Juke F15 (2012 year). Service Repair Manual — part 108

SERVICE DATA AND SPECIFICATIONS (SDS)

DLN-117

< SERVICE DATA AND SPECIFICATIONS (SDS)

[TRANSFER: TY21B]

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SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

INFOID:0000000006360067

Preload Torque

INFOID:0000000006360068

Unit: N·m (kg-m, in-lb)

Backlash

INFOID:0000000006360069

Unit: mm (in)

Companion Flange Runout

INFOID:0000000006360070

Unit: mm (in)

Applied model

4WD

Transfer model

TY21B

Oil capacity (Approx.)

(lmp pt)

0.37 (5/8)

Gear ratio

0.404

Number of teeth

Ring gear

42

Drive pinion

17

Item

Standard

Drive pinion bearing preload (P

1

)

0.30 – 0.80 (0.03 – 0.08, 3.0 – 7.0)

Total preload

With all oil seals

P

1

+ 0.55 – 0.80 (0.06 – 0.08, 5.0 – 7.0)

Without adapter case oil seal

P

1

+ 0.35 – 0.60 (0.04 – 0.06, 3.0 – 5.0)

Item

Standard

Ring gear to drive pinion

0.16 – 0.21 (0.0063 – 0.0083)

Item

Limit

Companion flange face (inner side of the propeller shaft bolt holes)

0.15 (0.0059)

Inside of companion flange (socket diameter)

0.2 (0.008)

DLN-118

< PRECAUTION >

[REAR PROPELLER SHAFT: 3F

φ

16-ETJ75]

PRECAUTIONS

PRECAUTION

PRECAUTIONS

Service Notice or Precautions for Rear Propeller Shaft

INFOID:0000000006359815

• Replace the propeller shaft assembly if there is a breakage or deflection on tube.
• Never hit the tube or apply an impact on it during repair service. Never damage the tube as well.
• The joint cannot be disassembled. Never disassemble it.

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

DLN-119

< SYMPTOM DIAGNOSIS >

[REAR PROPELLER SHAFT: 3F

φ

16-ETJ75]

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SYMPTOM DIAGNOSIS

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

INFOID:0000000006600701

Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.

×

: Applicable

Reference

DL

N-12

0, "

In

sp

ectio

n

"

DL

N-12

3, "

In

sp

ectio

n

"

—

DL

N-12

3, "

In

sp

ectio

n

"

—

DL

N-12

3, "

In

sp

ectio

n

"

DL

N-12

0, "

In

sp

ectio

n

"

NV

H

of

R

E

A

R

FI

NA

L D

R

IV

E

in

th

is

se

ct

ion

N

V

H

in F

A

X

, RAX,

FSU and RSU section

NV

H

in

WT s

e

cti

o

n

NV

H

in

WT s

e

cti

o

n

NV

H

in

F

A

X

an

d R

A

X

se

c

tio

n

NV

H

in

B

R

s

e

c

tio

n

NV

H

in

S

T

s

e

c

ti

o

n

Possible cause and SUSPECTED PARTS

Un

ev

en

rot

a

ti

ng

to

rqu

e

Cen

ter be

ari

n

g i

m

pro

p

e

r in

st

a

lla

ti

on

Exce

ss

iv

e c

e

n

te

r be

ari

n

g

ax

ia

l e

n

d

pl

ay

Cen

ter be

ari

n

g mo

un

ti

n

g

(i

ns

ul

at

o

r)

c

rac

ks

, d

a

m

a

g

e

or d

e

te

rio

rat

io

n

Exce

ss

iv

e j

o

in

t a

n

g

le

Rot

a

ti

on

im

ba

la

n

c

e

Exce

ss

iv

e ru

no

ut

DIF

F

ERENTI

AL

AX

LE A

N

D

SUSPENSION

TI

RE

ROAD W

H

EEL

DRIV

E

SHAFT

BRA

K

E

ST

EERING

Symptom

Noise

×

×

×

×

×

×

×

×

×

×

×

×

×

×

Shake

×

×

×

×

×

×

×

×

Vibration

×

×

×

×

×

×

×

×

×

×

×

DLN-120

< PERIODIC MAINTENANCE >

[REAR PROPELLER SHAFT: 3F

φ

16-ETJ75]

REAR PROPELLER SHAFT

PERIODIC MAINTENANCE

REAR PROPELLER SHAFT

Inspection

INFOID:0000000006359818

APPEARANCE AND NOISE

• Check the propeller shaft tube surface for dents or cracks. If damaged, replace propeller shaft assembly.
• If center bearing is noisy or damaged, replace propeller shaft assembly.

