mt.pdf

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MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
SECTION MT MT
MANUAL TRANSAXLE
D
E
CONTENTS
F
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 ................... 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 (PNP) 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
COMPONENTS ................................................. 17
REMOVAL .......................................................... 17
INSTALLATION .................................................. 18
Disassembly and Assembly ................................... 19
COMPONENTS .................................................. 19
DISASSEMBLY .................................................. 23
ASSEMBLY ........................................................ 27
ADJUSTMENT ................................................... 33
INPUT SHAFT AND GEARS ................................... 37
Disassembly and Assembly ................................... 37
DISASSEMBLY .................................................. 37
INSPECTION AFTER DISASSEMBLY ............... 38
ASSEMBLY ........................................................ 41
MAINSHAFT AND GEARS ...................................... 46
Disassembly and Assembly ................................... 46
DISASSEMBLY .................................................. 46
INSPECTION AFTER DISASSEMBLY ............... 47
ASSEMBLY ........................................................ 50
REVERSE IDLER SHAFT AND GEARS ................. 55
Disassembly and Assembly ................................... 55
DISASSEMBLY .................................................. 55
INSPECTION AFTER DISASSEMBLY ............... 55
ASSEMBLY ........................................................ 56
FINAL DRIVE ........................................................... 57
Disassembly and Assembly ................................... 57
PRE-INSPECTION ............................................. 57
DISASSEMBLY .................................................. 57
INSPECTION AFTER DISASSEMBLY ............... 58
ASSEMBLY ........................................................ 58
SHIFT CONTROL .................................................... 61
Inspection .............................................................. 61
SHIFT FORK ...................................................... 61
SERVICE DATA AND SPECIFICATIONS (SDS) ..... 62
General Specifications ........................................... 62
TRANSAXLE ...................................................... 62
FINAL GEAR ...................................................... 63
Gear End Play ....................................................... 63
Baulk Ring Clearance ............................................ 63
Available Snap Rings ............................................ 64
INPUT SHAFT BEARING SPACER ................... 64
5TH MAIN GEAR ............................................... 64
Available C-Rings .................................................. 65
G
H
I
J
K
L
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MT-1
Revision: 2005 March
2005 X-Trail
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MAINSHAFT C-RING ......................................... 65
Available Thrust Washer ........................................ 65
INPUT SHAFT THRUST WASHER .................... 65
DIFFERENTIAL SIDE GEAR THRUST WASHER
... 65
Available Adjusting Shims ..................................... 66
4TH MAIN GEAR ADJUSTING SHIM ................ 66
INPUT SHAFT REAR BEARING ADJUSTING
SHIM ...................................................................66
MAINSHAFT REAR BEARING ADJUSTING
SHIM ...................................................................66
REVERSE IDLER GEAR ADJUSTING SHIM .....67
Available Shims .....................................................67
BEARING PRELOAD ..........................................67
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM(S) ..............................................................67
MT-2
Revision: 2005 March
2005 X-Trail
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PRECAUTIONS
PRECAUTIONS
PFP:00001
A
Service Notice or Precautions
ACS007XX
Do not reuse transaxle oil, once it has been drained.
Check oil level or replace oil with vehicle on level surface.
B
During removal or installation, keep inside of transaxle clear of dust or dirt.
Check for the correct installation status prior to removal or disassembly. If matching marks are required,
be certain they do not interfere with the function of the parts they are applied.
MT
In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it.
D
Be careful not to damage sliding surfaces and mating surfaces.
E
F
G
H
I
J
K
L
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MT-3
Revision: 2005 March
2005 X-Trail
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PREPARATION
PREPARATION
PFP:00002
Special Service Tools
ACS007XY
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name
Description
KV381054S0
(J-34286)
Puller
Removing differential side bearing outer
race
Removing mainshaft front bearing
ZZA0601D
ST35321000
(
Installing input shaft oil seal
Installing reverse main gear
—)
Drift
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
Installing 1st main gear bushing
Installing 1st-2nd synchronizer hub
assembly
Installing 2nd main gear bushing
Installing 3rd main gear
ZZA1000D
Removing differential side bearing (clutch
housing side)
ST30720000
(J-25405)
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
Installing differential side oil seal
Installing differential side bearing outer race
Installing mainshaft rear bearing
Installing differential side bearing
ZZA0811D
ST33200000
(J-26082)
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
Installing mainshaft front bearing
Installing 4th main gear
Installing 5th main gear
ZZA1002D
KV40105320
(
Installing differential side bearing outer race
—)
Drift
a: 88 mm (3.46 in) dia.
ZZA0898D
ST33061000
(J-8107-2)
Drift
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
Installing bore plug
Removing differential side bearing
(transaxle case side)
ZZA1000D
MT-4
Revision: 2005 March
2005 X-Trail
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PREPARATION
Tool number
(Kent-Moore No.)
Tool name
A
Description
ST33052000
(
Installing welch plug
B
—)
Removing input shaft rear bearing
Drift
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.
Removing input shaft bearing spacer and
5th stopper
MT
Removing 5th input gear bushing, thrust
washer, 4th input gear, 4th input gear
bushing, 3rd-4th synchronizer hub
assembly and 3rd input gear
D
Installing input shaft front bearing
ZZA1023D
Removing mainshaft rear bearing
E
Removing 4th main gear and 5th main gear
KV40105020
(
Removing 5th input gear and 5th
synchronizer hub assembly
—)
Drift
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in)
F
Removing 3rd main gear, 2nd main gear,
2nd main gear bushing, 1st-2nd
synchronizer hub assembly, 1st main gear,
reverse main gear and 1st main gear
bushing
G
ZZA1133D
KV40105710
( —)
Press stand
a: 46 mm (1.81 in) dia.
b: 41 mm (1.61 in)
Installing 3rd-4th synchronizer hub
assembly
H
Installing 4th input gear bushing
Installing 5th input gear bushing
Installing 5th synchronizer hub assembly
I
Installing 2nd main gear bushing
ZZA1058D
Installing 3rd main gear
J
ST30032000
(J-26010-01)
Drift
a: 80 mm (3.15 in) dia.
b: 38 mm (1.50 in) dia.
c: 31 mm (1.22 in) dia.
Installing 5th stopper and input shaft
bearing spacer
Installing input shaft front bearing
K
L
ZZA0978D
ST38220000
( —)
Press stand
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in)
Installing reverse main gear
Installing 1st main gear bushing
M
Installing 1st-2nd synchronizer hub
assembly
ZZA1058D
ST30901000
(J-26010-01)
Drift
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.
Installing input shaft rear bearing
Installing 4th main gear
Installing 5th main gear
Installing mainshaft rear bearing
ZZA0978D
MT-5
Revision: 2005 March
2005 X-Trail
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