Juke F15 (2012 year). Service Repair Manual — part 353
TM-80
< REMOVAL AND INSTALLATION >
[6MT: RS6F94R]
CONTROL LINKAGE
19. Disengage the pawls (A) of the grommet (1), and pull down-
wards to remove.
20. Remove the shifter cable and selector cable from the vehicle.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Install each cable without causing interference with other parts, a 120 mm (4.72 in)-or-less bend, and
a 180-degrees-or-more twist.
• Install boot of each cable without causing interference with other parts and a 90-degrees-or-more
twist.
• Fit boot of to center console assembly the groove on shifter lever knob.
• To install the shifter lever knob, press it into the shifter lever.
CAUTION:
• Never reuse shifter lever knob.
• Be careful with orientation of shifter lever knob.
• Tapping work for tapping bolts is not applied to new transaxle case. Do not perform tapping by other than
screwing tapping bolts because tapping is formed by screwing tapping bolts into transaxle case.
CAUTION:
Never reuse tapping bolt.
• Insert the each cable until it reaches the cable mounting bracket and M/T shift selector assembly.
• Insert the each cable until it reaches the shifter lever A and the selector lever.
• Shift the shifter lever to the neutral position.
• Install the shifter cable (1) and the selector cable (2) to the bracket
(3) as shown in the figure.
Install the selector cable (the M/T shift selector assembly side), as per the following procedure.
When M/T shift selector assembly is replaced:
1.
Install the selector cable to the M/T shift selector assembly.
2.
Shift the shifter lever to the neutral position.
3.
Install the lever stopper (A) to the M/T shift selector assembly as
shown in the figure.
CAUTION:
Selector cable cannot be adjusted accurately without using
the lever stopper.
4.
Check that the shifter lever does not move in the direction of the
select. If it moves, repeat step 3.
JPDIC0844ZZ
JPDIC0836ZZ
JPDIC0831ZZ
CONTROL LINKAGE
TM-81
< REMOVAL AND INSTALLATION >
[6MT: RS6F94R]
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5.
Insert the stopper (A) until it reaches the selector cable.
6.
Remove the lever stopper from the M/T shift selector assembly.
7.
Shift the shifter lever to each gear position to check that there
are no bindings. If any, repeat step 3.
When M/T shift selector assembly is not replaced:
1.
Install the selector cable to the M/T shift selector assembly.
2.
Shift the shifter lever to the 4th gear position.
3.
Adjust the length “L” between the stopper (A) and the lever to
the standard value.
4.
Insert the stopper (A) until it reaches the selector cable.
5.
Shift the shifter lever to each gear position to check that there
are no bindings. If any, repeat step 3.
Inspection
INFOID:0000000006417075
INSPECTION AFTER INSTALLATION
Shifter Lever Knob
Check that the shifter lever knob is installed in the right position.
Shifter Cable and Selector Cable
• Pull each cable in the removal direction to check that it dose not disconnect from the cable mounting
bracket.
• Pull each cable in the removal direction to check that it dose not disconnect from the M/T shift selector
assembly.
• Pull grommet in the removal direction to check that it dose not disconnect from the vehicle.
M/T Shift Selector Assembly and Shifter Lever
• Check that there is no tangle, hook, abnormal sound, looseness, and interference when the shifter lever is
moved to each position. If there is a malfunction, then repair or replace the malfunctioning part.
• Check that the shifter lever smoothly returns to the neutral position after moving the lever from 1st to 2nd
gear and moving hands off the lever. If there is a malfunction, then repair or replace the malfunctioning part.
• Check that the shifter lever smoothly returns to the neutral position after moving the lever from 5th to 6th
gear and moving hands off the lever. If there is a malfunction, then repair or replace the malfunctioning part.
JPDIC0832ZZ
Length “L”
: 3.51 – 4.11 mm (0.1382 – 0.1618 in)
JPDIC0834ZZ
JPDIC0832ZZ
TM-82
< REMOVAL AND INSTALLATION >
[6MT: RS6F94R]
AIR BREATHER HOSE
AIR BREATHER HOSE
MR16DDT
MR16DDT : Exploded View
INFOID:0000000006417190
MR16DDT : Removal and Installation
INFOID:0000000006417191
REMOVAL
1.
