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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 ....................................... 5      .           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 2006                                                    MT-1                                                               2007 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 2006                            MT-2                                             2007 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                                                                            Description
                                                                                                                                                 B
  (Kent-Moore No.)
  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 2006                                        MT-3                                                          2007 Xterra
                           PREPARATION

  Tool number                                 Description
  (Kent-Moore No.)
  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 2006      MT-4                                                  2007 Xterra
                                         PREPARATION

  Tool number                                               Description
  (Kent-Moore No.)                                                                                            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

Commercial Service Tools                                                                           ECS00DYQ


  Tool name                                                 Description                                        I
  Puller                                                    Removing each bearing, gear and bushing

                                                                                                              J



                                                                                                              K
                                                ZZB0823D


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



                                                                                                              M
                                                ZZA0815D


  Power tool                                                Loosening bolts and nuts




                                                PBIC0190E




Revision: September 2006                    MT-5                                            2007 Xterra
                           PREPARATION

  Tool name                                      Description
  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 2006      MT-6                                                2007 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 2006                                                                         MT-7                                                                                                                                                                                                                                                               2007 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 2006                         MT-8                                            2007 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 2006                            MT-9                                            2007 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 2006                              MT-10                                        2007 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 2006                              MT-11                                   2007 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 2006                            MT-12                               2007 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 2006              MT-13       2007 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 2006                              MT-14                                             2007 Xterra
                                             SHIFT CONTROL

INSTALLATION
Installation is the reverse order of removal.                                                                        A
G    Install shift knob according to the following.



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