2003 NISSAN X-TRAIL Electronic Repair Manual

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NISSAN X-TRAIL 2003 Electronic Repair Manual MT-1
MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
CONTENTS
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SECTION
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MANUAL TRANSAXLE
PRECAUTIONS .......................................................... 3
Caution ...........

MT-1
MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
CONTENTS
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SECTION
A
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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

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NISSAN X-TRAIL 2003 Electronic Repair Manual MT-2
ASSEMBLY ......................................................... 70
Assembly and Disassembly (RS6F51A) ................. 74
DISASSEMBLY ................................................... 74
IN

MT-2
ASSEMBLY ......................................................... 70
Assembly and Disassembly (RS6F51A) ................. 74
DISASSEMBLY ................................................... 74
INSPECTION AFTER DISASSEMBLY ................ 76
ASSEMBLY ......................................................... 77
REVERSE IDLER SHAFT AND GEARS .................. 83
Assembly and Disassembly (RS5F51A) ................. 83
DISASSEMBLY ................................................... 83
INSPECTION AFTER DISASSEMBLY ................ 83
ASSEMBLY ......................................................... 84
Assembly and Disassembly (RS6F51A) ................. 84
DISASSEMBLY ................................................... 84
INSPECTION AFTER DISASSEMBLY ................ 84
ASSEMBLY ......................................................... 85
FINAL DRIVE ............................................................ 86
Assembly and Disassembly (RS5F51A) ................. 86
PRE-INSPECTION .............................................. 86
DISASSEMBLY ................................................... 86
INSPECTION AFTER DISASSEMBLY ................ 87
ASSEMBLY ......................................................... 87
Assembly and Disassembly (RS6F51A) ................. 89
PRE-INSPECTION .............................................. 89
DISASSEMBLY ................................................... 90
INSPECTION AFTER DISASSEMBLY ................ 91
ASSEMBLY ......................................................... 91
SHIFT CONTROL ...................................................... 94
Inspection (RS5F51A) ............................................ 94
SHIFT FORK ....................................................... 94
Inspection (RS6F51A) ............................................ 95
SHIFT FORK ....................................................... 95SERVICE DATA AND SPECIFICATIONS (SDS) ......96
General Specifications ............................................96
TRANSAXLE ........................................................96
FINAL GEAR ........................................................97
Gear End Play .........................................................97
Clearance Between Baulk Ring and Gear ..............97
3RD,4TH,5TH,6TH & REVERSE BAULK RING... 97
1ST AND 2ND DOUBLE BAULK RING ...............97
Available Snap Rings ..............................................98
INPUT SHAFT SPACER ......................................98
5TH MAIN GEAR .................................................98
Available C-rings .....................................................98
MAINSHAFT C-RING ..........................................98
Available Thrust Washer .........................................98
INPUT SHAFT THRUST WASHER .....................98
DIFFERENTIALSIDE GEAR THRUST WASHER
...99
Available Adjusting Shims .......................................99
MAINSHAFT ADJUSTING SHIM .........................99
INPUT SAFT REAR BEARING ADJUSTING
SHIM ....................................................................99
MAINSAFT REAR BEARING ADJUSTING SHIM.100
REVERASE IDLER GEAR ADJUSTING SHIM . 100
6TH MAIN GEAR ADJUSTING SHIM ................ 100
Available Shims .................................................... 100
BEARING PRELOAD ......................................... 100
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM(S) ............................................................. 100

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NISSAN X-TRAIL 2003 Electronic Repair Manual PRECAUTIONS
MT-3
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PRECAUTIONSPFP:00001
CautionECS001WO
lDo not reuse transaxle oil, once it has been drained.
lCheck oil level or replace oil with vehicle on level ground.
lDu

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NISSAN X-TRAIL 2003 Electronic Repair Manual MT-4
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsECS001WP
Tool name
Tool numberDescription
Drift
ST33400001
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
Installing transaxle side oil sea

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NISSAN X-TRAIL 2003 Electronic Repair Manual PREPARATION
MT-5
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Drift
ST33061000
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.lBore plug installation
lDifferential side bearing removal
Drift
ST33052000
a: 22 mm (0.87

Page 2542 of 3066

NISSAN X-TRAIL 2003 Electronic Repair Manual MT-6
PREPARATION
Commercial Service Tools
ECS004NA
Drift
ST30901000
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.lInput shaft rear bearing installation
l4th main gear inst

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NISSAN X-TRAIL 2003 Electronic Repair Manual PREPARATION
MT-7
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PullerEach bearing gear and bushing removal
Pin punch
Tip diameter: 4.5 mm (0.177 in) dia.Each retaining pin removal and installation To o l n a m eDescripti

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NISSAN X-TRAIL 2003 Electronic Repair Manual MT-8
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
NVH Troubleshooting ChartECS0044N
Use the chart below to help you find the ca

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