differential NISSAN X-TRAIL 2003 Electronic Repair Manual

AT-4
Differential Side Oil Seal Replacement .................457
Revolution Sensor Replacement ..........................457
REMOVAL AND INSTALLATION ...........................458
Removal ...............................................................458
Installation .............................................................459
OVERHAUL .............................................................461
Components .........................................................461
Oil Channel ...........................................................464
Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings ..........................465
DISASSEMBLY .......................................................466
Disassembly .........................................................466
REPAIR FOR COMPONENT PARTS ......................482
Manual Shaft ........................................................482
Oil Pump ...............................................................485
Control Valve Assembly ........................................489
Control Valve Upper Body ....................................498
Control Valve Lower Body ....................................502
Reverse Clutch .....................................................504
High Clutch ...........................................................507
Forward and Overrun Clutches ............................512
Low & Reverse Brake ...........................................518
Rear Internal Gear, Forward Clutch Hub and Over-
run Clutch Hub ......................................................521
Output Shaft, Idler Gear, Reduction Pinion Gear and
Bearing Retainer ...................................................525
Band Servo Piston Assembly ...............................530
Final Drive ............................................................535ASSEMBLY ............................................................. 540
Assembly (1) ......................................................... 540
Adjustment (1) ....................................................... 541
Assembly (2) ......................................................... 546
Adjustment (2) ....................................................... 553
Assembly (3) ......................................................... 556
SERVICE DATA AND SPECIFICATIONS (SDS) .... 563
General Specifications .......................................... 563
Shift Schedule ....................................................... 563
Stall Revolution ..................................................... 563
Line Pressure ........................................................ 563
Control Valves ....................................................... 564
Accumulator .......................................................... 564
Clutch and Brakes ................................................. 564
Final Drive ............................................................. 566
Planetary Carrier and Oil Pump ............................ 567
Input Shaft ............................................................. 568
Reduction Pinion Gear .......................................... 568
Band Servo ........................................................... 569
Output Shaft .......................................................... 569
Bearing Retainer ................................................... 569
Total End Play ....................................................... 569
Reverse Clutch End Play ...................................... 570
Removal and Installation ....................................... 570
Shift Solenoid Valves ............................................ 570
Solenoid Valves .................................................... 570
A/T Fluid Temperature Sensor .............................. 570
Revolution Sensor ................................................. 571
Dropping Resistor ................................................. 571

PREPARATION
AT-9
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PREPARATIONPFP:00100
Special Service ToolsECS004Q5
Tool number
To o l n a m eDescription
KV381054S0 Puller
lRemoving differential side oil seals
lRemoving differential side bearing outer race
lRemoving idler gear bearing outer race
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
ST33400001 Drift
lInstalling differential side oil seal
F04B
lInstalling oil seal on oil pump housing
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
ST2505S001 Oil
pressure gauge set 1
ST25051001 Oil
pressure gauge 2
ST25052000 Hose 3
ST25053000 Joint pipe
4 ST25054000 Adapter
5 ST25055000 Adapter
lMeasuring line pressure
ST27180001 Puller
lRemoving idler gear
a: 100 mm (3.94 in)
b: 110 mm (4.33 in)
c: M8 x 1.25P
ST23540000 Pin punch
lRemoving and installing parking rod plate and
manual plate pins
a: 2.3 mm (0.091 in) dia.
b: 4 mm (0.16 in) dia.
ST25710000 Pin punch
lAligning groove of manual shaft and hole of
transmission case
a: 2 mm (0.08 in) dia.
NT414
NT086
NT097
NT424
NT442
NT410

AT-10
PREPARATION
KV32101000 Pin
punchlRemoving and installing manual shaft retaining
pin
lRemoving and installing pinion mate shaft lock
pin
a: 4 mm (0.16 in) dia.
KV31102400 Clutch
spring compres-sor
lRemoving and installing clutch return springs
lInstalling low and reverse brake piston
a: 320 mm (12.60 in)
b: 174 mm (6.85 in)
KV40100630 Drift
lInstalling reduction gear bearing inner race
lInstalling idler gear bearing inner race
a: 67.5 mm (2.657 in) dia.
b: 44 mm (1.73 in) dia.
c: 38.5 mm (1.516 in) dia.
ST30720000 Bearing
installer
lInstalling idler gear bearing outer race
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ST35321000 Drift
lInstalling output shaft bearing
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
ST33230000 Drift
lInstalling differential side bearing inner race
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.
ST33220000 Drift
lSelecting differential side bearing adjusting shim
a: 37 mm (1.46 in) dia.
b: 31 mm (1.22 in) dia.
c: 22 mm (0.87 in) dia. Tool number
Tool nameDescription
NT410
NT423
NT107
NT115
NT073
NT084
NT085

