differential NISSAN X-TRAIL 2005 Service Owner's Manual

TRANSAXLE ASSEMBLY
MT-45
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5. Remove check plugs (4 pieces), check springs (4 pieces), check
balls (4 pieces) and shift check sleeve (2 pieces).
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-46
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. Remove retaining pin of reverse bracket using a pin punch.
19. Pull out reverse bracket and reverse bracket fork rod.
20. Remove check ball (2 pieces) and interlock pin from clutch
housing.
21. Shift 3rd-4th fork rod to 3rd position. Remove retaining pin of 5th
- 6th shift fork using a pin punch.
22. Remove stopper rings for 5th-6th bracket.
23. Pull out 5th-6th fork rod and remove 5th-6th shift fork and 5th-
6th bracket.
24. Remove check balls (2 pieces) and interlock pin.
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TRANSAXLE ASSEMBLY
MT-47
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25. Remove retaining pin of 3rd-4th bracket using a pin punch.
26. Remove stopper rings for 3rd-4th shift fork.
27. Pull out 3rd-4th fork rod and remove 3rd-4th shift fork and 3rd-
4th bracket.
28. Remove shift check sleeve from clutch housing.
29. Remove retaining pin of 1st-2nd shift fork using a pin punch.
30. Pull out 1st-2nd fork rod with 1st-2nd bracket.
31. Remove 1st-2nd shift fork.
32. Remove retaining pin of 1st-2nd bracket using a pin punch and
separate fork rod and 1st-2nd bracket.
33. 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.
34. Remove mainshaft bearing retainer and then mainshaft front
bearing from clutch housing using the puller.
35. Remove oil channel from clutch housing.
36. Remove differential side oil seal from clutch housing.
CAUTION:
Be careful not to damage clutch housing.
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MT-48
TRANSAXLE ASSEMBLY

37. Remove differential side bearing outer race from clutch housing
using the puller.
38. 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)
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Dimension A: 1.8 - 2.8 mm (0.071 - 0.110 in)
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TRANSAXLE ASSEMBLY
MT-49
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3. Install oil channel on mainshaft side.
CAUTION:
Be careful with the orientation of installation.
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-41, "
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.
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TRANSAXLE ASSEMBLY
MT-51
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19. Install retaining pin onto 5th-6th shift fork.
CAUTION:
Do not reuse retaining pin.
20. Install 2 check balls.
21. Install check ball, shift check sleeve, check spring and check
plug.
CAUTION:

Do not reuse check plug.

Do not drop check ball.
22. Install reverse bracket fork rod and reverse bracket.
23. Install retaining pin onto reverse bracket.
CAUTION:
Do not reuse retaining pin.
24. Install reverse shift fork and reverse fork rod.
25. 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.
b. While lifting reverse shift fork, align cam with reverse bracket.
c. Install reverse lever assembly to clutch housing, and then
tighten mounting bolts to the specified torque. Refer to MT-43,
"Shift Control Components" .
26. 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.
27. Install the magnet onto clutch housing.
28. 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.
29. Install selected differential side bearing adjusting shim and dif-
ferential side bearing outer race.

For selection of adjusting shim, refer to MT-54, "Differential
Side Bearing Preload" .
30. Install selected reverse idler gear adjusting shim onto reverse
idler gear assembly.
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MT-54
TRANSAXLE ASSEMBLY

37. Apply recommended sealant to threads of park/neutral position
switch and back-up lamp switch. Then install them to transaxle
case and tighten to the specified torque. Refer to MT-40, "
Case
and Housing Components" .
38. Install gaskets onto drain plug and plug, and then install them
into transaxle case. Tighten drain plug and plug to the specified
torque. Refer to MT-40, "
Case and Housing Components" .
CAUTION:
Do not reuse gasket.
39. Install O-ring onto plug (for 2WD models) or gasket onto filler
plug (for 4WD models), and then install it into clutch housing.
Tighten plug mounting bolt or filler plug to the specified torque.
Refer to MT-40, "
Case and Housing Components" .
CAUTION:

Do not reuse O-ring or gasket.

