Juke F15 (2012 year). Service Repair Manual — part 106
HEAVY TIGHT-CORNER BRAKING SYMPTOM OCCURS
DLN-85
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HEAVY TIGHT-CORNER BRAKING SYMPTOM OCCURS
Description
INFOID:0000000006359938
Heavy tight-corner braking symptom occurs when the vehicle is driven and the steering wheel is turned fully to
either side after the engine is started.
NOTE:
Light tight-corner braking symptom may occur depending on driving conditions. This is not malfunction.
Diagnosis Procedure
INFOID:0000000006359939
1.
PERFORM ECM SELF-DIAGNOSIS
With CONSULT-III
Perform self-diagnosis for “ENGINE”.
Is any DTC detected?
YES
>> Check the DTC. Refer to
.
NO
>> GO TO 2.
2.
PERFORM SELF-DIAGNOSIS
With CONSULT-III
Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is any DTC detected?
YES
>> Check the DTC. Refer to
NO
>> GO TO 3.
3.
CHECK 4WD SOLENOID
Perform the trouble diagnosis of the 4WD solenoid. Refer to
(right).
Is the inspection result normal?
YES
>> GO TO 4.
NO
>> Repair or replace the error-detected parts.
4.
CHECK ELECTRIC CONTROLLED COUPLING
1.
Turn the ignition switch OFF.
2.
Set the transmission to neutral. Release the parking brake.
3.
Lift up the vehicle.
4.
Rotate the rear propeller shaft.
5.
Hold the front propeller shaft lightly.
Does the front propeller shaft rotate?
YES
>> Replace electric controlled coupling for mechanical malfunction (clutch sticking etc.). Refer to
DLN-139, "Removal and Installation"
NO
>> Check each harness connector pin terminal for disconnection.
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VEHICLE DOES NOT ENTER 4WD MODE
VEHICLE DOES NOT ENTER 4WD MODE
Description
INFOID:0000000006359940
Vehicle does not enter 4-wheel drive mode even though 4WD warning lamp turned to OFF.
Diagnosis Procedure
INFOID:0000000006359941
1.
CHECK 4WD WARNING LAMP
Turn the ignition switch ON.
Does 4WD warning lamp turn ON?
YES
>> GO TO 2.
NO
>> Proceed to diagnosis procedure. Refer to
2.
CHECK PARKING BRAKE SWITCH SIGNAL
With CONSULT-III
Check “PKB SW” of CONSULT-III “DATA MONITOR” for “ALL MODE AWD/4WD”.
Is the inspection result normal?
YES
>> GO TO 3.
NO
>> Proceed to diagnosis procedure. Refer to
BRC-208, "Diagnosis Procedure"
.
3.
CRUISE TEST
Drive the vehicle for a period of time.
Does any symptom occur?
YES
>> Replace electric controlled coupling for mechanical malfunction (mechanical engagement of
clutch is not possible). Refer to
DLN-139, "Removal and Installation"
NO
>> Check each harness connector pin terminal for disconnection.
Monitor Item
Condition
Status
PKB SW
When the parking brake switch is operation.
On
When the parking brake switch is not operation.
Off
4WD WARNING LAMP BLINKS QUICKLY
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4WD WARNING LAMP BLINKS QUICKLY
Description
INFOID:0000000006359942
While driving, 4WD warning lamp blinks 2 times in 1 second and it turns OFF after 1 minute.
NOTE:
• This symptom protects drivetrain parts when a heavy load is applied to the electric controlled coupling and
multiple disc clutch temperature increases. Also, optional distribution of torque sometimes becomes rigid
before lamp blinks quickly. Both cases are not malfunction. Refer to
• When this symptom occurs, stop vehicle and allow it to idle for some times. Blinking will stop and system will
be restored.
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4WD WARNING LAMP BLINKS SLOWLY
4WD WARNING LAMP BLINKS SLOWLY
Description
INFOID:0000000006359943
4WD warning lamp blinks at approximately 2 seconds intervals while driving.
Diagnosis Procedure
INFOID:0000000006359944
1.
CHECK TIRE
Check the following.
• Tire pressure
• Wear condition
• Front and rear tire size (There is no difference between front and rear tires.)
Is the inspection result normal?
YES
>> GO TO 2.
