2005 NISSAN X-TRAIL check

FL-22
[YD22DDTi]
FUEL LEVEL SENSOR UNIT

INSPECTION AFTER REMOVAL
Make sure fuel pump strainer is free from foreign materials. If any are found, remove them.
INSTALLATION
Note the following, and install in the reverse order of removal.

Connect quick connector as follows.
1. Check connection for damage and foreign materials.
2. Align the connector with the tube, then insert connector straight into tube until a click is heard.
3. After connecting, make sure that the connection is secure by following the steps below.

Visually confirm that the two tabs are connected to connector.

Pull the tube and connector to make sure they are securely
connected.

Install fuel level sensor unit with mating mark (triangular pro-
trusion) facing between two carved lines on fuel tank. (Figure
shows left side of fuel tank.)
NOTE:
On right side of fuel tank, there are three carved lines on fuel
tank. Set mating mark between two outer carved lines.

Install inspection hole cover with the front mark (arrow) facing front of vehicle (both for RH and LH).
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.

Start engine and rev it up and make sure there is no fuel leakage at connections.
PBIC1653E
PBIC2032E

CLUTCH PEDAL
CL-5
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CLUTCH PEDALPFP:46540
On-Vehicle Inspection and AdjustmentECS001WB
1. Make sure that clevis pin floats freely in bore of clutch pedal. It
should not be bound by clevis or clutch pedal.
a. If clevis pin is not free, make sure that pedal stopper bolt or
ASCD clutch switch is not applying pressure to clutch pedal
causing clevis pin to bind. To adjust, loosen lock nut and turn
pedal stopper bolt or ASCD clutch switch.
b. Tighten lock not.
c. Make sure that clevis pin floats in bore of clutch pedal. It should
not be bound by clutch pedal.
d. If clevis pin is still not free, remove clevis pin and check for
deformation or damage. Replace clevis pin if necessary. Leave
clevis pin removed for step 2.
2. Check clutch pedal stroke for free range of movement.
a. With clevis pin removed, manually move clutch pedal up and
down to determine if it moves freely.
b. If any sticking is found, replace related parts (clutch pedal
bracket, assist spring, bushing etc.). Reassemble clutch pedal
and again make sure that clevis pin floats freely in bore of clutch
pedal.
3. Check clutch hydraulic and system components (clutch master
cylinder, clutch operating cylinder, clutch withdrawal lever, clutch
release bearing, etc.) for sticking or binding.
a. If any sticking or binding is found, repair or replace related parts as necessary.
b. If hydraulic system repair was necessary, bleed the clutch hydraulic system. Refer to CL-8, "
Air Bleeding
Procedure" .
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system.
PCIB0876E

CLUTCH PEDAL
CL-7
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4. Remove clutch pedal assembly mounting nuts and bolt, and then remove clutch pedal assembly from the
vehicle.
INSPECTION AFTER REMOVAL

Check clutch pedal for bend, damage or a cracked weld. If bend, damage or a cracked weld is found,
replace clutch pedal.

Check assist spring for settling. If settling is found, replace assist spring.
INSTALLATION
Installation is the reverse order of removal.
NOTE:
Tighten pedal stopper bolt lock nut or ASCD clutch switch lock nut to the specified torque after installing clutch
pedal assembly in vehicle and adjusting the pedal free play.

CL-10
CLUTCH MASTER CYLINDER

Removal and InstallationECS008BA
REMOVAL
1. Using one of the following methods, remove hose from nipple.

Drain clutch fluid from reservoir tank and remove hose.

