2005 NISSAN X-TRAIL manual transmission

EC-24
[QR (WITH EURO-OBD)]
PRECAUTIONS

PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EBS010L0
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:

To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.

Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.

Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
On Board Diagnostic (OBD) System of Engine and A/TEBS010L1
The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of
a malfunction causing emission deterioration.
CAUTION:

Be sure to turn the ignition switch OFF and disconnect the battery ground cable before any repair
or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will
cause the MI to light up.

Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)

Certain systems and components, especially those related to OBD, may use a new style slide-
locking type harness connector. For description and how to disconnect, refer to PG-74, "
HAR-
NESS CONNECTOR" .

Be sure to route and secure the harnesses properly after work. The interference of the harness
with a bracket, etc. may cause the MI to light up due to the short circuit.

Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MI to light up due to the malfunction of the fuel injection system, etc.

Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM and
TCM (Transmission control module) before returning the vehicle to the customer.
PrecautionEBS010L2

Always use a 12 volt battery as power source.

Do not attempt to disconnect battery cables while engine is
running.

Before connecting or disconnecting the ECM harness con-
nector, turn ignition switch OFF and disconnect battery
ground cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned OFF.

Before removing parts, turn ignition switch OFF and then
disconnect battery ground cable.
SEF289H

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

MA-4
DESCRIPTION

DESCRIPTIONPFP:00000
Pre-Delivery Inspection ItemsELS000Y5
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
Install vehicle protection kit
Fit all accessories ordered (if applicable) (e.g. towbar, audio, navigation, air conditioner, styling kit)
UNDER HOOD — engine off
Check coolant level and cooling system for leaks
Charge battery and check terminals for condition
Check drive belts tension (diesel only)
Check fuel filter for water or dust (diesel only) and fuel system for leaks
Check engine oil level and for oil leaks
Check brake and clutch fluid levels and fluid lines for leaks
Check and top up washer reservoirs
Check power steering fluid level and fluid lines for leaks (if applicable)
Check air conditioning system for gas leaks (if applicable)
ON INSIDE AND OUTSIDE
Install transit fuse if removed for vehicle storage
Check instruments, gauges, lamps, horn and accessories for operation
Check wipers and washers for operation and adjustment
Check interior and door mirrors and sun visors for operation
Set radio code and set clock
Check parking brake adjustment
Check clutch pedal adjustment
Check steering lock operation
Check seat adjusters and seat belts for operation
Check all windows for operation and alignment
Check mouldings, trim and fittings for fit and alignment
Check weatherstrips for fit and adhesion
Check hood, trunk lid, door panels and fuel lid for fit and alignment
Check latches, keys, remote key, door locks and remote trunk lid and fuel lid release for operation
Check wheel nut torques
Check tyre pressure (incl. spare tyre)
Check tool kit and jack for operation
Check automatic transmission/transaxle starter inhibitor (if applicable)
Check sunroof for operation and alignment (if applicable)
UNDER BODY
Check manual transmission/transaxle, differential and transfer box for oil level and oil leaks
Tighten bolts and nuts steering linkage and gear box, axle/suspension parts, propeller and exhaust system
Check brake and clutch lines, and oil/fluid reservoirs for leaks
Remove front suspension spacer blocks (if applicable)
Check body mounting torque (if applicable)

RECOMMENDED FLUIDS AND LUBRICANTSMA-17
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RECOMMENDED FLUIDS AND LUBRICANTSPFP:00000
Fluids and LubricantsELS000C8
*1: For further details, see “SAE Viscosity Number”.
*2: Never use API CG-4.
*3: Use Genuine NISSAN Anti-freeze Coolant (L250) or equivalent in its quality, in order to avoid possible aluminum corrosion w ithin the
engine cooling system caused by the use of non-genuine engine coolant.
Note that any repairs for the incidents within the engine cooling system while using non-genuine engine coolant may not be
covered by the warranty even if such incidents occurred during the warranty period.
*4: Contact a NISSAN dealership for more information regarding suitable fluids, including recommended brand(s) of DEXRON
TM III/
MERCONTM Automatic Transmission Fluid.
*5: Never mix different types of fluids (DOT 3 and DOT 4). Capacity (Approximate)
Recommended Fluids/Lubricants
Liter Imp measure
Engine oil
Drain and refill With oil filter
change
QR20DE,
QR25DE
4.1 3-5/8 qt

Gasoline engine
API SG, SH, SJ or SL *1
ILSAC grade GF-I, GF-II or GF-III *1
ACEA A2

Diesel engine
API CF-4*1, *2
ACEA B1, B3, B4, B5 *1, *2
YD22DDTi 5.2 4-5/8 qt
Without oil filter
change QR20DE,
QR25DE
3.7 3-1/4 qt
YD22DDTi 4.9 4-3/8 qt
Dry engine (engine overhaul) QR20DE,
QR25DE
4.7 4-1/8 qt
YD22DDTi 6.3 5-1/2 qt
Cooling system (with reservoir) QR20DE,
QR25DE
7.1 6-1/4 qt

Genuine NISSAN Anti-freeze Coolant (L250)
or equivalent in its quality*3
YD22DDTi 9.5 8-3/8 qt
Reservoir tank QR20DE,
QR25DE
0.7 5/8 qt
YD22DDTi 0.7 5/8 qt
Manual transaxle gear oil
2.2 3-7/8 pt

Genuine NISSAN gear oil or API GL-4, Vis-
cosity SAE 75W-85
Transfer gear oil 0.31 1/2 pt

API GL-5, Viscosity SAE 80W-90
Differential gear oil 0.55 1 pt

API GL-5, Viscosity SAE 80W-90
Automatic transaxle fluid 8.5 7-1/2 qt Genuine NISSAN ATF or equivalent*4
Power steering fluid — — DEXRON
TM III type ATF or equivalent
Brake and clutch fluid — —

DOT 3 or DOT 4 (US FMVSS No. 116)*5
Multi-purpose grease — — NLGI No. 2 (Lithium soap base)