2003 NISSAN X-TRAIL manual transmission

GI-40
TOW TRUCK TOWING
TOW TRUCK TOWING
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To w Tr u c k To w i n gEAS000FL
CAUTION:
lAll applicable local laws regarding the towing operation must be obeyed.
lIt is necessary to use proper towing equipment to avoid possible damage to the vehicle during
towing operation. Towing is in accordance with Towing Procedure Manual at dealer.
lAlways attach safety chains before towing.
lWhen towing, make sure that the transmission, steering system and power train are in good order.
If any unit is damaged, dollies must be used.
lNever tow an automatic transmission model from the rear (that is backward) with four wheels on
the ground. This may cause serious and expensive damage to the transmission.
NISSAN recommends that towing dollies be used when towing your
vehicle beplaced on a flat bed truck as illustrated.
TOWING AN AUTOMATIC TRANSAXLE MODEL WITH FOUR WHEELS ON GROUND
Observe the following restricted towing speeds and distances.
CAUTION:
Never tow an automatic transaxle model from the rear (i.e., backward) with four wheels on the ground
as this may cause serious and expensive damage to the transaxle.
PAIA0012E
Speed :Below 50 km/h (30 MPH)
Distance :Less than 65 km(40 miles)

MA-4
DESCRIPTION
DESCRIPTION
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Pre-delivery Inspection ItemsELS000AK
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD — engine off
Radiator coolant level and coolant hose connections for leaks
Battery fluid level, specific gravity and conditions of battery terminals
Drive belts tension
Fuel filter for water or dusts (Diesel only), and fuel lines and connections for leaks
Engine oil level and oil leaks
Clutch and brake reservoir fluid level and fluid lines for leaks
Windshield and rear window washer and headlamp cleaner reservoir fluid level
Power steering reservoir fluid level and hose connections for leaks
ON INSIDE AND OUTSIDE
Remove front spring/strut spacer (If applicable)
Operation of all instruments, gauges, lights and accessories
Operation of horn(s), wiper and washer
Steering lock for operation
Check air conditioner for gas leaks
Front and rear seats, and seat belts for operation
All moldings, trims and fittings for fit and alignment
All windows for operation and alignment
Hood, trunk lid, door panels for fit and alignment
Latches, keys and locks for operation
Weatherstrips for adhesion and fit
Headlamp aiming
Tighten wheel nuts (Inc. inner nuts if applicable)
Tire pressure (Inc. spare tire)
Check front wheels for toe-in
Install clock/voltmeter/room lamp fuse (If applicable)
Install deodorizing filter to air conditioner (If applicable)
Remove wiper blade protectors (If applicable)
UNDER BODY
Manual transmission/transaxle, transfer and differential gear oil level
Brake and fuel lines and oil/fluid reservoirs for leaks
Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts
Tighten rear body bolts and nuts (Models with wooden bed only)
ROAD TEST
Clutch operation
Parking brake operation
Service brake operation
Automatic transmission/transaxle shift timing and kickdown
Steering control and returnability
Engine performance
Squeaks and rattles
ENGINE OPERATING AND HOT
Adjust idle speed
Automatic transmission/transaxle fluid level

RECOMMENDED FLUIDS AND LUBRICANTS
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RECOMMENDED FLUIDS AND LUBRICANTSPFP:00000
Fluids and LubricantsELS000C8
*1: For further details, see “SAE Viscosity Number”.
*2: Never use API CG-4.
*3: Use Genuine Nissan Anti-freeze Coolant (L2N)] or equivalent in its quality, in order to avoid possible aluminum corrosion within the
engine cooling system caused by the use of non-genuine engine coolant.
Note that any repairs for the incidents within the engine cooling system while using non-genuine engine coolant may not be
covered by the warranty even if such incidents occurred during the warranty period.
*4: Contact a Nissan dealership for more information regarding suitable fluids, including recommended brand(s) of Dexron
TMIII/Mer-
conTMAutomatic Transmission Fluid.
*5: Never mix different types of fluids (DOT 3 and DOT 4).Capacity (Approximate)
Recommended Fluids/Lubricants
Liter Imp measure
Engine oil
Drain and refillWith oil filter
changeQR20DE 3.9 3-3/8 qt
lGasoline engine
API SG, SH or SJ*1
ILSAC grade GF-I or GF-II*1
ACEA 96-A2
lDiesel engine
API CF-4*1, *2
ACEA 98-B1 YD22DDTi 5.2 4-5/8 qt
Without oil filter
changeQR20DE 3.5 3-1/8 qt
YD22DDTi 4.9 4-3/8 qt
Dry engine (engine overhaul)QR20DE 4.5 4 qt
YD22DDTi 6.3 5-1/2 qt
Cooling system (with reservoir)QR20DE 7.1 6-1/4 qt
lGenuine Nissan Anti-freeze Coolant (L2N) or
equivalent in its quality*3 YD22DDTi 9.5 8-3/8 qt
Reservoir tankQR20DE 0.6 1/2 qt
YD22DDTi 0.6 1/2 qt
Manual transaxle gear oil
2.3 4pt
lGenuine Nissan gear oil or API GL-4, Viscosity
SAE 75W-85
Transfer gear oil 0.31 1/2 pt
lAPI GL-5*1, Viscosity SAE 80W-90
Differential gear oil 0.55 1 pt
lAPI GL-5*1, Viscosity SAE 80W-90
Automatic transaxle fluid 8.0 7.01 pt Genuine Nissan ATF or equivalent*4
Power steering fluid — —
Ty p e D e x r o n
TMIII or equivalent
Brake and clutch fluid — —
lDOT 3 or DOT 4 (US FMVSS No. 116)*5
Multi-purpose grease — — NLGI No. 2 (Lithium soap base)

