NISSAN X-TRAIL 2005 Service Repair Manual

TRANSAXLE ASSEMBLY
MT-25
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Shift Control Components
1. 3rd-4th bracket 2. Retaining pin 3. Stopper ring
4. 5th-reverse bracket 5. Reverse lever assembly 6. Shifter cap
7. Reverse shift fork 8. Reverse fork rod 9. Check plug
10. Check spring 11. Shift check sleeve 12. Check ball
13. 5th-reverse fork rod 14. 5th shift fork 15. Check spring
16. 3rd-4th fork rod 17. Interlock pin 18. Shift check sleeve
19. 1st-2nd fork rod 20. 1st-2nd bracket 21. 1st-2nd shift fork
22. 3rd-4th shift fork 23. Control assembly 24. Transaxle case
25. Stopper bolt 26. Shift check 27. O-ring
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MT-26
TRANSAXLE ASSEMBLY

Final Drive Components
DISASSEMBLY
1. Remove plug (for 2WD models) or filler plug (for 4WD models) from clutch housing.
2. Remove drain plug and plug from transaxle case.
3. Remove park/neutral position switch and back-up lamp switch
from transaxle case.
4. Remove shift check and stopper bolt from transaxle case, and
then remove control assembly from transaxle case.
1. Differential side bearing outer race
(clutch housing side)2. Differential side bearing (clutch
housing side)3. Speedometer drive gear (for 2WD
models)
4. Differential case 5. Final gear 6. Differential side bearing (transaxle
case side)
7. Differential side bearing outer race
(transaxle case side)8. Differential side bearing adjusting
shim9. Pinion mate shaft
10. Side gear 11. Side gear thrust washer 12. Pinion mate gear
13. Pinion mate thrust washer 14. Retaining pin
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TRANSAXLE ASSEMBLY
MT-27
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5. Remove check plugs (3 pieces), check springs (3 pieces), check
balls (3 pieces) and shift check sleeve (1 piece).
6. Remove transaxle case mounting bolts.
7. Remove bore plug from transaxle case.
CAUTION:
Be careful not to damage transaxle case.
8. While spreading the snap ring of mainshaft rear bearing located
at bore plug hole, remove transaxle case from clutch housing.
9. Remove oil gutter, baffle plate from transaxle case.
10. Remove snap ring, mainshaft rear bearing adjusting shim from
transaxle case.
11. Remove input shaft rear bearing adjusting shim and reverse
idler gear adjusting shim.
12. Remove differential side bearing outer race from transaxle case
using the puller, and then remove differential side bearing
adjusting shim from transaxle case.
13. Remove welch plug from transaxle case.
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MT-28
TRANSAXLE ASSEMBLY

14. Remove differential side oil seal from transaxle case.
CAUTION:
Be careful not to damage transaxle case.
15. Remove magnet from clutch housing.
16. With shift lever in 5th position, remove mounting bolts from
reverse lever assembly. Lift reverse lever assembly to remove.
CAUTION:
Be careful not to lose shifter cap.
17. Pull out reverse fork rod then remove reverse shift fork.
18. Shift 3rd-4th fork rod to 3rd position. Remove retaining pin of 5th
shift fork using a pin punch.
19. Remove stopper rings for 5th-reverse bracket.
20. Pull out 5th-reverse fork rod and remove 5th shift fork and 5th-
reverse bracket.
21. Remove check balls (2 pieces) from clutch housing.
22. Remove retaining pin of 3rd-4th bracket using a pin punch.
23. Remove stopper rings for 3rd-4th shift fork.
24. Pull out 3rd-4th fork rod and remove 3rd-4th shift fork and 3rd-
4th bracket.
25. Remove interlock pin and shift check sleeve from clutch hous-
ing.
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TRANSAXLE ASSEMBLY
MT-29
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26. Remove retaining pin of 1st-2nd shift fork using a pin punch.
27. Pull out 1st-2nd fork rod with 1st-2nd bracket.
28. Remove 1st-2nd shift fork.
29. Remove retaining pin of 1st-2nd bracket using a pin punch and
separate 1st-2nd fork rod and 1st-2nd bracket.
30. Remove gear components from clutch housing in the following
procedure.
a. Remove input shaft assembly, mainshaft assembly and reverse
idler gear assembly as a set, tapping input shaft with plastic
hammer.
CAUTION:
Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
b. Remove final drive assembly.
31. Remove mainshaft bearing retainer and then mainshaft front
bearing from clutch housing using the puller.
32. Remove oil channel from clutch housing.
33. Remove differential side oil seal from clutch housing.
CAUTION:
Be careful not to damage clutch housing.
34. Remove differential side bearing outer race from clutch housing
using the puller.
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MT-30
TRANSAXLE ASSEMBLY

35. Remove input shaft oil seal from clutch housing.
CAUTION:
Be careful not to damage clutch housing.
ASSEMBLY
1. Install input shaft oil seal to clutch housing using the drift.
CAUTION:
Do not reuse input shaft oil seal.
2. Install differential side oil seal until it become flush with end face
of clutch housing using the drift.
CAUTION:

Do not reuse differential side oil seal.

