Juke F15 (2012 year). Service Repair Manual — part 350

TM-32

< UNIT REMOVAL AND INSTALLATION >

[5MT: RS5F92R]

TRANSAXLE ASSEMBLY

• Tapping work for tapping bolts is not applied to new clutch housing. Do not perform tapping by other

than screwing tapping bolts because tapping is formed by screwing tapping bolts into clutch hous-
ing.

• Tighten transaxle assembly mounting bolts to the specified torque.

The figure is the view from the engine.

Inspection

INFOID:0000000006415696

INSPECTION AFTER INSTALLATION

• Check the operation of the control linkage. Refer to

TM-27, "Inspection"

.

• Check the oil leakage and the oil level. Refer to

TM-22, "Inspection"

.

Bolt symbol

A

B

C

D

Insertion direction

Transaxle to

engine

Engine to transaxle

Quantity

2

3

2

1

Bolt length

“

” mm (in)

55 (2.17)

49 (1.93)

69 (2.72)

Tightening torque
N·m (kg-m, ft-lb)

48.0 (4.9, 35)

JPDIC0813ZZ

TRANSAXLE ASSEMBLY

TM-33

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

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UNIT DISASSEMBLY AND ASSEMBLY

TRANSAXLE ASSEMBLY

Exploded View

INFOID:0000000006415700

CASE AND HOUSING

1.

Differential side oil seal

2.

Clutch housing

3.

2 way connector

4.

Oil gutter

5.

Air breather inner tube

6.

Filler plug

7.

Gasket

8.

Transaxle case

9.

O-ring

10. Rear housing

11. Position switch

12. Dowel pin

13. Magnet

14. Drain plug

15. Oil channel

: Apply Genuine Liquid Gasket, Three Bond 1215 or an equivalent.

: Always replace after every disassembly.

JPDIC0680GB

TM-34

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

TRANSAXLE ASSEMBLY

SHAFT AND GEAR

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

1.

Input shaft front bearing

2.

Input shaft

3.

Snap ring

4.

Input shaft rear bearing

5.

Adapter plate

6.

Bushing

7.

5th input gear

8.

5th-reverse baulk ring

9.

Synchronizer lever

10. 5th-reverse synchronizer hub

11. 5th-reverse coupling sleeve

12. Retaining pin

13. Reverse gear

: Apply gear oil.

: Replace the parts as a set.

: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

JPDIC0731GB

TRANSAXLE ASSEMBLY

TM-35

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

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SHIFT FORK AND FORK ROD

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.

Spread spring

9.

1st-2nd synchronizer hub

10.

1st-2nd coupling sleeve

11. 2nd outer baulk ring

12. 2nd synchronizer cone

13.

2nd inner baulk ring

14. Mainshaft bushing

15. 2nd main gear

16.

Thrust washer

17. 3rd main gear

18. 3rd baulk ring

19.

3rd-4th synchronizer hub

20. 3rd-4th coupling sleeve

21. Spring

22.

Insert key

23. 4th baulk ring

24. 4th main gear

25.

Adjusting shim

26. Mainshaft rear bearing inner race

27. Mainshaft rear bearing outer race

28.

5th main gear

: Apply gear oil.

: Apply Thread Locking Sealant, Loctite Frenbloc or an equivalent.

: Replace the parts as a set.

: Always replace after every disassembly.

: Select with proper thickness.

: N·m (kg-m, ft-lb)

JPDIC0681GB

TM-36

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

TRANSAXLE ASSEMBLY

FINAL DRIVE

1.

Retaining pin

2.

1st-2nd shift fork

3.

Bushing

4.

1st-2nd fork rod

5.

Lock pin

6.

5th-reverse fork rod

7.

5th-reverse shift fork

8.

Check ball

9.

3rd-4th shift fork

10. 3rd-4th fork rod

11. Control shaft

12. O-ring

13. Selector

14. Check ball plug

15. Bushing

16. Spring

17. Gear catch

: Apply gear oil.

: Apply Genuine Liquid Gasket, Three Bond 1215 or an equivalent.

: Replace the parts as a set.

: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

JPDIC0682GB

TRANSAXLE ASSEMBLY

TM-37

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

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Disassembly

INFOID:0000000006415701

1.

Remove drain plug and gasket from clutch housing, using a socket [Commercial service tool] and drain
gear oil.

2.

