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C TRANSMISSION/TRANSAXLE

B
SECTION
MANUAL TRANSMISSION MT

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

ZZC0499D

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

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

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

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

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.)

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

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.

E
PCIB0594E

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.

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

WCIA0553E

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

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

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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