NISSAN X-TRAIL 2003 Service Repair Manual

TRANSFER ASSEMBLY
TF-55
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TRANSFER ASSEMBLYPFP:33100
Removal and InstallationEDS0004U
COMPONENTS
REMOVAL
1. Remove exhaust front tube. Refer to EX-2, "Removal and Installation" .
2. Remove propeller shaft. Refer to PR-4, "
Removal and Installation" .
3. Remove RH drive shaft. Refer to FAX-11, "
Removal and Installation" .
4. Remove side shaft. Refer to FA X - 11 , "
Removal and Installation" .
CAUTION:
Be careful not to damage oil seal.
5. Remove air breather hose. Refer to TF-54, "
AIR BREATHER HOSE" .
6. Remove transfer gusset (YD engine models only).
7. Support transaxle assembly with a jack.
8. Remove center member. Refer to EM-78, "
ENGINE ASSEMBLY" (QR engine models), EM-208,
"ENGINE ASSEMBLY" (YD engine models).
9. Remove suspension member. Refer to FSU-12, "
FRONT SUSPENSION MEMBER" .
10. Remove rear engine mounting bracket. Refer to EM-78, "
ENGINE ASSEMBLY" (QR engine models),
EM-208, "
ENGINE ASSEMBLY" (YD engine models).
11. Support transfer assembly with a jack.
12. Remove bolts fixing transaxle assembly and transfer assembly.
13. Remove the transfer assembly from vehicle.
CAUTION:
Be careful not to damage oil seal of transaxle.
1. Transaxle assembly 2. Transfer assembly 3. Side shaft
4. Transfer gusset
(YD engine models only)5. Grommet 6. Insulator
7. Center member
PDIA0465E

TF-56
TRANSFER ASSEMBLY

INSTALLATION
Note the following, and install in the reverse order of removal.

When installing the transfer to the transaxle, install the mounting
bolts following the standard below.
CAUTION:
When installing transfer to transaxle, be careful not to dam-
age oil seal of transaxle.

When installing transfer gusset, tighten mounting bolts with the specified torque. Refer to TF-55, "COM-
PONENTS" . (YD engine models only)

After the installation, check the oil level and oil leakage. Refer to TF-9, "Inspection" .
Bolt No. 1 2
Quantity 4 2
Bolt length “ ” mm (in)65 (2.56) 40 (1.57)
Tightening torque
N·m (kg-m, ft-lb)34.3 (3.5, 25)
SDIA1178E

TRANSFER ASSEMBLY
TF-57
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Disassembly and AssemblyEDS001YQ
COMPONENTS
1. Pinion lock nut 2. Companion flange 3. Pinion sleeve oil seal
4. Pinion rear bearing 5. Dust cover 6. Pinion sleeve
7. O-ring 8. Collapsible spacer 9. Pinion front bearing
10. Drive pinion 11. Pinion sleeve shim 12. Adapter case oil seal
13. Drain plug 14. Adapter case 15. Oil gutter
16. O-ring 17. Gear ring bearing adjusting shim
(Adapter case side)18. Gear ring bearing (Adapter case
side)
19. Gear ring oil seal 20. Gear ring 21. Drive gear
22. Gear ring bearing (Transfer case
side)23. Gear ring bearing adjusting shim
(Transfer case side)24. Oil defense
25. Filler plug 26. Transfer case oil seal 27. Transfer case
28. Breather tube 29. Plug
SDIA1860E

TF-58
TRANSFER ASSEMBLY

ASSEMBLY INSPECTION
Backlash
1. Install a bolt to the companion flange.
2. Fit a dial gauge onto the bolt.
3. Measure the circumference backlash of the companion flange,
and make sure it satisfies the standard below.

If measured value is out of the specification, disassemble it to
check and adjust each part.
Tooth Contact
1. Remove the pinion sleeve assembly. Refer to TF-62, "Pinion Sleeve Assembly" .
2. Apply red lead to the drive gear.
CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on the drive gear.
3. Install the pinion sleeve shims and pinion sleeve assembly.
Refer to TF-72, "
Pinion Sleeve Assembly" .
4. Remove the plug on the upper side of the transfer case.
When installing plug, apply recommended sealant on screw
part, and tighten it at the specified torque. Refer to TF-57,
"COMPONENTS" .
5. Rotate the companion flange back and forth several times, and
check the drive pinion gear to drive gear tooth contact by view-
ing from the plug hole.Backlash : 0.13 - 0.19 mm (0.0051 - 0.0075 in)
SDIA1937J
TFB0212D
SDIA1938E

TRANSFER ASSEMBLY
TF-59
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6. If tooth contact is poorly adjusted, adjust pinion height (dimen-
sion X) in the following manner.
SDIA0520E
SDIA0517E

TF-60
TRANSFER ASSEMBLY


If the tooth contact is near the face (face contact), or near the
heal (heel contact), thin the pinion sleeve shims to move the
drive pinion closer to the drive gear.
Refer to TF-75, "
Pinion Sleeve Shim" .