Remove filler plug and gasket from transaxle case.

3.

Remove rear housing and O-ring.

CAUTION:

Remove to axial direction of input shaft (

) because rear

housing oil channel is inserted to input shaft center hole.

4.

Shift the shifter lever A (1) to the 3rd gear position (A).

NOTE:
• If it is not shifted to the 3rd gear position, transaxle case can-

not be removed from clutch housing.

• Shifter lever A is set in the 3rd gear position by turning in the

direction indicated by arrow.

1.

Differential side bearing outer race

2.

Differential side bearing

3.

Final drive

: Replace the parts as a set.

JPDIC0481ZZ

SCIA1709J

B

: Neutral position

C

: Approx. 15 degrees

JPDIC0841ZZ

TM-38

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

TRANSAXLE ASSEMBLY

5.

Remove 5th-reverse shift fork (1) and 5th-reverse coupling
sleeve, as per the following procedure.

a.

Remove retaining pin from 5th-reverse shift fork, using a pin
punch (A).

b.

Press 5th-reverse shift fork, shift to 5th, and then engage it with
3rd gear.

c.

Remove mounting bolt (B).

d.

Remove mounting nut (C) and washer.

CAUTION:

Never use an impact wrench for removal, or otherwise each
gear may be damaged.

e.

Remove 5th-reverse shift fork and 5th-reverse coupling sleeve from 5th-reverse synchronizer hub.

6.

Remove 5th-reverse synchronizer hub from input shaft, using a
puller [Commercial service tool].

CAUTION:

Set claw of the puller to the wider side of the hub when set-
ting the puller in 5th-reverse synchronizer hub.

7.

Remove synchronizer levers, 5th-reverse baulk ring, 5th input
gear, bushing, and adapter plate from input shaft.

8.

Remove 5th main gear from mainshaft, using the pullers.

9.

Remove position switch from transaxle case.

JPDIC0532ZZ

PCIB1526E

A

: Puller [SST: KV32300QAC]

B

: Puller [SST: KV32300QAD]

PCIB1527E

PCIB1627E

TRANSAXLE ASSEMBLY

TM-39

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

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10. Remove transaxle case mounting bolts (

).

11. Remove transaxle case from clutch housing.

12. Remove mainshaft rear bearing inner race (1), adjusting shim,

and 4th main gear (2) from mainshaft.

13. Remove 5th-reverse fork rod (1), as per the following procedure.

a.

Pull 5th-reverse fork rod up until it contacts claw (A) of reverse
gear.

b.

Press gear portion (B) of reverse gear down, and then remove
5th-reverse fork rod from clutch housing.

14. Remove 3rd-4th fork rod assembly (1), 3rd-4th coupling sleeve,

and input shaft (2), as per the following procedure.

a.

Remove 4th baulk ring, insert keys, and springs from mainshaft.

b.

Pull gear of reverse gear (3) up.

c.

Pull 1st-2nd fork rod (4) up, and then maintain the neutral posi-
tion.

d.

Remove 3rd-4th fork rod assembly, 3rd-4th coupling sleeve, and
input shaft from clutch housing at the same time.

15. Remove retaining pin from 3rd-4th shift fork, using a pin punch.

16. Remove 3rd-4th shift fork from 3rd-4th shift fork rod.

17. Remove lock pins (

) from clutch housing.

JPDIC0610ZZ

JPDIC0666ZZ

JPDIC0710ZZ

JPDIC0711ZZ

JPDIC0534ZZ

TM-40

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

TRANSAXLE ASSEMBLY

18. Remove 1st-2nd fork rod assembly (1) and mainshaft assembly

(2) from clutch housing at the same time.

19. Remove retaining pin from 1st-2nd shift fork, using a pin punch.

20. Remove 1st-2nd shift fork from 1st-2nd shift fork rod.

21. Remove retaining pin from reverse gear, using a pin punch.
22. Remove reverse gear from clutch housing.

23. Remove final drive (1) from clutch housing.

24. Remove magnet and dowel pins (2) from clutch housing.

25. Remove input shaft front bearing from clutch housing, using a

drift (A) [Commercial service tool].

26. Cut oil channel tube at the root.

27. Remove mainshaft front bearing outer race from clutch housing,

using a remover [Commercial service tool].

