2003 NISSAN X-TRAIL RFD-1

RFD-1
REAR FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
C
E
F
G
H
I
J
K
L
M
SECTION
A
B
RFD

REAR FINAL DRIVE
PRECAUTIONS .......................................................... 2
Service Notice or Precautions .................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 6
NVH Troubleshooting Chart ..................................... 6
REAR FINAL DRIVE SYSTEM ................................... 7
Sectional View .......................................................... 7
DIFFERENTIAL GEAR OIL ........................................ 8
Changing Differential Gear Oil ................................. 8
DRAINING ............................................................. 8
FILLING ................................................................. 8
Checking Differential Gear Oil .................................. 8
OIL LEAKAGE AND OIL LEVEL ........................... 8
FRONT OIL SEAL ...................................................... 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9
SIDE OIL SEAL .........................................................11
Removal and Installation ......................................... 11
REMOVAL ............................................................ 11
INSTALLATION .................................................... 11
ELECTRIC CONTROLLED COUPLING .................. 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 13REAR FINAL DRIVE ASSEMBLY ............................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 15
Components ........................................................... 16
Pre-inspection ......................................................... 17
TOTAL PRELOAD ............................................... 17
DRIVE GEAR TO DRIVE PINION BACKLASH ... 18
DRIVE GEAR RUNOUT ...................................... 19
COMPANION FLANGE RUNOUT ....................... 19
TOOTH CONTACT .............................................. 19
Disassembly and Assembly .................................... 22
DISASSEMBLY ................................................... 22
ASSEMBLY ......................................................... 25
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 32
General Specification ............................................. 32
Drive Gear Vibration ............................................... 32
Side Gear Clearance Adjustment ........................... 32
THRUST WASHER FOR ADJUSTMENT OF
SIDE GEAR BACK CLEARANCE ....................... 32
Drive Pinion Gear Preload Adjustment ................... 32
DRIVE PINION GEAR PRELOAD ADJUSTING
SHIM ................................................................... 32
Side Bearing Preload Adjustment ........................... 32
ADJUSTING SHIM FOR SIDE BEARING PRE-
LOAD ................................................................... 32
Total Preload ........................................................... 33

RFD-6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS001Z1
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: ApplicableReference page
—
Refer to RFD-19, "
TOOTH CONTACT
" .
—
Refer to RFD-18, "
DRIVE GEAR TO DRIVE PINION BACKLASH
" .
Refer to RFD-19, "
COMPANION FLANGE RUNOUT
" .
Refer to RFD-8, "
Checking Differential Gear Oil
" .
NVH in PR section.
NVH in FAX, RAX, FSU and RSU sections.
NVH in WT section.
NVH in WT section.
NVH in FAX and RAX section.
NVH in BR section.
NVH in PS section.
Possible cause and SUSPECTED PARTS
Gear tooth rough
Gear contact improper
Tooth surfaces worn
Backlash incorrect
Companion flange excessive runout
Gear oil improper
PROPELLER SHAFT
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
STEERING
Symptom Noise×××××××××××××

RFD-8
DIFFERENTIAL GEAR OIL

DIFFERENTIAL GEAR OILPFP:KLD30
Changing Differential Gear OilEDS0027G
DRAINING
1. Stop engine.
2. Remove drain plug and drain oil.
3. Set a gasket on drain plug and install it to final drive assembly
and tighten to the specified torque. Refer to RFD-16, "
Compo-
nents" .
CAUTION:
Do not reuse gasket.
FILLING
1. Remove filler plug. Fill with new oil until oil level reaches the
specified level near filler plug mounting hole.
2. After refilling oil, check oil level. Set a gasket to filler plug, then
install it to final drive assembly. Refer to RFD-16, "
Components"
.
CAUTION:
Do not reuse gasket.
Checking Differential Gear OilEDS0027H
OIL LEAKAGE AND OIL LEVEL

Make sure that oil is not leaking from final drive assembly or around it.

Check oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
Do not start engine while checking oil level.

