Juke F15 (2012 year). Service Repair Manual — part 110
ELECTRIC CONTROLLED COUPLING
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6.
Apply liquid gasket (1) to mating surface of coupling cover.
CAUTION:
• Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adher-
ing to the mounting surfaces.
• Overlap both ends of the bead for at least 3 mm (0.12 in).
7.
Install electric controlled coupling (1) to spline of stem center
with grommet of harness facing upward, temporarily tighten
reamer bolts (2) to the positions shown in the figure.
8.
Tighten reamer bolts and coupling cover mounting bolts to the
specified torque.
CAUTION:
Never allow harness to get caught in the bolt.
9.
Install the new connector clip (
) to final drive assembly.
CAUTION:
Never reuse connector clip.
10. Connect electric controlled coupling connector (1) to sub-har-
ness (2).
11. When oil leaks while removing, check oil level after the installa-
.
JSDIA2241ZZ
: Vehicle front
JSDIA2242GB
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ELECTRIC CONTROLLED COUPLING
Inspection
INFOID:0000000006361904
INSPECTION AFTER DISASSEMBLY
Oil Seal
• Whenever disassembled, replace.
• If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace them.
CENTER STEM ASSEMBLY
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CENTER STEM ASSEMBLY
Exploded View
INFOID:0000000006363655
1.
Filler plug
2.
Gasket
3.
Drain plug
4.
Breather tube
5.
Clip
6.
Breather hose
7.
Breather
8.
sub-harness clip
9.
sub-harness
10. Rear cover
11.
Center stem
12. Side bearing (right)
13. Side bearing adjusting shim (right)
14. Side oil seal (right)
15. Connector clip
16. Electric controlled coupling (right)
17. Electric controlled coupling oil seal
18. Reamer bolt
19. Drive pinion
20. Drive pinion adjusting shim
21. Pinion rear bearing
22. Collapsible spacer
23. Breather
24. Gear carrier
25. Carrier bracket (right)
26. Pinion front bearing
27. Front oil seal
28. Companion flange
29. Drive pinion lock nut
30. Carrier bracket (left)
31. Drive gear
32. Side bearing (left)
33. Side bearing adjusting shim (left)
34. Electric controlled coupling (left)
35. Side oil seal (left)
A.
Oil seal lip
B.
Gear carrier mounting face
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
: Apply gear oil.
: Apply anti-corrosive oil.
: Apply multi purpose grease
JSDIA2246GB
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CENTER STEM ASSEMBLY
Disassembly
INFOID:0000000006363656
1.
Remove carrier bracket.
2.
Remove electric controlled coupling. Refer to
.
3.
Remove side oil seal. Refer to
.
4.
Remove rear cover mounting bolts.
5.
Set drifts (A and B) to the right and left side bearing adjusting
shims individually. Press center stem assembly with side bear-
ing to remove gear carrier assembly and rear cover assembly.
CAUTION:
The pressure shall be as low as possible to remove gear
carrier assembly and rear cover assembly. The maximum
pressure shall be 10 kN (1 ton, 1.0 Imp ton).
NOTE:
Center stem assembly, side bearings, and adjusting shims are
compressed and integrated in gear carrier and rear cover.
6.
Remove drain plug and filler plug.
7.
Remove side bearing adjusting shims and side bearing outer races.
CAUTION:
Mark the side bearing adjusting shims so that the original mounting positions (right/left) can be
identified later.
8.
Remove side bearing inner race, using a puller (A) and drift (B).
9.
Remove drive gear from center stem, using a drift (A)
(SST:ST33220000).
10. Perform inspection after diassembly. Refer to
: Apply Genuine Liquid Gasket 1217 or equivalent.
: Select with proper thickness.
A
: Drift (SST: KV38109820)
B
: Drift (SST: KV38109810)
A
: Puller (commercial service tool)
B
: Drift (SST: ST33052000)
JSDIA2247ZZ
JSDIA2248ZZ
JSDIA2249ZZ
CENTER STEM ASSEMBLY
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Assembly
INFOID:0000000006363657
1.
