Nissan Juke (2014 year). Service Repair Manual — part 248
INPUT SHAFT AND GEARS
TM-113
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
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Disassembly and Assembly
INFOID:0000000010281901
DISASSEMBLY
1.
Before disassembling, measure end play for 3rd, 4th, 5th, and
6th input gears.
2.
Remove oil channel.
3.
Press out input shaft rear bearing using Tool and a puller.
4.
Remove snap ring.
5.
Press out 6th input gear, 6th needle bearing, 6th input gear
bushing, 5th-6th synchronizer hub assembly, and 5th input gear
using Tool (A) and a puller (B).
6.
Remove 5th needle bearing.
7.
Press out 5th input gear bushing, thrust washer, 4th input gear,
4th needle bearing, 4th input gear bushing, 3rd-4th synchronizer
hub assembly, and 3rd input gear using Tool and a puller.
8.
Remove 3rd needle bearing.
End play standard value
: Refer to
SCIA0966E
Tool number
: ST33052000 (
—
)
SCIA1037E
Tool number
A: ST33052000 (
—
)
PCIB1882E
Tool number
: ST33052000 (
—
)
SCIA1030E
Revision: 2013 October
2014 JUKE
TM-114
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
INPUT SHAFT AND GEARS
9.
Press out input shaft front bearing using a puller.
INSPECTION AFTER DISASSEMBLY
Input Shaft and Gears
Check items below. If necessary, replace them with new ones.
• Damage, peeling, dent, uneven wear, bending, etc. of shaft
• Excessive wear, damage, peeling, etc. of gears
Synchronizer
Check items below. If necessary, replace them with new ones.
• Damage and excessive wear of contact surfaces of coupling
sleeve, synchronizer hub and shifting insert
• Coupling sleeve and synchronizer hub must move smoothly.
• If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
BAULK RING CLEARANCE
• Single-cone synchronizer (4th, 5th, and 6th)
SCIA0920E
SCIA1074J
SMT387A
SMT867D
Revision: 2013 October
2014 JUKE
INPUT SHAFT AND GEARS
TM-115
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
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Push baulk ring on the cone and measure the clearance between
baulk ring and cone. If measurement is below limit, replace it with a
new one.
• Double-cone synchronizer (3rd)
Check the clearance between outer baulk ring, synchronizer cone,
and inner baulk ring as follows.
CAUTION:
The clearances (A) and (B) are controlled with outer baulk
ring, synchronizer cone, and inner baulk ring as a set.
Replace them as a set if the clearances are outside the limit
value.
1.
Measure the clearance (A) at 2 points or more diagonally oppo-
site using a dial indicator. And then calculate mean value.
2.
Measure the clearance (B) at 2 points or more diagonally oppo-
site using a feeler gauge. And then calculate mean value.
Bearing
Clearance
Standard value
: Refer to
.
Limit value
: Refer to
.
SMT140
SCIA0950E
Tool number
: ST30031000 (J-22912-01)
Clearance (A)
Standard value
: Refer to
.
Limit value
: Refer to
.
PCIB0945E
Clearance (B)
Standard value
: Refer to
.
Limit value
: Refer to
.
SCIA1084E
Revision: 2013 October
2014 JUKE
TM-116
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
INPUT SHAFT AND GEARS
Check items below. If necessary, replace them with new ones.
• Damage and rough rotation of bearing
ASSEMBLY
1.
Install 3rd needle bearing to input shaft.
2.
Install 3rd input gear, 3rd inner baulk ring, 3rd synchronizer cone, and 3rd outer baulk ring to input shaft.
CAUTION:
Replace 3rd inner baulk ring, 3rd synchronizer cone, and 3rd outer baulk ring as a set.
3.
Install 3rd-4th spread springs, 3rd-4th shifting inserts, and 3rd-4th synchronizer hub onto 3rd-4th coupling
sleeve.
CAUTION:
• Be careful with orientation of 3rd-4th synchronizer hub.
• Do not reuse 3rd-4th synchronizer hub and 3rd-4th cou-
pling sleeve.
• Replace 3rd-4th synchronizer hub and 3rd-4th coupling
sleeve as a set.
• Be careful with orientation of 3rd-4th coupling sleeve.
• Be sure not to hook center projection of 2 spread springs
on same shifting insert.
MTF0041D
SCIA0921E
PCIB0799E
SCIA1083E
Revision: 2013 October
2014 JUKE
INPUT SHAFT AND GEARS
TM-117
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
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4.
Press in 3rd-4th synchronizer hub assembly using Tool.
CAUTION:
Align grooves of 3rd-4th shifting insert and 3rd outer baulk
ring.
