Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Xterra 2005-2007.2009 Approved Nissan Xterra 2006 mt
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C TRANSMISSION/TRANSAXLE
A
SECTION
MANUAL TRANSMISSION
MT B
MT
D
E
CONTENTS
PRECAUTIONS ......................................................... 2 . SHIFT CONTROL .................................................... 14 . F
Service Notice or Precautions ................................. 2 . Removal and Installation ....................................... 14 .
PREPARATION .......................................................... 3 . COMPONENTS .................................................. 14 .
Special Service Tools .............................................. 3 . REMOVAL .......................................................... 14. G
Commercial Service Tools ....................................... 6 . INSTALLATION .................................................. 15 .
NOISE, VIBRATION AND HARSHNESS (NVH) INSPECTION AFTER INSTALLATION ............... 15 .
TROUBLESHOOTING ............................................... 7 . AIR BREATHER HOSE ........................................... 16 .
H
NVH Troubleshooting Chart .................................... 7 . Removal and Installation ....................................... 16 .
DESCRIPTION ........................................................... 8. TRANSMISSION ASSEMBLY ................................. 17 .
Cross-Sectional View .............................................. 8 . Removal and Installation from Vehicle (For 2WD
DOUBLE-CONE SYNCHRONIZER ..................... 9 . Models) .................................................................. 17
. I
TRIPLE-CONE SYNCHRONIZER ....................... 9 . COMPONENTS .................................................. 17 .
M/T OIL .................................................................... 10
. REMOVAL .......................................................... 18.
Changing ............................................................... 10
. INSTALLATION .................................................. 18 . J
DRAINING .......................................................... 10. Removal and Installation from Vehicle (For 4WD
FILLING .............................................................. 10
. Models) .................................................................. 19
.
Checking ............................................................... 10
. COMPONENTS .................................................. 19 .
K
OIL LEAKAGE AND OIL LEVEL ........................ 10 . REMOVAL .......................................................... 19.
REAR OIL SEAL ......................................................11 . INSTALLATION .................................................. 20 .
Removal and Installation ........................................11 . Disassembly and Assembly ................................... 22 .
REMOVAL ...........................................................11 . COMPONENTS .................................................. 22 . L
INSTALLATION ...................................................11 . DISASSEMBLY .................................................. 28 .
POSITION SWITCH ................................................. 13 . INSPECTION AFTER DISASSEMBLY ............... 42 .
Checking ............................................................... 13
. ASSEMBLY ........................................................ 46 . M
BACK-UP LAMP SWITCH ................................. 13 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 69 .
PARK/NEUTRAL POSITION SWITCH .............. 13 . General Specifications ........................................... 69 .
Gear End Play ....................................................... 70
.
Snap Rings ............................................................ 70
.
Baulk Ring Clearance ............................................ 71 .
Revision: September 2005 MT-1 2006 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: September 2005 MT-2 2006 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: September 2005 MT-3 2006 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 G Installing counter rear bearing
(J-26082) G Installing rear oil seal
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
ZZA1002D
KV38100500 Installing dust seal (for 2WD models)
( -- ) a: 80 mm (3.15 in) dia.
Drift b: 60 mm (2.36 in) dia.
S-NT086
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: September 2005 MT-4 2006 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: September 2005 MT-5 2006 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: September 2005 MT-6 2006 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-22
MT-14
MT-26
MT-24
Reference page
MT
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
D
E
F
SUSPECTED PARTS
(Possible cause)
SHIFT CONTROL LINKAGE (Worn)
BAULK RING (Worn or damaged)
G
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: September 2005 MT-7 2006 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: September 2005 MT-8 2006 Xterra
DESCRIPTION
DOUBLE-CONE SYNCHRONIZER
The 1st, 3rd and 4th gears are 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: September 2005 MT-9 2006 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-22, "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 as shown.
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-22, "Case Components" .
PCIB0268E
CAUTION:
Do not reuse gasket.
Checking ECS00DYU
OIL LEAKAGE AND OIL LEVEL
1. Make sure that oil is not leaking from the transmission or around it.
2. Check oil level from the filler plug hole as shown.
CAUTION:
Do not start engine while checking oil level.
3. Set a gasket on the filler plug and install it to the transmission.
Tighten the filler plug to the specified torque. Refer to MT-22,
"Case Components" .
CAUTION:
Do not reuse gasket.
PCIB0268E
Revision: September 2005 MT-10 2006 Xterra
REAR OIL SEAL
REAR OIL SEAL PFP:33140
A
Removal and Installation ECS00DYV
REMOVAL
For 2WD Models B
1. Remove rear propeller shaft. Refer to PR-10, "Removal and
Installation" .
2. Remove dust seal and rear oil seal using suitable tool. MT
CAUTION:
Do not damage rear extension.
D
E
LCIA0383E
For 4WD Models
1. Remove front and rear propeller shafts. Refer to PR-5, "Removal and Installation" (front) and PR-10, F
"Removal and Installation" (rear).
2. Remove transfer assembly. Refer to TF-111, "Removal and Installation" .
3. Remove rear oil seal using Tool. G
Tool number : KV381054S0 (J-34286)
CAUTION: H
Do not damage OD gear case.
I
PCIB1218E
J
INSTALLATION
Installation is the reverse order of removal. K
For 2WD Models
G Drive the new rear oil seal (1) and new dust seal (2) using Tools.
L
Tool number : ST33200000 (J-26082)
: KV38100500 ( -- )
Dimension "H1" : 1.2 - 2.2 mm (0.047 - 0.087 in) M
Dimension "H2" : 0.5 - 1.5 mm (0.020 - 0.059 in)
CAUTION:
Do not incline the dust seal and rear oil seal during installa-
tion.
(A): Seal lip
PCIB1660E
Revision: September 2005 MT-11 2006 Xterra
REAR OIL SEAL
For 4WD Models
G Drive the rear oil seal using Tool.
Tool number : ST33200000 (J-26082)
Dimension "A" : -0.5 - 0.5 mm (-0.020 - 0.020 in
CAUTION:
Do not incline the rear oil seal during installation.
PCIB1632E
G Check the transmission oil level after installation. Refer to MT-10, "Checking" .
Revision: September 2005 MT-12 2006 Xterra
POSITION SWITCH
POSITION SWITCH PFP:32005
A
Checking ECS00DYW
BACK-UP LAMP SWITCH
G Check continuity. B
Gear position Continuity
Reverse Yes
MT
Except reverse No
D
PCIB1633E
E
PARK/NEUTRAL POSITION SWITCH
G Check continuity.
F
Gear position Continuity
Neutral Yes
Except neutral No G
H
I
J
K
L
M
Revision: September 2005 MT-13 2006 Xterra
SHIFT CONTROL
SHIFT CONTROL PFP:34103
Removal and Installation ECS00DYX
COMPONENTS
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.
Revision: September 2005 MT-14 2006 Xterra
SHIFT CONTROL
INSTALLATION
Installation is the reverse order of removal. A
G Install shift knob according to the following.
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