Press drive gear to center stem, using a drift (A)
(SST:ST33052000).
2.
Press side bearing inner race to center stem assembly, using a
drift (A) (SST: KV40104840).
3.
Install new side bearing adjusting shims (2 pieces for one side)
with the same thickness as the ones installed prior to disassem-
bly or re-install the old ones, with side bearing outer race to cen-
ter stem assembly.
If side bearing adjusting shims have been already selected, use
them.
CAUTION:
• Never reuse side bearing outer race.
• Apply gear oil to side bearings.
4.
Set drifts (A and B) to the right and left side bearing adjusting
shims individually. Press center stem assembly with side bear-
ing to install gear carrier to center stem assembly.
CAUTION:
• The drift shall be placed on the center of the adjusting
shims.
• The pressure shall be as low as possible to install differ-
ential assembly into gear carrier assembly. The maximum
pressure shall be 10 kN (1 ton, 1.0 Imp ton).
• If the adjusting shims are installed by tapping, the gear carrier may be damaged. Avoid tapping.
5.
Install dummy cover set, check and adjust drive gear runout, tooth contact, backlash, and total preload
torque. Refer to
6.
Remove dummy cover set.
7.
Apply liquid gasket (1) to mating surface of rear cover. Overlap
both ends of the bead for at least 3 mm (0.12 in).
CAUTION:
Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering
to the mounting surfaces.
JSDIA2250ZZ
JSDIA2251ZZ
A
: Drift (SST: KV38109820)
B
: Drift (SST: KV38109810)
JSDIA2247ZZ
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CENTER STEM ASSEMBLY
8.
Set the drifts (A and B) to the right and left side bearing adjusting
shims individually. Compress center stem assembly and side
bearing to install rear cover.
CAUTION:
• The drift shall be placed on the center of the adjusting
shims.
• The pressure shall be as low as possible to install the rear
cover. The maximum pressure shall be 10 kN (1 ton, 1.0
Imp ton).
• If rear cover is forced in by tapping, rear cover may be damaged by adjusting shims. Avoid tap-
ping.
9.
Tighten rear cover mounting bolts to the specified torque.
10. Install side oil seal. Refer to
11. Check total preload torque. Refer to
.
Adjustment
INFOID:0000000006698787
TOTAL PRELOAD TORQUE
1.
Remove electric controlled coupling assembly. Refer to
2.
Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
3.
Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
4.
Measure the total preload, using the preload gauge (A) (SST:
3127S000).
NOTE:
Total preload torque = Pinion bearing torque + Side bearing
torque
• If measured value is out of the specification, disassemble it to
check and adjust each part. Adjust the pinion bearing preload and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bearing preload.
DRIVE GEAR RUNOUT
1.
Remove rear cover. Refer to
.
2.
Following the procedure below, install a dummy cover set (SST: KV381096S0) to gear carrier.
a.
Temporarily tighten bearing guides (SST: KV38109610, KV38109620) to gear carrier.
b.
Position dummy cap spacers (SST: KV38109630, KV38109640) and angle (SST:KV38109650) to bearing
guide.
c.
Tighten rear cover mounting bolts to the specified torque. Refer to
.
d.
Tighten dummy cap spacer mounting bolts evenly to the specified torque.
A
: Drift (SST: KV38109820)
B
: Drift (SST: KV38109810)
JSDIA2247ZZ
Total preload torque
: Refer to
When the preload torque is large
On pinion bearings:
Replace the collapsible spacer.
On side bearings:
Use thinner side bearing adjusting shims.
When the preload is small
On pinion bearings:
Tighten the drive pinion nut.
On side bearings:
Use thicker side bearing adjusting shims.
JSDIA2253ZZ
CENTER STEM ASSEMBLY
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3.
Fit a dial indicator to the drive gear back face.
4.
Rotate the drive gear to measure runout.