28. Remove oil channel from clutch housing.

PCIB1532E

MCIB0033E

PCIB1533E

JPDIC0713ZZ

MCIB0079E

TRANSAXLE ASSEMBLY

TM-41

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

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29. Remove bushings (1) from clutch housing, using a remover

[Commercial service tool].

30. Remove differential side oil seals (1) from clutch housing and

transaxle case, using an oil seal remover.

CAUTION:

Never damage transaxle case and clutch housing.

31. Remove differential side bearing outer races (1) from clutch

housing and transaxle case, using a brass rod.

CAUTION:

Never damage transaxle case and clutch housing.

32. Pull 2 way connector (1) straight to remove it from air breather

inner tube (2).

33. Remove air breather inner tube from transaxle case.

34. Remove oil gutter from transaxle case.

35. Remove retaining pin (1) from selector, using a pin punch.

PCIB1537E

PCIB1534E

JPDIC0484ZZ

PCIB1541E

JPDIC0096ZZ

TM-42

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

TRANSAXLE ASSEMBLY

36. Remove mounting bolt (

), and then remove bushing, spring,

and gear catch from transaxle case.

37. Remove check ball plug from transaxle case.

38. Remove mounting bolts (

), and then remove control shaft (1)

and selector from transaxle case.

39. Remove O-ring from control shaft.

40. Remove check balls (1) from transaxle case.

41. Remove bushings (2) from transaxle case, using a remover (A)

[Commercial service tool].

42. Expand snap ring (1) and remove input shaft rear bearing from

transaxle case, using a drift (A) [Commercial service tool].

43. Remove snap ring from transaxle case.

44. Remove mainshaft rear bearing outer race from transaxle case,

using a drift (A) [Commercial service tool].

JPDIC0533ZZ

PCIB1540E

JPDIC0667ZZ

JPDIC0668ZZ

JPDIC0669ZZ

TRANSAXLE ASSEMBLY

TM-43

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

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Assembly

INFOID:0000000006415702

1.

Install mainshaft rear bearing outer race to transaxle case, using
a drift [Commercial service tool].

CAUTION:

Replace mainshaft rear bearing outer race and mainshaft
rear bearing inner race as a set.

2.

Install snap ring (1) along transaxle case groove so that notch
mates with housing as shown in the figure.

CAUTION:

Check snap ring installing direction. Never misassemble.

3.

Expand snap ring (1) and install input shaft rear bearing to tran-
saxle case, using a drift (A) [Commercial service tool].

CAUTION:

Check that snap ring is correctly installed within bearing
groove.

4.

Install bushings (1) until they reach transaxle case, using a drift
(A) [Commercial service tool].

5.

Install check balls to transaxle case.

6.

Apply gear oil to O-ring, and then install it to control shaft.

CAUTION:

Never reuse O-ring.

MCIB0078E

JPDIC0670ZZ

JPDIC0668ZZ

JPDIC0636ZZ

TM-44

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

TRANSAXLE ASSEMBLY

7.

Install control shaft (1) and selector to transaxle case, and
tighten mounting bolts (

) to the specified torque.

CAUTION:

• Replace control shaft and selector as a set.
• Be careful with the orientation of selector.

8.

Install retaining pin (1) to selector, using a pin punch.

CAUTION:

Never reuse retaining pin.

9.

Install gear catch, spring, and bushing to transaxle case, and
then tighten mounting bolt (

) to the specified torque.

CAUTION:

Replace gear catch, spring, and bushing as a set.

10. Install oil gutter to transaxle case.

11. Install air breather inner tube (2) to transaxle case.

CAUTION:

Never damage air breather inner tube.
NOTE:
It is easier to install when air breather inner tube end is wrapped
and narrowed by tape. Remove tape after installation.

12. Insert 2 way connector (1) straight, and then install it to air

breather inner tube.

CAUTION:

Check air breather inner tube for twists after installing.

13. Install differential side bearing outer races until they reach clutch

housing and transaxle case, using a drift (A) [Commercial ser-
vice tool].

CAUTION:

Replace differential side bearing outer race and differential
side bearing as a set.

PCIB1540E

JPDIC0096ZZ

JPDIC0533ZZ

PCIB1541E

JPDIC0714ZZ

TRANSAXLE ASSEMBLY

TM-45

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

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14. Install differential side oil seals (1) to clutch housing and tran-

saxle case, using the drift [Stamping number: B.vi 1666-B] of the
drift set [SST: KV32500QAA].

