transaxle NISSAN X-TRAIL 2005 Service Service Manual

MT-1
MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
CONTENTS
D
E
F
G
H
I
J
K
L
M
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
D
E
F
G
H
I
J
K
L
MA
B
MT

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

MT-6
PREPARATION

Commercial Service ToolsECS008BO
ST30031000
PullerMeasuring wear of inner baulk ring
KV40101630
Drift
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.Installing reverse main gear
KV38102510
Drift
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.

Installing 1st main gear bushing

Installing 1st-2nd synchronizer hub
assembly

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

Installing differential side bearing (transaxle
case side for 4WD models)
KV40104830
Drift
a: 70 mm (2.76 in) dia.
b: 63.5 mm (2.500 in) dia.Installing differential side bearing (clutch
housing side for 4WD models)
ST15243000
Drift
a: 30 mm (1.18 in) dia.Measuring end play of side gear Tool number
Tool nameDescription
ZZA0537D
ZZA1003D
ZZA0838D
ZZA0936D
SCIA1088J
Tool nameDescription
PullerRemoving each bearing, gear and bushing
ZZA0537D

MT-12
M/T OIL

M/T OILPFP:KLD20
Changing M/T OilECS008BR
DRAINING
1. Start engine and let it run to warm up transaxle.
2. Stop engine. Remove drain plug and then drain oil.
3. Set a gasket on drain plug and install it to transaxle case. Tighten drain plug to the specified torque. Refer
to MT-22, "
Case and Housing Components" (RS5F51A) or MT-40, "Case and Housing Components"
(RS6F51A).
CAUTION:
Do not reuse gasket.
FILLING
1. Remove plug (for 2WD models) or filler plug (for 4WD models).
Fill with new oil to transaxle.
2. After refilling oil, check oil level.
3. Set a O-ring on plug (for 2WD models) or gasket on filler plug
(for 4WD models) and then install it to clutch housing.
CAUTION:
Do not reuse O-ring or gasket.
4. Tighten plug mounting bolt (for 2WD models) or filler plug (for 4WD models) to the specified torque. Refer
to MT-22, "
Case and Housing Components" (RS5F51A) or MT-40, "Case and Housing Components"
(RS6F51A).
Checking M/T OilECS008BS
OIL LEAKAGE AND OIL LEVEL

Make sure that oil is not leaking from transaxle or around it.

Remove plug (for 2WD models) or filler plug (for 4WD models).

Measure oil level using a suitable gauge as shown in the figure, and then check if it is within the specifica-
tions.
CAUTION:
Do not start engine while checking oil level.
–For 2WD modelsOil grade and viscosity: Refer to MA-17, "
Fluids and
Lubricants" .
Oil capacity (reference):
Approx. 2.2 (3-7/8 lmp pt)
PCIB1572E
Oil level “L” : 55.0 - 61.0 mm (2.17 - 2.40 in)
PCIB1477E

MT-14
SIDE OIL SEAL

SIDE OIL SEALPFP:32113
Removal and InstallationECS008BT
REMOVAL

Clutch housing side oil seal used on 4WD vehicles is attached to transfer. Be sure to replace it
when transfer is removed.
1. Remove drive shaft from transaxle. Refer to FAX-11, "
Removal and Installation" .
2. Remove oil seal with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage the case surface when removing
oil seal.
INSTALLATION
1. Using the drift, drive the oil seal straight until it protrudes from
the case end equal to dimension A shown in the figure.
CAUTION:

Apply multi-purpose grease onto oil seal lip. (For clutch
housing side of 4WD models)

Do not reuse oil seal.
2. Install all parts in the reverse order of removal and check oil
level after installation. Refer to MT-12, "
Checking M/T Oil" .
SCIA0824E
Dimension “A”
: Within 0.5 mm (0.020 in) of flush with the case.
Drift to be used:
Transaxle case side : ST30720000
Clutch housing side : ST30720000
SCIA1776E

CONTROL LINKAGE
MT-17
D
E
F
G
H
I
J
K
L
MA
B
MT

Removal and InstallationECS00CY6
Note the following, when removal and installation.

Shift the control lever to the neutral position for removal.

Keep in mind that the select side lock plate for securing control cable is different from the shift side lock
plate.

After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st, 2nd, or
Reverse.
Install select cable according to the following procedure.
1. Install select cable of transaxle side to control assembly.
2. Install select cable to pin on select lever part of control device
assembly.
3. Push lock part (A) of select cable all the way to the direction of
the arrow. (For 6M/T models)
4. Slide stopper part (B) all the way to lock part (A) as shown by
the arrow. (For 6M/T models)
CAUTION:
Make sure that select cable and select lever are installed
securely.
PCIB0815E
PCIB0817E

MT-18
AIR BREATHER HOSE

AIR BREATHER HOSEPFP:31098
Removal and InstallationECS008BW
Refer to the figure for air breather hose removal and installation information.
QR engine models
YD engine models
CAUTION:

Make sure there are no pinched or restricted areas on air breather hose caused by bending or
winding when installing it.

Be sure to insert air breather hose into air breather tube until overlap area reaches the spool.
PCIB0778E
1. Air cleaner case 2. Transaxle assembly 3. Clip
4. Air breather hose 5. Clip 6. PCV hose
7. Resonator
PCIB0779E
1. Air cleaner case 2. Transaxle assembly 3. Clip
4. Clip 5. Air breather hose 6. Clip
7. Bracket 8. Mass air flow sensor

TRANSAXLE ASSEMBLY
MT-19
D
E
F
G
H
I
J
K
L
MA
B
MT

TRANSAXLE ASSEMBLYPFP:32010
Removal and InstallationECS008BX
COMPONENTS
2WD models
PCIB0866E
1. Rear engine mounting insulator 2. Rubber seat 3. Rear engine mounting bracket
4. Grommet 5. Center member 6. Transaxle assembly
7. LH engine mounting insulator 8. Stopper 9. Rubber seat
10. LH engine mounting bracket