• If the runout is outside of the repair limit, check drive gear
assembly condition; foreign material may be caught between
drive gear and differential case, or differential case or drive
gear may be deformed, etc.
CAUTION:
Replace drive gear and drive pinion as a set.
TOOTH CONTACT
1.
Remove rear cover. Refer to
.
2.
Following the procedure below, install a dummy cover set (SST: KV381096S0) to gear carrier.
a.
Temporarily tighten bearing guides (SST: KV38109610, KV38109620) to gear carrier.
b.
Position dummy cap spacers (SST: KV38109630, KV38109640) and angle (SST:KV38109650) to bearing
guide.
c.
Tighten rear cover mounting bolts to the specified torque. Refer to
.
d.
Tighten dummy cap spacer mounting bolts evenly to the specified torque.
3.
Apply red lead to drive gear.
CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on drive gear.
4.
Rotate drive gear back and forth several times, check drive pin-
ion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side and reverse side.
Tightening torque
: 5.9 N·m (0.6 kg-m, 52 in-lb)
Drive gear back face
runout
: Refer to
JSDIA2254ZZ
Tightening torque
: 5.9 N·m (0.6 kg-m, 52 in-lb)
JSDIA2255ZZ
SDIA0570E
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CENTER STEM ASSEMBLY
Tooth Contact Judgment Guide
5.
If tooth contact is improperly adjusted, follow the procedure
below to adjust the pinion height (dimension X).
• If the tooth contact is near the face (face contact), or near the
heel (heel contact), thicken drive pinion gear adjusting shim to
move drive pinion closer to drive gear.
SDIA2549E
SDIA0517E
PDIA0440E
CENTER STEM ASSEMBLY
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• If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thin drive pinion gear adjusting shim to move
drive pinion farther from drive gear.
BACKLASH
1.
Remove rear cover. Refer to
.
2.
Following the procedure below, install a dummy cover set (SST: KV381096S0) to gear carrier.
a.
Temporarily tighten bearing guides (SST: KV38109610, KV38109620) to gear carrier.
b.
Position dummy cap spacers (SST: KV38109630, KV38109640) and angle (SST:KV38109650) to bearing
guide.
c.
Tighten rear cover mounting bolts to the specified torque. Refer to
.
d.
Tighten dummy cap spacer mounting bolts evenly to the specified torque.
3.
Fit a dial indicator to the drive gear face to measure the back-
lash.
• If the backlash is outside of the specified value, change the
thickness of side bearing adjusting shims.
Inspection
INFOID:0000000006363658
INSPECTION AFTER DISASSEMBLY
Drive Gear and Drive Pinion
• Clean up the disassembled parts.
• If the gear teeth never mesh or line-up correctly, determine the cause and adjust or replace as necessary.
• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new drive
gear and drive pinion as a set.
Bearing
• Clean up the disassembled parts.
• If any chipped (by friction), pitted, worn, rusted or scratched marks, or unusual noise from the bearing is
observed, replace as a bearing assembly (as a new set).
Oil Seal
• Whenever disassembled, replace.
• If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace them.
Companion Flange
• Clean up the disassembled parts.
PDIA0441E
Tightening torque
: 5.9 N·m (0.6 kg-m, 52 in-lb)
Backlash
: Refer to
.
When the backlash is large:
Make drive gear back adjusting shims thicker, and drive
gear front adjusting shims thinner.
When the backlash is small:
Make drive gear back adjusting shims thinner, and
drive gear front adjusting shims thicker.
JSDIA2256ZZ
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CENTER STEM ASSEMBLY
• If any chipped mark [about 0.1 mm, (0.004 in)] or other damage on the contact sides of the lips of the com-
panion flange is found, replace.
DRIVE PINION
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DRIVE PINION
Exploded View
INFOID:0000000006363822
1.
Filler plug
2.
Gasket
3.
Drain plug
4.
Breather tube
5.
Clip
6.
Breather hose
7.
