2005 NISSAN X-TRAIL check

TF-58
TRANSFER ASSEMBLY

INSTALLATION
Note the following, and install in the reverse order of removal.

When installing the transfer to the transaxle, install the mounting
bolts following the standard below.
CAUTION:
When installing transfer to transaxle, be careful not to dam-
age oil seal of transaxle.

When installing transfer gusset, tighten mounting bolts with the specified torque. Refer to TF-57, "COM-
PONENTS" . (YD engine models only)

After the installation, check the oil level and oil leakage. Refer to TF-10, "Inspection" .
Bolt No. 1 2
Quantity 4 2
Bolt length “ ” mm (in)65 (2.56) 40 (1.57)
Tightening torque
N·m (kg-m, ft-lb)34.3 (3.5, 25)
SDIA1178E

TF-60
TRANSFER ASSEMBLY

ASSEMBLY INSPECTION
Backlash
1. Install a bolt to the companion flange.
2. Fit a dial indicator onto the bolt.
3. Measure the circumference backlash of the companion flange,
and make sure it satisfies the standard below.

If measured value is out of the specification, disassemble it to
check and adjust each part.
Tooth Contact
1. Remove the pinion sleeve assembly. Refer to TF-64, "Pinion Sleeve Assembly" .
2. Apply red lead to the drive gear.
CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on the drive gear.
3. Install the pinion sleeve shims and pinion sleeve assembly.
Refer to TF-74, "
Pinion Sleeve Assembly" .
4. Remove the plug on the upper side of the transfer case.
When installing plug, apply recommended sealant on screw
part, and tighten it at the specified torque. Refer to TF-59,
"COMPONENTS" .
5. Rotate the companion flange back and forth several times, and
check the drive pinion gear to drive gear tooth contact by view-
ing from the plug hole.Backlash : 0.13 - 0.19 mm (0.0051 - 0.0075 in)
SDIA1937J
TFB0212D
SDIA1938E

TF-62
TRANSFER ASSEMBLY


If the tooth contact is near the face (face contact), or near the
heal (heel contact), thin the pinion sleeve shims to move the
drive pinion closer to the drive gear.
Refer to TF-77, "
Pinion Sleeve Shim" .

If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thicken the pinion sleeve shims to move the
drive pinion farther from the drive gear.
Refer to TF-77, "
Pinion Sleeve Shim" .
Pinion Bearing Preload Torque
1. Remove the pinion sleeve assembly. Refer to TF-64, "Pinion Sleeve Assembly" .
2. Rotate the companion flange back and forth 2 to 3 times. Check for unusual noise, rotation malfunction,
and other malfunctions.
3. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
SDIA0518E
SDIA0519E

TRANSFER ASSEMBLY
TF-63
C
E
F
G
H
I
J
K
L
MA
B
TF

4. Using the preload gauge, measure the preload torque of the pin-
ion bearing.
CAUTION:
Every rotational part shall rotate smoothly with the speci-
fied gear oil.

If measured value is out of the specification, disassemble the
pinion sleeve assembly to check and adjust each part.
Total Preload Torque
1. Measure pinion bearing preload torque (P1 ). Refer to TF-62, "Pinion Bearing Preload Torque" .
2. Install the pinion sleeve shims and pinion sleeve assembly.
3. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
4. Using the preload gauge, measure the total preload torque.