Remove air cleaner case. Refer to
EM-26, "Removal and Installation"
.
2.
Remove clips (1).
3.
Remove air breather hose from the 2 way connector.
CAUTION:
When removing air breather hose, be sure to hold 2 way
connector securely.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Install air breather hose, preventing crush and clogging caused by bending.
• Insert the allowance of air breather hose to the spool of the 2 way connector.
• Install air breather hose to the 2 way connector with the paint mark faced forward of the vehicle.
• Securely engage the clips in the mounting hole.
K9K
1.
Clip
2.
Air breather hose
3.
2 way connector
JPDIC0827ZZ
: Vehicle front
JPDIC0839ZZ
AIR BREATHER HOSE
TM-83
< REMOVAL AND INSTALLATION >
[6MT: RS6F94R]
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K9K : Exploded View
INFOID:0000000006417192
K9K : Removal and Installation
INFOID:0000000006417193
REMOVAL
1.
Remove clips (1).
2.
Remove air breather hose from the 2 way connector.
CAUTION:
When removing air breather hose, be sure to hold 2 way
connector securely.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Install air breather hose, preventing crush and clogging caused by bending.
• Insert the allowance of air breather hose to the spool of the 2 way connector.
• Install air breather hose to the 2 way connector with the paint mark faced forward of the vehicle.
• Securely engage the clips in the mounting hole.
1.
Clip
2.
Air breather hose
3.
2 way connector
JPDIC0828ZZ
: Vehicle front
JPDIC0839ZZ
TM-84
< UNIT REMOVAL AND INSTALLATION >
[6MT: RS6F94R]
TRANSAXLE ASSEMBLY
UNIT REMOVAL AND INSTALLATION
TRANSAXLE ASSEMBLY
MR16DDT
MR16DDT : Exploded View
INFOID:0000000006415751
MR16DDT : Removal and Installation
INFOID:0000000006415752
CAUTION:
Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position every
time when removing transaxle assembly. At this timing, dust on the sliding parts may damage a seal of
CSC and may cause clutch fluid leakage. Refer to
CL-27, "Removal and Installation"
REMOVAL
1.
Disconnect battery cable from negative terminal. Refer to
PG-124, "Removal and Installation"
.
2.
Shift the shifter lever to the neutral position.
3.
Remove battery. Refer to
PG-124, "Removal and Installation"
.
4.
Remove air cleaner case. Refer to
EM-26, "Removal and Installation"
.
5.
Remove air breather hose. Refer to
TM-82, "MR16DDT : Removal and Installation"
6.
Disconnect position switch connector. Refer to
TM-77, "Removal and Installation"
.
7.
Remove harness clip from transaxle assembly.
8.
Disconnect selector cable and shifter cable from transaxle assembly. Refer to
.
9.
Remove starter motor. Refer to
STR-29, "MR16DDT : Removal and Installation"
10. Remove clutch tube from CSC (Concentric Slave Cylinder). Refer to
CL-25, "Removal and Installation"
CAUTION:
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immedi-
ately and wash the affected area with water.
• Never depress clutch pedal during removal procedure.
11. Remove engine under cover.
12. Remove fender protector LH. Refer to
EXT-22, "Removal and Installation"
13. Disconnect ground cable.
14. Remove front suspension member. Refer to
FSU-18, "Removal and Installation"
1.
Transaxle assembly
: Refer to "INSTALLATION" in
TM-84, "MR16DDT : Removal and Installation"
for the locations and tightening torque.
JPDIC0632ZZ
TRANSAXLE ASSEMBLY
TM-85
< UNIT REMOVAL AND INSTALLATION >
[6MT: RS6F94R]
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15. Remove front drive shafts. Refer to
FAX-22, "LEFT SIDE : Removal and Installation"
(LEFT SIDE) and
FAX-24, "RIGHT SIDE : Removal and Installation"
(RIGHT SIDE).
NOTE:
Insert a suitable plug into differential side oil seal after removing front drive shaft.