MT-1
MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
CONTENTS
D
E
F
G
H
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M
SECTION
A
B
MT
MANUAL TRANSAXLE
PRECAUTIONS .......................................................... 3
Caution ..................................................................... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 6
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 8
NVH Troubleshooting Chart ..................................... 8
MANUAL TRANSAXLE ......................................... 8
DESCRIPTION ............................................................ 9
Cross-sectional View ................................................ 9
DOUBLE-CONE SYNCHRONIZER .................... 10
REVERSE GEAR NOISE PREVENTION FUNC-
TION (SYNCHRONIZING METHOD) ................. 10
M/T OIL ......................................................................11
Changing M/T Oil ....................................................11
DRAINING ............................................................11
FILLING ................................................................11
Checking M/T Oil .....................................................11
OIL LEAKAGE AND OIL LEVEL ..........................11
SIDE OIL SEAL ........................................................ 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
POSITION SWITCH .................................................. 13
Checking ................................................................ 13
BACK-UP LAMP SWITCH .................................. 13
PARK/NEUTRAL POSITION SWITCH ............... 13
CONTROL LINKAGE ............................................... 14
Removal and Installation of Control Device and
Cable ...................................................................... 14
AIR BREATHER HOSE ............................................ 15
Removal and Installation ........................................ 15
TRANSAXLE ASSEMBLY ........................................ 16
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSTALLATION ................................................... 17
Component Parts (RS5F51A) ................................ 18CASE AND HOUSING COMPONENTS .............. 18
GEAR COMPONENTS ....................................... 19
SHIFT CONTROL COMPONENTS ..................... 21
FINAL DRIVE COMPONENTS ........................... 22
Component Parts (RS6F51A) ................................. 23
CASE AND HOUSING COMPONENTS .............. 23
GEAR COMPONENTS ....................................... 24
SHIFT CONTROL COMPONENTS ..................... 26
FINAL DRIVE COMPONENTS ........................... 27
Disassembly and Assembly (RS5F51A) ................. 27
DISASSEMBLY ................................................... 27
ASSEMBLY ......................................................... 30
Disassembly and Assembly (RS6F51A) ................. 35
DISASSEMBLY ................................................... 35
ASSEMBLY ......................................................... 39
Adjustment (RS5F51A) ........................................... 44
INPUTSHAFT END PLAY ................................... 44
DIFFERENTIAL SIDE BEARING PRELOAD ...... 45
MAINSHAFT END PLAY ..................................... 46
REVERSE IDLER GEAR END PLAY .................. 47
Adjustment (RS6F51A) ........................................... 48
INPUTSHAFT END PLAY ................................... 48
DIFFERENTIAL SIDE BEARING PRELOAD ...... 49
MAINSHAFT END PLAY ..................................... 51
REVERSE IDLER GEAR END PLAY .................. 52
INPUT SHAFT AND GEARS .................................... 53
Assembly and Disassembly (RS5F51A) ................. 53
DISASSEMBLY ................................................... 53
INSPECTION AFTER DISASSEMBLY ................ 54
ASSEMBLY ......................................................... 55
Assembly and Disassembly (RS6F51A) ................. 60
DISASSEMBLY ................................................... 60
INSPECTION AFTER DISASSEMBLY ................ 61
ASSEMBLY ......................................................... 62
MAINSHAFT AND GEARS ....................................... 67
Assembly and Disassembly (RS5F51A) ................. 67
DISASSEMBLY ................................................... 67
INSPECTION AFTER DISASSEMBLY ................ 68