If measured value is out of the specification, disassemble it to
check and adjust each part. If measuring the total preload
torque after the disassembly, measure it with the transfer case oil seals and gear ring oil seals
removed, then install the oil seals.
Companion Flange Runout
1. Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
2. Rotate the companion flange to check for runout.
3. Fit a test indicator to the inner side of the companion flange
(socket diameter).
4. Rotate the companion flange to check for runout.
5. If the runout value is outside the repair limit, follow the procedure
below to adjust.
a. While changing the phase between companion flange and drive pinion gear by 90° at a time, check runout
and determine which phase angle minimizes the runout.
b. If the runout value is still outside of the limit after the phase has been changed, replace the companion
flange.
c. If the runout is out of the specification after replacement of companion flange, adjust the assembly status
of the pinion bearings and drive pinion gear, or replace the pinion bearings.Tool number : ST3127S000
Preload torque
: 0.10 - 0.39 N·m (0.01 - 0.04 kg-m, 1 - 3 in-lb)
SDIA2076E
Pinion bearing preload torque (P1)
: 0.10 - 0.39 N·m (0.01 - 0.04 kg-m, 1 - 3 in-lb)
Tool number : ST3127S000
Total preload torque
With all oil seals
: P
1 + 0.16 - 0.22 N·m (0.016 - 0.023 kg-m, 1.4 - 1.9 in-lb)
Without transfer case oil seal and adapter case oil seal
: P
1 + 0.06 - 0.12 N·m (0.006 - 0.013 kg-m, 0.6 - 1.1 in-lb)
SDIA2077E
Runout limit : 0.1 mm (0.004 in)
Runout limit : 0.1 mm (0.004 in)
SDIA2078E

TF-68
TRANSFER ASSEMBLY

4. Using a flat-bladed screwdriver, remove the transfer case oil
seal.
CAUTION:
Be careful not to damage the transfer case.
5. Remove the oil defense.
6. Using a brass rod, tap the gear ring bearing adjusting shim
evenly from the 2 cutouts on the transfer case to remove the
gear ring bearing adjusting shim and gear ring bearing outer
race.
7. Remove the filler plug, plug and breather tube.
INSPECTION AFTER DISASSEMBLY
Gears

Check the gear faces and shaft for wear, cracks, damage, and seizure.
CAUTION:
If a malfunction is detected on the drive gear or drive pinion, replace the drive gear and drive pinion as
a set.
Bearings

Check for seizure, peeling, wear, corrosion, sticking/abnormal noise/roughness in hand turning, and other
damage.
CAUTION:
When replacing the bearing, always replace the inner race and outer race as a pair.
Washers and Shims

Check for seizure, damage, and unusual wear.
Oil Seals

Discard old oil seals, replace with new ones.

If wear, deterioration of adherence (sealing force of lips), or damage is detected on the lips, replace them.
TFB0297D
SDIA1533E
SDIA0536E

TRANSFER ASSEMBLY
TF-69
C
E
F
G
H
I
J
K
L
MA
B
TF

SELECTING ADJUSTING SHIMS
Measurement points
Gear Ring Bearing Adjusting Shim (Transfer Case Side)
1. Measure the points F, H, I, R and U shown in the measurement points.
2. Convert the values F, H, I, R and U according to the standards below.
3. Check dimension Z on the drive gear side face.
NOTE:
Dimension Z indicates the difference between the optimum engagement and the standard dimensions in
increments of 0.01mm (0.0004 in) written on the drive gear side face.
4. Use the formula below to calculate gear ring bearing adjusting shim (transfer case side) thickness T
1 .
5. Select the gear ring bearing adjusting shim (transfer case side).

For information on selecting an adjusting shim, refer to TF-76, "Gear ring Bearing Adjusting Shim
(Transfer Case Side)" .
CAUTION:

Only one adjusting shim can be selected.

If no adjusting shim with the calculated value is available, select the thicker and closest one.
Gear Ring Bearing Adjusting Shim (Adapter Case Side)
1. Measure the points F, H, J, K, U and V shown in the measurement points.
2. Convert the values F, H, J, K, U and V according to the standards below.
SDIA1179E
F: Value obtained by subtracting 163.00 mm (6.42 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
H: Value obtained by subtracting 83.00 mm (3.27 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
I: Value obtained by subtracting 131.90 mm (5.19 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
R: Value obtained by subtracting 17.00 mm (0.67 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
U: Value obtained by subtracting 89.50 mm (3.524 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
T
1 = (I - F + H + Z - U - R) × 0.01 mm (0.0004 in) + 1.49 mm (0.0587 in)

TF-70
TRANSFER ASSEMBLY

3. Check dimension Z on the drive gear side face.
NOTE:
Dimension Z indicates the difference between the optimum engagement and the standard dimensions in
increments of 0.01mm (0.0004 in) written on the drive gear side face.
4. Use the formula below to calculate gear ring bearing adjusting shim (adapter case side) thickness T
2 .
5. Select the gear ring bearing adjusting shim (adapter case side).

