NISSAN X-TRAIL 2003 Service Repair Manual

RFD-1
REAR FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
C
E
F
G
H
I
J
K
L
M
SECTION
A
B
RFD

REAR FINAL DRIVE
PRECAUTIONS .......................................................... 2
Service Notice or Precautions .................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 6
NVH Troubleshooting Chart ..................................... 6
REAR FINAL DRIVE SYSTEM ................................... 7
Sectional View .......................................................... 7
DIFFERENTIAL GEAR OIL ........................................ 8
Changing Differential Gear Oil ................................. 8
DRAINING ............................................................. 8
FILLING ................................................................. 8
Checking Differential Gear Oil .................................. 8
OIL LEAKAGE AND OIL LEVEL ........................... 8
FRONT OIL SEAL ...................................................... 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9
SIDE OIL SEAL .........................................................11
Removal and Installation ......................................... 11
REMOVAL ............................................................ 11
INSTALLATION .................................................... 11
ELECTRIC CONTROLLED COUPLING .................. 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 13REAR FINAL DRIVE ASSEMBLY ............................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 15
Components ........................................................... 16
Pre-inspection ......................................................... 17
TOTAL PRELOAD ............................................... 17
DRIVE GEAR TO DRIVE PINION BACKLASH ... 18
DRIVE GEAR RUNOUT ...................................... 19
COMPANION FLANGE RUNOUT ....................... 19
TOOTH CONTACT .............................................. 19
Disassembly and Assembly .................................... 22
DISASSEMBLY ................................................... 22
ASSEMBLY ......................................................... 25
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 32
General Specification ............................................. 32
Drive Gear Vibration ............................................... 32
Side Gear Clearance Adjustment ........................... 32
THRUST WASHER FOR ADJUSTMENT OF
SIDE GEAR BACK CLEARANCE ....................... 32
Drive Pinion Gear Preload Adjustment ................... 32
DRIVE PINION GEAR PRELOAD ADJUSTING
SHIM ................................................................... 32
Side Bearing Preload Adjustment ........................... 32
ADJUSTING SHIM FOR SIDE BEARING PRE-
LOAD ................................................................... 32
Total Preload ........................................................... 33

RFD-2
PRECAUTIONS

PRECAUTIONSPFP:00001
Service Notice or PrecautionsEDS001YY

Check for the correct installation status prior to removal or disassembly. If matching marks are required,
be certain they do not interfere with the function of the parts when applied.

Overhaul should be done in a clean work area, it is preferable to work in dustproof area.

Before disassembly, using steam or white gasoline, completely remove sand and mud from the exterior of
the unit, preventing them from entering into the unit during disassembly or assembly.

Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary.

Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.

In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.

Clean and flush the parts sufficiently and blow-dry them.

Be careful not to damage sliding surfaces and mating surfaces.

When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.

Always use shop paper for cleaning the inside of components.

Avoid using cotton gloves or shop rags to prevent entering of lint.

During assembly, observe the specified tightening torque, and apply new differential oil, petroleum jelly, or
multi-purpose grease as specified for each vehicle, if necessary.

PREPARATION
RFD-3
C
E
F
G
H
I
J
K
L
MA
B
RFD

PREPARATIONPFP:00002
Special Service ToolsEDS001YZ
Tool number
Tool nameDescription
ST27861000
Drift
a: 62 mm (2.44 in) dia.
b: 52 mm (2.05 in) dia.

Installing final drive front oil seal

Installing final drive side oil seal
KV38100200
Drift
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.

Installing final drive front oil seal

Installing final drive side oil seal
ST3127S000
Preload gaugeMeasuring preload torque
ST33052000
Drift
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.Removing side bearing inner race
KV40100610
Drift
a: 63 mm (2.48 in) dia.
b: 54.3 mm (2.138 in) dia.

Removing and installing gear carrier
and rear cover (2 pieces are used)

Installing pinion front bearing inner
race
ST23550000
Pin punch
a:4.5 mm (0.177 in) dia.Removing and installing lock pin
ST17130000
Drift
a: 31.8 mm (1.252 in) dia.
b: 58 mm (2.28 in) dia.Installing pinion rear bearing outer race
ZZA0832D
ZZA1143D
ZZA0503D
ZZA1023D
ZZA0810D
NT410
ZZA0836D

RFD-4
PREPARATION

ST33230000
Drift
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.
c: 28.5 mm (1.122 in) dia.Installing pinion front bearing outer race
ST23860000
Drift
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.