16. Set a suitable jack to transaxle assembly and then set a suitable jack to engine assembly.
CAUTION:
When setting a suitable jack, be careful so that it does not contact with the switch.
17. Remove engine mounting insulator (LH) mounting bolts from transaxle assembly. Refer to
.
18. Remove rear engine mounting bracket and rear torque rod. Refer to
EM-55, "2WD : Removal and Installa-
19. Remove transaxle assembly mounting bolts.
20. Remove transaxle assembly from the engine.
CAUTION:
• Fix transaxle assembly to a suitable jack.
• The transaxle assembly must not interfere with the wire harnesses and clutch tube.
21. Remove CSC. Refer to
CL-27, "Removal and Installation"
.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Fix transaxle assembly to a suitable jack.
• The transaxle assembly must not interfere with the wire harnesses and clutch tube.
• When installing transaxle assembly, never bring input shaft into contact with clutch cover.
• Tapping work for tapping bolts is not applied to new transaxle case. Do not perform tapping by other
than screwing tapping bolts because tapping is formed by screwing tapping bolts into transaxle
case.
• Tighten transaxle assembly mounting bolts to the specified torque.
The figure is the view from the engine.
MR16DDT : Inspection
INFOID:0000000006415753
INSPECTION AFTER INSTALLATION
• Check the operation of the control linkage. Refer to
.
• Check the oil leakage and the oil level. Refer to
.
K9K
: Vehicle front
Bolt symbol
A
B
Insertion direction
Transaxle to engine
Engine to transaxle
Quantity
3
6
Bolt length
“
” mm (in)
60 (2.36)
50 (1.97)
Tightening torque
N·m (kg-m, ft-lb)
62.0 (6.3, 46)
JPDIC0837ZZ
TM-86
< UNIT REMOVAL AND INSTALLATION >
[6MT: RS6F94R]
TRANSAXLE ASSEMBLY
K9K : Exploded View
INFOID:0000000006417155
K9K : Removal and Installation
INFOID:0000000006417156
CAUTION:
Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position every
time when removing transaxle assembly. At this timing, dust on the sliding parts may damage a seal of
CSC and may cause clutch fluid leakage. Refer to
CL-27, "Removal and Installation"
REMOVAL
1.
Disconnect battery cable from negative terminal. Refer to
PG-124, "Removal and Installation"
.
2.
Shift the shifter lever to the neutral position.
3.
Remove battery. Refer to
PG-124, "Removal and Installation"
.
4.
Remove air cleaner case. Refer to
EM-280, "Removal and Installation"
.
5.
Remove air breather hose. Refer to
TM-83, "K9K : Removal and Installation"
.
6.
Disconnect position switch connector. Refer to
TM-77, "Removal and Installation"
.
7.
Remove harness clip from transaxle assembly.
8.
Remove crankshaft position sensor. Refer to
EM-288, "Removal and Installation"
9.
Disconnect selector cable and shifter cable from transaxle assembly. Refer to
.
10. Remove starter motor. Refer to EM.
11. Remove clutch tube from CSC (Concentric Slave Cylinder). Refer to
CL-25, "Removal and Installation"
CAUTION:
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immedi-
ately and wash the affected area with water.
• Never depress clutch pedal during removal procedure.
12. Remove engine under cover.
13. Remove fender protector LH. Refer to
EXT-22, "Removal and Installation"
14. Disconnect ground cable.
15. Remove front drive shafts. Refer to
FAX-78, "LEFT SIDE : Removal and Installation"
FAX-79, "RIGHT SIDE : Removal and Installation"
(RIGHT SIDE).
NOTE:
Insert a suitable plug into differential side oil seal after removing front drive shaft.
16. Remove bracket from clutch housing.
1.
Transaxle assembly
: Refer to "INSTALLATION" in
TM-86, "K9K : Removal and Installation"
for the locations and tightening torque.
JPDIC0632ZZ
TRANSAXLE ASSEMBLY
TM-87
< UNIT REMOVAL AND INSTALLATION >
[6MT: RS6F94R]
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17. Set a suitable jack to transaxle assembly and then set a suitable jack to engine assembly.
