NISSAN X-TRAIL 2005 Service Repair Manual

MAINSHAFT AND GEARS
MT-75
D
E
F
G
H
I
J
K
L
MA
B
MT


If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
BAULK RING CLEARANCE
Triple-cone synchronizer (1st and 2nd)

Check the clearance between outer baulk ring, synchronizer
cone and inner baulk ring as follows.
CAUTION:
The clearances “A”, “B” and “C” are controlled with outer
baulk ring, synchronizer cone and inner baulk ring as a set.
Replace them as a set if the clearances are outside the limit
value.
1. Measure the clearance “A” at 2 points or more diagonally oppo-
site using a feeler gauge when pressing baulk ring toward clutch
gear taper cone. And then calculate mean value.
2. Measure the clearance “B” at 2 points or more diagonally oppo-
site using a feeler gauge. And then calculate mean value.
SMT867D
PCIB1358E
Clearance “A”
Standard value : 0.6 - 1.2 mm (0.024 - 0.047 in)
Limit value : 0.3 mm (0.012 in)
PCIB1359E
Clearance “B”
Standard value : 0.6 - 1.1 mm (0.024 - 0.043 in)
Limit value : 0.2 mm (0.008 in)
PCIB1360E

MT-76
MAINSHAFT AND GEARS

3. Measure the clearance “C” at 2 points or more diagonally oppo-
site using a feeler gauge when pressing baulk ring toward clutch
gear taper cone. And then calculate mean value.
Bearing
Check items below. If necessary, replace them with new ones.

Damage and rough rotation of bearing
ASSEMBLY
1. Press in reverse main gear using the drifts and the press stand.
CAUTION:

Be careful with orientation of reverse main gear.

Do not reuse reverse main gear.Clearance “C”
Standard value : 0.7 - 1.1 mm (0.028 - 0.043 in)
Limit value : 0.3 mm (0.012 in)
PCIB1361E
MTF0041D
SCIA0939E
SCIA0992E

MAINSHAFT AND GEARS
MT-77
D
E
F
G
H
I
J
K
L
MA
B
MT

2. Press in 1st main gear bushing using the drifts and the press
stand.
3. Install 1st needle bearing, and then 1st main gear.
4. Install 1st-2nd spread spring, 1st-2nd shifting insert and 1st-2nd synchronizer hub onto 1st-2nd coupling
sleeve.
CAUTION:

Be careful with orientation of 1st-2nd synchronizer hub.

Do not reuse 1st-2nd synchronizer hub.

Be careful with orientation of 1st-2nd coupling sleeve.

Do not reuse 1st-2nd coupling sleeve.

Be sure not to hook center projection of 2 spread springs
on same 1st-2nd shifting insert.
SCIA0940E
SCIA0921E
PCIB0803E
SCIA1083E

MT-78
MAINSHAFT AND GEARS

5. Install 1st inner baulk ring, 1st synchronizer cone, 1st outer
baulk ring onto mainshaft, and then press in 1st-2nd synchro-
nizer hub assembly onto mainshaft using the drifts and the press
stand.
CAUTION:

Outer baulk ring, synchronizer cone, and inner baulk ring
on 2nd gear-side must have been removed.

Be careful with orientation of coupling sleeve.
6. Press in 2nd main gear bushing using the drift and the press
stand.
7. Install 2nd outer baulk ring, 2nd synchronizer cone, and 2nd
inner baulk ring.
8. Install 2nd needle bearing and 2nd main gear.
9. Press in 3rd main gear using the drift and the press stand.
CAUTION:

Be careful with orientation of 3rd main gear.

Do not reuse 3rd main gear.
10. Install 3rd-4th mainshaft spacer.
11. Select 4th main gear adjusting shim so that dimension “C1” sat-
isfies the standard value below, and install 4th main gear adjust-
ing shim onto mainshaft. Refer to MT-106, "
4TH MAIN GEAR
ADJUSTING SHIM" .
CAUTION:
Only one adjusting shim can be selected.
SCIA0941E
SCIA0942E
SCIA0943E
Standard value for dimension C1
: 173.85 - 173.95 mm (6.844 - 6.848 in)
PCIB0804E

MAINSHAFT AND GEARS
MT-79
D
E
F
G
H
I
J
K
L
MA
B
MT

12. Press in 4th main gear using the drifts.
CAUTION:

Be careful with orientation of 4th main gear.

Do not reuse 4th main gear.
13. Press in 5th main gear using the drifts.
CAUTION:

Be careful with orientation of 5th main gear.

Do not reuse 5th main gear.
14. Install snap ring onto mainshaft, and check that end play of 5th
main gear satisfies the standard value.

If measurement is outside the standard range, reselect snap
ring. Refer to MT-105, "
5TH MAIN GEAR" .
15. Press in mainshaft rear bearing using the drifts.
16. Install mainshaft C-ring onto mainshaft, and check that end play
of mainshaft rear bearing satisfies the standard value.

