NISSAN X-TRAIL 2003 Service Repair Manual

TRANSAXLE ASSEMBLY
MT-29
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4. Remove check plugs (3 pieces), check springs (3 pieces), check
balls (3 pieces) and shift check sleeve (1 piece) from transaxle
case.
5. Remove transaxle case mounting bolts.
6. Remove bore plug from transaxle case.
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 from clutch housing.
8. Remove oil gutter, baffle plate from transaxle case.
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) from transaxle case using the puller, and then remove dif-
ferential side bearing adjusting shim from transaxle case.
11. Remove welch plug from transaxle case.
12. Remove differential oil seal (tansaxle case side) from transaxle
case.
13. Remove magnet from clutch housing.
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MT-30
TRANSAXLE ASSEMBLY

14. With shift lever in 5th position, remove mounting bolts from
reverse lever assembly. Lift reverse lever assembly to remove.
CAUTION:
Be careful not to lose shifter cap.
15. Pull out reverse fork rod then remove reverse shift fork.
16. Shift 3rd-4th fork rod to 3rd position. Remove retaining pin of 5th
shift fork using a pin punch.
17. Remove stopper rings for 5th-reverse bracket.
18. Pull out 5th-reverse fork rod and remove 5th shift fork and 5th-
reverse bracket.
19. Remove check balls (2 pieces) from clutch housing.
20. Remove retaining pin of 3rd-4th bracket using a pin punch.
21. Remove stopper rings for 3rd-4th shift fork.
22. Pull out 3rd-4th fork rod and remove 3rd-4th shift fork and 3rd-
4th bracket.
23. Remove interlock pin and shift check sleeve from clutch hous-
ing.
24. Remove retaining pin of 1st-2nd shift fork using a pin punch.
25. Pull out 1st-2nd fork rod with 1st-2nd bracket.
26. Remove 1st-2nd shift fork.
27. Remove retaining pin of 1st-2nd bracket using a pin punch and
separate 1st-2nd fork rod and 1st-2nd bracket.
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TRANSAXLE ASSEMBLY
MT-31
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28. Remove gear components from clutch housing in the following
procedure.
a. Remove input shaft assembly, mainshaft assembly and reverse
idler gear assembly as a set, tapping input shaft with plastic
hammer.
CAUTION:
Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
b. Remove final drive assembly.
29. Remove mainshaft bearing retainer and then mainshaft front
bearing from clutch housing using the puller.
30. Remove oil channel from clutch housing.
31. Remove differential oil seal (clutch housing side) from clutch
housing.
CAUTION:
Be careful not to damage clutch housing.
32. Remove differential side bearing outer race (clutch housing
side) from clutch housing using the puller.
33. Remove input shaft oil seal from clutch housing.
CAUTION:
Be careful not to damage clutch housing.
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MT-32
TRANSAXLE ASSEMBLY

ASSEMBLY
1. Apply multi-purpose grease to input shaft oil seal lip. Install a
new input shaft oil seal 1.8-2.8mm (0.071-0.110 in) above from
clutch housing edge surface using the drift.
CAUTION:
Do not reuse oil seals.
2. Apply multi-purpose grease to differential oil seal lip, and then
install a new oil seal to clutch housing using the drift.
CAUTION:
Do not reuse oil seals.
3. Install oil channel on mainshaft side.
CAUTION:
Be careful with the orientation of installation.
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TRANSAXLE ASSEMBLY
MT-33
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4. Install mainshaft front bearing to clutch housing using the drift.
CAUTION:
Be careful with the orientation of installation.
5. Install mainshaft bearing retainer to clutch housing and tighten
mounting bolt to the specified torque. Refer to MT-20, "
GEAR
COMPONENTS" .
CAUTION:
Install with punched surface facing up.
6. Install differential side bearing outer race to clutch housing using
the drifts.
7. Install final drive assembly into clutch housing.
8. Install input shaft assembly, mainshaft assembly, and reverse
idler gear assembly into clutch housing.
CAUTION:
Be sure not to damage input shaft oil seal.
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MT-34
TRANSAXLE ASSEMBLY

9. Install 1st-2nd bracket onto 1st-2nd fork rod, and then install a
new retaining pin to 1st-2nd bracket.
CAUTION:
Do not reuse retaining pins.
10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install a
new retaining pin to1st-2nd shift fork.
CAUTION:
Do not reuse retaining pins.
11. Install shift check sleeve to clutch housing.
12. Install interlock pin to 3rd-4th fork rod.
13. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod.
14. Install a new stopper ring onto 3rd-4th shift fork.
CAUTION:
Do not reuse stopper ring.
15. Install a new retaining pin onto 3rd-4th bracket.
CAUTION:
Do not reuse retaining pins.
16. Install 2 check balls to clutch housing.
17. Install 5th-reverse bracket, 5th shift fork, and 5th-reverse fork
rod.
18. Install a new stopper ring onto 5th-reverse bracket.
CAUTION:
Do not reuse stopper ring.
19. Install a new retaining pin onto 5th shift fork.
CAUTION:
Do not reuse retaining pins.
20. Install reverse shift fork and reverse fork rod.
21. Install reverse lever assembly following the procedures below.
a. Install shifter cap onto reverse lever assembly cam, and then
install them onto reverse shift fork.
CAUTION:
Do not drop shifter cap.
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TRANSAXLE ASSEMBLY
MT-35
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b. While lifting reverse shift fork, align cam with 5th-reverse
bracket.
c. Install reverse lever assembly to clutch housing, and then
tighten mounting bolts to the specified torque. Refer to MT-22,
"SHIFT CONTROL COMPONENTS" .
22. Install check ball, shift check sleeve, check spring and a new
check plug to clutch housing.
CAUTION:

Do not reuse check plug.

