Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Xterra 2005-2007.2009 Approved Nissan Xterra 2005 MT

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MT


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C TRANSMISSION/TRANSAXLE

                                                                                                                                                                   A


                                                                                                                                                                   B
                                                                                                  SECTION
                                                                                  MANUAL TRANSMISSION                                                              MT



                                                                                                                                                                   D


                                                                                                                                                                   E
                                                                  CONTENTS
PRECAUTIONS ......................................................... 2  .        SHIFT CONTROL .................................................... 13   .        F
 Service Notice or Precautions ................................. 2       .         Removal and Installation ....................................... 13    .
PREPARATION .......................................................... 3 .           COMPONENTS .................................................. 13     .
 Special Service Tools .............................................. 3  .           REMOVAL .......................................................... 13.        G
 Commercial Service Tools ....................................... 6      .           INSTALLATION .................................................. 13   .
NOISE, VIBRATION AND HARSHNESS (NVH)                                              AIR BREATHER HOSE ........................................... 15        .
TROUBLESHOOTING ............................................... 7        .         Removal and Installation ....................................... 15    .
                                                                                                                                                                   H
 NVH Troubleshooting Chart .................................... 7        .        TRANSMISSION ASSEMBLY ................................. 16              .
DESCRIPTION ........................................................... 8.         Removal and Installation from Vehicle (For 2WD
 Cross-Sectional View .............................................. 8   .         models) .................................................................. 16
                                                                                                                                                          .
   DOUBLE-CONE SYNCHRONIZER ..................... 9                      .           COMPONENTS .................................................. 16     .         I
   TRIPLE-CONE SYNCHRONIZER ....................... 9                    .           REMOVAL .......................................................... 17.
M/T OIL .................................................................... 10
                                                                         .           INSTALLATION .................................................. 17   .
 Changing ............................................................... 10
                                                                         .         Removal and Installation from Vehicle (For 4WD                                  J
   DRAINING .......................................................... 10.         models) .................................................................. 18
                                                                                                                                                          .
   FILLING .............................................................. 10
                                                                         .           COMPONENTS .................................................. 18     .
 Checking ............................................................... 10
                                                                         .           REMOVAL .......................................................... 18.
                                                                                                                                                                   K
   OIL LEAKAGE AND OIL LEVEL ........................ 10                 .           INSTALLATION .................................................. 19   .
REAR OIL SEAL ......................................................11   .         Disassembly and Assembly ................................... 21        .
 Removal and Installation (For 2WD models) .........11                   .           COMPONENTS .................................................. 21     .
   REMOVAL ...........................................................11 .           DISASSEMBLY .................................................. 27    .        L
   INSTALLATION ...................................................11    .           INSPECTION AFTER DISASSEMBLY ............... 41                      .
POSITION SWITCH ................................................. 12     .           ASSEMBLY ........................................................ 45 .
 Checking ............................................................... 12
                                                                         .        SERVICE DATA AND SPECIFICATIONS (SDS) ..... 68                          .        M
   BACK-UP LAMP SWITCH ................................. 12              .         General Specifications ........................................... 68  .
   PARK/NEUTRAL POSITION SWITCH .............. 12                        .         Gear End Play ....................................................... 69
                                                                                                                                                          .
                                                                                   Snap Rings ............................................................ 69
                                                                                                                                                          .
                                                                                   Baulk Ring Clearance ............................................ 70   .




Revision: February 2006                                                     MT-1                                                               2005 Xterra
                                             PRECAUTIONS

PRECAUTIONS                                                                                             PFP:00001

Service Notice or Precautions                                                                              ECS00DYO


G   Do not reuse transmission oil once it has been drained.
G   Check oil level or replace oil with vehicle on level surface.
G   During removal or installation, keep inside of transmission clear of dust or dirt.
G   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 to.
G   In principle, tighten nuts and bolts gradually in several steps working diagonally from inside to outside. If
    tightening sequence is specified, use it.
G   Be careful not to damage sliding surfaces and mating surfaces.