If measurement is outside the standard range, reselect main-
shaft C-ring. Refer to MT-105, "
MAINSHAFT C-RING" .
SCIA0945E
SCIA0946E
End play standard value : 0 - 0.1 mm (0 - 0.004 in)
SCIA0947E
SCIA0948E
End play standard value : 0 - 0.06 mm (0 - 0.0024 in)
SCIA0949E

MT-80
MAINSHAFT AND GEARS

17. Install C-ring holder, and then install snap ring.
CAUTION:
Do not reuse snap ring.
18. Check end play of 1st and 2nd main gears.
Disassembly and Assembly (RS6F51A)ECS008C7
DISASSEMBLY
1. Before disassembling, measure the end play of 1st and 2nd
main gears.
2. Remove snap ring.
3. Remove C-ring holder, and then remove mainshaft C-ring.
PCIB0802E
End play standard value
1st main gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd main gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0933E
End play standard value
1st main gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd main gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0973E
PCIB0805E

MAINSHAFT AND GEARS
MT-81
D
E
F
G
H
I
J
K
L
MA
B
MT

4. Press out mainshaft rear bearing, 6th main adjusting shim and
6th main gear using the drift and a puller.
5. Remove 5th-6th mainshaft spacer.
6. Press out 4th main gear and 5th main gear using the drift and a
puller.
7. Remove 4th main gear adjusting shim.
8. Remove 3rd-4th mainshaft spacer.
9. Press out 3rd main gear, 2nd main gear, 2nd needle bearing,
2nd main gear bushing, 1st-2nd synchronizer hub assembly, 1st
main gear, 1st needle bearing, and 1st main gear bushing
reverse main gear using the drift.
INSPECTION AFTER DISASSEMBLY
Mainshaft and Gears
Check items below. If necessary, replace them with new ones.

Damage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the shaft.

Excessive wear, damage, peeling, and other non-standard con-
ditions of the gears.
SCIA0976E
SCIA0937E
SCIA0938E
SCIA1076J

MT-82
MAINSHAFT AND GEARS

Synchronizer
Check items below. If necessary, replace them with new ones.

Damage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub and shifting insert.

Coupling sleeve and synchronizer hub must move smoothly.

If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
BAULK RING CLEARANCE
Triple-cone synchronizer (1st and 2nd)

Check the clearance between outer baulk ring, synchronizer
cone and inner baulk ring as follows.
CAUTION:
The clearances “A”, “B” and “C” are controlled with outer
baulk ring, synchronizer cone and inner baulk ring as a set.
Replace them as a set if the clearances are outside the limit
value.
1. Measure the clearance “A” at 2 points or more diagonally oppo-
site using a feeler gauge when pressing baulk ring toward clutch
gear taper cone. And then calculate mean value.
SMT387A
SMT867D
PCIB1358E
Clearance “A”
Standard value : 0.6 - 1.2 mm (0.024 - 0.047 in)
Limit value : 0.3 mm (0.012 in)
PCIB1359E

MAINSHAFT AND GEARS
MT-83
D
E
F
G
H
I
J
K
L
MA
B
MT

2. Measure the clearance “B” at 2 points or more diagonally oppo-
site using a feeler gauge. And then calculate mean value.
3. Measure the clearance “C” at 2 points or more diagonally oppo-
site using a feeler gauge when pressing baulk ring toward clutch
gear taper cone. And then calculate mean value.
Bearing
Check items below. If necessary, replace them with new ones.

Damage and rough rotation of bearing
ASSEMBLY
1. Press in reverse main gear using the drifts and the press stand.Clearance “B”
Standard value : 0.6 - 1.1 mm (0.024 - 0.043 in)
Limit value : 0.2 mm (0.008 in)
PCIB1360E
Clearance “C”
Standard value : 0.7 - 1.1 mm (0.028 - 0.043 in)
Limit value : 0.3 mm (0.012 in)
PCIB1361E
MTF0041D
SCIA0939E

MT-84
MAINSHAFT AND GEARS

CAUTION:

Be careful with orientation of reverse main gear.

Do not reuse reverse main gear.
2. Press in 1st main gear bushing using the drifts and the press
stand.
3. Install 1st needle bearing, and then 1st main gear.
4. Install 1st-2nd spread spring, 1st-2nd shifting insert and 1st-2nd synchronizer hub onto 1st-2nd coupling
sleeve.
CAUTION:

Be careful with orientation of 1st-2nd synchronizer hub.

Do not reuse 1st-2nd synchronizer hub.

Be careful with orientation of 1st-2nd coupling sleeve.

Do not reuse 1st-2nd coupling sleeve.
SCIA0992E
SCIA0940E
SCIA0921E
PCIB0803E