NO
>> Repair or replace error-detected parts. And then, drive the vehicle at speed of 20 km/h (12 MPH)
or more for 5 seconds or more. Improper size information is initialized accordingly.
2.
TERMINAL INSPECTION
Check 4WD control unit harness connector for disconnection.
Is the inspection result normal?
YES
>> Replace 4WD control unit. Refer to
DLN-91, "Removal and Installation"
NO
>> Repair or replace the error-detected parts.
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
DLN-89
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
INFOID:0000000006359951
Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these
parts.
Reference
SUSPECTED PARTS
(Possible cause)
T
R
ANSFER OIL (Level
low
)
T
R
ANSFER OIL (W
rong)
T
R
ANSFER OIL (Level
too high)
LI
QUI
D
GASKET
(Dam
ag
ed
)
OIL
SEAL
(W
orn
or da
ma
ge
d
)
GEAR
(W
orn
o
r
da
ma
ge
d)
B
EARING (W
orn
or
da
ma
ge
d)
Symptom
Noise
1
2
3
3
3
Transfer oil leakage
3
1
2
2
DLN-90
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TRANSFER OIL
PERIODIC MAINTENANCE
TRANSFER OIL
Inspection
INFOID:0000000006359775
OIL LEAKAGE
Check transfer surrounding area (oil seal, drain plug, filler plug, and transfer case etc.) for oil leakage.
OIL LEVEL
1.
Remove filler plug (1) and gasket. Then check that oil is filled up
from mounting hole for the filler plug.
CAUTION:
Never start engine while checking oil level.
2.
Before installing filler plug, set a new gasket. Install filler plug on
transfer and tighten to the specified torque. Refer to
CAUTION:
Never reuse gasket.
Draining
INFOID:0000000006359776
1.
Run the vehicle to warm up the transfer unit sufficiently.
2.
Stop the engine and remove the drain plug (1) and gascket to
drain the transfer oil.
3.
Before installing drain plug, set a new gasket. Install drain plug
on the transfer and tighten to the specified torque. Refer to
CAUTION:
Never reuse gasket.
Refilling
INFOID:0000000006359777
1.
Remove filler plug (1) and gasket. Then fill oil up to mounting
hole for the filler plug.
CAUTION:
Carefully fill the oil. (Fill up for approximately 3 minutes.)
2.
Leave the vehicle for 3 minutes, and check the oil level again.
3.
Before installing filler plug, set a new gasket. Install filler plug on transfer and tighten to the specified
torque. Refer to
CAUTION:
Never reuse gasket.
: Vehicle front
JSDIA2080ZZ
: Vehicle front
JSDIA2081ZZ
: Vehicle front
Oil and viscosity
: Refer to
.
Oil capacity
: Refer to
JSDIA2080ZZ
4WD CONTROL MODULE
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REMOVAL AND INSTALLATION
4WD CONTROL MODULE
Removal and Installation
INFOID:0000000006598861
REMOVAL
1.
Turn the ignition switch OFF.
2.
Remove front (left side) seat. Refer to
SE-27, "Removal and Installation"
.
3.
Remove floor carpet. Refer to
INT-23, "Removal and Installation"
4.
Remove G sensor. Refer to
TM-282, "Removal and Installation"
.
5.
Disconnect 4WD control module harness connector.
6.
Remove 4WD control module mounting nuts.
7.
Remove 4WD control module.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Perform “G SENSOR CALIBRATION”. Refer to
• When installing 4WD control module, install it following procedure.
1.
Align the securing holes (A) of bracket as shown in the figure
and temporarily tighten mounting bolts.
2.
When replace 4WD control module, hold 4WD control module
and remove protector paper on the adhesion area of bracket to
bond to the front floor (LH).
3.
Tighten mounting bolts to the specified torque.
• When replacing 4WD control module, perform writing unit parame-
ter. Refer to
.
: Vehicle front
Tightening torque
: 8.0 N·m (0.82 kg-m, 71in-lb)
JSDIA2082GB
DLN-92
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4WD MODE SWITCH
4WD MODE SWITCH
Removal and Installation
INFOID:0000000006607877
REMOVAL
1.
Remove instrument lower panel. Refer to
.
2.
Remove 4WD mode switch.
