxle case fixing bolts.
6. Remove bore plug.
CAUTION:
Be careful not to damage transaxle case.
7. While spreading the snap ring of mainshaft rear bearing located
at bore plug hole, remove transaxle case.
8. Remove oil gutter, baffle plate.
9. Remove snap ring, mainshaft rear bearing adjusting shim and
input shaft rear bearing adjusting shim from transaxle case.
10. Remove differential side bearing outer race (transaxle case
side) and then adjusting shim.
11. Remove differential oil seal.
12. Remove magnet from clutch housing.
SCIA0389E
SCIA0959E
SCIA0983E
SCIA0897E
SCIA0397E