NISSAN X-TRAIL 2003 Service Repair Manual

REPAIR FOR COMPONENT PARTS
AT-505
[ALL]
D
E
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MA
B
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Bearings

Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.

When replacing taper roller bearing, replace outer and inner
race as a set.
ASSEMBLY
1. Attach side gear thrust washers to side gears, then install pinion
mate thrust washers and pinion mate gears in place.
CAUTION:
Apply ATF to any parts.
2. Insert pinion mate shaft.
CAUTION:
When inserting, be careful not to damage pinion mate
thrust washers.
3. Measure the clearance between side gear and differential case
with washers following the procedure below:
a. Set the special tool and dial indicator on side gear.
SPD715
SMT839
SMT087A
SMT097CA

AT-506
[ALL]
REPAIR FOR COMPONENT PARTS

b. Move side gear up and down to measure dial indicator deflec-
tion. Always measure indicator deflection on both side gears.
c. If not within specification, adjust the clearance by changing the
thickness of differential side gear thrust washers. Refer to AT-
535, "Final Drive" .
4. Install lock pin.
CAUTION:

Do not reuse lock pin.

Make sure that lock pin is flush with case.
5. Press on differential side bearings.
CAUTION:
Apply ATF to differential side bearings.
6. Install differential side bearing outer race and differential side
bearing adjusting shim on transaxle case. Refer to AT- 5 0 8 ,
"Adjustment (1)" .
7. Tighten final gear and tighten fixing bolts to the specified torque
in numerical order shown in the figure after temporarily tighten-
ing them. Refer to AT- 5 0 3 , "
COMPONENTS" . Clearance between side gear and differential case
with washer:
0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
SMT699BA
SAT545FA
ATM0432D

ASSEMBLY
AT-507
[ALL]
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ASSEMBLYPFP:00000
Assembly (1)ECS004MD
1. Install differential side oil seals on transaxle case and converter housing.
CAUTION:

Do not reuse differential side oil seals.

Apply ATF to differential side oil seals.
2. Install parking actuator support to transaxle case. Tighten park-
ing actuator support bolts to the specified torque. Refer to AT-
416, "Components" .
CAUTION:
Pay attention to the direction of parking actuator support.
3. Install parking pawl on transaxle case and fix it with parking
shaft.
4. Install return spring and parking pawl spacer.
SAT181FC
SAT182F
SAT183F
SCIA4881E

AT-508
[ALL]
ASSEMBLY

Adjustment (1)ECS004ME
DIFFERENTIAL SIDE BEARING PRELOAD
1. Install differential side bearing outer race without differential side
bearing adjusting shim on transaxle case.
CAUTION:
Apply ATF to differential side bearing outer race.
2. Install differential side bearing outer race on converter housing.
CAUTION:
Apply ATF to differential side bearing outer race.
3. Place final drive assembly on transaxle case.
4. Install transaxle case on converter housing. Tighten transaxle
case fixing bolts to the specified torque. Refer to AT- 4 1 6 , "
Com-
ponents" .
5. Attach dial indicator on differential case at converter housing
side.
6. Insert Tool into differential side gear from transaxle case side.
7. Move SST up and down and measure dial indicator deflection.
8. Select proper thickness of differential side bearing adjusting
shim(s). Refer to AT- 5 3 6 , "
DIFFERENTIAL SIDE BEARING
PRELOAD ADJUSTING SHIMS" .
Suitable shim thickness = Dial indicator deflection + Speci-
fied bearing preload
SAT870D
ATM0024D
Bearing preload:
0.05 - 0.09 mm (0.0020 - 0.0035 in)
SAT186FA

ASSEMBLY
AT-509
[ALL]
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9. Remove converter housing from transaxle case.
10. Remove final drive assembly from transaxle case.
11. Remove differential side bearing outer race from transaxle case.
12. Reinstall differential side bearing outer race and differential side
bearing adjusting shim selected from SDS table on transaxle
case. Refer to AT- 5 3 6 , "
DIFFERENTIAL SIDE BEARING PRE-
LOAD ADJUSTING SHIMS" .
13. Reinstall converter housing on transaxle case and tighten con-
verter housing mounting bolts to the specified torque. Refer to
AT- 4 1 6 , "
Components" .
14. Insert SST and measure turning torque of final drive assembly.

Turn final drive assembly in both directions several times
to seat bearing rollers correctly.

When old bearing is used again, turning torque will be
slightly less than the above.

Make sure torque is close to the specified range.
REDUCTION PINION GEAR BEARING PRELOAD
1. Remove converter housing and final drive assembly from tran-
saxle case.
2. Select proper thickness of reduction pinion gear adjusting shim
using the following procedures.
a. Place reduction pinion gear on transaxle case as shown.
b. Place idler gear bearing on transaxle case.
c. Measure the dimensions “B” “C” and “D” and calculate dimen-
sion “A”.
SAT010FC
Turning torque of final drive assembly (New bearing):
0.78 - 1.37 N-m (0.8 - 14.0 kg-cm, 6.9 - 12.2 in-lb)
Preload adapter: KV38105210
SAT188FA
SAT332DA
A = D − (B + C)
“A”: Distance between the surface of idler gear bear-
ing inner race and the adjusting shim mating
surface of reduction pinion gear.
SAT333DA

AT-510
[ALL]
ASSEMBLY


Measure the dimension “B” between the end of reduction pin-
ion gear and the surface of transaxle case.