Revision: February 2006                             MT-2                                             2005 Xterra
                                                       PREPARATION

PREPARATION                                                                                                                     PFP:00002
                                                                                                                                                 A
Special Service Tools                                                                                                                 ECS00DYP

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
  Tool number
                                                                                                                                                 B
  (Kent-Moore No.)                                                                       Description
  Tool name
  ST30911000                                                                             G   Installing mainshaft bearing
  (    --  )                                                                             G   Installing 5th-6th synchronizer hub assem-
                                                                                                                                                 MT
  Inserter                                                                                   bly
                                                                                         G   Installing reverse main gear bushing
                                                                                         G   Installing 3rd gear bushing                         D
                                                                                         G   Installing 3rd-4th synchronizer hub assem-
                                                                                             bly
                                                                        ZZA0920D
                                                                                         a: 98 mm (3.86 in) dia.                                 E
                                                                                         b: 40 mm (1.57 in) dia.
  ST30022000                                                                             G   Installing 3rd main gear
  (    --  )                                                                             G   Installing 4th main gear                            F
  Inserter
                                                                                         a: 110 mm (4.33 in) dia.
                                                                                         b: 46 mm (1.81 in) dia.
                                                                                                                                                 G
                                                                        ZZA0920D


  ST27861000                                                                             G   Installing 1st-2nd synchronizer hub assem-          H
  (   --      )                                                                              bly
  Support ring                                                                           G   Installing 1st gear bushing
                                                                                         a: 62 mm (2.44 in) dia.
                                                                                         b: 52 mm (2.05 in) dia.                                  I

                                                                        ZZA0832D


  ST30032000                                                                             Installing counter rear bearing inner race
                                                                                                                                                 J
  (J-26010-01)                                                                           a: 80 mm (3.15 in) dia.
  Inserter                                                                               b: 31 mm (1.22 in) dia.
                                                                                                                                                 K


                                                                        ZZA0920D                                                                 L
  KV32102700                                                                             Installing main drive gear bearing
  (     -- )                                                                             a: 48 mm (1.89 in) dia.
  Drift                                                                                  b: 41 mm (1.61 in) dia.
                                                                                                                                                 M



                                                                        ZZA0534D


  ST23860000                                                                             Installing reverse counter gear
  (     -- )                                                                             a: 38 mm (1.50 in) dia.
  Drift                                                                                  b: 33 mm (1.30 in) dia.




                                                                        ZZA0534D




Revision: February 2006                                         MT-3                                                          2005 Xterra
                          PREPARATION

  Tool number
  (Kent-Moore No.)                           Description
  Tool name
  ST01530000                                 Installing reverse synchronizer hub assembly
  (     -- )                                 a: 50 mm (1.97 in) dia.
  Drift                                      b: 41 mm (1.61 in) dia.




                                 ZZA0534D


  KV381054S0                                 Removing rear oil seal
  (J-34286)
  Puller




                                 ZZA0601D


  ST33200000                                 Installing counter rear bearing
  (J-26082)                                  a: 60 mm (2.36 in) dia.
  Drift                                      b: 44.5 mm (1.752 in) dia.




                                 ZZA1002D


  ST30621000                                 Installing dust seal
  (J-25742-5)                                a: 79 mm (3.11 in) dia.
  Drift                                      b: 59 mm (2.32 in) dia.




                                 ZZA1000D


  KV40100630                                 Installing 4th counter gear thrust washer
  (J-26092)                                  a: 67 mm (2.64 in) dia.
  Inserter                                   b: 38 mm (1.50 in) dia.




                                 ZZA0920D


  KV38102100                                 Installing front cover oil seal
  (J-25803-01)                               a: 44 mm (1.73 in) dia.
  Drift                                      b: 28 mm (1.10 in) dia.