Remove hose from nipple. Immediately plug hose and reservoir tank to prevent clutch fluid from drip-
ping.
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
2. Remove clutch tube using a flare nut torque wrench.
3. Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal.
4. Remove mounting nuts on master cylinder assembly, and then master cylinder assembly from vehicle.
INSTALLATION
1. Check position of clevis and push rod. If measurement is outside
the standard length, adjust position of clevis and push rod.
2. Connect clutch tube to master cylinder assembly and tempo-
rarily tighten flare nut.
3. Install master cylinder assembly and tighten mounting nuts to
the specified torque. Refer to CL-9, "
Components" .
4. Tighten clutch tube flare nut to the specified torque using a flare
nut torque wrench. Refer to CL-13, "
Removal and Installation" .
5. Set clevis to clutch pedal and insert clevis pin.
6. Attach snap pin to clevis pin.
7. Install hose to nipple.
8. After completing this procedure, inspect and adjust for clutch pedal and then bleed the air from the clutch
hydraulic system. Refer to CL-5, "
On-Vehicle Inspection and Adjustment" and CL-8, "Air Bleeding Proce-
dure" .
Disassembly and AssemblyECS008BB
DISASSEMBLY
1. Remove spring pin using a pin punch.
2. Remove nipple and seal from cylinder body.
3. Loosen push rod lock nut then remove clevis and lock nut, if
necessary.
NOTE:
Clutch pedal height is controlled with position of clevis and push
rod.
4. Remove seat from cylinder body.
5. Remove stopper ring and stopper. Remove push rod from cylin-
der body while holding it securely to prevent piston assembly
popping out.
6. Remove piston assembly and return spring.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.

Damaged cylinder internal wall, foreign matter, wear, corrosion, or pinhole

Damaged or deformed nipple or reservoir tank

Settling of return spring

Cracked or deformed seatLength “L”
RHD models : 125.5 mm (4.80 in)
LHD models : 122.0 mm (4.94 in)
SCIA5158E
PCIB0274E

CLUTCH MASTER CYLINDER
CL-11
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ASSEMBLY
1. Apply rubber lubricant to the internal surface of cylinder body, the sliding surface of piston assembly, and
piston cup. Insert return spring and piston assembly to cylinder body.
2. Apply silicon grease to push rod and install stopper. Install stopper ring while holding down push rod by
hand to prevent piston assembly from popping out.
3. Install seat to cylinder body.
4. Install seal and nipple to cylinder body. Install spring pin using a pin punch.
5. Install clevis to push rod.
6. Check and adjust the positions of clevis and push rod. After
adjusting “L”, tighten lock nut to the specified torque. Refer to
CL-9, "
Components" .
Length “L”
RHD models : 125.5 mm (4.80 in)
LHD models : 122.0 mm (4.94 in)
SCIA5158E

CL-12
OPERATING CYLINDER

OPERATING CYLINDERPFP:30620
ComponentsECS00G84
Removal and InstallationECS008BC
REMOVAL
1. Drain clutch fluid.
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
2. Remove clutch hose from operating cylinder.
3. Remove operating cylinder mounting bolts and remove operating cylinder from the vehicle.
INSTALLATION
Note the following, and install in the reverse order of removal.

Install hose with care so that it will not be bent or twisted.

After completing the procedure, bleed the air from the clutch hydraulic system. Refer to CL-8, "Air Bleed-
ing Procedure" .
Disassembly and AssemblyECS008BD
DISASSEMBLY

Remove dust cover and push rod. Then remove piston, piston cup, and piston spring from inside cylinder
body.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.

Damage to cylinder internal surface or piston sliding surface. Foreign matter, wear, corrosion, or pinhole

Settling of piston spring

Cracked or deformed dust cover
ASSEMBLY
1. Apply rubber lubricant to cylinder body internal surface and rubber grease to piston cup and piston. Insert
piston assembly and piston spring into cylinder body.
2. Apply rubber grease to dust cover and install push rod and dust cover.
1. Air bleeder valve 2. Copper washer 3. Union bolt
4. Clutch hose 5. Cylinder body 6. Dust cover
7. Push rod 8. Piston assembly 9. Piston cup
10. Piston spring
PCIB0765E

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CL-17
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INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc

Measure circumferential runout relative to clutch disc center
spline. If it is outside the specification, replace clutch disc.

Measure clutch disc spline and input shaft spline backlash at the
circumference of clutch disc. If outside the specification, replace
clutch disc.

Using calipers, measure the depth to clutch disc facing rivet
heads. If it exceeds the allowable wear limit, replace 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 the 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 indicator, measure runout at the flywheel clutch contact
surface. If runout is outside the specification, replace 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) /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) or less
Tool number : ST20050240
PCIB0276E
Allowable flywheel runout
QR engine models
: Refer to EM-116, "
FLYWHEEL DEFLECTION (M/T
MODELS)" .
YD engine models
: Refer to EM-255, "
FLYWHEEL DEFLECTION" .PBIC2168E

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