INSTALLATION
Install in the reverse order of removal.
TRANSFER ASSEMBLY
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UNIT REMOVAL AND INSTALLATION
TRANSFER ASSEMBLY
Exploded View
INFOID:0000000006359778
Removal and Installation
INFOID:0000000006359779
REMOVAL
1.
Separate the rear propeller shaft. Refer to
DLN-121, "Removal and Installation"
2.
Remove right side drive shaft. Refer to
FAX-24, "RIGHT SIDE : Removal and Installation"
3.
Remove catalyst convertor support bracket (RH).
EM-35, "4WD : Removal and Installation"
.
4.
Remove heat insulator (1).
1.
Transfer gusset
2.
Transfer assembly
3.
Heat insulator
: Vehicle front
: N·m (kg-m, ft-lb)
JSDIA2083GB
JSDIA2311ZZ
DLN-94
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TRANSFER ASSEMBLY
5.
Remove transfer gusset (1).
6.
Remove catalyst convertor upport bracket rear.
.
7.
Remove rear torque rod and rear torque rod bracket. Refer to
EM-59, "4WD : Removal and Installation"
8.
Remove the mounting bolts of transaxle assembly and transfer
assembly.
9.
Remove transfer assembly from the vehicle.
CAUTION:
Never damage ring gear shaft.
INSTALLATION
Note the following, and install in the reverse order of removal.
• When installing the transfer to the transaxle, install the mounting
bolts following the standard below.
CAUTION:
• When installing transfer assembly to transaxle assembly,
replace the side oil seal (transfer joint). Refer to
.
• Never damage side oil seal (the joint part of transfer).
• When installing heat insulator (1), install the mounting bolts and
nut following procedure.
• Check oil level and check for oil leakage after installation. Refer to
JSDIA2084ZZ
: Vehicle front
JSDIA2085ZZ
Bolt symbol
A
B
Installation direction
Transfer
⇒
Transaxle
Transaxle
⇒
Transfer
JSDIA2086ZZ
Tightening order
1
2
3
4
5
6
Bolt symbol
A
B
C
A
B
C
Tightening torque
Temporary tightening
Specified torque
JSDIA2312ZZ
RING GEAR SHAFT
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UNIT DISASSEMBLY AND ASSEMBLY
RING GEAR SHAFT
Exploded View
INFOID:0000000006359785
1.
Pinion lock nut
2.
Companion flange
3.
Drive pion oil seal
4.
Pinon rear bearing
5.
Transfer case
6.
Gasket
7.
Filler plug
8.
Collapsible spacer
9.
Drive pinion adjust shim
10. Drive pinion
11.
Pinion front bearing
12. Ring gear
13. Ring gear shaft
14. Ring gear bearing (right)
15. Ring gear bearing adjust shim (right)
16. Spacer (right)
17. Transfer case oil seal (right)
18. Drive shaft oil seal
19. Transfer cover
20. Oil defense
21. Ring gear bearing (left)
22. Ring gear bearing adjust shim (left)
23. Spacer (left)
24. Transfer case oil seal (left)
25. Drain plug
26. Dowel pin
A.
Oil seal lip
B.
Transfer case mounting face
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
: Apply gear oil.
: Apply anti-corrosive oil.
: Apply multi purpose grease
: Apply Genuine Liquid Gasket 1215 or equivalent.
: Select with proper thickness.
JSDIA2087GB
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RING GEAR SHAFT
Disassembly
INFOID:0000000006359786
1.
Remove transfer cover. Refer to
.
2.
Remove transfer case oil seal (right and left side).
3.
Remove ring gear shaft assembly from transfer case.
4.
Remove ring gear bearing outer race (right and left side) from ring gear shaft assembly.
5.
Remove ring gear bearing adjust shim (right and left side) from ring gear shaft assembly.
6.
Remove spacer (right and left side) from ring gear shaft assembly.
7.
Remove gear ring bearing inner race (left side) from ring gear
shaft with the drift (A) and a replacer (B).
8.
Remove gear ring bearing inner race (right side) from ring gear
shaft with a replacer (A) (commercial service tool).
9.
Remove the ring gear mounting bolts.
10. Lightly tap adapter case with a plastic hammer to remove drive
gear from ring gear shaft.
