NISSAN X-TRAIL 2003 Service Repair Manual

TRANSAXLE ASSEMBLY
MT-39
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12. Remove differential oil seal (transaxle case side) from transaxle
case.
13. Remove magnet from clutch housing.
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. Remove retaining pin of reverse bracket using a pin punch.
17. Pull out reverse bracket and reverse bracket fork rod.
18. Remove check ball (2 pieces) and interlock pin from clutch
housing.
19. Shift 3rd-4th fork rod to 3rd position. Remove retaining pin of 5th
- 6th shift fork using a pin punch.
20. Remove stopper rings for 5th-6th bracket.
21. Pull out 5th-6th fork rod and remove 5th-6th shift fork and 5th-
6th bracket.
22. Remove check balls (2 pieces) and interlock pin.
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MT-40
TRANSAXLE ASSEMBLY

23. Remove retaining pin of 3rd-4th bracket using a pin punch.
24. Remove stopper rings for 3rd-4th shift fork.
25. Pull out 3rd-4th fork rod and remove 3rd-4th shift fork and 3rd-
4th bracket.
26. Remove shift check sleeve from clutch housing.
27. Remove retaining pin of 1st-2nd shift fork using a pin punch.
28. Pull out 1st-2nd fork rod with 1st-2nd bracket.
29. Remove 1st-2nd shift fork.
30. Remove retaining pin of 1st-2nd bracket using a pin punch and
separate fork rod and 1st-2nd bracket.
31. 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.
32. Remove mainshaft bearing retainer and then mainshaft front
bearing from clutch housing using the puller.
33. Remove oil channel from clutch housing.
34. Remove differential oil seal (clutch housing side) from clutch
housing.
CAUTION:
Be careful not to damage clutch housing.
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TRANSAXLE ASSEMBLY
MT-41
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35. Remove differential side bearing outer race (clutch housing
side) from clutch housing using the puller.
36. Remove input shaft oil seal from clutch housing.
CAUTION:
Be careful not to damage clutch housing.
ASSEMBLY
1. Apply multi-purpose grease to input shaft oil seal lip. Install a
new input shaft oil seal 1.8-2.8 mm (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.
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MT-42
TRANSAXLE ASSEMBLY

3. Install oil channel on mainshaft side.
CAUTION:
Be careful with the orientation of installation.
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-25, "
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.
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TRANSAXLE ASSEMBLY
MT-43
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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.
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 pin.
10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install a
new retaining pin to 1st-2nd shift fork.
CAUTION:
Do not reuse retaining pin.
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 pin.
16. Install 2 check balls to clutch housing.
17. Install 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod
with interlock pin.
18. Install a new stopper ring onto 5th-6th bracket.
CAUTION:
Do not reuse stopper ring.
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MT-44
TRANSAXLE ASSEMBLY

19. Install a new retaining pin onto 5th-6th shift fork.
CAUTION:
Do not reuse retaining pin.
20. Install 2 check balls.
21. Install check ball, shift check sleeve, check spring and a new
check plug.
CAUTION:

Do not reuse check plug.

Do not drop check ball.
22. Install reverse bracket fork rod and reverse bracket.
23. Install a new retaining pin onto reverse bracket.
CAUTION:
Do not reuse retaining pin.
24. Install reverse shift fork and reverse fork rod.
25. 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.
b. While lifting reverse shift fork, align cam with reverse bracket.
c. Install reverse lever assembly to clutch housing, and then
tighten mounting bolts to the specified torque. Refer to MT-27,
"SHIFT CONTROL COMPONENTS" .
26. 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.
27. Install the magnet onto clutch housing.
28. 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.
29. Install selected input shaft rear bearing adjusting shim onto input
shaft.

For selection of adjusting shims, refer to MT-50, "INPUT
SHAFT END PLAY" .
30. Install selected differential side bearing adjusting shim and dif-
ferential side bearing. For selection adjusting shim, refer to MT-
52, "DIFFERENTIAL SIDE BEARING PRELOAD" .
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TRANSAXLE ASSEMBLY
MT-45
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31. Install baffle plate and oil gutter to transaxle case.
32. Install transaxle case following the procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.