CAUTION:
When setting a suitable jack, be careful so that it does not contact with the switch.
18. Remove engine mounting bracket (LH) (TBD) mounting bolts from transaxle assembly. Refer to
19. Remove bracket stay mounting bolts and move thermo plunger unit aside not to interfere with work. Refer
CO-72, "Removal and Installation"
.
20. Remove transaxle assembly mounting bolts.
21. Remove transaxle assembly from the engine.
CAUTION:
• Fix transaxle assembly to a suitable jack.
• The transaxle assembly must not interfere with the wire harnesses and clutch tube.
22. Remove CSC. Refer to
CL-27, "Removal and Installation"
.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Fix transaxle assembly to a suitable jack.
• The transaxle assembly must not interfere with the wire harnesses and clutch tube.
• When installing transaxle assembly, never bring input shaft into contact with clutch cover.
• Tapping work for tapping bolts is not applied to new transaxle case. Do not perform tapping by other
than screwing tapping bolts because tapping is formed by screwing tapping bolts into transaxle
case.
• Tighten transaxle assembly mounting bolts to the specified torque.
The figure is the view from the engine.
K9K : Inspection
INFOID:0000000006417157
INSPECTION AFTER INSTALLATION
• Check the operation of the control linkage. Refer to
.
• Check the oil leakage and the oil level. Refer to
.
: Vehicle front
Bolt symbol
A
B
C
D
Insertion direction
Transaxle to engine
Engine to transaxle
Quantity
2
1
4
1
Bolt length
“
” mm (in)
50 (1.97)
80 (3.15)
65 (2.56)
80 (3.15)
Tightening torque
N·m (kg-m, ft-lb)
48 (4.9, 35)
JPDIC0838ZZ
TM-88
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F94R]
TRANSAXLE ASSEMBLY
UNIT DISASSEMBLY AND ASSEMBLY
TRANSAXLE ASSEMBLY
Exploded View
INFOID:0000000006415754
CASE AND HOUSING
1.
Filler plug
2.
Gasket
3.
Transaxle case
4.
Bushing
5.
Snap ring
6.
Oil channel
7.
Oil gutter
8.
Position switch
9.
Bracket
10. Differential side oil seal
11. Magnet
12. Drain plug
13. Input shaft oil seal
14. Clutch housing
15. 2 way connector
16. Plug
17. Pinion shaft
18. Pinion gear
: Apply Genuine Liquid Gasket, Three Bond 1215 or an equivalent.
: Always replace after every disassembly.
JPDIC0437GB
TRANSAXLE ASSEMBLY
TM-89
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F94R]
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SHAFT AND GEAR
: Select with proper thickness.
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
1.
Input shaft front bearing
2.
Input shaft
3.
3rd input gear
4.
Spacer
5.
Snap ring
6.
3rd baulk ring
7.
3rd-4th coupling sleeve
8.
3rd-4th synchronizer hub
9.
Insert key
10. 4th baulk ring
11. 4th input gear
12. 5th input gear
13. 5th baulk ring
14. 5th-6th coupling sleeve
15. 5th-6th synchronizer hub
16. 6th baulk ring
17. Needle bearing
18. 6th input gear
19. Input shaft rear bearing
A.
First step
B.
Final step
: Apply gear oil.
: Replace the parts as a set.
: Always replace after every disassembly.
: N·m (kg-m, ft-lb)
JPDIC0407GB
TM-90
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F94R]
TRANSAXLE ASSEMBLY
1.
Mainshaft front bearing outer
race
2.
Mainshaft front bearing inner race
3.
Mainshaft
4.
1st main gear
5.
1st inner baulk ring
6.
1st synchronizer cone
7.
1st outer baulk ring
8.
1st-2nd coupling sleeve
9.
Insert key
10.
1st-2nd synchronizer hub
11. 2nd outer baulk ring
12. 2nd synchronizer cone
13.
2nd inner baulk ring
14. 2nd main gear
15. Bushing
16.
3rd main gear
17. Mainshaft adjusting shim
18. 4th main gear
19.
