2003 NISSAN X-TRAIL Service Repair Manual

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NISSAN X-TRAIL 2003 Service Repair Manual CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CL-15
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INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc
Measure circumferential runout relative to the clutch disc center
spline.

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CL-15
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INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc
Measure circumferential runout relative to the clutch disc center
spline. If it is outside the specification, replace the clutch disc.
Measure clutch disc spline and input shaft spline backlash at the
circumference of the disc. If outside the specification, replace.
Using calipers, measure the depth to the clutch disc facing rivet
heads. If it exceeds the allowable wear limit, replace the clutch
disc.
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using a diaphragm adjusting wrench.
Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
NOTE:
Worn thrust ring will generate a beating noise when tapped at
the rivet with a hammer.
Broken thrust ring will make a clinking sound when cover is shaken up and down.
If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.
Flywheel Runout
Using a dial gauge, measure runout at the flywheel clutch contact
surface. If runout is outside the specification, replace the flywheel. If
a trace of burn or discoloration is found on the surface, repair it with
sandpaper.
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch cover mounting hole).Runout limit/diameter of the area to be measured:
1.0 mm (0.039 in) or less/230 mm(9.06 in) dia.
Maximum allowable spline backlash:
1.0 mm (0.039 in)
SCL221
Facing wear limit (depth to the rivet head):
0.3 mm (0.012 in)
SCL229
Tolerance for diaphragm spring lever unevenness:
0.7 mm (0.028 in)
Tool number : ST 20050240
PCIB0276E
Allowable flywheel runout:
Vehicles with QR engine models:
Refer to EM-108, "
FLYWHEEL DEFLECTION (M/T
MODELS)" .
Vehicles with YD engine models:
Refer toEM-235, "
FLYWHEEL DEFLECTION" .AEM100

Page 1930 of 4179

NISSAN X-TRAIL 2003 Service Repair Manual CL-16
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

INSTALLATION
1. Apply recommended grease to clutch disc and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noi

Page 1931 of 4179

NISSAN X-TRAIL 2003 Service Repair Manual SERVICE DATA AND SPECIFICATIONS (SDS)CL-17
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Clutch Control SystemECS008BH
Clutch Master CylinderECS008BI
Clutch Operating Cyli

Page 1932 of 4179

NISSAN X-TRAIL 2003 Service Repair Manual CL-18
SERVICE DATA AND SPECIFICATIONS (SDS)

Page 1933 of 4179

NISSAN X-TRAIL 2003 Service 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
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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
TRIPLE-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
Components of Control Device and Cable ............. 14
Removal and Installation ........................................ 15
AIR BREATHER HOSE ............................................ 16
Removal and Installation ........................................ 16
TRANSAXLE ASSEMBLY ........................................ 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 18
Component Parts (RS5F51A) ................................ 19CASE AND HOUSING COMPONENTS .............. 19
GEAR COMPONENTS ....................................... 20
SHIFT CONTROL COMPONENTS ..................... 22
FINAL DRIVE COMPONENTS ........................... 23
Component Parts (RS6F51A) ................................. 24
CASE AND HOUSING COMPONENTS .............. 24
GEAR COMPONENTS ....................................... 25
SHIFT CONTROL COMPONENTS ..................... 27
FINAL DRIVE COMPONENTS ........................... 28
Disassembly and Assembly (RS5F51A) ................. 28
DISASSEMBLY ................................................... 28
ASSEMBLY ......................................................... 32
Disassembly and Assembly (RS6F51A) ................. 37
DISASSEMBLY ................................................... 37
ASSEMBLY ......................................................... 41
Adjustment (RS5F51A) ........................................... 47
INPUT SHAFT END PLAY .................................. 47
MAINSHAFT END PLAY ..................................... 48
DIFFERENTIAL SIDE BEARING PRELOAD ...... 48
REVERSE IDLER GEAR END PLAY .................. 49
Adjustment (RS6F51A) ........................................... 50
INPUT SHAFT END PLAY .................................. 50
MAINSHAFT END PLAY ..................................... 51
DIFFERENTIAL SIDE BEARING PRELOAD ...... 52
REVERSE IDLER GEAR END PLAY .................. 53
INPUT SHAFT AND GEARS .................................... 54
Assembly and Disassembly (RS5F51A) ................. 54
DISASSEMBLY ................................................... 54
INSPECTION AFTER DISASSEMBLY ................ 55
ASSEMBLY ......................................................... 57
Assembly and Disassembly (RS6F51A) ................. 61
DISASSEMBLY ................................................... 61
INSPECTION AFTER DISASSEMBLY ................ 62
ASSEMBLY ......................................................... 64
MAINSHAFT AND GEARS ....................................... 68
Assembly and Disassembly (RS5F51A) ................. 68
DISASSEMBLY ................................................... 68
INSPECTION AFTER DISASSEMBLY ................ 69

