NISSAN X-TRAIL 2005 Service Repair Manual

CLUTCH RELEASE MECHANISM
CL-15
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INSPECTION AFTER REMOVAL

If release bearing is seized, damaged, not properly centered or
does not rotate smoothly, replace it.

If contact surface of withdrawal lever is excessively worn,
replace it.

If dust cover is cracked, replace it.
INSTALLATION
CAUTION:

Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing
from the parts.

Be careful not to bring any grease to the clutch disk facing, pressure plate surface and flywheel
surface.
1. Following the instructions below, apply grease to the specified points.
CAUTION:
Wipe off any old grease, debris, or powdery residue left on the grease applying surfaces.

Evenly apply approximately 1 mm (0.04 in) thick coating of recommended grease to withdrawal lever
and release bearing sliding surface.

Apply recommended grease to withdrawal lever ball pin contact surface and inner slots of release bear-
ing. The grease surface should be level with the surrounding area.

Apply a thin coat of recommended grease evenly to release bearing sliding surface. Install release
bearing. Wipe off any excess grease that oozes from the parts and then remove release bearing.
2. Note the following, and install in the reverse order of removal.
CAUTION:

Before installing manual transaxle to the vehicle, make sure that each sliding surface slides
smoothly by operating withdrawal lever.

When assembling, make sure that both ends of snap
spring touch the end face of withdrawal lever. (For YD
engine models)

Be careful with the orientation snap spring. (For YD
engine models)
SCL733
SCL815
SCIA6903E

CL-16
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

CLUTCH DISC, CLUTCH COVER AND FLYWHEELPFP:30100
Removal and InstallationECS008BG
COMPONENTS
QR engine models
YD engine models
CAUTION:
Be careful not to bring any grease to the clutch disc facing, pressure plate surface and flywheel sur-
face.
REMOVAL
1. Remove manual transaxle from the vehicle. Refer to MT-19, "Removal and Installation"
2. Loosen clutch cover mounting bolts evenly. Then remove clutch cover and clutch disc.
PCIB0768E
1. Flywheel 2. Clutch disc 3. Clutch cover
PCIB0769E
1. Flywheel 2. Clutch disc 3. Clutch cover

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CL-17
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INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc

Measure circumferential runout relative to clutch disc center
spline. If it is outside the specification, replace clutch disc.

Measure clutch disc spline and input shaft spline backlash at the
circumference of clutch disc. If outside the specification, replace
clutch disc.

Using calipers, measure the depth to clutch disc facing rivet
heads. If it exceeds the allowable wear limit, replace clutch disc.
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench.

Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
NOTE:

Worn thrust ring will generate a beating noise when tapped at
the rivet with a hammer.

Broken thrust ring will make a clinking sound when cover is shaken up and down.

If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.
Flywheel Runout
Using a dial indicator, measure runout at the flywheel clutch contact
surface. If runout is outside the specification, replace flywheel. If a
trace of burn or discoloration is found on the surface, repair it with
sandpaper.
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch cover mounting hole).Runout limit/diameter of the area to be measured
: 1.0 mm (0.039 in) /230 mm (9.06 in) dia.
Maximum allowable spline backlash
: 1.0 mm (0.039 in)
SCL221
Facing wear limit (depth to the rivet head)
: 0.3 mm (0.012 in)
SCL229
Tolerance for diaphragm spring lever unevenness
: 0.7 mm (0.028 in) or less
Tool number : ST20050240
PCIB0276E
Allowable flywheel runout
QR engine models
: Refer to EM-116, "
FLYWHEEL DEFLECTION (M/T
MODELS)" .
YD engine models
: Refer to EM-255, "
FLYWHEEL DEFLECTION" .PBIC2168E

CL-18
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

INSTALLATION
1. Apply recommended grease to clutch disc and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing
from the parts.
2. Install clutch disc and clutch cover. Pre-tighten mounting bolts
and install clutch aligning bar.
3. Tighten clutch cover mounting bolts evenly in two steps in the
order shown in the figure. Refer to CL-16, "
COMPONENTS" .
4. Install manual transaxle. Refer to MT-19, "
Removal and Installa-
tion" . Tool number
QR engine models : KV30101600
YD engine models : KV30100100SCIA0909E