Do not drop check ball.
23. Install the magnet onto clutch housing.
24. Apply multi-purpose grease to differential oil seal lip, and then
install a new differential oil seal to transaxle case using the drift.
CAUTION:
Do not reuse differential oil seals.
25. Install selected input shaft rear bearing adjusting shim onto input
shaft.

For selection of adjusting shims, refer to MT-47, "INPUT
SHAFT END PLAY" .
26. Install selected differential side bearing adjusting shim and dif-
ferential side bearing. For selection adjusting shim, refer to MT-
48, "DIFFERENTIAL SIDE BEARING PRELOAD" .
27. Install baffle plate and oil gutter to transaxle case.
28. Install transaxle case following the procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.

For selection of adjusting shims, refer to MT-48, "MAINSHAFT END PLAY" .
b. Temporarily install a new snap ring of mainshaft rear bearing into transaxle case.
CAUTION:
Do not reuse snap ring.
c. Apply recommended sealant to mating surfaces of transaxle
case and clutch housing.
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
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MT-36
TRANSAXLE ASSEMBLY

d. With snap ring of mainshaft rear bearing temporarily installed,
place transaxle case over clutch housing.
e. Through bore plug mounting hole, with snap ring stretched, and
lift up mainshaft assembly from the control assembly mounting
hole.
f. Securely install snap ring onto mainshaft rear bearing.
g. Tighten mounting bolts to the specified torque.
CAUTION:
Always replace bolts B as they are self-sealing bolts.
h. Install control assembly to transaxle case.
CAUTION:
Do not reuse O-ring.
i. Install a new shift check to transaxle case, and then tighten shift check to the specified torque. Refer to
MT-22, "
SHIFT CONTROL COMPONENTS" .
CAUTION:
Do not reuse shift check.
j. Install a new stopper bolt to transaxle case, and then tighten stopper bolt to the specified torque. Refer to
MT-22, "
SHIFT CONTROL COMPONENTS" .
CAUTION:
Do not reuse stopper bolt.
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Bolt A:
: 52 N·m (5.3 kg-m, 38 ft-lb)
Bolt B:
: 65 N·m (6.6 kg-m, 48 ft-lb)
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TRANSAXLE ASSEMBLY
MT-37
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29. Install a new bore plug to transaxle case using the drift.
CAUTION:
Do not reuse bore plug.
30. Install a new welch plug to transaxle case using the drift.
CAUTION:
Do not reuse welch plug.
31. Install 2 check balls, 2 check springs and 2 new check plugs to
transaxle case, and then tighten check plug to the specified
torque. Refer to MT-22, "
SHIFT CONTROL COMPONENTS" .
CAUTION:
Do not reuse check plug.
32. Install new O-ring applied gear oil on control assembly. And then
install control assembly on transaxle case. After the previous
service tighten bolts to the specified torque. Refer to MT-22,
"SHIFT CONTROL COMPONENTS" .
CAUTION:
Do not reuse O-ring.
33. Apply genuine liquid gasket or equivalent to threads of park/neu-
tral position switch and back-up lamp switch. Then install them
into transaxle case. Tighten park/neutral position switch and
back-up lamp switch to the specified torque. Refer to MT-19,
"CASE AND HOUSING COMPONENTS" .
34. Install new gaskets onto drain plug and filler plug, and then install them into transaxle case. Tighten park/
neutral position switch and back-up lamp switch to the specified torque. Refer to MT-19, "
CASE AND
HOUSING COMPONENTS" .
CAUTION:

Do not reuse gasket.

After oil is filled, tighten filler plug to specified torque.
Disassembly and Assembly (RS6F51A)ECS008C1
DISASSEMBLY
1. Remove drain plug and filler plug from transaxle case.
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MT-38
TRANSAXLE ASSEMBLY

2. Remove park/neutral position switch and back-up lamp switch
from transaxle case.
3. Remove shift check and stopper bolt from transaxle case, and
then remove control assembly from transaxle case.
4. Remove check plugs (4 pieces), check springs (4 pieces), check
balls (4 pieces) and shift check sleeve (2 pieces) from transaxle
case.
5. Remove transaxle case mounting bolts.
6. Remove bore plug from transaxle case.
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 from clutch housing.
8. Remove oil gutter, baffle plate from transaxle case.
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) from transaxle case using the puller, and then remove dif-
ferential side bearing adjusting shim from transaxle case.
11. Remove welch plug from transaxle case.
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