Juke F15 (2012 year). Service Repair Manual — part 349
TM-16
< PREPARATION >
[5MT: RS5F92R]
PREPARATION
Drift
a: 62 mm (2.44 in) dia.
• Installing mainshaft rear bearing outer race
• Installing differential side bearing outer race
Drift
a: 58 mm (2.28 in) dia.
• Removing mainshaft rear bearing outer
race
• Removing and installing input shaft rear
bearing
• Installing mainshaft front bearing outer race
Drift
a: 30 mm (1.18 in) dia.
Installing mainshaft front bearing inner race
Drift
a: 33 mm (1.30 in) dia.
Installing mainshaft bushing
Puller
• Removing 5th-reverse synchronizer hub
• Removing differential side bearing
• Removing mainshaft front bearing inner
race
Remover
• Removing mainshaft front bearing outer
race
• Removing bushing
Tool name
Description
S-NT063
S-NT063
S-NT063
JPDIC0679ZZ
NT077
S-NT134
COMPONENT PARTS
TM-17
< SYSTEM DESCRIPTION >
[5MT: RS5F92R]
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SYSTEM DESCRIPTION
COMPONENT PARTS
Component Parts Location
INFOID:0000000006415672
POSITION SWITCH
1
: Position switch
JPDIC0072ZZ
TM-18
< SYSTEM DESCRIPTION >
[5MT: RS5F92R]
STRUCTURE AND OPERATION
STRUCTURE AND OPERATION
Sectional View
INFOID:0000000006415673
System Description
INFOID:0000000006415674
DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizers are adopted for 1st and 2nd gears to
reduce operating force of the shifter lever.
1.
5th input gear
2.
5th-reverse synchronizer hub as-
sembly
3.
Input shaft
4.
Mainshaft
5.
5th main gear
6.
Mainshaft rear bearing
7.
4th main gear
8.
3rd-4th synchronizer hub assembly
9.
3rd main gear
10. 2nd main gear
11.
1st-2nd synchronizer hub assembly
12. Differential side bearing
13. Final gear
14. Differential
15. 1st main gear
16. Mainshaft front bearing
17. Input shaft front bearing
18. Clutch housing
19. 1st double-cone synchronizer
20. 2nd double-cone synchronizer
21. Input shaft rear bearing
JPDIC0404ZZ
1
: Outer baulk ring
2
: 2nd main gear
3
: Synchronizer cone
4
: Inner baulk ring
5
: 1st main gear
6
: 1st-2nd coupling sleeve
SCIA7117E
STRUCTURE AND OPERATION
TM-19
< SYSTEM DESCRIPTION >
[5MT: RS5F92R]
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REVERSE GEAR NOISE PREVENTION FUNCTION (REVERSE BRAKE)
Description
Soon after the clutch is disengaged, the input shaft is still rotating due to inertia. This may cause a gear noise
when the gear is shifted to reverse position. The reverse gear noise prevention function stops the rotation of
the input shaft and enables smooth gear shifting when the reverse gear is selected.
Operation Principle
1.
When the gear is shifted to reverse position, 5th-reverse cou-
pling sleeve (1) slides in the reverse direction. (
)
2.
Synchronizer levers (2) with support point (A) at 5th-reverse
synchronizer hub (3) presses 5th-reverse baulk ring (4). (
)
3.
Friction that is generated at 5-reverse baulk ring presses syn-
chronizer lever on 5th-reverse coupling sleeve. (
)
4.
5th-reverse coupling sleeve that is pressed by synchronizer
lever stops the rotation of input shaft.
5
: 5th input gear
JPDIC0415ZZ
TM-20
< DTC/CIRCUIT DIAGNOSIS >
[5MT: RS5F92R]
POSITION SWITCH
DTC/CIRCUIT DIAGNOSIS
POSITION SWITCH
BACK-UP LAMP SWITCH
BACK-UP LAMP SWITCH : Component Inspection
INFOID:0000000006415675
1.
CHECK BACK-UP LAMP SWITCH
1.
Disconnect position switch connector. Refer to
TM-24, "Removal and Installation"
.
2.
Check continuity between position switch terminals.
Is the inspection result normal?
YES
>> INSPECTION END
NO
>> Replace position switch. Refer to
PARK/NEUTRAL POSITION (PNP) SWITCH
PARK/NEUTRAL POSITION (PNP) SWITCH : Component Inspection
INFOID:0000000006415676
1.
CHECK PARK/NEUTRAL POSITION (PNP) SWITCH
1.
Disconnect position switch connector. Refer to
TM-24, "Removal and Installation"
.
2.
Check continuity between position switch terminals.
Is the inspection result normal?
YES
>> INSPECTION END
NO
>> Replace position switch. Refer to
Terminals
Condition
Continuity
1
2
Reverse gear position
Existed
Except reverse gear position
Not existed
MCIA0157E
Terminals
Condition
Continuity
2
3
Neutral gear position
Existed
Except neutral gear position
Not existed
JPDIC0092ZZ
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
TM-21
< SYMPTOM DIAGNOSIS >
[5MT: RS5F92R]
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SYMPTOM DIAGNOSIS
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
INFOID:0000000006415677
Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. If nec-
essary, repair or replace these parts.