                                 NT084


  KV32103300                                 Installing reverse synchronizer hub assembly
  (J-46529)                                  a: 73 mm (2.87 in)
  Press plate




                                 PCIB0165J




Revision: February 2006      MT-4                                              2005 Xterra
                          PREPARATION

  Tool number
  (Kent-Moore No.)                          Description                                   A
  Tool name
  ST30031000                                Measuring wear of inner baulk ring
  (J-22912-01)                                                                            B
  Puller


                                                                                          MT

                                 ZZC0499D


  ST22490000                                Holding a adapter plate                       D
  (   --      )
  Adapter setting plate

                                                                                          E

                                 ZZC0465D


  ST33400001                                Installing oil seal
                                                                                          F
  (J-26082)                                 a: 60 mm (2.36 in) dia.
  Drift                                     b: 47 mm (1.85 in) dia.
                                                                                          G


                                 NT086                                                    H



                                                                                           I


                                                                                          J



                                                                                          K


                                                                                          L



                                                                                          M




Revision: February 2006      MT-5                                           2005 Xterra
                                         PREPARATION

Commercial Service Tools                                                                              ECS00DYQ


  Tool name                                                    Description
  Puller                                                       Removing each bearing, gear and bushing




                                                   ZZB0823D


  Pin punch                                                    Removing and installing each retaining pin
  Tip diameter: 6.0 mm (0.236 in) dia.




                                                   ZZA0815D


  Power tool                                                   Loosening bolts and nuts




                                                   PBIC0190E


  Puller                                                       G   Removing reverse synchronizer hub as-
                                                                   sembly
                                                               G   Removing reverse counter gear
                                                               G   Removing reverse main gear



                                                   NT077


  Drift                                                        Removing counter end bearing
                                                               a: 32 mm (1.26 in) dia.




                                                   LCIA0362E




Revision: February 2006                     MT-6                                                2005 Xterra
        NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING                                                                                                                                                                                                                                                                                                                                     PFP:00003
                                                                                                                                                                                                                                                                                                                                                                                                                                    A
NVH Troubleshooting Chart                                                                                                                                                                                                                                                                                                                                                                               ECS00DYR


Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.                                                                                                                                                                                                                                                                                                                                                                                  B




                                                                              MT-10




                                                                                                                                                MT-21



                                                                                                                                                                                     MT-13



                                                                                                                                                                                                                                                                                MT-25




                                                                                                                                                                                                                                                                                                                                                                 MT-23
 Reference page

                                                                                                                                                                                                                                                                                                                                                                                                                                    MT




                                                                                                                                                                                                                    CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
                                                                                                                                                                                                                                                                                                                                                                                                                                    D


                                                                                                                                                                                                                                                                                                                                                                                                                                    E



                                                                                                                                                                                                                                                                                                                                                                                                                                    F
 SUSPECTED PARTS
 (Possible cause)




                                                                                                                                                                                     SHIFT CONTROL LINKAGE (Worn)
                                                                                                                                                                                                                                                                                                                                                                                                                                    G




                                                                                                                                                                                                                                                                                                                                                                         BAULK RING (Worn or damaged)
                                                                                                                                                                                                                                                                                                                                     BEARING (Worn or damaged)
                                                                                                                                                        OIL SEAL (Worn or damaged)




                                                                                                                                                                                                                                                                                                                                                                                                          INSERT SPRING (Damaged)
                                                                                                                                                                                                                                                                                                            GEAR (Worn or damaged)
                                                                                                                                                                                                                                                                                                                                                                                                                                    H
                                                                                                  OIL (Oil level is high.)


                                                                                                                             GASKET (Damaged)




                                                                                                                                                                                                                                                                                        SHIFT FORK (Worn)
                                                    OIL (Oil level is low.)


                                                                              OIL (Wrong oil.)