Measure the dimension “B” in at least two places.

Measure the dimension “C” between the surface of idler gear
bearing inner race and the surface of transaxle case.

Measure the dimension “C” in at least two places.

Measure the dimension “D” between the end of reduction pin-
ion gear and the adjusting shim mating surface of reduction
pinion gear.

Measure the dimension “D” in at least two places.

Calculate dimension “A”.
d. Measure the dimension “E” between the end of idler gear and
the idler gear bearing inner race mating surface of idler gear.

Measure the dimension “E” in at least two places.
e. Select proper thickness of reduction pinion gear bearing adjust-
ing shim. Refer to AT- 5 3 7 , "
REDUCTION PINION GEAR BEAR-
ING ADJUSTING SHIMS" .
3. Install reduction gear and reduction gear bearing adjusting shim
selected in step 2-e on transaxle case.
4. Press idler gear bearing inner race on idler gear.
CAUTION:

Do not reuse idler gear bearing.

Apply ATF to idler gear bearing.
5. Press idler gear on reduction gear.
CAUTION:
Press idler gear until idler gear fully contacts adjusting
shim.
SAT334DA
SAT335D
A = D − (B + C)
SAT336DA
Proper shim thickness = A − E − 0.05 mm (0.0020 in)*
(*... Bearing preload)
SAT337D
SAT873DE

ASSEMBLY
AT-511
[ALL]
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6. Set manual shaft to “P” position to fix idler gear.
7. Tighten idler gear lock nut to the specified torque. Refer to AT-
416, "Components" .
CAUTION:
Lock idler gear with parking pawl when tightening lock nut.
8. Measure turning torque of reduction pinion gear.

When measuring turning torque, turn reduction pinion
gear in both directions several times to seat bearing roll-
ers correctly.

If turning torque is out of specification, decrease or
increase the thickness of reduction pinion gear bearing
adjusting shim.
9. After properly adjusting turning torque, clinch idler gear lock nut
as shown.
CAUTION:
Do not reuse idler gear lock nut.
OUTPUT SHAFT END PLAY

Measure the clearance between side cover and the end of the
output shaft bearing.

Select proper thickness of output shaft adjusting shim so that
clearance is within specifications.
SAT189F
Turning torque of reduction pinion gear:
0.05 - 0.39 N-m (0.5 - 4.0 kg-cm, 0.43 - 3.47 in-lb)
SAT190FB
SCIA4451E
SAT341D

AT-512
[ALL]
ASSEMBLY

1. Install bearing retainer for output shaft. Refer to AT- 4 1 6 , "Com-
ponents" .
2. Install needle bearing on bearing retainer.
CAUTION:

Apply petroleum jelly to needle bearing.

Be careful with the direction of needle bearing.
3. Install output shaft on transaxle case.
4. Measure the dimensions “
1 ” and “2 ” at side cover and then
calculate dimension “A”.

Measure dimension “1 ” and “2 ” in at least two places.
5. Measure the dimensions “
2 ” and “3 ” and then calculate
dimension “B”.

Measure “2 ” and “3 ” in at least two places.
SAT191F
SCIA4329E
SAT035F
“A”: Distance between transaxle case fitting sur-
face and adjusting shim mating surface.
A =
1 − 2
2
:Height of gauge
SAT374F
“B”: Distance between the end of output shaft bear-
ing outer race and the side cover fitting sur-
face of transaxle case.
B =
2 − 3
2
:Height of gauge
SAT375F

ASSEMBLY
AT-513
[ALL]
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6. Select proper thickness of output shaft adjusting shim so that
output shaft end play (clearance between side cover and output
shaft bearing) is within specifications. Refer to AT- 5 3 8 , "
OUT-
PUT SHAFT ADJUSTING SHIMS" .
7. Install output shaft adjusting shim on output shaft bearing.
Assembly (2)ECS004MF
1. Apply locking sealant (Locktite #518) to transaxle case as
shown in illustration.
2. Fit the mounting part of output shaft bearing on side cover to
output shaft bearing, and after adjusting knock pin position,
install it with light taps using a soft hammer and things like that.
CAUTION:
When installing, to avoid getting damaged and deformed,
set the mounting part straight to parallel with the mounting
surface.
3. Tighten side cover fixing bolts to specified torque. Refer to AT-
416, "Components" .
CAUTION:

Do not mix bolts A and B.

Always replace bolts A as they are self-sealing bolts.Output shaft end play (A − B):
0 - 0.15 mm (0 - 0.0059 in)
SAT440D
SCIA4919E
SAT442D
AAT850

AT-514
[ALL]
ASSEMBLY

4. Install thrust washer on bearing retainer.
CAUTION:
Apply petroleum jelly to thrust washer.
5. Install forward clutch assembly.
CAUTION:

Align teeth of low & reverse brake before installing.

Make sure that bearing retainer seal rings are not spread.

If forward clutch assembly is correctly seated, points 1
and 2 are at almost same level.
6. Install needle bearing.
CAUTION:

Apply petroleum jelly to needle bearing.

Be careful with the direction of needle bearing.
7. Install overrun clutch hub.
CAUTION:
Align teeth of overrun clutch before installing.
SCIA4454E
SCIA4920E
SCIA4921E
SAT030F