NISSAN X-TRAIL 2003 Service Repair Manual

TRANSAXLE ASSEMBLY
MT-49
D
E
F
G
H
I
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MA
B
MT

1. Using depth micrometer and straightedge, measure dimension
"L
1 " between transaxle case end face and mounting face of
adjusting shim.
2. Install differential side bering outer race onto differential side
bearing on final gear side. Holding lightly differential side bear-
ing outer race horizontally by hand, rotate final gear five times or
more (for smooth movement of bearing roller).
3. Using depth micrometer and straightedge as shown in the fig-
ure, measure dimension "L
2 " between differential side bearing
outer race and clutch housing end face.
4. Install selected differential side bearing adjusting shim, and then
install differential side bearing outer race using the drift.
REVERSE IDLER GEAR END PLAY

When adjusting reverse idler gear end play, select adjusting
shim for reverse idler gear. To select adjusting shim, measure
clearance between transaxle case and reverse idler gear. Refer
to MT-102, "
REVERSE IDLER GEAR ADJUSTING SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.

Calculate dimension "Q" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for
reverse idler gear.Preload: 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension“L” = (L
1 - L2 ) + Preload
L: Thickness of adjusting shim
L
1 : Distance between transaxle case end face and
mounting face of adjusting shim
L
2 : Distance between differential side bearing
outer race and clutch housing end face
SCIA1078E
SCIA1079E
SCIA0898E
End play: 0.04 - 0.10 mm (0.0016 - 0.0039 in)
Dimension“Q” = (Q
1 - Q2 ) - End play
PCIB0796E

MT-50
TRANSAXLE ASSEMBLY

1. Using depth micrometer and straightedge, measure dimension
"Q
1 " between transaxle case end face and mounting face of
adjusting shim.
2. Using depth micrometer and straightedge as shown in the fig-
ure, measure dimension "Q
2 " between clutch housing end face
and end face of reverse idler gear (Rear).
3. Install selected reverse idler gear adjusting shim onto reverse
idler gear assembly.
Adjustment (RS6F51A)ECS008C3
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.Q: Thickness of adjusting shim
Q
1 : Distance between transaxle case end face and
mounting face of adjusting shim
Q
2 : Distance between clutch housing end face
and end face of reverse idler gear (Rear)
SCIA1003E
PCIB0797E
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
SCIA1001E

TRANSAXLE ASSEMBLY
MT-51
D
E
F
G
H
I
J
K
L
MA
B
MT

1. Using depth micrometer and straightedge, measure dimension
"O
1 " between transaxle case end face and mounting face of
adjusting shim.
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”.
SCIA1002E
PCIB0792E
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
face and transaxle case end facePCIB0793E
PCIB0794E

MT-52
TRANSAXLE ASSEMBLY

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.
1. Using depth micrometer and straightedge, measure dimension
"L
1 " between transaxle case end face and mounting face of
adjusting shim.
2. Install differential side bearing outer race onto differential side
bearing on final gear side. Holding lightly differential side bear-
ing outer race horizontally by hand, rotate final gear five times or
more (for smooth movement of bearing roller).
3. Using depth micrometer and straightedge as shown in the fig-
ure, measure dimension "L
2 " between differential side bearing
outer race and clutch housing end face.
4. Install selected differential side bearing adjusting shim, and then
install differential side bearing outer race using the drift.Preload: 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension“L” = (L
1 - L2 ) + Preload
L: Thickness of adjusting shim
L
1 : Distance between transaxle case end face
and mounting face of adjusting shim
L
2 : Distance between differential side bearing
outer race and clutch housing end face
PCIB0795E
SCIA1078E
SCIA1079E
SCIA0898E

TRANSAXLE ASSEMBLY
MT-53
D
E
F
G
H
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J
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L
MA
B
MT

REVERSE IDLER GEAR END PLAY

When adjusting reverse idler gear end play, select adjusting
shim for reverse idler gear. To select adjusting shim, measure
clearance between transaxle case and reverse idler gear. Refer
to MT-102, "
REVERSE IDLER GEAR ADJUSTING SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.