SUSPECTED PARTS
(Possible cause)
OIL
(Oil
lev
e
l is
l
o
w)
OI
L (W
ro
ng
oi
l)
OIL
(Oil
lev
e
l is
h
igh
)
GASKE
T (Damaged)
OIL SEAL (W
orn or
damaged)
O-RING (W
orn
or
da
ma
ge
d)
SHIF
T CONTROL L
INKAGE
(W
o
rn)
SHIF
T FORK (W
o
rn)
GEAR (W
o
rn o
r da
m
age
d)
BEAR
ING
(W
orn
o
r
da
ma
ge
d)
BAUL
K
RING (W
orn
o
r da
ma
ge
d)
INSE
R
T
S
P
RING (Dam
ag
ed
)
Reference
Symptoms
Noise
1
2
3
3
Oil leakage
3
1
2
2
2
Hard to shift or will not shift
1
1
2
3
3
Jumps out of gear
1
2
2
TM-22
< PERIODIC MAINTENANCE >
[5MT: RS5F92R]
GEAR OIL
PERIODIC MAINTENANCE
GEAR OIL
Inspection
INFOID:0000000006415678
OIL LEAKAGE
Make sure that gear oil is not leaking from transaxle or around it.
OIL LEVEL
1.
Remove filler plug (1) and gasket from transaxle case.
2.
Check the oil level from filler plug mounting hole as shown in the
figure.
CAUTION:
Never start engine while checking oil level.
3.
Set a gasket on filler plug and then install it to transaxle case.
CAUTION:
Never reuse gasket.
4.
Tighten filler plug to the specified torque. Refer to
Draining
INFOID:0000000006415679
1.
Start engine and let it run to warm up transaxle.
2.
Stop engine. Remove drain plug (1) and gasket, using a socket
[Commercial service tool] and then drain gear oil.
3.
Set a gasket on drain plug and install it to clutch housing, using
a socket [Commercial service tool].
CAUTION:
Never reuse gasket.
4.
Tighten drain plug to the specified torque. Refer to
Refilling
INFOID:0000000006415680
1.
Remove filler plug (1) and gasket from transaxle case.
2.
Fill with new gear oil until oil level reaches the specified limit at
filler plug mounting hole as shown in the figure.
3.
After refilling gear oil, check the oil level. Refer to
4.
Set a gasket on filler plug and then install it to transaxle case.
CAUTION:
Never reuse gasket.
5.
Tighten filler plug to the specified torque. Refer to
SCIA7119E
PCIB1504E
Oil grade and
viscosity
: Refer to
MA-13, "Fluids and Lubricants"
Oil capacity
: Refer to
SCIA7119E
SIDE OIL SEAL
TM-23
< REMOVAL AND INSTALLATION >
[5MT: RS5F92R]
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REMOVAL AND INSTALLATION
SIDE OIL SEAL
Removal and Installation
INFOID:0000000006415681
REMOVAL
1.
Remove front drive shafts. Refer to
FAX-53, "Removal and Installation"
.
2.
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.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Install differential side oil seals (1) to clutch housing and transaxle
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.
Inspection
INFOID:0000000006415682
INSPECTION AFTER INSTALLATION
Check the oil level and oil leakage. Refer to
.
JPDIC0118ZZ
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
TM-24
< REMOVAL AND INSTALLATION >
[5MT: RS5F92R]
POSITION SWITCH
POSITION SWITCH
Removal and Installation
INFOID:0000000006415683
REMOVAL
1.
Drain gear oil. Refer to
.
2.
Disconnect position switch connector (A).
3.
Remove position switch from transaxle case.
INSTALLATION
1.
Apply recommended sealant to threads of position switch.
• Use Genuine Liquid Gasket, Three Bond 1215 or an equivalent.
CAUTION:
Remove old sealant and oil adhering to threads.
2.
Install position switch to transaxle case.
3.
Tighten position switch to the specified torque. Refer to
4.
Refill gear oil. Refer to
Inspection
INFOID:0000000006415684
INSPECTION AFTER INSTALLATION
• Check continuity between position switch terminals. Refer to
TM-20, "BACK-UP LAMP SWITCH : Compo-
TM-20, "PARK/NEUTRAL POSITION (PNP) SWITCH : Compo-
(PNP switch).
• Check the oil leakage and the oil level. Refer to
.
JPDIC0733ZZ
CONTROL LINKAGE
TM-25
< REMOVAL AND INSTALLATION >
[5MT: RS5F92R]
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CONTROL LINKAGE
Exploded View
INFOID:0000000006417070
Removal and Installation
INFOID:0000000006417071
REMOVAL
1.
Shift the shifter lever to the neutral position.
2.
Remove air cleaner case. Refer to
EM-161, "Removal and Installation"
.
3.
Pull out and disconnect the each cable from the shifter lever A and the selector lever, using a suitable
remover.
1.
Bracket
2.
Selector cable
3.
Shifter lever A
4.
Selector lever
5.
Cable mounting bracket
6.
Tapping bolt
7.