Page 1934 of 4179

NISSAN X-TRAIL 2003 Service Repair Manual MT-2 ASSEMBLY ......................................................... 72
Assembly and Disassembly (RS6F51A) ................. 76
DISASSEMBLY ................................................... 76
I

MT-2 ASSEMBLY ......................................................... 72
Assembly and Disassembly (RS6F51A) ................. 76
DISASSEMBLY ................................................... 76
INSPECTION AFTER DISASSEMBLY ................ 77
ASSEMBLY ......................................................... 80
REVERSE IDLER SHAFT AND GEARS .................. 85
Assembly and Disassembly (RS5F51A) ................. 85
DISASSEMBLY ................................................... 85
INSPECTION AFTER DISASSEMBLY ................ 85
ASSEMBLY ......................................................... 86
Assembly and Disassembly (RS6F51A) ................. 86
DISASSEMBLY ................................................... 86
INSPECTION AFTER DISASSEMBLY ................ 87
ASSEMBLY ......................................................... 87
FINAL DRIVE ............................................................ 89
Assembly and Disassembly (RS5F51A) ................. 89
PRE-INSPECTION .............................................. 89
DISASSEMBLY ................................................... 89
INSPECTION AFTER DISASSEMBLY ................ 90
ASSEMBLY ......................................................... 90
Assembly and Disassembly (RS6F51A) ................. 92
PRE-INSPECTION .............................................. 92
DISASSEMBLY ................................................... 92
INSPECTION AFTER DISASSEMBLY ................ 93
ASSEMBLY ......................................................... 94
SHIFT CONTROL ...................................................... 96
Inspection (RS5F51A) ............................................ 96
SHIFT FORK ....................................................... 96
Inspection (RS6F51A) ............................................ 97
SHIFT FORK ....................................................... 97SERVICE DATA AND SPECIFICATIONS (SDS) ...... 98
General Specifications ............................................ 98
TRANSAXLE ........................................................ 98
FINAL GEAR ........................................................ 99
End Play .................................................................. 99
Baulk Ring Clearance ............................................. 99
Available Snap Rings ............................................100
INPUT SHAFT BEARING SPACER ...................100
6TH INPUT GEAR BUSHING ............................100
5TH MAIN GEAR ...............................................100
Available C-Rings .................................................100
MAINSHAFT C-RING ........................................100
Available Thrust Washer .......................................101
INPUT SHAFT THRUST WASHER ...................101
DIFFERENTIAL SIDE GEAR THRUST WASHER
.101
Available Adjusting Shims .....................................101
4TH MAIN GEAR ADJUSTING SHIM ................101
INPUT SHAFT REAR BEARING ADJUSTING
SHIM ..................................................................102
MAINSHAFT REAR BEARING ADJUSTING
SHIM ..................................................................102
REVERSE IDLER GEAR ADJUSTING SHIM ....102
6TH MAIN GEAR ADJUSTING SHIM ................102
Available Shims ....................................................103
BEARING PRELOAD .........................................103
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM(S) .............................................................103

Page 1935 of 4179

NISSAN X-TRAIL 2003 Service Repair Manual PRECAUTIONS
MT-3
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PRECAUTIONSPFP:00001
CautionECS008BM
Do not reuse transaxle oil, once it has been drained.
Check oil level or replace oil with vehicle on level ground.

Page 1936 of 4179

NISSAN X-TRAIL 2003 Service Repair Manual MT-4
PREPARATION

PREPARATIONPFP:00002
Special Service ToolsECS008BN
Tool number
Tool nameDescription
KV381054S0
Puller
Differential side bearing outer race removal
Mainshaft front bearing removal

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