5.
Press in 4th input gear bushing using Tool.
6.
Install 4th baulk ring.
7.
Install 4th needle bearing and 4th input gear to input shaft.
8.
Select thrust washer so that dimension "C2" satisfies the stan-
dard value below. Then install thrust washer onto input shaft.
Refer to
TM-140, "Available Thrust Washer"
.
CAUTION:
Only one thrust washer can be selected.
9.
Press in 5th input gear bushing using Tool.
CAUTION:
Do not reuse 5th input gear bushing.
10. Install 5th needle bearing and 5th input gear to input shaft.
11. Install 5th baulk ring.
Tool number
: KV40105710 (
—
)
SCIA1031E
Tool number
: KV40105710 (
—
)
PCIB0922E
Standard value for dimension "C2”
: Refer to
TM-140, "Available Thrust Washer"
SCIA0925E
Tool number
: KV40105710 (
—
)
SCIA1033E
Revision: 2013 October
2014 JUKE
TM-118
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
INPUT SHAFT AND GEARS
12. Install 5th-6th synchronizer hub, 5th-6th spread springs, and 5th-6th shifting inserts onto 5th-6th coupling
sleeve.
CAUTION:
• Be careful with orientation of 5th-6th synchronizer hub.
• Do not reuse 5th-6th synchronizer hub and 5th-6th cou-
pling sleeve.
• Replace 5th-6th synchronizer hub and 5th-6th coupling
sleeve as a set.
• Be careful with orientation of 5th-6th coupling sleeve.
• Be sure not to hook center projection of 2 spread springs
on same shifting insert.
13. Press in 5th-6th synchronizer hub assembly using Tool.
CAUTION:
Align grooves of 5th-6th shifting insert and 5th baulk ring.
A
: Front side
B
: Rear side
PCIB1883E
A
: 5th input gear side
B
: 6th input gear side
PCIB1884E
SCIA1083E
Tool number
: KV40105710 (
—
)
SCIA1039E
Revision: 2013 October
2014 JUKE
INPUT SHAFT AND GEARS
TM-119
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
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14. Install 6th needle bearing, 6th input gear, 6th baulk ring onto 6th
input gear bushing and then press in 6th input gear bushing onto
input shaft using Tool.
15. Install snap ring onto input shaft and make sure that end play
(gap between snap ring and groove) of 6th input gear bushing
satisfies the standard value.
• If measurement is outside the standard range, select snap
ring. Refer to
TM-139, "Available Snap Rings"
CAUTION:
Do not reuse snap ring.
16. Press in input shaft rear bearing using Tool.
CAUTION:
Install input shaft rear bearing with its brown surface facing
the 6th input gear side.
17. Press in input shaft front bearing using Tools.
18. Install oil channel onto input shaft.
19. Check end play of 3rd, 4th, 5th, and 6th input gears.
Tool number
: ST33200000 (J-26082)
WCIA0309E
End play standard value
:Refer to
TM-139, "Available Snap Rings"
.
SCIA0970E
Tool number
: ST30901000 (J-26010-01)
WCIA0310E
Tool number
A: ST33052000 (
—
)
B: ST30032000 (J-26010-01)
WCIA0311E
End play standard value
: Refer to
SCIA0966E
Revision: 2013 October
2014 JUKE
TM-120
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
MAINSHAFT AND GEARS
MAINSHAFT AND GEARS
Exploded View
INFOID:0000000010291443
MAINSHAFT AND GEARS
Disassembly and Assembly
INFOID:0000000010281902
DISASSEMBLY
1.
Mainshaft front bearing
2.
Mainshaft bearing retainer
3.
Mainshaft
4.
Reverse main gear
5.
1st main gear
6.
1st main gear bushing
7.
1st needle bearing
8.
1st inner baulk ring
9.
1st synchronizer cone
10. 1st outer baulk ring
11. 1st-2nd spread spring
12. 1st-2nd shifting insert
13. 1st-2nd synchronizer hub
14. 2nd outer baulk ring
15. 2nd synchronizer cone
16. 2nd inner baulk ring
17. 1st-2nd coupling sleeve
18. 2nd main gear bushing
19. 2nd needle bearing
20. 2nd main gear
21. 3rd main gear
22. 3rd-4th mainshaft spacer
23. 4th main gear adjusting shim
24. 4th main gear
25. 5th main gear
26. 5th-6th mainshaft spacer
27. 6th main gear
28. 6th main gear adjusting shim 29. Mainshaft rear bearing
30. Mainshaft C-ring
31. C-ring holder
32. Snap ring
33. Mainshaft rear bearing adjust-
ing shim
: Apply gear oil.