Installing pinion rear bearing inner
race

Installing pinion front bearing inner
race
ST38220000
Press stand
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in)Installing pinion front bearing inner race
KV40105020
Drift
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in)Installing side bearing inner race
ST35271000
Drift
a: 72 mm (2.83 in) dia.
b: 63 mm (2.48 in) dia.Installing center oil seal
KV381086S1
Dummy cover set
1. KV38108610
Dummy cover
2. KV38108621
Dummy cap spacer
3. KV38108630
Dummy cap shim

Checking backlash

Checking drive gear runout

Checking tooth contact
KV38108500
Drive pinion gear socket

Measuring preload

Removing and installing drive pinion
nut Tool number
Tool nameDescription
ZZA1046D
ZZA0534D
ZZA1058D
ZZA1133D
ZZA0814D
SDIA2313E
ZZA1205D

PREPARATION
RFD-5
C
E
F
G
H
I
J
K
L
MA
B
RFD

Commercial Service ToolsEDS0027I
KV38108400
Pinion nut wrenchMeasuring preload
ST22360002
(J-25679-01)
Drift
a: 29 mm (1.14 in) dia.
b: 23 mm (0.91 in) dia.
c: 150 mm (5.91 in)Installing coupling front bearing Tool number
Tool nameDescription
ZZA1206D
ZZA0546D
Tool nameDescription
Flange wrench Removing and installing companion flange
lock nut
Power toolLoosening nuts and bolts
NT771
PBIC0190E

RFD-6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS001Z1
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: ApplicableReference page
—
Refer to RFD-19, "
TOOTH CONTACT
" .
—
Refer to RFD-18, "
DRIVE GEAR TO DRIVE PINION BACKLASH
" .
Refer to RFD-19, "
COMPANION FLANGE RUNOUT
" .
Refer to RFD-8, "
Checking Differential Gear Oil
" .
NVH in PR section.
NVH in FAX, RAX, FSU and RSU sections.
NVH in WT section.
NVH in WT section.
NVH in FAX and RAX section.
NVH in BR section.
NVH in PS section.
Possible cause and SUSPECTED PARTS
Gear tooth rough
Gear contact improper
Tooth surfaces worn
Backlash incorrect
Companion flange excessive runout
Gear oil improper
PROPELLER SHAFT
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
STEERING
Symptom Noise×××××××××××××

REAR FINAL DRIVE SYSTEM
RFD-7
C
E
F
G
H
I
J
K
L
MA
B
RFD

REAR FINAL DRIVE SYSTEMPFP:38300
Sectional ViewEDS001ZL
SDIA0141E

RFD-8
DIFFERENTIAL GEAR OIL

DIFFERENTIAL GEAR OILPFP:KLD30
Changing Differential Gear OilEDS0027G
DRAINING
1. Stop engine.
2. Remove drain plug and drain oil.
3. Set a gasket on drain plug and install it to final drive assembly
and tighten to the specified torque. Refer to RFD-16, "
Compo-
nents" .
CAUTION:
Do not reuse gasket.
FILLING
1. Remove filler plug. Fill with new oil until oil level reaches the
specified level near filler plug mounting hole.
2. After refilling oil, check oil level. Set a gasket to filler plug, then
install it to final drive assembly. Refer to RFD-16, "
Components"
.
CAUTION:
Do not reuse gasket.
Checking Differential Gear OilEDS0027H
OIL LEAKAGE AND OIL LEVEL

Make sure that oil is not leaking from final drive assembly or around it.

Check oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
Do not start engine while checking oil level.

Set a gasket on filler plug and install it on final drive assembly.
Refer to RFD-16, "
Components" .
CAUTION:
Do not reuse gasket.
PDIA0454E
Oil grade and Viscosity:
Refer to MA-17, "
Fluids and Lubricants" .
Oil capacity:
Approx. 0.55 (1 Imp pt)
PDIA0453E
PDIA0453E

FRONT OIL SEAL
RFD-9
C
E
F
G
H
I
J
K
L
MA
B
RFD

FRONT OIL SEALPFP:38189
Removal and InstallationEDS001Z2
REMOVAL
1. Remove propeller shaft. Refer to PR-4, "Removal and Installation" .
2. Put matching mark on the thread edge of electric controlled cou-
pling. The matching mark should be in line with the matching
mark on companion flange.
CAUTION:
For matching mark, use paint. Do not damage electric con-
trolled coupling.
3. Remove companion flange lock nut, using a flange wrench.
Then remove companion flange.
4. Remove front oil seal from coupling cover, using a flat-bladed
screwdriver.
CAUTION:
Be careful not to damage coupling cover.
INSTALLATION
1. Apply multi-purpose grease to front oil seal lips.
2. Install front oil seal until it becomes flush with the case end,
using the drifts.
CAUTION:

Do not reuse oil seal.

When installing, do not incline oil seal.
PDIA0455E
PDIA0456E
PDIA0457E
Tool number A: KV38100200
B: ST27861000
PDIA0038E

RFD-10
FRONT OIL SEAL

3. Align the matching mark of electric controlled coupling with the
matching mark of companion flange, then install the companion
flange.
4. Install companion flange lock nut with a flange wrench, tighten
the to the specified torque. Refer to RFD-16, "
Components" .
CAUTION:
Do not reuse companion flange lock nut.
5. Install propeller shaft. Refer to PR-4, "
Removal and Installation"
.
PDIA0455E