Breather
8.
sub-harness clip
9.
sub-harness
10. Rear cover
11.
Center stem
12. Side bearing (right)
13. Side bearing adjusting shim (right)
14. Side oil seal (right)
15. Connector clip
16. Electric controlled coupling (right)
17. Electric controlled coupling oil seal
18. Reamer bolt
19. Drive pinion
20. Drive pinion adjusting shim
21. Pinion rear bearing
22. Collapsible spacer
23. Breather
24. Gear carrier
25. Carrier bracket (right)
26. Pinion front bearing
27. Front oil seal
28. Companion flange
29. Drive pinion lock nut
30. Carrier bracket (left)
31. Drive gear
32. Side bearing (left)
33. Side bearing adjusting shim (left)
34. Electric controlled coupling (left)
35. Side oil seal (left)
A.
Oil seal lip
B.
Gear carrier mounting face
: Always replace after every disassembly.
: Select with proper thickness.
: N·m (kg-m, ft-lb)
: Apply gear oil.
: Apply anti-corrosive oil.
JSDIA2246GB
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DRIVE PINION
Disassembly
INFOID:0000000006363823
1.
Remove electric controlled coupling. Refer to
.
2.
Remove center stem assembly. Refer to
3.
Remove drive pinion lock nut with the flange wrench (A) (com-
mercial service tool).
4.
Put matching mark (B) on the end of drive pinion. The matching
mark should be in line with the matching mark (A) on companion
flange (1).
CAUTION:
For matching mark, use paint. Never damage companion
flange and drive pinion.
NOTE:
The matching mark on the final drive companion flange indicates
the maximum vertical runout position.
When replacing companion flange, matching mark is not neces-
sary.
5.
Remove companion flange using the pullers (A) (commercial
service tool).
6.
Press drive pinion assembly out of gear carrier.
CAUTION:
Never drop drive pinion assembly.
7.
Remove front oil seal.
8.
Remove pinion front bearing inner race.
9.
Remove collapsible spacer.
: Apply multi purpose grease
: Apply Genuine Liquid Gasket 1217 or equivalent.
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DRIVE PINION
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10. Remove pinion rear bearing inner race and pinion height adjust-
ing washer with the replacer (A) (commercial service tool).
11. Remove pinion height adjusting washer.
12. Tap pinion front/rear bearing outer races uniformly using a brass
rod or equivalent to remove them.
CAUTION:
Never damage gear carrier.
13. Perform inspection after disassembly. Refer to
Assembly
INFOID:0000000006363824
1.
Install pinion front bearing outer race to the gear carrier with drift
(A) (SST: ST17130000).
CAUTION:
• At first, using a hammer, tap bearing outer race until it
becomes flat to gear carrier.
• Never reuse pinion front and rear bearing outer race.
2.
Install pinion rear bearing outer race to the gear carrier with drift
(A) (SST: KV38100300).
CAUTION:
• At first, using a hammer, tap bearing outer race until it
becomes flat to gear carrier.
• Never reuse pinion front and rear bearing outer race.
PDIA0801J
JSDIA2269ZZ
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JSDIA2296ZZ
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DRIVE PINION
3.
Temporarily install pinion height adjusting washer (1).
When hypoid gear set has been replaced
• Select pinion height adjusting washer. Refer to
.
When hypoid gear set has been reused
• Temporarily install the removed pinion height adjusting washer
or same thickness washer to drive pinion.
CAUTION:
Pay attention to the direction of pinion height adjusting
washer. (Assemble as shown in the figure.)
4.
Install pinion rear bearing inner race (1) to drive pinion with the
drift (A) (SST: ST30032000).
CAUTION:
Never reuse pinion rear bearing inner race.
5.
Check and adjust the tooth contact and back lash of drive gear
and drive pinion following the procedure below.
a.
Assemble drive pinion into gear carrier.
CAUTION:
• Never assemble a collapsible spacer.
• Apply gear oil to pinion rear bearing.
b.