If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thicken the pinion sleeve shims to move the
drive pinion farther from the drive gear.
Refer to TF-75, "
Pinion Sleeve Shim" .
Pinion Bearing Preload Torque
1. Remove the pinion sleeve assembly. Refer to TF-62, "Pinion Sleeve Assembly" .
2. Rotate the companion flange back and forth 2 to 3 times. Check for unusual noise, rotation malfunction,
and other malfunctions.
3. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
SDIA0518E
SDIA0519E

TRANSFER ASSEMBLY
TF-61
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4. Using a preload gauge, measure the preload torque of the pin-
ion bearing.
CAUTION:
Every rotational part shall rotate smoothly with the speci-
fied gear oil.

If measured value is out of the specification, disassemble the
pinion sleeve assembly to check and adjust each part.
Total Preload Torque
1. Measure pinion bearing preload torque (P1 ). Refer to TF-60, "Pinion Bearing Preload Torque" .
2. Install the pinion sleeve shims and pinion sleeve assembly.
3. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
4. Using a preload gauge, measure the total preload torque.

If measured value is out of the specification, disassemble it to
check and adjust each part. If measuring the total preload
torque after the disassembly, measure it with the transfer case oil seals and gear ring oil seals
removed, then install the oil seals.
Companion Flange Runout
1. Fit a dial gauge onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
2. Rotate the companion flange to check for runout.
3. Fit a test indicator to the inner side of the companion flange
(socket diameter).
4. Rotate the companion flange to check for runout.
5. If the runout value is outside the repair limit, follow the procedure
below to adjust.
a. While changing the phase between companion flange and drive pinion gear by 90° at a time, check runout
and determine which phase angle minimizes the runout.
b. If the runout value is still outside of the limit after the phase has been changed, replace the companion
flange.
c. If the runout is out of the specification after replacement of companion flange, adjust the assembly status
of the pinion bearings and drive pinion gear, or replace the pinion bearings.Tool number : ST3127S000
Preload torque
: 0.10 - 0.39 N·m (0.01 - 0.04 kg-m, 1 - 3 in-lb)
SDIA2076E
Pinion bearing preload torque (P1)
: 0.10 - 0.39 N·m (0.01 - 0.04 kg-m, 1 - 3 in-lb)
Tool number : ST3127S000
Total preload torque
With all oil seals
: P
1 + 0.16 - 0.22 N·m (0.016 - 0.023 kg-m, 1.4 - 1.9 in-lb)
Without transfer case oil seal and adapter case oil seal
: P
1 + 0.06 - 0.12 N·m (0.006 - 0.013 kg-m, 0.6 - 1.1 in-lb)
SDIA2077E
Runout limit : 0.1 mm (0.004 in)
Runout limit : 0.1 mm (0.004 in)
SDIA2078E

TF-62
TRANSFER ASSEMBLY

DISASSEMBLY
Pinion Sleeve Assembly
1. Remove pinion sleeve mounting bolts.
2. Using a plastic hammer, tap companion flange to remove pinion
sleeve assembly.
3. Remove the pinion sleeve shim.
4. Remove the pinion lock nut.
5. Using a drift, remove drive pinion assembly from pinion sleeve
with a press.
6. Remove companion flange.
7. Remove the O-ring from pinion sleeve.
8. Using a flat-bladed screwdriver, remove the pinion sleeve oil
seal.
CAUTION:
Be careful not to damage the pinion sleeve.
9. Remove the pinion rear bearing inner race.
SDIA1803J
SDIA1861J
Tool number : ST33220000
SDIA1806E
TFB0286D

TRANSFER ASSEMBLY
TF-63
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10. Using a puller, remove the pinion rear bearing outer race.
11. Using a puller, remove the pinion front bearing outer race.
12. Remove dust cover.
13. Remove the collapsible spacer from the drive pinion.
14. Using a replacer, press the pinion front bearing inner race out of
the drive pinion.
Adapter Case
1. Remove the adapter case mounting bolts.Tool number : KV381054S0
SDIA2079E
Tool number : KV381054S0
SDIA1558E
Tool number : ST30031000
SDIA1559E
SDIA1862J

TF-64
TRANSFER ASSEMBLY

2. Using a plastic hammer, tap the adapter case to remove.
3. Remove the O-ring.
4. Using a flat-bladed screwdriver, remove the adapter case oil
seal.
CAUTION:
Be careful not to damage the adapter case.
5. Using a brass rod, tap the gear ring bearing adjusting shim from
the cutout on the adapter case to remove the gear ring bearing
adjusting shim and gear ring bearing outer race.
6. Remove the oil gutter.
7. Remove the drain plug.
Drive Gear Assembly
1. Remove the adapter case. Refer to TF-63, "Adapter Case" .
2. Remove the drive gear assembly from the transfer case.
TFB0290D
TFB0291D
SDIA0529E
SDIA0530E