                                                                                                                                                                                                                                                                                                                                                                                                                                     I


                                                                                                                                                                                                                                                                                                                                                                                                                                    J
                  Noise                                      1                      2                                                                                                                                                                                                                               3                          3
                  Oil leakage                                                       3                      1                       2                              2
 Symptoms                                                                                                                                                                                                                                                                                                                                                                                                                           K
                  Hard to shift or will not shift                                   1                      1                                                                                    2                                                                                                                                                                                   2                              2
                  Jumps out of gear                                                                                                                                                             1                                          1                                                  2                     2
                                                                                                                                                                                                                                                                                                                                                                                                                                    L



                                                                                                                                                                                                                                                                                                                                                                                                                                    M




Revision: February 2006                                                                          MT-7                                                                                                                                                                                                                                                               2005 Xterra
                                         DESCRIPTION

DESCRIPTION                                                                                        PFP:00000

Cross-Sectional View                                                                                    ECS00DYS




                                                                                                  PCIB1297E

  1.   Mainshaft                 2.   Reverse synchronizer hub   3.   Reverse coupling sleeve
  4.   Reverse main gear         5.   4th main gear              6.   3rd main gear
  7.   1st main gear             8.   1st-2nd coupling sleeve    9.   1st-2nd synchronizer hub
  10. 2nd main gear              11. 6th main gear               12. 5th-6th coupling sleeve
  13. 5th-6th synchronizer hub   14. Main drive gear             15. Front cover
  16. Transmission case          17. Counter gear                18. Filler plug
  19. 3rd counter gear           20. 3rd-4th synchronizer hub    21. 3rd-4th coupling sleeve
  22. Drain plug                 23. Adapter plate               24. 4th counter gear
  25. Reverse idler gear         26. Reverse idler shaft         27. Reverse counter gear
  28. OD gear case               29. Rear extension



Revision: February 2006                          MT-8                                            2005 Xterra
                                             DESCRIPTION

DOUBLE-CONE SYNCHRONIZER
The 1st and 3rd, 4th gears is equipped with a double-cone synchronizer to reduce the operating force of the       A
shift lever.
TRIPLE-CONE SYNCHRONIZER
                                                                                                                  B
The 2nd gear is equipped with a triple-cone synchronizer to reduce the operating force of the shift lever.


                                                                                                                  MT



                                                                                                                  D


                                                                                                                  E
                                                                                                      PCIB0594E



                                                                                                                  F


                                                                                                                  G


                                                                                                                  H



                                                                                                                   I


                                                                                                                  J



                                                                                                                  K


                                                                                                                  L



                                                                                                                  M




Revision: February 2006                             MT-9                                            2005 Xterra
                                                      M/T OIL

M/T OIL                                                                                                       PFP:KLD20

Changing                                                                                                           ECS00DYT

DRAINING
1.   Start the engine and let it run to warm up the transmission.
2.   Stop the engine. Remove the transmission drain plug and drain the oil.
3.   Set a gasket on the drain plug and install it to the transmission. Tighten the drain plug to the specified
     torque. Refer to MT-21, "Case Components" .
     CAUTION:
     Do not reuse gasket.
FILLING
1.   Remove the filler plug. Fill with new oil until oil level reaches the specified limit near the filler plug hole.
        Oil grade and Viscosity        : Refer to MA-11, "Fluids and Lubricants" .
        Oil capacity                   : Refer to MA-11, "Fluids and Lubricants" .
2.   After refilling the oil, check oil level. Set a gasket to the filler plug, then install it to the transmission.
     Tighten the filler plug to the specified torque. Refer to MT-21, "Case Components" .
     CAUTION:
     Do not reuse gasket.
Checking                                                                                                           ECS00DYU

OIL LEAKAGE AND OIL LEVEL
G    Make sure that oil is not leaking from the transmission or around it.
G    Check oil level from the filler plug hole as shown.
     CAUTION:
     Do not start engine while checking oil level.
G    Set a gasket on the filler plug and install it to the transmission.
     Tighten the filler plug to the specified torque. Refer to MT-21,
     "Case Components" .
     CAUTION:
     Do not reuse gasket.

                                                                                                                PCIB0268E




Revision: February 2006                                MT-10                                                2005 Xterra
                                             REAR OIL SEAL

REAR OIL SEAL                                                              PFP:33140
                                                                                         A
Removal and Installation (For 2WD models)                                     ECS00DYV

REMOVAL
1.   Remove rear propeller shaft. Refer to PR-10, "Removal and
                                                                                         B
     Installation" .
2.   Remove dust seal and rear oil seal using suitable tool.
     CAUTION:                                                                            MT
     G Do not damage rear extension assembly.