For selection of adjusting shims, refer toMT-51, "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.
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.
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MT-46
TRANSAXLE ASSEMBLY

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 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-27, "
SHIFT CONTROL COMPONENTS" .
CAUTION:
Does 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-27, "
SHIFT CONTROL COMPONENTS" .
CAUTION:
Do not reuse stopper bolt.
33. Install a new bore plug to transaxle case using the drift.
CAUTION:
Do not reuse bore plug.
34. Install a new welch plug to transaxle case using the drift.
CAUTION:
Do not reuse welch plug.
35. 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-27, "
SHIFT CONTROL COMPONENTS" .
CAUTION:
Do not reuse check plug.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-47
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36. Install new O-ring applied gear oil on control assembly. And then
install control assembly on transaxle case. After the precious
service tighten bolts to the specified torque. Refer to MT-27,
"SHIFT CONTROL COMPONENTS" .
CAUTION:
Do not reuse O-ring.
37. 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-24,
"CASE AND HOUSING COMPONENTS" .
38. Install new gaskets onto drain plug and filler plug, and then install them into transaxle case. Tighten drain
plug and filler plug to the specified torque. Refer to MT-24, "
CASE AND HOUSING COMPONENTS" .
CAUTION:

Do not reuse gasket.

After oil is filled, tighten filler plug to specified torque.
Adjustment (RS5F51A)ECS008C2
INPUT SHAFT END PLAY

When adjusting input shaft end play, select adjusting shim for
input shaft rear bearing. To select adjusting shim, measure
clearance between transaxle case and input shaft rear bearing.
Refer to MT-102, "
INPUT SHAFT REAR BEARING ADJUSTING
SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.

Calculate dimension "O" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for input
shaft rear bearing.
1. Using depth micrometer and straightedge, measure dimension
"O
1 " between transaxle case end face and mounting face of
adjusting shim.
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End play: 0 - 0.06 mm (0 - 0.0024 in)
Dimension“O” = (O
1 - O2 ) - End play
O: Thickness of adjusting shim
O
1 : Distance between transaxle case end face and
mounting face of adjusting shim
O
2 : Distance between clutch housing end face
and end face of input shaft rear bearing
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MT-48
TRANSAXLE ASSEMBLY

2. Using depth micrometer and straightedge as shown in the fig-
ure, measure dimension "O
2 " between clutch housing end face
and end face of input shaft rear bearing.
3. Install selected input shaft rear bearing adjusting shim onto input
shaft.
MAINSHAFT END PLAY

When adjusting mainshaft end play, select adjusting shim for
mainshaft rear bearing. To select adjusting shim, measure clear-
ance “M” between transaxle case and mainshaft rear bearing.
Refer to MT-102, "
MAINSHAFT REAR BEARING ADJUSTING
SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.

Calculate dimension "P" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for main-
shaft rear bearing.
1. Install mainshaft assembly to clutch housing.
2. Install snap ring to transaxle case.
3. Install transaxle case to clutch housing, and temporarily assemble them with fixing bolts. Install tempo-
rarily snap ring to mainshaft rear bearing.
4. Install dial gauge to bore plug mounting hole, and expand snap
ring. Lift mainshaft assembly through control assembly installa-
tion hole, and push it against transaxle case. This state shall be
defined as base. Moving distance of mainshaft assembly, with
snap ring fit on main rear bearing, becomes “M”.
DIFFERENTIAL SIDE BEARING PRELOAD

When adjusting differential side bearing preload, select adjust-
ing shim for differential side bearing. To select adjusting shim,
measure clearance “L” between transaxle case and differential
side bearing outer race. Refer to MT-103, "
DIFFERENTIAL
SIDE BEARING ADJUSTING SHIM(S)" .
CAUTION:
Up to 2 adjusting shims can be selected.

Calculate dimension “L” (thickness of adjusting shim) using the
following procedure to satisfy specification of preload for differ-
ential side bearing.
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End play: 0 - 0.06 mm (0 - 0.0024 in)
Dimension“P” = "M" - End play
P: Thickness of adjusting shim
M: Distance between mainshaft rear bearing end
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