11. Remove drive shaft oil seal from the gear ring with a puller (A)
(SST: KV381054S0).
12. Perform inspection after disassembly. Refer to
A
: Drift (SST:ST33200000)
B
: Replacer (commercial service tool)
JSDIA2165ZZ
JSDIA2166ZZ
SDIA1807J
JPDIE0032ZZ
RING GEAR SHAFT
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Assembly
INFOID:0000000006359787
1.
Select ring gear bearing adjust shim (right and left side). Refer to
.
2.
Install drive shaft oil seal until it becomes flush with ring gear
shaft end, using the drift (A) (SST: ST33230000).
CAUTION:
• Never reuse the oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease to oil seal lip.
3.
Install the gear ring bearing inner race (right side) to gear ring
with the drift (A) (commercial service tool).
CAUTION:
• Never reuse the ring gear bearing.
• Apply gear oil to gear ring bearing inner race.
4.
Install the gear ring bearing inner race (left side) to gear ring with
the drift (A) (commercial service tool).
CAUTION:
• Never reuse the ring gear bearing.
• Apply gear oil to gear ring bearing inner race.
5.
Install spacer (right and left side) to ring gear shaft assembly.
6.
Install selected ring gear bearing adjust shim (right and left side)
to ring gear shaft assembly.
7.
Install ring gear bearing outer race (right and left side) to ring
gear shaft assembly.
CAUTION:
• Never reuse the ring gear bearing.
• Apply gear oil to gear ring bearing outer race.
8.
Set the drifts (A and B) to right and left side spacers individually.
Compress ring gear shaft assembly and ring gear bearing to
install ring gear shaft assembly to transfer case.
CAUTION:
• The drift shall be placed on the center of the spacers.
• The pressure shall be as low as to install ring gear shaft
assembly into transfer case. The maximum pressure shall
be 10 kN (1 ton, 1.0 Imp ton).
• If the adjusting shims and spacers are installed by tap-
ping, the transfer case may be damaged. Avoid tapping.
9.
Install transfer cover.Refer to
.
10. Check backlash, tooth contact, total preload and companion flange runout. Refer to
.
CAUTION:
Measure the total preload without the adapter case oil seal.
JPDIE0037ZZ
JSDIA1055ZZ
A
: Drift (commercial service tool)
B
: Drift (commercial service tool)
JSDIA1056ZZ
JSDIA1106ZZ
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RING GEAR SHAFT
11. Install the transfer case oil seal (left and right side). Refer to
Adjustment
INFOID:0000000006359788
Adjusting shim selection
Measurement point
Ring gear bearing adjusting shim (right side)
1.
Measure the dimensions of each measuring point with the following procedure:
Dimension “A” measurement
JSDIA2169ZZ
1.
Transfer assembly
RING GEAR SHAFT
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• Measure dimension (A) of transfer case with a pair of vernier
calipers. Refer to “Measuring point”.
Dimension “X” measurement
• Measure the diameter (X) of transfer case with a pair of vernier
calipers. Refer to “Measuring point”.
Dimension “Y” measurement
• Measure dimension (Y) of transfer case with a pair of vernier
calipers. Refer to “Measuring point”.
Dimension “Z” measurement
• Measure dimension (Z) of transfer case with a pair of vernier
calipers and straightedge. Refer to “Measuring point”.
Dimension “V” measurement
JSDIA2170ZZ
JSDIA2171ZZ
JSDIA2173ZZ
JSDIA2174ZZ
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RING GEAR SHAFT
• Measure dimension (V) of ring gear shaft with a pair of vernier
calipers. Refer to “Measuring point”.
Dimension “W” measurement
• Measure dimension (W) of ring gear shaft with a pair of vernier
calipers. Refer to “Measuring point”.
Dimension “E” measurement
• Measure dimension (E) of ring gear shaft with a pair of vernier
calipers. Refer to “Measuring point”.
Dimension “F” measurement
• Measure dimension (F) from outer race edge surface of ring
gear shaft bearing (right side) to inner race edge surface with
a pair of vernier calipers and straightedge. Refer to “Measur-
ing point”.
Dimension “G” measurement
JSDIA2175ZZ
JSDIA2176ZZ
JSDIA2177ZZ
JSDIA2178ZZ
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