     G Do not reuse dust seal and rear oil seal.

                                                                                         D


                                                                            LCIA0383E
                                                                                         E
INSTALLATION
Installation is the reverse order of removal.
G    Drive the new rear oil seal (1) and dust seal (2) using Tool A.                     F
        Tool number         : ST33400001 (J-26082)

        Dimension B         : 0.5 - 1.5 mm (0.020 - 0.059 in)                            G
        Dimension C         : 1.2 - 2.2 mm (0.047 - 0.087 in)
     CAUTION:                                                                            H
     G Do not reuse dust seal and rear oil seal.

     G Apply multi-purpose grease to seal lips before installing.

     G Do not incline the dust seal and rear oil seal during instal-
                                                                                          I
       lation.
G    Check the transmission oil level after installation. Refer to MT-
     10, "Checking" .
                                                                                         J



                                                                                         K


                                                                                         L

                                                                            WCIA0553E


                                                                                         M




Revision: February 2006                             MT-11                2005 Xterra
                                POSITION SWITCH

POSITION SWITCH                                     PFP:32005

Checking                                               ECS00DYW

BACK-UP LAMP SWITCH
G      Check continuity.
                Gear position      Continuity
    Reverse                           Yes
    Except reverse                    No




                                                     SCIA0645E


PARK/NEUTRAL POSITION SWITCH
G      Check continuity.
                Gear position      Continuity
    Neutral                           Yes
    Except neutral                    No




Revision: February 2006               MT-12       2005 Xterra
                                                SHIFT CONTROL

SHIFT CONTROL                                                                                             PFP:34103
                                                                                                                          A
Removal and Installation                                                                                       ECS00DYX

COMPONENTS
                                                                                                                          B


                                                                                                                          MT



                                                                                                                          D


                                                                                                                          E



                                                                                                                          F


                                                                                                                          G


                                                                                                                          H



                                                                                                                           I


                                                                                                                          J



                                                                                                                          K


                                                                                                                          L



                                                                                                                          M
                                                                                                         WCIA0508E

     1.   Retaining plate              2.    Dust boot cover (upper)     3.   Dust boot cover (lower)
     4.   Shift knob                    5.   Shift lever assembly        6.   Clip (A)
     7.   Boot                         8.    Guide plate                 9.   Socket
     10. Bushing                       11. Clip (B)                      12. Spring

REMOVAL
1.    Remove the shift knob.
2.    Remove the M/T finisher. Refer to IP-13, "M/T FINISHER" .
3.    Remove the retaining plate and dust boot covers.
4.    Remove the clip (B) and then separate the boot from the control housing.
5.    Remove the guide plate bolts and then separate the guide plate.
6.    Remove the shift lever assembly and spring from the transmission.
INSTALLATION
Installation is the reverse order of removal.

Revision: February 2006                                MT-13                                            2005 Xterra
                                          SHIFT CONTROL

CAUTION:
G  Apply multi-purpose grease to the socket and bushing.
G  Do not reuse clip.
G  Apply cement to threads of the shift lever assembly.
G  Temporarily tighten guide plate bolts. Then tighten guide plate
   bolts to the specified torque in the order shown. Refer to MT-13,
   "COMPONENTS" .
G  When shift lever assembly is shifted to each position, make sure
   there is no binding or disconnection in either boot.
G  When shifted to each position, make sure there is no noise,
   bending, and backlash. Especially when shift lever assembly is
   shifted to 5th, 6th without pressing downward, check for bend-
   ing.
G  When shift lever assembly is shifted to 1st, 2nd side and 5th, 6th
   side, confirm shift lever assembly returns to neutral position                                 LCIA0398E


   smoothly.
G  In any position other than reverse, confirm that shift lever assembly can be pressed downward.
G  With shift lever assembly pressed downward, confirm that it can be shifted to reverse.
G  When shifted from reverse to neutral position, confirm shift lever assembly returns to neutral position
   smoothly with spring power.
G  Without shift lever assembly pressed downward, confirm that it cannot be shifted to reverse.