: Replace the parts as a set.
: Always replace after every disassembly.
: N·m (kg-m, ft-lb)
PCIB1889E
Revision: 2013 October
2014 JUKE
MAINSHAFT AND GEARS
TM-121
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
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1.
Before disassembling, measure the end play of 1st and 2nd
main gears.
2.
Remove snap ring.
3.
Remove C-ring holder and then remove mainshaft C-rings.
4.
Press out mainshaft rear bearing, 6th main gear adjusting shim,
and 6th main gear using Tool and a puller.
5.
Remove 5th-6th mainshaft spacer.
6.
Press out 4th main gear and 5th main gear using Tool and a
puller.
7.
Remove 4th main gear adjusting shim.
8.
Remove 3rd-4th mainshaft spacer.
9.
Press out 3rd main gear and 2nd main gear using Tool (A) and a
puller (B).
10. Remove 2nd needle bearing.
End play standard value
: Refer to
SCIA0973E
PCIB0805E
Tool number
: ST33052000 (
—
)
SCIA1056E
Tool number
: ST33052000 (
—
)
SCIA1044E
Tool number
A: KV40105020 (
—
)
PCIB1885E
Revision: 2013 October
2014 JUKE
TM-122
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
MAINSHAFT AND GEARS
11. Press out 2nd main gear bushing, 1st-2nd synchronizer hub
assembly, 1st main gear, 1st needle bearing, 1st main gear
bushing, and reverse main gear using Tool (A).
INSPECTION AFTER DISASSEMBLY
Mainshaft and Gears
Check items below. If necessary, replace them with new ones.
• Damage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the shaft.
• Excessive wear, damage, peeling, and other non-standard condi-
tions of the gears.
Synchronizer
Check items below. If necessary, replace them with new ones.
• Damage and unusual wear on contact surfaces of coupling sleeve,
synchronizer hub and shifting insert.
• Coupling sleeve and synchronizer hub must move smoothly.
• If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
BAULK RING CLEARANCE
Triple-cone synchronizer (1st and 2nd)
Tool number
A: KV40105020 (
—
)
PCIB1886E
SCIA1076J
SMT387A
SMT867D
Revision: 2013 October
2014 JUKE
MAINSHAFT AND GEARS
TM-123
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
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• Check the clearance between outer baulk ring, synchronizer cone,
and inner baulk ring as follows.
CAUTION:
The clearances (A), B, and (C) are controlled with outer baulk
ring, synchronizer cone, and inner baulk ring as a set.
Replace them as a set if the clearances are outside the limit
value.
1.
Measure the clearance (A) at 2 points or more diagonally oppo-
site using a feeler gauge when pressing baulk ring toward clutch
gear taper cone. And then calculate mean value.
2.
Measure the clearance (B) at 2 points or more diagonally oppo-
site using a feeler gauge. And then calculate mean value.
3.
Measure the clearance (C) at 2 points or more diagonally oppo-
site using a feeler gauge when pressing baulk ring toward clutch
gear taper cone. And then calculate mean value.
Bearing
PCIB1358E
Clearance (A)
Standard value
: Refer to
Limit value
: Refer to
PCIB1359E
Clearance (B)
Standard value
: Refer to
.
Limit value
: Refer to
.
PCIB1360E
Clearance (C)
Standard value
: Refer to
Limit value
: Refer to
PCIB1361E
Revision: 2013 October
2014 JUKE
TM-124
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
MAINSHAFT AND GEARS
Check items below. If necessary, replace them with new ones.
• Damage and rough rotation of bearing
ASSEMBLY
1.
Press in reverse main gear using Tools.
CAUTION:
• Be careful with orientation of reverse main gear.
• Do not reuse reverse main gear.
2.
Press in 1st main gear bushing using Tools.
3.
Install 1st needle bearing and then 1st main gear.
4.
Install 1st-2nd spread springs, 1st-2nd shifting inserts, and 1st-2nd synchronizer hub onto 1st-2nd cou-
pling sleeve.
CAUTION:
MTF0041D
Tool number
: KV40101630 (J-35870)
: ST35321000 (
—
)
: ST38220000 (
—
)
PCIB0946E
SCIA0992E
Tool number
: KV38102510 (
—
)
: ST35321000 (
—
)
: ST38220000 (
—
)
SCIA1049E
Revision: 2013 October
2014 JUKE
MAINSHAFT AND GEARS
TM-125
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
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• Be careful with orientation of 1st-2nd synchronizer hub.
• Do not reuse 1st-2nd synchronizer hub and 1st-2nd cou-
pling sleeve.