Apply multi-purpose grease onto oil seal lip. (For 4WD
models)
3. Install oil channel on mainshaft side.
CAUTION:
Be careful with the orientation of installation.
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Dimension A: 1.8 - 2.8 mm (0.071 - 0.110 in)
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TRANSAXLE ASSEMBLY
MT-31
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4. Install mainshaft front bearing to clutch housing using the drift.
CAUTION:
Be careful with the orientation of installation.
5. Install mainshaft bearing retainer to clutch housing and tighten
mounting bolt to the specified torque. Refer to MT-23, "
Gear
Components" .
CAUTION:
Install with punched surface facing up.
6. Install differential side bearing outer race to clutch housing using
the drifts.
7. Install final drive assembly into clutch housing.
8. Install input shaft assembly, mainshaft assembly, and reverse
idler gear assembly into clutch housing.
CAUTION:
Be sure not to damage input shaft oil seal.
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MT-32
TRANSAXLE ASSEMBLY

9. Install 1st-2nd bracket onto 1st-2nd fork rod, and then install
retaining pin to 1st-2nd bracket.
CAUTION:
Do not reuse retaining pin.
10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install
retaining pin to1st-2nd shift fork.
CAUTION:
Do not reuse retaining pin.
11. Install shift check sleeve to clutch housing.
12. Install interlock pin to 3rd-4th fork rod.
13. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod.
14. Install stopper rings onto 3rd-4th shift fork.
CAUTION:
Do not reuse stopper ring.
15. Install retaining pin onto 3rd-4th bracket.
CAUTION:
Do not reuse retaining pin.
16. Install 2 check balls to clutch housing.
17. Install 5th-reverse bracket, 5th shift fork, and 5th-reverse fork
rod.
18. Install stopper rings onto 5th-reverse bracket.
CAUTION:
Do not reuse stopper ring.
19. Install retaining pin onto 5th shift fork.
CAUTION:
Do not reuse retaining pin.
20. Install reverse shift fork and reverse fork rod.
21. Install reverse lever assembly following the procedures below.
a. Install shifter cap onto reverse lever assembly cam, and then
install them onto reverse shift fork.
CAUTION:
Do not drop shifter cap.
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TRANSAXLE ASSEMBLY
MT-33
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b. While lifting reverse shift fork, align cam with 5th-reverse
bracket.
c. Install reverse lever assembly to clutch housing, and then
tighten mounting bolts to the specified torque. Refer to MT-25,
"Shift Control Components" .
22. Install check ball, shift check sleeve, check spring and check
plug to clutch housing.
CAUTION:

Do not reuse check plug.

Do not drop check ball.
23. Install the magnet onto clutch housing.
24. Install differential side oil seal until it is flush with end face of
transaxle case using the drift.
CAUTION:
Do not reuse differential side oil seal.
25. Install selected differential side bearing adjusting shim and dif-
ferential side bearing outer race.

For selection of adjusting shim, refer to MT-36, "Differential
Side Bearing Preload" .
26. Install selected reverse idler gear adjusting shim onto reverse
idler gear assembly.

For selection of adjusting shims, refer to MT-37, "Reverse
Idler Gear End Play" .
27. Install selected input shaft rear bearing adjusting shim onto input shaft.

For selection of adjusting shims, refer to MT-37, "Input Shaft End Play" .
28. Install baffle plate and oil gutter to transaxle case.
29. Install transaxle case following the procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.

For selection of adjusting shims, refer to MT-38, "Mainshaft End Play" .
b. Temporarily install snap ring of mainshaft rear bearing into transaxle case.
CAUTION:
Do not reuse snap ring.
c. Apply recommended sealant to mating surfaces of transaxle
case and clutch housing.
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
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MT-34
TRANSAXLE ASSEMBLY

d. With snap ring of mainshaft rear bearing temporarily installed,
place transaxle case over clutch housing.
e. Through bore plug mounting hole, with snap ring stretched, and
lift up mainshaft assembly from the control assembly mounting
hole.
f. Securely install snap ring onto mainshaft rear bearing.
g. Tighten mounting bolts to the specified torque.
CAUTION:
Always replace bolts B as they are self-sealing bolts.
h. Apply gear oil to O-ring and install it to control assembly. Then
install control assembly to transaxle case. Tighten bolts to the
specified torque. Refer to MT-25, "
Shift Control Components" .
CAUTION:
Do not reuse O-ring.
i. Install shift check to transaxle case, and then tighten shift check to the specified torque. Refer to MT-25,
"Shift Control Components" .
CAUTION:
Do not reuse shift check.
j. Install stopper bolt to transaxle case, and then tighten stopper bolt to the specified torque. Refer to MT-25,
"Shift Control Components" .
CAUTION:
Do not reuse stopper bolt.
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Bolt A:
: 52 N·m (5.3 kg-m, 38 ft-lb)
Bolt B:
: 65 N·m (6.6 kg-m, 48 ft-lb)
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