VIBRATION

If vibration is present at high speed, inspect propeller shaft runout first.

1.

With a dial indicator, measure propeller shaft runout at runout
measuring points by rotating final drive companion flange with
hands.

• Propeller shaft runout measuring point (Point “ ”)

2.

If runout still exceeds specifications, separate propeller shaft at
final drive companion flange or transfer companion flange; then
change the phase between companion flange and propeller
shaft by the one bolt hole at a time and install propeller shaft.

3.

Check runout again. If runout still exceeds specifications,
replace propeller shaft assembly.

4.

Check the vibration by driving vehicle.

Propeller shaft runout

: Refer to

DLN-125, "Pro-

peller Shaft Runout"

.

JPDID0419ZZ

: Front

Dimension

A: 542 mm (21.34 in)

B: 516.5 mm (20.33 in)

JSDIA2286ZZ

REAR PROPELLER SHAFT

DLN-121

< REMOVAL AND INSTALLATION >

[REAR PROPELLER SHAFT: 3F

φ

16-ETJ75]

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REMOVAL AND INSTALLATION

REAR PROPELLER SHAFT

Exploded View

INFOID:0000000006359819

Removal and Installation

INFOID:0000000006359820

REMOVAL

1.

Shift the transaxle to the neutral position, and then release the parking brake.

2.

Put matching marks on propeller shaft flange yoke and final drive companion flanges.

CAUTION:

For matching marks, use paint. Never damage propeller shaft flange yoke and final drive compan-
ion flange.

3.

Put matching marks on propeller shaft flange yoke and transfer companion flanges.

CAUTION:

For matching marks, use paint. Never damage propeller shaft flange yoke and transfer companion
flange.

4.

Loosen mounting nuts of center bearing mounting bracket.
NOTE:
Tighten mounting nuts temporarily.

5.

Remove propeller shaft assembly fixing bolts and nuts.

6.

Remove center bearing mounting bracket fixing nuts.

7.

Remove propeller shaft assembly.

CAUTION:

• This procedure requires 2 workers. Constant velocity joint must be handled with care.

1.

Propeller shaft assembly

: Vehicle front

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

JPDID0420GB

DLN-122

< REMOVAL AND INSTALLATION >

[REAR PROPELLER SHAFT: 3F

φ

16-ETJ75]

REAR PROPELLER SHAFT

• If constant velocity joint was bent during propeller shaft

assembly removal, installation, or transportation, its boot
(1) may be damaged. Wrap boot interference area to metal
part (2) with shop cloth or rubber to protect boot from
breakage.

• Since no retaining pin is included in sliding direction, the

boot may be damaged or dropped if the constant velocity
joint is slid out 25 mm (0.98 in) or more from the original
length. Therefore, handle constant velocity joint by slid-
ing it inward.

8.

Perform inspection after removal. Refer to

DLN-123, "Inspec-

tion"

.

INSTALLATION

Note the following, and install in the reverse order of removal.
• Align matching marks to install propeller shaft assembly to final drive and transfer companion flanges.
• To install, adjust front and rear position of mount bracket to avoid deflection (front-rear direction of the vehi-

cle) to the center bearing insulator.

• Perform inspection after installation. Refer to

DLN-123, "Inspection"

.

• After tightening the bolts and nuts to the specification torque,

check that the bolts (3) on the flange side is tightened as shown in
the figure.

• If propeller shaft assembly or final drive assembly has been replaced, connect them as follows:

CAUTION:

Constant velocity joint of a new propeller shaft has a pre-
installed protector (1). Protector must be removed after
installing propeller shaft.