For information on selecting an adjusting shim, refer to TF-77, "Gear ring Bearing Adjusting Shim
(Adapter Case Side)" .
CAUTION:

Only one adjusting shim can be selected.

If no adjusting shim with the calculated value is available, select the thicker and closest one.
Pinion Sleeve Shim
1. Measure the points L, N and Q shown in the measurement points.
2. Check the dimension S written on the gear end of the drive pinion.
NOTE:
The dimension S indicates the difference between the optimum engagement and the standard dimensions
in increments of 0.01 mm (0.0004 in) written on the gear end of the drive pinion.
3. Use the formula below to calculate pinion sleeve shim thickness T
3 .
4. Select the pinion sleeve shim.

For information on selecting a pinion sleeve shim, refer to TF-77, "Pinion Sleeve Shim" .
CAUTION:
Only one pinion sleeve shim can be selected.
ASSEMBLY
Transfer Case
1. Select the gear ring bearing adjusting shim (transfer case side). Refer to TF-69, "SELECTING ADJUST-
ING SHIMS" . F: Value obtained by subtracting 163.00 mm (6.42 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
H: Value obtained by subtracting 83.00 mm (3.27 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
J: Value obtained by subtracting 109.50 mm (4.31 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
K: Value obtained by subtracting 14.40 mm (0.5669 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
U: Value obtained by subtracting 89.50 mm (3.524 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
V: Value obtained by subtracting 17.00 mm (0.67 in) from
the reading [in increments of 0.01 mm (0.0004 in)].
T
2 = (K + F - H - Z + U - J - V) × 0.01 mm (0.0004 in) + 1.49 mm (0.0587 in)
T
3 = [74.6 mm (2.937 in) + S] + N + Q - L

TRANSFER ASSEMBLY
TF-71
C
E
F
G
H
I
J
K
L
MA
B
TF

2. Using the drifts, install the selected gear ring bearing adjusting
shim (transfer case side) and gear ring bearing outer race
(transfer case side).
3. Install the oil defense, and tighten the mounting bolts to the
specified torque. Refer to TF-59, "
COMPONENTS" . The clear-
ance between the oil defense and transfer case (dimension A)
should be the following.
CAUTION:
Do not reuse the mounting bolts.
4. Using the drift, drive the transfer case oil seal until it becomes
flush with the case end.
CAUTION:

When checking the total preload torque, measure it with-
out the oil seal, then install the oil seal.

Do not reuse the oil seal.

Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of the oil seal.
5. Apply recommended sealant to filler plug and plug before install-
ing them to the transfer case. Refer to TF-59, "
COMPONENTS"
.
6. Apply recommended sealant to breather tube and install it to the transfer case.
7. Install the drive gear assembly. Refer to TF-71, "
Drive Gear Assembly" .
8. Install the adapter case. Refer to TF-72, "
Adapter Case" .
9. Install the pinion sleeve assembly. Refer to TF-74, "
Pinion Sleeve Assembly" .
10. Check backlash, preload torque, tooth contact, and companion flange runout. Refer to TF-60, "
ASSEM-
BLY INSPECTION" .
CAUTION:
Measure the total preload torque without the oil seal.
Drive Gear Assembly
1. Using the drift, drive the gear ring oil seal into the gear ring.
CAUTION:

Do not reuse the oil seal.

Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of the oil seal.

The oil seal back position after the installation shall be
56.5 mm (2.22 in) from the gear ring end.Tool number : ST30720000
SDIA3171E
Clearance between oil defense and transfer case
Dimension A : 1.0 - 3.5 mm (0.04 - 0.138 in)
TFB0283D
Tool number : ST30720000
SDIA1564E
Tool number : ST33230000
SDIA1809E