NISSAN X-TRAIL 2003 Service Repair Manual

INPUT SHAFT AND GEARS
MT-59
D
E
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H
I
J
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L
MA
B
MT

CAUTION:

Be careful with orientation of 5th synchronizer hub and
shifting insert.

Do not reuse 5th synchronizer hub.

Be careful with orientation of 5th coupling sleeve.

Do not reuse 5th coupling sleeve.

Be sure not to hook center projection of 2 spread springs
on same shifting insert.
13. Press in 5th synchronizer hub assembly using the press stand.
CAUTION:
Align grooves of 5th shifting insert and 5th baulk ring.
SCIA0927E
SCIA0994E
SCIA1083E
SCIA0928E

MT-60
INPUT SHAFT AND GEARS

14. Press in 5th stopper and then input shaft bearing spacer using
the drift.
15. Install a new snap ring onto input shaft, and check that end play
(gap between snap ring and groove) of input shaft bearing
spacer satisfies the standard value.

If measurement is outside the standard range, select snap
ring. Refer to MT-100, "
INPUT SHAFT BEARING SPACER" .
CAUTION:
Do not reuse snap ring.
16. Press in input shaft rear bearing using the drift.
CAUTION:
Install input shaft rear bearing with its brown surface facing
the input gear side.
17. Press in input shaft front bearing using the drifts.
18. Install oil channel onto input shaft.
19. Check end play of 3rd, 4th, and 5th input gears.
SCIA0929E
End play standard value : 0 - 0.1 mm (0 - 0.004 in)
SCIA0930E
SCIA0931E
PCIB0825E
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

INPUT SHAFT AND GEARS
MT-61
D
E
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H
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B
MT

Assembly and Disassembly (RS6F51A)ECS008C5
DISASSEMBLY
1. Before disassembling, measure end play for 3rd, 4th, 5th and
6th input gears.
2. Remove oil channel.
3. Press out input shaft rear bearing using the drift and a puller.
4. Remove snap ring.
5. Press out 6th input gear, 6th needle bearing and 6th input gear
bushing using the drift and a puller.
6. Remove 6th baulk ring.
7. Press out 5th input gear and 5th-6th synchronizer hub assembly
using the drift and a puller.
8. Remove 5th needle bearing.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)
6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0966E
SCIA0967E
SCIA0968E
SCIA0918E

MT-62
INPUT SHAFT AND GEARS

9. 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.
10. Remove 3rd needle bearing.
11. 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
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.
SCIA0919E
SCIA0920E
SCIA1074J
SMT387A

INPUT SHAFT AND GEARS
MT-63
D
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MT


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
SMT867D
Clearance
Standard value
3rd and 4th : 0.9 - 1.45 mm (0.035 - 0.057 in)
5th and 6th : 0.95 - 1.4 mm (0.037 - 0.055 in)
Limit value : 0.7 mm (0.028 in)
SMT140
MTF0041D

MT-64
INPUT SHAFT AND GEARS

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

INPUT SHAFT AND GEARS
MT-65
D
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MT

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-6th synchronizer hub, 5th-6th spread spring and 5th-6th shifting insert onto a new 5th-6th
coupling sleeve.
PCIB0800E
Standard value for dimension C2
: 154.7 - 154.8 mm (6.091 - 6.094 in)
SCIA0925E
SCIA0926E

MT-66
INPUT SHAFT AND GEARS

CAUTION:

Be careful with orientation of 5th-6th synchronizer hub.

Do not reuse 5th-6th synchronizer hub.

Be careful with orientation of 5th-6th coupling sleeve.

Do not reuse 5th-6th coupling sleeve.

Be sure not to hook center projection of 2 spread springs
on same shifting insert.
13. Press in 5th-6th synchronizer hub assembly using the press
stand.
CAUTION:
Align grooves of 5th-6th shifting insert and 5th baulk ring
and 6th baulk ring.
SCIA0921E
PCIB0801E
SCIA1083E
SCIA0928E

INPUT SHAFT AND GEARS
MT-67
D
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B
MT

14. Install 6th needle bearing, 6th input gear, 6th baulk ring onto 6th
input gear bushing, and then press in 6th bushing onto input
shaft using the drift.
15. Install a new snap ring onto input shaft, and check that end play
(gap between snap ring and groove) of 6th input gear bushing
satisfies the standard value.

If measurement is outside the standard range, select snap
ring. Refer to MT-100, "
6TH INPUT GEAR BUSHING" .
CAUTION:
Do not reuse snap ring.
16. Press in input shaft rear bearing using the drift.
CAUTION:
Install input shaft rear bearing with its brown surface facing
the 6th input gear side.
17. Press in input shaft front bearing using the drifts.
18. Install oil channel onto input shaft.
19. Check end play of 3rd, 4th, 5th and 6th input gears.
SCIA0969E
End play standard value : 0 - 0.1 mm (0 - 0.004 in)
SCIA0970E
SCIA0971E
PCIB0826E
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)
6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0966E

MT-68
MAINSHAFT AND GEARS

MAINSHAFT AND GEARSPFP:32241
Assembly and Disassembly (RS5F51A)ECS008C6
DISASSEMBLY
1. Before disassembling, measure the end play of 1st and 2nd
main gears.
2. Remove snap ring.
3. Remove C-ring holder, and then remove mainshaft C-ring.
4. Remove mainshaft rear bearing using the drift and pullers.
5. Remove snap ring.End play standard value
1st main gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd main gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0933E
PCIB0802E
SCIA0935E
SCIA0936E