Calculate dimension "Q" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for
reverse idler gear.
1. Using depth micrometer and straightedge, measure dimension
"Q
1 " between transaxle case end face and mounting face of
adjusting shim.
2. Using depth micrometer and straightedge as shown in the fig-
ure, measure dimension "Q
2 " between clutch housing end face
and end face of reverse idler gear (Rear).
3. Install selected reverse idler gear adjusting shim onto reverse
idler gear assembly.End play: 0.04 - 0.10 mm (0.0016 - 0.0039 in)
Dimension“Q” = (Q
1 - Q2 ) - End play
Q: Thickness of adjusting shim
Q
1 : Distance between transaxle case end face and
mounting face of adjusting shim
Q
2 : Distance between clutch housing end face and
end face of reverse idler gear (Rear)
PCIB0796E
SCIA1003E
PCIB0797E

MT-54
INPUT SHAFT AND GEARS

INPUT SHAFT AND GEARSPFP:32200
Assembly and Disassembly (RS5F51A)ECS008C4
DISASSEMBLY
1. Before disassembling, measure end play for 3rd, 4th, and 5th
input gears.
2. Remove oil channel.
3. Press out input shaft rear bearing using the drift and a puller.
4. Remove the snap ring.
5. Press out input shaft bearing spacer and 5th stopper using the
drift and a puller.End play standard value
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0914E
SCIA0915E
SCIA0916E
SCIA0917E

INPUT SHAFT AND GEARS
MT-55
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6. Press out 5th input gear and 5th synchronizer hub assembly
using the drift and a puller.
7. Remove 5th needle bearing.
8. Press out 5th input gear bushing, thrust washer, 4th input gear,
4th needle bearing, 4th input gear bushing, 4th baulk ring, 3rd-
4th synchronizer hub assembly, 3rd baulk ring and 3rd input
gear using the drift and a puller.
9. Remove 3rd needle bearing.
10. Press out input shaft front bearing using a puller.
INSPECTION AFTER DISASSEMBLY
Input Shaft and Gears
Check items below. If necessary, replace them with new ones.

Damage, peeling, dent, uneven wear, bending, etc. of shaft

Excessive wear, damage, peeling, etc. of gears
SCIA0918E
SCIA0919E
SCIA0920E
SCIA1073J

MT-56
INPUT SHAFT AND GEARS

Synchronizer
Check items below. If necessary, replace them with new ones.

Damage and excessive wear of contact surfaces of coupling
sleeve, synchronizer hub, and shifting insert

Coupling sleeve and synchronizer hub must move smoothly.

If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
Baulk ring clearance

Push baulk ring on the cone, and measure the clearance
between baulk ring and cone. If measurement is below limit,
replace it with a new one.
Bearing
Check items below. If necessary, replace them with new ones.

Damage and rough rotation of bearing
SMT387A
SMT867D
Clearance
Standard value
3rd and 4th : 0.9 - 1.45 mm (0.035 - 0.057 in)
5th : 0.95 - 1.4 mm (0.037 - 0.055 in)
Limit value : 0.7 mm (0.028 in)
SMT140
MTF0041D

INPUT SHAFT AND GEARS
MT-57
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ASSEMBLY
1. Install 3rd needle bearing to input shaft.
2. Install 3rd input gear and 3rd baulk ring to input shaft.
3. Install 3rd-4th spread spring, 3rd-4th shifting insert and a new 3rd-4th synchronizer hub onto a new 3rd-
4th coupling sleeve.
CAUTION:

Be careful with orientation of 3rd-4th synchronizer hub.

Do not reuse 3rd-4th synchronizer hub.

Be careful with orientation of 3rd-4th coupling sleeve.

Do not reuse 3rd-4th coupling sleeve.

Be sure not to hook center projection of 2 spread springs
on same shifting insert.
4. Press in 3rd-4th synchronizer hub assembly using the press
stand.
CAUTION:
Align grooves of 3rd-4th shifting insert and 3rd baulk ring.
SCIA0921E
PCIB0799E
SCIA1083E
SCIA0922E

MT-58
INPUT SHAFT AND GEARS

5. Press in 4th input gear bushing using the press stand.
6. Install 4th baulk ring.
7. Install 4th needle bearing and 4th input gear to input shaft.
8. Select thrust washer so that dimension “C2” satisfies the stan-
dard value below. Then install thrust washer onto input shaft.
Refer to MT-101, "
INPUT SHAFT THRUST WASHER" .
CAUTION:
Only one thrust washer can be selected.
9. Press in a new 5th input gear bushing using the press stand.
CAUTION:
Do not reuse 5th input gear bushing.
10. Install 5th needle bearing and 5th input gear to input shaft.
11. Install 5th baulk ring.
12. Install a new 5th synchronizer hub and 5th spread spring, 5th shifting insert onto a new 5th coupling
sleeve.
PCIB0800E
Standard for dimension C2
: 154.7 - 154.8 mm (6.091 - 6.094 in)
SCIA0925E
SCIA0926E