Assemble pinion front bearing inner race to drive pinion assem-
bly.
CAUTION:
• Never reuse pinion front bearing inner race.
• Apply gear oil to pinion front bearing.
c.
Using drift (A) (SST: ST37710000), press the pinion front bear-
ing inner race to drive pinion as far as drive pinion nut can be
tightened.
d.
Install companion flange (1).
CAUTION:
Never assemble front oil seal.
NOTE:
When reusing drive pinion, align the matching mark (B) of drive
pinion with the matching mark (A) of companion flange, and then
install companion flange.
JSDIA0760ZZ
JSDIA0761ZZ
JSDIA2271ZZ
JSDIA2118ZZ
DRIVE PINION
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e.
Temporarily tighten removed drive pinion nut to drive pinion
using flange wrench (commercial service tool).
NOTE:
Use removed drive pinion nut only for the preload measurement.
f.
Rotate drive pinion more than 20 times to adjust bearing.
g.
Tighten to drive pinion lock nut using flange wrench (commercial
service tool), while adjusting pinion bearing preload torque using
preload gauge (A) (SST: ST3127S000).
CAUTION:
Drive pinion lock nut is tightened with no collapsible
spacer. Be careful not to overtighten it. While measuring the
preload, tighten it by 5
°
to 10
°
.
h.
Assemble removed drive side bearing adjusting washer or same
thickness of it and install center stem assembly. Refer to
.
CAUTION:
Apply differential gear oil to the side bearings.
i.
Check and adjust tooth contact, drive gear to drive pinion back-
lash. Refer to
j.
Remove center stem assembly.
k.
Remove companion flange.
l.
Remove drive pinion assembly from gear carrier.
m. Remove pinion front bearing inner race.
6.
Assemble collapsible spacer.
CAUTION:
Never reuse collapsible spacer.
7.
Assemble drive pinion into gear carrier.
CAUTION:
Apply gear oil to pinion rear bearing.
8.
Assemble pinion front bearing inner race to drive pinion assembly.
CAUTION:
• Never reuse pinion front bearing inner race.
• Apply gear oil to pinion front bearing.
9.
Using drift (A) (SST: ST37710000), press the pinion front bear-
ing inner race to drive pinion as far as drive pinion nut can be
tightened.
Pinion bearing preload
(without oil seal)
: 1.0 - 1.3 N·m (0.11 – 0.13
kg-m, 9 – 11 in-lb)
JSDIA2273ZZ
JSDIA2271ZZ
DLN-164
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[REAR FINAL DRIVE: RTVS]
DRIVE PINION
10. Install front oil seal as shown in figure with the drift (A) (commer-
cial service tool).
CAUTION:
• Never reuse oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal.
11. Install companion flange (1).
NOTE:
When reusing drive pinion, align the matching mark (B) of drive
pinion with the matching mark (A) of companion flange, and then
install companion flange.
12. Apply anti-corrosion oil to the thread and seat of drive pinion
lock nut, and temporarily tighten drive pinion lock nut to drive
pinion, using flange wrench (commercial service tool).
CAUTION:
Never reuse drive pinion lock nut.
13. Adjust to the drive pinion lock nut tightening torque and pinion
bearing preload torque, using preload gauge (A) (SST:
ST3127S000).
CAUTION:
• Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
• If the preload torque exceeds the specified value, replace
collapsible spacer and tighten it again to adjust. Never
loosen drive pinion lock nut to adjust the preload torque.
• After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
14. Install center stem assembly. Refer to
.
CAUTION:
Never install rear cover at this timing.
15. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion
flange runout. Refer to
16. Check total preload torque. Refer to
.
17. Install rear cover. Refer to
Adjustment
INFOID:0000000006363825
PINION GEAR HEIGHT
If the hypoid gear set has been replaced, select the pinion height adjusting washer.
JSDIA2272ZZ
JSDIA2118ZZ
Pinion bearing preload
: Refer to
.
JSDIA2273ZZ
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