After oil is filled, tighten plug mounting bolt or filler plug to specified torque.
ADJUSTMENT
Differential Side Bearing Preload

When adjusting differential side bearing preload, select adjust-
ing shim for differential side bearing. To select adjusting shim,
measure clearance “L” between transaxle case and differential
side bearing outer race. Refer to MT-108, "
DIFFERENTIAL
SIDE BEARING ADJUSTING SHIM(S)" .
CAUTION:
Up to 2 adjusting shims can be selected.

Calculate dimension “L” (thickness of adjusting shim) using the
following procedure to satisfy specification of preload for differ-
ential side bearing.
1. Using depth micrometer and straightedge, measure dimension
“L
1 ” between transaxle case end face and mounting face of
adjusting shim.
2. Install differential side bearing outer race onto differential side
bearing on final gear side. Holding lightly differential side bear-
ing outer race horizontally by hand, rotate final gear five times or
more (for smooth movement of bearing roller).
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Preload: 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension“L” = (L
1 - L2 ) + Preload
L: Thickness of adjusting shim
L
1 : Distance between transaxle case end face
and mounting face of adjusting shim
L
2 : Distance between differential side bearing
outer race and clutch housing end face
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TRANSAXLE ASSEMBLY
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3. Using depth micrometer and straightedge as shown in the fig-
ure, measure dimension “L
2” between differential side bearing
outer race and clutch housing end face.
4. Install selected differential side bearing adjusting shim, and then
install differential side bearing outer race using the drift.
Reverse Idler Gear End Play

When adjusting reverse idler gear end play, select adjusting
shim for reverse idler gear. To select adjusting shim, measure
clearance between transaxle case and reverse idler gear. Refer
to MT-107, "
REVERSE IDLER GEAR ADJUSTING SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.

Calculate dimension “Q” (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for
reverse idler gear.
1. Using depth micrometer and straightedge, measure dimension
“Q
1 ” between transaxle case end face and mounting face of
adjusting shim.
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End play: 0.04 - 0.10 mm (0.0016 - 0.0039 in)
Dimension“Q” = (Q
1 - Q2 ) - End play
Q: Thickness of adjusting shim
Q
1 : Distance between transaxle case end face
and mounting face of adjusting shim
Q
2 : Distance between clutch housing end face
and end face of reverse idler gear (Rear)
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FINAL DRIVE
MT-93
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FINAL DRIVEPFP:38411
Disassembly and Assembly (RS5F51A)ECS008CA
PRE-INSPECTION

Check the clearance between side gear and differential case as
follows.
1. Clean final drive assembly sufficiently to prevent side gear thrust
washer, differential case, side gear, and other parts from sticking
by gear oil.
2. Put differential case vertically so that side gear to be measured faces upward.
3. Place the drift and a dial indicator onto side gear. Move side
gear up and down, and measure the clearance.
CAUTION:
There should be no resistance and gears should rotate
freely.
4. If not within specification, adjust the clearance by changing side
gear thrust washer thickness.
5. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
DISASSEMBLY
1. Remove final gear mounting bolts, and then separate the final gear from differential case.
2. Remove differential side bearing (clutch housing side) using the
drift and pullers.
3. Remove differential side bearing (transaxle case side) using the
drift and pullers.
4. Remove speedometer drive gear. (For 2WD models)
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Clearance between side gear and differential case
: 0.1 - 0.2 mm (0.004 - 0.008 in)
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MT-94
FINAL DRIVE

5. Remove retaining pin from differential case using a pin punch,
and then remove pinion mate shaft.
6. Rotate pinion mate gears, and remove pinion mate gears, pinion
mate thrust washers, side gears, and side gear thrust washers
from differential case.
INSPECTION AFTER DISASSEMBLY
Gear, Washer, Shaft and Case

Check side gears, side gear thrust washers, pinion mate shaft,
pinion mate gears, pinion mate thrust washers and differential
case. If necessary, replace with a new one.
Bearing

Check for bearing damage and rough rotation. If necessary,
replace with a new one.
CAUTION:
When replacing tapered roller bearing, replace outer and inner
races as a set.
ASSEMBLY
1. Apply gear oil to sliding area of differential case, each gear, and thrust washer.
2. Install side gear thrust washers and side gears into differential
case.
3. While rotating pinion mate thrust washers and pinion mate
gears, aligning them diagonally, install them into differential
case.
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