CAUTION:

• Never incline differential side oil seal.
• Never damage clutch housing and transaxle case.

15. Install bushings (1) until they reach clutch housing, using a drift

(A) [Commercial service tool].

16. Install oil channel to clutch housing.

CAUTION:

Never reuse oil channel.

17. Install mainshaft front bearing outer race until they reach clutch

housing, using a drift [Commercial service tool].

CAUTION:

• Never reuse mainshaft front bearing outer race.
• Replace mainshaft front bearing outer race and mainshaft

front bearing inner race as a set.

18. Install input shaft front bearing so that it becomes even to clutch

housing surface, using a drift (A) [Commercial service tool].

CAUTION:

Never reuse input shaft front bearing.

B

: Transaxle case side

C

: Clutch housing side

Dimension “L

1

”

: 5.7 – 6.3 mm (0.224 – 0.248 in)

Dimension “L

2

”

: 2.4 – 3.0 mm (0.094 – 0.118 in)

JPDIC0401ZZ

JPDIC0637ZZ

MCIB0080E

JPDIC0713ZZ

TM-46

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

TRANSAXLE ASSEMBLY

19. Install final drive (1) to clutch housing.

20. Install dowel pins (2) and magnet to clutch housing.

21. Install reverse gear to clutch housing, and then install retaining

pin to clutch housing, using a pin punch.

CAUTION:

Never reuse retaining pin.

22. Install 1st-2nd shift fork to 1st-2nd fork rod, and then install

retaining pin to 1st-2nd shift fork.

CAUTION:

• Never reuse retaining pin.
• Replace 1st-2nd fork rod and 1st-2nd shift fork as a set.

23. Set 1st-2nd fork rod assembly (1) onto mainshaft assembly (2),

and then install them to clutch housing.

24. Install lock pins (

) to clutch housing.

25. Install 3rd-4th shift fork to 3rd-4th fork rod, and then install

retaining pin to 3rd-4th shift fork.

CAUTION:

• Never reuse retaining pin.
• Replace 3rd-4th fork rod and 3rd-4th shift fork as a set.

26. Install 3rd-4th fork rod assembly (1), 3rd-4th coupling sleeve,

and input shaft (2) to clutch housing, as per the following proce-
dure.

a.

Pull 1st-2nd fork rod (3) up, and then maintain the neutral posi-
tion.

b.

Set 3rd-4th fork rod assembly onto 3rd-4th coupling sleeve, and
then install them together with input shaft to clutch housing.

CAUTION:

• Set lock pin (3rd-4th fork rod side) onto 1st-2nd fork rod

groove and then install 3rd-4th fork rod assembly.

PCIB1533E

MCIB0033E

PCIB1532E

JPDIC0534ZZ

JPDIC0715ZZ

TRANSAXLE ASSEMBLY

TM-47

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

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• Be careful with the orientation of 3rd-4th coupling sleeve.

• Install 3rd input gear of input shaft so that it is set under

reverse main gear of 3rd-4th coupling sleeve.

• Replace 3rd-4th coupling sleeve and 3rd-4th synchronizer

hub as a set.

c.

Install springs and insert keys to 3rd-4th synchronizer hub.

d.

Apply gear oil to 4th baulk ring.

e.

Install 4th baulk ring.

27. Install 5th-reverse fork rod (1) to clutch housing, as per the fol-

lowing procedure.

CAUTION:

Replace 5th-reverse fork rod and 5th-reverse shift fork as a
set.

a.

Pull gear (A) of reverse gear up.

b.

Temporarily install 5th-reverse fork rod to clutch housing.

c.

Press gear (A) of reverse gear down and then install 5th-reverse
fork rod (1) to clutch housing.

CAUTION:

Set levers of 5th-reverse fork rod so as to align with reverse
gear groove (B).

28. Install 4th main gear to mainshaft.

29. Install adjusting shim to mainshaft.

CAUTION:

After replacing the following parts, adjust mainshaft rear bearing preload to install a selected
adjusting shim to the mainshaft.
• Mainshaft
• Mainshaft front bearing inner race
• Mainshaft front bearing outer race
• Mainshaft rear bearing inner race
• Mainshaft rear bearing outer race
• Clutch housing
• Transaxle case

A

: 4th main gear side

B

: 3rd main gear side

PCIB1551E

MCIB0061E

JPDIC0716ZZ

JPDIC0717ZZ