Revision: February 2006                          MT-14                                          2005 Xterra
                                        AIR BREATHER HOSE

AIR BREATHER HOSE                                                                                     PFP:31098
                                                                                                                      A
Removal and Installation                                                                                   ECS00DYY


Refer to the figure below for air breather hose removal and installation information.
                                                                                                                      B


                                                                                                                      MT



                                                                                                                      D


                                                                                                                      E



                                                                                                                      F


                                                                                                                      G


                                                                                                                      H



                                                                                                                       I


                                                                                                                      J



                                                                                                                      K
                                                                                                     LCIA0392E

   1.   Water outlet                   2.   Bracket                        3.   Air breather hose
   4.   Breather tube                                                                                                 L
CAUTION:
G  Make sure there are no pinched or blocked areas on the air breather hose after installation.
G  When inserting the air breather hose, be sure to insert it fully until its end reaches the end of the              M
   tube radius.
G  Install the air breather hose with the paint mark side up.




Revision: February 2006                               MT-15                                         2005 Xterra
                               TRANSMISSION ASSEMBLY

TRANSMISSION ASSEMBLY                                                   PFP:32010

Removal and Installation from Vehicle (For 2WD models)                        ECS00DYZ

COMPONENTS




                                                                       LCIA0394E

  1.   Transmission assembly    2.   Crossmember     3.   Insulator
  4.   Dynamic damper




Revision: February 2006                      MT-16                    2005 Xterra
                                      TRANSMISSION ASSEMBLY

REMOVAL
1.      Drain transmission oil. Refer to MT-10, "DRAINING" .                                                       A
2.      Disconnect the battery cable from the negative terminal.
3.      Remove the shift lever assembly. Refer to MT-13, "Removal and Installation" .
                                                                                                                   B
4.      Remove the LH fender protector. Refer to EI-19, "FENDER PROTECTOR" .
5.      Remove the crankshaft position sensor (POS) from M/T assem-
        bly.
                                                                                                                  MT
        CAUTION:
        Do not damage the sensor edge.
6.      Remove the undercovers using power tool.
                                                                                                                   D
7.      Remove the front crossmember using power tool.
8.      Remove the starter motor. Refer to SC-22, "Removal and Instal-
        lation" .
                                                                                                                   E
9.      Remove the rear propeller shaft. Refer to PR-10, "Removal and
        Installation" .                                                                                 LCIA0367E

10.     Remove the left and right front exhaust tubes. Refer to EX-3,
                                                                                                                   F
        "Removal and Installation" .
11.     Remove the clutch operating cylinder from the transmission. Refer to CL-11, "Removal and Installation" .
12.     Support the transmission using a suitable jack.
                                                                                                                   G
13.     Remove the nuts securing the insulator to the crossmember.
14.     Remove the crossmember using power tool.
        WARNING:                                                                                                   H
        Support the transmission using suitable jack.
15.     Tilt the transmission slightly to gain clearance between the body and the transmission, then disconnect
        the air breather hoses. Refer to MT-15, "Removal and Installation" .                                       I
16.     Disconnect the following:
        G Back-up lamp switch connector

        G Park/neutral position (PNP) switch connector                                                             J
17.     Remove the wiring harness from the retainers.
18.     Remove the transmission to engine bolts using power tool.
19.     Separate the transmission from the engine and remove it from the vehicle.                                  K
        WARNING:
        Support the transmission while removing it using suitable jack.
                                                                                                                   L
INSTALLATION
Installation is the reverse order of removal.
G    When installing the transmission to the engine, tighten the bolts                                            M
     to the specified torque.
    Quantity                                     10

    Bolt length "   "
                                              65 (2.56)
    mm (in)
    Tightening torque
                                             75 (7.7, 55)
    N



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