PDIA0982J

PDIA0983J

1.

Final drive assembly

2.

Propeller shaft assembly

JSDIA0196ZZ

JSDIA2289ZZ

REAR PROPELLER SHAFT

DLN-123

< REMOVAL AND INSTALLATION >

[REAR PROPELLER SHAFT: 3F

φ

16-ETJ75]

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1.

Install propeller shaft (1) while aligning its matching mark (A) of
propeller shaft with the matching mark (B) of final drive (2) on
the joint as close as possible.

2.

Temporary tighten bolts and nuts.

3.

Press down propeller shaft (1) with matching mark (C) of final
drive (2) facing upward. Then tighten fixing bolts and nuts to the
specified torque.

Inspection

INFOID:0000000006359821

INSPECTION AFTER REMOVAL

Appearance

Check the propeller shaft for bend and damage. If damage is detected, replace propeller shaft assembly.

Propeller Shaft Runout

Check propeller shaft runout at measuring points with a dial indica-
tor. If runout exceeds specifications, replace propeller shaft assem-
bly.

• Propeller shaft runout measuring point (Point “ ”)

Journal Axial Play

JSDIA2287ZZ

JSDIA2288ZZ

Propeller shaft runout

: Refer to

DLN-125, "Pro-

peller Shaft Runout"

.

JSDIA0193ZZ

: Front

Dimension

A: 542 mm (21.34 in)

B: 516.5 mm (20.33 in)

JSDIA2286ZZ

DLN-124

< REMOVAL AND INSTALLATION >

[REAR PROPELLER SHAFT: 3F

φ

16-ETJ75]

REAR PROPELLER SHAFT

As shown in the figure, while fixing yoke on one side, check axial
play of joint. If it is outside the standard, replace propeller shaft
assembly.

CAUTION:

Never disassemble joints.

Center Bearing

Check center bearing for noise and damage. If noise or damage is detected, replace propeller shaft assembly.

CAUTION:

Never disassemble center bearing.

INSPECTION AFTER INSTALLATION

After assembly, perform a driving test to check propeller shaft vibration. If vibration occurred, separate propel-
ler shaft from final drive or transfer. Reinstall companion flange by changing the phase between companion
flange and propeller shaft by the one bolt hole at a time. Then perform driving test and check propeller shaft
vibration again at each point.

Journal axial play

: Refer to

DLN-125, "Jour-

nal Axial Play"

.

PDA0005D

SERVICE DATA AND SPECIFICATIONS (SDS)

DLN-125

< SERVICE DATA AND SPECIFICATIONS (SDS)

[REAR PROPELLER SHAFT: 3F

φ

16-ETJ75]

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SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

INFOID:0000000006360071

Propeller Shaft Runout

INFOID:0000000006360072

Unit: mm (in)

Journal Axial Play

INFOID:0000000006360073

Unit: mm (in)

Applied model

4WD

Propeller shaft model

3F

φ

16-ETJ75

Number of joints

3

Shaft length

1st (Spider to CVJ joint center)

1051 mm (41.38 in)

2nd (CVJ joint center to spider)

1000 mm (39.37 in)

Shaft outer diameter

1st

57 mm (2.500 in)

2nd

75 mm (2.95 in)

Type of journal bearings
(Non-disassembly type)

1st joint

Sell type

2nd joint

CVJ type

3rd joint

Shell type

Coupling method

Transfer side

Flange type

Rear final drive side

Flange type

Item

Limit

Propeller shaft runout

1.0 (0.031)

Item

Standard

Journal axial play

0 (0)

DLN-126

< PRECAUTION >

[REAR FINAL DRIVE: RTVS]

PRECAUTIONS

PRECAUTION

PRECAUTIONS

Service Notice or Precautions for Rear Final Drive

INFOID:0000000006359829

• 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 when applied.

• Overhaul should be done in a clean work area, it is preferable to work in dustproof area.
• Before disassembly, using steam or white gasoline, completely remove sand and mud from the exterior of

the unit, preventing them from entering into the unit during disassembly or assembly.

• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them

with a new one if necessary.

• Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.
• In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tight-

ening sequence is specified, observe it.

• Clean and flush the parts sufficiently and blow-dry them.
• Never damage sliding surfaces and mating surfaces.
• When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,

and foreign materials from the application and mounting surfaces.

• Always use shop paper for cleaning the inside of components.
• Avoid using cotton gloves or shop rags to prevent entering of lint.
• During assembly, observe the specified tightening torque, and apply new gear oil, petroleum jelly, or multi-

purpose grease as specified for each vehicle, if necessary.

PREPARATION

DLN-127

< PREPARATION >

[REAR FINAL DRIVE: RTVS]

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PREPARATION

PREPARATION

Special Service Tools

INFOID:0000000006706411

Tool number
Tool name

Description

ST3127S000
Preload gauge

Measuring pinion bearing preload and total
preload

KV38100200
Drift
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.

Installing side oil seal (right side)

KV38100500
Drift
a: 85 mm (3.35 in) dia.
b: 60 mm (2.36 in) dia.

Installing side oil seal (left side)

KV38109700
Drift

Installing electric controlled coupling oil seal

KV38109820
Drift
a: 54.6 mm (2.150 in) dia.

• Removing and Installing rear cover
• Removing and Installing center stem as-

sembly

KV38109210
Base tube
a: 79.9 mm (3.146 in) dia.
b: 60 mm (2.36 in) dia.

• Removing and Installing rear cover
• Removing and Installing center stem as-

sembly

ZZA0806D

ZZA1143D

ZZA0811D

JSDIA2282ZZ

JPDID0368ZZ

ZZA0832D

DLN-128

< PREPARATION >

[REAR FINAL DRIVE: RTVS]

PREPARATION

ST33052000
Drift
a: 28 mm (1.10 in) dia.
b: 22 mm (0.87 in) dia.

Removing side bearing inner race

ST33220000
Drift
a: 37 mm (1.46 in) dia.
b: 22 mm (0.87 in) dia.

Removing center stem

ST33052000
Drift
a: 28 mm (1.10 in) dia.
b: 22 mm (0.87 in) dia.

Installing center stem

KV40104810
Attachment
A: 49 mm (1.93 in)
B: 42 mm (1.65 in)
C: 25 mm (0.98 in)

Installing side bearing inner race

KV381096S0
Dummy cover set
1.

KV38109610
Bearing guide 90

2.

KV38109620
Bearing guide 68

3.

KV38109630
Dammy cap spacer 90

4.

KV38109640
Dammy cap spacer 68

5.

KV38109640
Angle

• Checking backlash
• Checking drive gear runout
• Checking tooth contact

ST17130000
Drift
a: 31.8 mm (1.252 in) dia.
b: 58 mm (2.28 in) dia.

Installing pinion front bearing outer race.

Tool number
Tool name

Description

ZZA1000D

NT084

ZZA1000D

ZZA1133D

JSDIA2283ZZ

ZZA0836D

PREPARATION

DLN-129

< PREPARATION >

[REAR FINAL DRIVE: RTVS]

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Commercial Service Tools

INFOID:0000000006706412

KV38100300
Drift
a: 54 mm (2.13 in) dia.
b: 46 mm (1.81 in) dia.
c: 32 mm (1.26 in) dia.

Installing pinion rear bearing outer race.

KV37710000
Drift
a: 38 mm (1.50 in) dia.
b: 60 mm (2.36 in) dia.
c: 77 mm (3.03 in) dia.

Installing pinion rear bearing outer race.

Tool number
Tool name

Description

ZZA1046D

JSDIA2284ZZ

Tool name

Description

Flange wrench

Removing and installing drive pinion lock nut

Puller

Removing companion flange

Drift
a: 76 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.

Installing front oil seal

Replacer

Removing pinion rear bearing inner race

NT035

ZZA0119D

ZZA0811D

ZZA0700D

DLN-130

< SYSTEM DESCRIPTION >

[REAR FINAL DRIVE: RTVS]

STRUCTURE AND OPERATION

SYSTEM DESCRIPTION

STRUCTURE AND OPERATION

Sectional View

INFOID:0000000006359833

Electric controlled coupling

INFOID:0000000006603826

The electric controlled coupling operates as the 4WD system. For the operation, refer to

DLN-15, "Operation

Principle"

.