SERVICE DATA AND SPECIFICATIONS (SDS)
CL-19
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Clutch Control SystemECS008BH
Clutch Master CylinderECS008BI
Clutch Operating CylinderECS008BJ
Clutch DiscECS008BK
Clutch CoverECS008BL
Type of clutch controlHydraulic
Inner diameter15.87 mm (5/8 in)
Inner diameter19.05 mm (3/4 in)
Engine type QR20DE QR25DE YD22DDTi
Model240
Facing size
(outer dia. x inner dia. x thickness)240 mm x 160 mm x 3.5 mm (9.45 in x 6.30 in x 0.138 in)240 mm x 170 mm x 3.5 mm
(9.45 in x 6.69 in x 0.138 in)
Thickness of disc assembly with load7.90 - 8.30 mm (0.3110 - 0.3268 in) with 5,688 N (580 kg,
1,279 lb)7.70 - 8.10 mm (0.303 -
0.319 in) with 7,845N (800
kg, 1,764 lb)
Wear limit of facing surface to rivet head 0.3 mm (0.012 in)
Runout limit/diameter of the area to be
measured1.0 mm (0.039 in) / 230 mm (9.06 in) dia.
Maximum spline backlash
(at outer edge of disc)1.0 mm (0.039 in)
Engine type QR20DE QR25DE YD22DDTi
Model 240 250
Set-load 4,903 N (500 kg, 1,103 lb) 5,884 N (600 kg, 1,323 lb) 7,600 N (775 kg, 1,708 lb)
Diaphragm spring lever height 37.0 - 39.0 mm (1.457 - 1.535 in)
Uneven limit diaphragm spring toe height 0.7 mm (0.028 in) or less

CL-20
SERVICE DATA AND SPECIFICATIONS (SDS)

MT-1
MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
CONTENTS
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SECTION MT
A
B
MT

MANUAL TRANSAXLE
PRECAUTIONS .......................................................... 3
Service Notice or Precautions .................................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 6
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 8
NVH Troubleshooting Chart ..................................... 8
DESCRIPTION ............................................................ 9
Cross-Sectional View ............................................... 9
DOUBLE-CONE SYNCHRONIZER ..................... 11
TRIPLE-CONE SYNCHRONIZER ....................... 11
REVERSE GEAR NOISE PREVENTION FUNC-
TION (SYNCHRONIZING METHOD) .................. 11
M/T OIL ..................................................................... 12
Changing M/T Oil ................................................... 12
DRAINING ........................................................... 12
FILLING ............................................................... 12
Checking M/T Oil .................................................... 12
OIL LEAKAGE AND OIL LEVEL ......................... 12
SIDE OIL SEAL ........................................................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
POSITION SWITCH .................................................. 15
Checking ................................................................ 15
BACK-UP LAMP SWITCH .................................. 15
PARK/NEUTRAL POSITION SWITCH ............... 15
CONTROL LINKAGE ............................................... 16
Components of Control Device and Cable ............. 16
Removal and Installation ........................................ 17
AIR BREATHER HOSE ............................................ 18
Removal and Installation ........................................ 18
TRANSAXLE ASSEMBLY ........................................ 19
Removal and Installation ........................................ 19
COMPONENTS .................................................. 19
REMOVAL ........................................................... 20
INSTALLATION ................................................... 21
Disassembly and Assembly (RS5F51A) ................ 22
COMPONENTS .................................................. 22DISASSEMBLY ................................................... 26
ASSEMBLY ......................................................... 30
ADJUSTMENT .................................................... 36
Disassembly and Assembly (RS6F51A) ................. 40
COMPONENTS ................................................... 40
DISASSEMBLY ................................................... 44
ASSEMBLY ......................................................... 48
ADJUSTMENT .................................................... 54
INPUT SHAFT AND GEARS .................................... 58
Disassembly and Assembly (RS5F51A) ................. 58
DISASSEMBLY ................................................... 58
INSPECTION AFTER DISASSEMBLY ................ 59
ASSEMBLY ......................................................... 62
Disassembly and Assembly (RS6F51A) ................. 66
DISASSEMBLY ................................................... 66
INSPECTION AFTER DISASSEMBLY ................ 67
ASSEMBLY ......................................................... 69
MAINSHAFT AND GEARS ....................................... 73
Disassembly and Assembly (RS5F51A) ................. 73
DISASSEMBLY ................................................... 73
INSPECTION AFTER DISASSEMBLY ................ 74
ASSEMBLY ......................................................... 76
Disassembly and Assembly (RS6F51A) ................. 80
DISASSEMBLY ................................................... 80
INSPECTION AFTER DISASSEMBLY ................ 81
ASSEMBLY ......................................................... 83
REVERSE IDLER SHAFT AND GEARS .................. 89
Disassembly and Assembly (RS5F51A) ................. 89
DISASSEMBLY ................................................... 89
INSPECTION AFTER DISASSEMBLY ................ 89
ASSEMBLY ......................................................... 90
Disassembly and Assembly (RS6F51A) ................. 90
DISASSEMBLY ................................................... 90
INSPECTION AFTER DISASSEMBLY ................ 91
ASSEMBLY ......................................................... 91
FINAL DRIVE ............................................................ 93
Disassembly and Assembly (RS5F51A) ................. 93
PRE-INSPECTION .............................................. 93
DISASSEMBLY ................................................... 93
INSPECTION AFTER DISASSEMBLY ................ 94