• Replace 1st-2nd synchronizer hub and 1st-2nd coupling
sleeve as a set.
• Be careful with orientation of 1st-2nd coupling sleeve.
• Be sure not to hook center projection of 2 spread springs
on same 1st-2nd shifting insert.
5.
Install 1st inner baulk ring, 1st synchronizer cone, and 1st outer
baulk ring onto mainshaft and then press in 1st-2nd synchro-
nizer hub assembly onto mainshaft using Tools.
CAUTION:
• Outer baulk ring, synchronizer cone, and inner baulk ring
on 2nd gear-side must have been removed.
• Be careful with orientation of coupling sleeve.
• Replace 1st inner baulk ring, 1st synchronizer cone, and 1st outer baulk ring as a set.
SCIA0921E
PCIB0803E
SCIA1083E
Tool number
: KV40101630 (J-35870)
: ST35321000 (
—
)
: ST38220000 (
—
)
SCIA1050E
Revision: 2013 October
2014 JUKE
TM-126
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
MAINSHAFT AND GEARS
6.
Press in 2nd main gear bushing using Tools.
7.
Install 2nd outer baulk ring, 2nd synchronizer cone, and 2nd
inner baulk ring.
CAUTION:
Replace 2nd outer baulk ring, 2nd synchronizer cone, and
2nd inner baulk ring as a set.
8.
Install 2nd needle bearing and 2nd main gear.
9.
Press in 3rd main gear using Tools.
CAUTION:
• Be careful with orientation of 3rd main gear.
• Do not reuse 3rd main gear.
10. Install 3rd-4th mainshaft spacer.
11. Select 4th main gear adjusting shim so that dimension “C1” sat-
isfies the standard value below and install 4th main gear adjust-
ing shim onto mainshaft. Refer to
.
CAUTION:
Only one adjusting shim can be selected.
12. Press in 4th main gear using Tools.
CAUTION:
• Be careful with orientation of 4th main gear.
• Do not reuse 4th main gear.
Tool number
: KV40105710 (
—
)
: ST35321000 (
—
)
SCIA1051E
Tool number
: KV40105710 (
—
)
: ST35321000 (
—
)
SCIA1052E
Standard value for dimension “C1”
: Refer to
TM-141, "Available Adjusting Shims"
.
PCIB0804E
Tool number
: ST33200000 (J-26082)
: ST30901000 (J-26010-01)
PCIB0947E
Revision: 2013 October
2014 JUKE
MAINSHAFT AND GEARS
TM-127
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
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13. Press in 5th main gear using Tools.
CAUTION:
• Be careful with orientation of 5th main gear.
• Do not reuse 5th main gear.
14. Install 5th-6th mainshaft spacer.
15. Press in 6th main gear using Tools (A), (B).
CAUTION:
Do not reuse 6th main gear.
16. Select 6th main gear adjusting shim and then install it onto mainshaft.
• Calculate thickness (S) of 6th main gear adjusting shim follow-
ing the procedure below so that end play dimension between
6th main gear and mainshaft rear bearing becomes the dimen-
sion shown below. Refer to
CAUTION:
Only one adjusting shim can be selected.
a.
Measure dimension (S
1)
and (S
2
) using a height gauge (A) and
pick tester (B).
b.
Install selected 6th main gear adjusting shim to mainshaft.
17. Press in mainshaft rear bearing using Tools.
Tool number
: ST33200000 (J-26082)
: ST30901000 (J-26010-01)
PCIB0948E
Tool number
A: ST33200000 (J-26082)
B: ST30901000 (J-26010-01)
WCIA0313E
End play
:Refer to
.
Dimension S = (S
1
- S
2
) - End play
S
: Thickness of adjusting shim
S
1
: Dimension from mainshaft standard face to
mainshaft rear bearing press-fit end face
S
2
: Dimension from mainshaft standard face to
6th main gear end face
PCIB1887E
Tool number
A: ST30720000 (J-25405)
B: ST30901000 (J-26010-01)
WCIA0314E
Revision: 2013 October
2014 JUKE
TM-128
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F52H]
MAINSHAFT AND GEARS
18. Install mainshaft C-rings onto mainshaft and check that end play
of mainshaft rear bearing satisfies the standard value.
• If measurement is outside the standard range, reselect main-
shaft C-rings. Refer to
19. Install C-ring holder and then install snap ring.
CAUTION:
Do not reuse snap ring.
20. Check end play of 1st and 2nd main gears.
End play standard value
: Refer to
.
SCIA0979E
PCIB0805E
End play standard value
: Refer to
SCIA0973E
Revision: 2013 October
2014 JUKE
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