1.

4WD solenoid (RH)

2.

Pinion rear bearing

3.

Collapsible spacer

4.

Pinion front bearing

5.

Companion flange

6.

Drive pinion

7.

Gear carrier

8.

Drive gear

9.

4WD solenoid (LH)

10. Electric controlled coupling (LH)

11.

Side bearing (LH)

12. Center stem

13. Rear cover

14. Side bearing (RH)

15. Electric controlled coupling (RH)

JSDIA2112ZZ

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

DLN-131

< SYMPTOM DIAGNOSIS >

[REAR FINAL DRIVE: RTVS]

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SYMPTOM DIAGNOSIS

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

INFOID:0000000006600702

Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.

×

: Applicable

Reference

DLN

-15

7,

"

In

sp

ec

ti

o

n

"

DLN

-15

4,

"

Ad

ju

s

tm

e

n

t"

DLN

-15

7,

"

In

sp

ec

ti

o

n

"

DLN

-15

4,

"

Ad

ju

s

tm

e

n

t"

DLN

-15

4,

"

Ad

ju

s

tm

e

n

t"

DLN

-13

2,

"

In

sp

ec

ti

o

n

"

NVH of REA

R

PROPELLER SHAF

T in this section

NVH in F

AX,

RAX, FSU and

R

S

U sections

NVH in WT section

NVH in WT section

NVH i

n

F

AX and RAX

secti

o

n

NVH in B

R

section

NVH in S

T

section

Possible cause and SUSPECTED PARTS

Gea

r to

ot

h ro

ug

h

Ge

ar co

nt

a

c

t im

pro

p

e

r

T

o

o

th su

rfac

es

wo

rn

Ba

ck

la

sh

in

co

rrec

t

Com

p

ani

on

fl

an

ge

ex

ce

ss

iv

e

run

o

u

t

Ge

ar oi

l im

pro

p

e

r

PROPELLER S

H

AFT

AXLE AND S

U

S

PENSION

TI

RE

ROAD WHEE

L

DRIVE SHAFT

BRAKE

STE

E

RING

Symptom

Noise

×

×

×

×

×

×

×

×

×

×

×

×

×

DLN-132

< PERIODIC MAINTENANCE >

[REAR FINAL DRIVE: RTVS]

REAR DIFFERENTIAL GEAR OIL

PERIODIC MAINTENANCE

REAR DIFFERENTIAL GEAR OIL

Inspection

INFOID:0000000006359834

OIL LEAKAGE

Check rear final drive surrounding area (oil seal, drain plug, filler plug, and carrier case, etc.) for oil leakage.

OIL LEVEL

1.

Remove filler plug (1) and check oil level from filler plug mount-
ing hole as shown in the figure.

CAUTION:

Never start engine while checking oil level.

2.

Set a new gasket on filler plug and install it on final drive assem-
bly. Refer to

DLN-151, "Exploded View"

.

CAUTION:

Never reuse gasket.

Draining

INFOID:0000000006359835

1.

Stop engine.

2.

Remove drain plug (1) and drain gear oil.

3.

Set a new gasket on drain plug and install it to final drive assem-
bly and tighten to the specified torque. Refer to

DLN-151,

"Exploded View"

.

CAUTION:

Never reuse gasket.

Refilling

INFOID:0000000006359836

1.

Remove filler plug (1). Fill with new gear oil until oil level reaches
the specified level near filler plug mounting hole.

2.

After refilling oil, check oil level. Set a new gasket to filler plug,
then install it to final drive assembly. Refer to

DLN-151,

"Exploded View"

.

CAUTION:

Never reuse gasket.

JSDIA2113ZZ

JSDIA2114ZZ

Oil grade and viscosity

: Refer to

MA-13, "Fluids

and Lubricants"

.

Oil capacity

: Refer to

DLN-167, "Gen-

eral Specification"

.

JSDIA2113ZZ