MT-2 ASSEMBLY ......................................................... 94
Disassembly and Assembly (RS6F51A) ................. 97
PRE-INSPECTION .............................................. 97
DISASSEMBLY ................................................... 97
INSPECTION AFTER DISASSEMBLY ................ 98
ASSEMBLY ......................................................... 98
SHIFT CONTROL ....................................................101
Inspection (RS5F51A) ..........................................101
SHIFT FORK .....................................................101
Inspection (RS6F51A) ..........................................102
SHIFT FORK .....................................................102
SERVICE DATA AND SPECIFICATIONS (SDS) ....103
General Specifications ..........................................103
TRANSAXLE .....................................................103
Gear End Play ......................................................104
Baulk Ring Clearance ...........................................104
Available Snap Rings ............................................105
INPUT SHAFT BEARING SPACER ..................105
6TH INPUT GEAR BUSHING ...........................1055TH MAIN GEAR ...............................................105
Available C-Rings .................................................105
MAINSHAFT C-RING ........................................105
Available Thrust Washer .......................................106
INPUT SHAFT THRUST WASHER ...................106
DIFFERENTIAL SIDE GEAR THRUST WASHER
.106
Available Adjusting Shims .....................................106
4TH MAIN GEAR ADJUSTING SHIM ................106
INPUT SHAFT REAR BEARING ADJUSTING
SHIM ..................................................................107
MAINSHAFT REAR BEARING ADJUSTING
SHIM ..................................................................107
REVERSE IDLER GEAR ADJUSTING SHIM ....107
6TH MAIN GEAR ADJUSTING SHIM ................107
Available Shims ....................................................108
BEARING PRELOAD .........................................108
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM(S) .............................................................108

PRECAUTIONS
MT-3
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PRECAUTIONSPFP:00001
Service Notice or PrecautionsECS008BM

Do not reuse transaxle oil, once it has been drained.

Check oil level or replace oil with vehicle on level surface.

During removal or installation, keep inside of transaxle clear of dust or dirt.

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

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

Be careful not to damage sliding surfaces and mating surfaces.

MT-4
PREPARATION

PREPARATIONPFP:00002
Special Service ToolsECS008BN
Tool number
Tool nameDescription
KV381054S0
Puller

Removing differential side bearing outer
race

Removing mainshaft front bearing
ST35321000
Drift
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.

Installing input shaft oil seal

Installing reverse main gear

Installing 1st main gear bushing

Installing 1st-2nd synchronizer hub
assembly

Installing 2nd main gear bushing

Installing 3rd main gear

Removing differential side bearing (clutch
housing side for 4WD models)
ST30720000
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.

Installing differential side oil seal

Installing differential side bearing outer race

Installing mainshaft rear bearing

Installing differential side bearing
ST33200000
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.

Installing mainshaft front bearing

Installing 6th input gear bushing
(RS6F51A)

Installing 4th main gear

Installing 5th main gear

Installing 6th main gear (RS6F51A)
KV40105320
Drift
a: 88 mm (3.46 in) dia.Installing differential side bearing outer race
ST33061000
Drift
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.

Installing bore plug

Removing differential side bearing (clutch
housing side for 2WD models)

Removing differential side bearing
(transaxle case side for 4WD models)
ZZA0601D
ZZA1000D
ZZA0811D
ZZA1002D
ZZA0898D
ZZA1000D