PREPARATION
AT-11
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Commercial Service ToolsECS004Q6
ST3306S001
Differential side
bearing puller set 1
ST33051001 Puller 2
ST33061000 AdapterlRemoving differential side bearing inner race
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
c: 130 mm (5.12 in)
d: 135 mm (5.31 in)
e: 100 mm (3.94 in)
ST3127S000 Preload
gauge 1 GG91030000
To r q u e w r e n c h 2
HT62940000 Socket
adapter 3 HT62900000
Socket adapter
lChecking differential side bearing preload
ST35271000 Drift
lInstalling idler gear
lInstalling differential side bearing inner race
a: 72 mm (2.83 in) dia.
b: 63 mm (2.48 in) dia.
KV38107700 Preload
adapter
lSelecting differential side bearing adjusting shim
lChecking differential side bearing preload
ST30613000 Drift
lInstalling differential side bearing inner race
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.
KV38105210 Preload
adapter
lSelecting differential side bearing adjusting shim
lChecking differential side bearing preload Tool number
To o l n a m eDescription
AMT153
NT124
NT115
NT087
NT073
NT075

AT-12
PREPARATION
Tool name Description
Puller
lRemoving idler gear bearing inner race
lRemoving and installing band servo piston
snap ring
Puller
lRemoving reduction gear bearing inner
race
a: 60 mm (2.36 in) dia.
b: 35 mm (1.38 in) dia.
Drift
lInstalling differential side oil seal
a: 90 mm (3.54 in) dia.
Drift
lInstalling needle bearing on bearing
retainer
a: 36 mm (1.42 in) dia.
Drift
lRemoving needle bearing from bearing
retainer
a: 33.5 mm (1.319 in) dia.
Drift
lInstalling differential side bearing outer
race
a: 75 mm (2.95 in) dia.
Drift
lInstalling differential side bearing outer
race
a: 100 mm (3.94 in) dia.
NT077
NT411
NT083
NT083
NT083
NT083
NT083

OVERALL SYSTEM
AT-17
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Cross-sectional ViewECS004QB
SCIA0688E
1. Band servo piston 9. Low one-way clutch 17. Pinion reduction gear
2. Reverse clutch drum 10. Rear planetary gear 18. Final gear
3. Converter housing 11. Forward clutch 19. Differential case
4. Oil pump 12. Overrun clutch 20. Input shaft
5. Brake band 13. Low & reverse brake 21. Torque converter
6. Reverse clutch 14. Output gear 22. Side cover
7. High clutch 15. Idler gear
8. Front planetary gear 16. Forward one-way clutch

ON-VEHICLE SERVICE
AT-457
[ALL]
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Differential Side Oil Seal ReplacementECS0040F
1. Remove left side drive shaft assemblies. Refer toFAX-11,
"FRONT DRIVE SHAFT".
2. Remove transfer from right side of transaxle.
Refer toTF-12, "
TRANSFER ASSEMBLY", then remove
oilseals with tool.
3. Install oil seals.
lApply ATF to oil seal surface before installing.
lDrift for installing
lInstall oil seals so that dimensions “A” and “B” are within
specifications.
Unit: mm (in)
4. Reinstall any part removed.
Revolution Sensor ReplacementECS0040G
1. Disconnect revolution sensor harness connector.
2. Remove harness bracket from A/T.
3. Remove revolution sensor from A/T.
4. Reinstall any part removed.
Always use new sealing parts.
SCIA0790E
Transaxle case side :ST3340 0001
converter housing side :KV4010 0621
SCIA0788E
AB
-0.5 to 0.5 (-0.020 to 0.020)-0.5to0.5(-0.020 to 0.020)
SCIA0791E
SCIA0792E

AT-470
[ALL]
DISASSEMBLY
c. Remove O-ring from differential oil port.
21. Remove final drive assembly from transmission case.
22. Remove differential side bearing outer race and side bearing
adjusting shim from transmission case.
23. Remove differential side bearing adjusting shim from transmis-
sion case.
SAT235F
SAT228F
SAT010FC
SAT031D

DISASSEMBLY
AT-471
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24. Remove differential side bearing outer race from converter
housing.
25. Remove oil seal with screwdriver from converter housing.
lBe careful not to damage case.
26. Remove differential lubricant tube from converter housing.
27. Remove oil pump according to the following procedures.
a. Remove O-ring from input shaft.
b. Remove oil pump assembly, baffle plate and gasket from trans-
mission case.
SAT011FC
SAT032D
SAT063K
SAT225F
SAT012F

AT-536
[ALL]
REPAIR FOR COMPONENT PARTS
2. Press out differential side bearings.
lBe careful not to mix up the right and left bearings.
3. Remove differential side bearing outer race, and side bearing
adjusting shim from transmission case.
4. Remove speedometer drive gear.
5. Drive out pinion mate shaft lock pin.
SMT744AA
SAT010FA
SAT313D
SAT904DA