5th main gear
20. 6th main gear
21. Mainshaft rear bearing inner race
22.
Mainshaft rear bearing outer race 23. Snap ring
24. Mainshaft rear bearing adjusting
shim
: Apply gear oil.
: Replace the parts as a set.
: Select with proper thickness.
: Always replace after every disassembly.
SFIA3293E
TRANSAXLE ASSEMBLY
TM-91
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F94R]
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SHIFT FORK AND FORK ROD
1.
Reverse output gear
2.
Snap ring
3.
Reverse baulk ring
4.
Return spring
5.
Needle bearing
6.
Seal washer
7.
Reverse idler shaft
8.
Spacer
9.
Reverse input gear
10.
Lock washer
11. Spring washer
: Replace the parts as a set.
: Always replace after every disassembly.
: N·m (kg-m, ft-lb)
JPDIC0425GB
TM-92
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F94R]
TRANSAXLE ASSEMBLY
FINAL DRIVE
1.
Shifter lever A
2.
Shifter lever B
3.
Retaining pin
4.
Selector
5.
Selector lever
6.
Reverse fork rod
7.
1st-2nd fork rod
8.
Fork rod
: Replace the parts as a set.
: Always replace after every disassembly.
JPDIC0603ZZ
TRANSAXLE ASSEMBLY
TM-93
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F94R]
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Disassembly
INFOID:0000000006415755
1.
Remove drain plug and gasket from clutch housing, using a socket [Commercial service tool] and then
drain gear oil.
2.
Remove filler plug and gasket from transaxle case.
3.
Remove selector lever (1) retaining pin with a pin punch to
remove selector lever.
4.
Remove bracket (2) and position switch (3) from transaxle case.
1.
Shim
2.
Differential side bearing outer race
(transaxle case side)
3.
Differential side bearing inner race
(transaxle case side)
4.
Final gear
5.
Differential case
6.
Differential side bearing inner race
(clutch housing side)
7.
Differential side bearing outer race
(clutch housing side)
: Replace the parts as a set.
: N·m (kg-m, ft-lb)
JPDIC0424GB
PCIB1693E
TM-94
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F94R]
TRANSAXLE ASSEMBLY
5.
Remove transaxle case mounting bolts (
).
6.
Remove reverse idler shaft mounting bolt (
) and seal washer.
7.
Remove transaxle case (2) while rotating shifter lever A (1) in
the direction as shown in the figure.
8.
Remove selector spring (1) from return bushing (A).
9.
Shift 1st-2nd fork rod (1), fork rod (2), and reverse fork rod (3) to
the neutral position.
10. Remove selector (4) from clutch housing.
PCIB1694E
PCIB1695E
JPDIC0444ZZ
JPDIC0445ZZ
PCIB1698E
TRANSAXLE ASSEMBLY
TM-95
< UNIT DISASSEMBLY AND ASSEMBLY >
[6MT: RS6F94R]
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11. Remove reverse idler shaft assembly (1), as per the following
procedure.
a.
Pull up input shaft assembly (2), mainshaft assembly (3), fork
rod (4), and 1st-2nd fork rod (5).
NOTE:
It is easier to pull up when shifting each fork rod to each shaft
side.
b.
Remove reverse idler shaft assembly and reverse fork rod (6)
from clutch housing.
12. Remove spring washer from clutch housing.
13. Pull up and remove input shaft assembly (1), mainshaft assem-
bly (2), fork rod (3), and 1st-2nd fork rod (4) from clutch housing.
NOTE:
It is easier to pull up when shifting each fork rod to each shaft
side.
14. Remove final drive assembly (1) from clutch housing.
15. Remove magnet from clutch housing.
16. Remove differential side oil seals (1) from clutch housing and
transaxle case.
CAUTION:
Never damage clutch housing and transaxle case.
17. Remove differential side bearing outer race (1) from clutch hous-
ing, using a brass rod.
CAUTION:
Never damage clutch housing.
JPDIC0606ZZ
JPDIC0607ZZ
PCIB1703E
PCIB1704E
PCIB1716E
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