differential NISSAN X-TRAIL 2003 Service User Guide

TRANSAXLE ASSEMBLY
MT-23
D
E
F
G
H
I
J
K
L
MA
B
MT

FINAL DRIVE COMPONENTS
1. Differential side bearing outer race 2. Differential side bearing (clutch
housing side)3. Differential case
4. Final gear 5. Differential side bearing (transaxle
case side)6. Differential side bearing outer race
7. Differential side bearing adjusting
shim8. Side gear 9. Side gear thrust washer
10. Retaining pin 11. Pinion mate thrust washer 12. Pinion mate gear
13. Pinion mate shaft
PCIB0785E

MT-24
TRANSAXLE ASSEMBLY

Component Parts (RS6F51A)ECS008BZ
CASE AND HOUSING COMPONENTS
1. Clutch housing 2. Differential oil seal 3. Ball pin
4. Washer 5. Input shaft oil seal 6. Oil channel
7. Magnet 8. Back-up lamp switch 9. Oil gutter
10. Baffle plate 11. Transaxle case 12. Filler plug
13. Gasket 14. Welch plug 15. Bore plug
16. Drain plug 17. Differential oil seal 18. Park/Neutral position switch
19. Air breather tube
PCIB0781E

MT-28
TRANSAXLE ASSEMBLY

FINAL DRIVE COMPONENTS
Disassembly and Assembly (RS5F51A)ECS008C0
DISASSEMBLY
1. Remove drain plug and filler plug from transaxle case.
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.
1. Differential side bearing outer race 2. Differential side bearing (clutch
housing side)3. Differential case
4. Final gear 5. Differential side bearing (transaxle
case side)6. Differential side bearing outer race
7. Differential side bearing adjusting shim 8. Side gear 9. Side gear thrust washer
10. Retaining pin 11. Pinion mate thrust washer 12. Pinion mate gear
13. Pinion mate shaft
PCIB0785E
SCIA0389E

TRANSAXLE ASSEMBLY
MT-29
D
E
F
G
H
I
J
K
L
MA
B
MT

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.
SCIA0396E
SCIA0983E
SCIA0897E
SCIA0402E
SCIA0397E

TRANSAXLE ASSEMBLY
MT-31
D
E
F
G
H
I
J
K
L
MA
B
MT

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.
SCIA0395E
SCIA1077J
SCIA1068J
SCIA1069J
SCIA0398E

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.
PCIB0807E
SCIA1070J
SCIA0986E

TRANSAXLE ASSEMBLY
MT-33
D
E
F
G
H
I
J
K
L
MA
B
MT

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.
SCIA0401E
PCIB0789E
SCIA0987E
SCIA0888E
SCIA0395E

TRANSAXLE ASSEMBLY
MT-35
D
E
F
G
H
I
J
K
L
MA
B
MT

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.
PCIB0790E
SCIA0390E
SCIA0887E
PCIB0816E

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.
SCIA0389E
SCIA0959E
SCIA0983E
SCIA0897E
SCIA0402E

TRANSAXLE ASSEMBLY
MT-39
D
E
F
G
H
I
J
K
L
MA
B
MT

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.
SCIA0397E
SCIA0960E
SCIA0961E
SCIA0962E
SCIA0963E