Set a gasket on filler plug and install it on final drive assembly.
Refer to RFD-16, "
Components" .
CAUTION:
Do not reuse gasket.
PDIA0454E
Oil grade and Viscosity:
Refer to MA-17, "
Fluids and Lubricants" .
Oil capacity:
Approx. 0.55 (1 Imp pt)
PDIA0453E
PDIA0453E

RFD-10
FRONT OIL SEAL

3. Align the matching mark of electric controlled coupling with the
matching mark of companion flange, then install the companion
flange.
4. Install companion flange lock nut with a flange wrench, tighten
the to the specified torque. Refer to RFD-16, "
Components" .
CAUTION:
Do not reuse companion flange lock nut.
5. Install propeller shaft. Refer to PR-4, "
Removal and Installation"
.
PDIA0455E

SIDE OIL SEAL
RFD-11
C
E
F
G
H
I
J
K
L
MA
B
RFD

SIDE OIL SEALPFP:38343
Removal and InstallationEDS001Z3
REMOVAL
1. Remove rear drive shaft with power tool. Refer to RAX-10, "REAR DRIVE SHAFT" .
2. Remove side oil seal, using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage gear carrier and rear cover.
INSTALLATION
1. Apply multi-purpose grease to side oil seal lips.
2. Install side oil seal until it becomes flush with the case end,
using the drift.
CAUTION:

Do not reuse oil seal.

When installing, do not incline oil seal.
3. Install rear drive shaft. Refer to RAX-10, "
REAR DRIVE
SHAFT" .
PDIA0431E
Tool number : KV38100200
PDIA0432E

RFD-12
ELECTRIC CONTROLLED COUPLING

ELECTRIC CONTROLLED COUPLINGPFP:38760
Removal and InstallationEDS0027J
REMOVAL
1. Remove propeller shaft. Refer to PR-4, "Removal and Installation" .
2. Put matching mark on the thread edge of electric controlled cou-
pling. The matching mark should be in line with the matching
mark on the companion flange.
CAUTION:
For matching mark, use paint. Do not damage electric con-
trolled coupling.
NOTE:
When replacing electric controlled coupling, matching mark is
not necessary.
3. Remove companion flange lock nut, using a flange wrench.
4. Remove companion flange.
5. Disconnect electric controlled coupling connector and remove
connector bracket.
6. Remove electric controlled coupling breather hose from cou-
pling cover.
7. Remove coupling cover with electric controlled coupling from
gear carrier.
8. Remove electric controlled coupling from coupling cover.
PDIA0455E
PDIA0456E
PDIA0458E

ELECTRIC CONTROLLED COUPLING
RFD-13
C
E
F
G
H
I
J
K
L
MA
B
RFD

INSTALLATION
1. Install electric controlled coupling to spline of drive pinion inside
gear carrier.
CAUTION:

Align the pin on electric controlled coupling with the
groove of gear carrier.

Be careful not to damage center oil seal.
2. Set electric controlled coupling harness guide to gear carrier.
3. Apply liquid gasket to mating surface of coupling cover. Overlap
both ends of the bead for at least 3 mm (0.12 in).

Use sealant (Three bound 1217 or equivalent).
CAUTION:
Remove old sealant adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering
to the mounting surfaces.
4. Install coupling cover to gear carrier with arrow facing upward,
temporarily tighten reamer bolts to the positions shown in the
figure.
5. Tighten reamer bolts and coupling cover mounting bolts to the
specified torque. Refer to RFD-16, "
Components" .
6. Install electric controlled coupling breather hose to coupling
cover.
7. Install connector bracket and connect electric controlled cou-
pling connector.
8. Install companion flange.
NOTE:
When reusing electric controlled coupling, align the matching
mark of electric controlled coupling with the matching mark of
companion flange, then install companion flange.
9. Install companion flange lock nut with flange wrench, tighten to
the specified torque. Refer to RFD-16, "
Components" .
CAUTION:
Do not reuse companion flange lock nut.
10. Install propeller shaft. Refer to PR-4, "
Removal and Installation"
.
PDIA0463E
PDIA0451E
SDIA0587E
PDIA0455E

RFD-14
REAR FINAL DRIVE ASSEMBLY

REAR FINAL DRIVE ASSEMBLYPFP:38300
Removal and InstallationEDS001ZA
REMOVAL
1. Remove propeller shaft. Refer to PR-4, "Removal and Installation" .
2. Remove drive shaft with power tool. Refer to RAX-10, "
Removal and Installation" .
3. Disconnect electric controlled coupling connector.
4. Remove rear final drive breather hose and electric controlled coupling breather hose.
5. Support rear final drive assembly with a suitable jack.
6. Remove rear final drive mounting nut at rear suspension mem-
ber.
7. Remove rear final drive mounting bolts at final drive mounting
bracket, and then remove rear final drive assembly.
If necessary, remove final drive mounting bracket.
CAUTION:
Secure rear final drive assembly to a suitable jack while
removing it.
1. Rear suspension member 2. Final drive mounting bracket 3. Harness bracket
4. Drive shaft 5. Propeller shaft 6. Rear final drive assembly
PDIA0433E
PDIA0434E
PDIA0435E