Shifter cable
8.
Grommet
9.
M/T shift selector assembly
10. Shifter lever
11.
Shifter lever knob
: Always replace after every disassembly.
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
JPDIC0829GB
TM-26
< REMOVAL AND INSTALLATION >
[5MT: RS5F92R]
CONTROL LINKAGE
4.
While pressing the lock of the selector cable in the direction of
the arrow shown in the figure, remove the selector cable from
the cable mounting bracket.
5.
While pressing the lock of the shifter cable in the direction of the
arrow shown in the figure, remove the shifter cable from the
cable mounting bracket.
6.
Remove cable mounting bracket from clutch housing.
7.
Pull the shifter lever knob upward to remove.
8.
Remove center console assembly. Refer to
.
9.
Pull out and disconnect the each cable from the pin of the M/T
shift selector assembly, using a suitable remover.
10. While pressing the lock of the selector cable in the direction of
the arrow shown in the figure, remove the selector cable from
the M/T shift selector assembly.
11. While pressing the lock of the shifter cable in the direction of the
arrow shown in the figure, remove the shifter cable from the M/T
shift selector assembly.
12. Remove the M/T shift selector assembly.
13. Remove exhaust front tube and heat plate. Refer to
14. Remove the bracket from the vehicle.
15. Disengage the pawls (A) of the grommet (1), and pull down-
wards to remove.
16. 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 clutch housing. Do not perform tapping by other than
screwing tapping bolts because tapping is formed by screwing tapping bolts into clutch housing.
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.
JPDIC0793ZZ
JPDIC0793ZZ
JPDIC0844ZZ
CONTROL LINKAGE
TM-27
< REMOVAL AND INSTALLATION >
[5MT: RS5F92R]
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• Install the shifter cable (1) and the selector cable (2) to the bracket
(3) as shown in the figure.
Inspection
INFOID:0000000006417072
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 the
reverse gear position and moving hands off the lever. If there is a malfunction, then repair or replace the mal-
functioning part.
JPDIC0835ZZ
TM-28
< REMOVAL AND INSTALLATION >
[5MT: RS5F92R]
AIR BREATHER HOSE
AIR BREATHER HOSE
Exploded View
INFOID:0000000006415688
Removal and Installation
INFOID:0000000006415689
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
JPDIC0826ZZ
: Vehicle front
JPDIC0839ZZ
5TH MAIN GEAR ASSEMBLY
TM-29
< REMOVAL AND INSTALLATION >
[5MT: RS5F92R]
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5TH MAIN GEAR ASSEMBLY
Removal and Installation
INFOID:0000000006415692
REMOVAL
1.
Shift the shifter lever to the 3rd gear position.
2.
Disconnect the shifter cable and the selector cable from shifter lever A and selector lever. Refer to
CAUTION:
Never move shifter lever A and the selector lever to disconnect each cable.
3.
Drain gear oil. Refer to
4.
Remove fender protector LH. Refer to
EXT-22, "Removal and Installation"
5.
Remove the harness clamp (A) from rear housing (1).
6.
Remove rear housing and O-ring.
CAUTION:
Remove in the input shaft axial direction because the oil
channel of the rear housing is inserted in the center hole of
the input shaft.
7.
Remove 5th main gear assembly, referring to Step 5 to 8 of “Dis-
assembly of TRANSAXLE ASSEMBLY” Refer to
.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Shift into 3rd with shifter lever to install the 5th main gear assembly, referring to Step 38 to 41 of “Assembly
of TRANSAXLE ASSEMBLY.” Refer to
• Install O-ring and the rear housing to the transaxle case and tighten the mounting bolts to the specified
.
CAUTION:
Never pinch O-ring when installing rear housing.
• Refill gear oil. Refer to
Inspection
INFOID:0000000006415693
INSPECTION AFTER INSTALLATION
• Check the operation of the control linkage. Refer to
.
• Check the oil leakage and the oil level. Refer to
.
JPDIC0734ZZ
TM-30
< UNIT REMOVAL AND INSTALLATION >
[5MT: RS5F92R]
TRANSAXLE ASSEMBLY
UNIT REMOVAL AND INSTALLATION
TRANSAXLE ASSEMBLY
Exploded View
INFOID:0000000006415694
Removal and Installation
INFOID:0000000006415695
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-161, "Removal and Installation"
.
5.
Remove bracket (1), as per the following procedure.
a.
Disconnect clips (A) from bracket.
b.
Remove bolts (B) from bracket.
c.
Remove bracket.
6.
Remove air breather hose. Refer to
.
1.
Transaxle assembly
: Refer to "INSTALLATION" in
TM-30, "Removal and Installation"
for the locations and tightening torque.
JPDIC0478ZZ
: Vehicle front
JPDIC0847ZZ
TRANSAXLE ASSEMBLY
TM-31
< UNIT REMOVAL AND INSTALLATION >
[5MT: RS5F92R]
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7.
Remove bracket (1).
8.
Disconnect selector cable and shifter cable from transaxle
assembly. Refer to
TM-25, "Removal and Installation"
9.
Remove crankshaft position sensor. Refer to
.
10. Remove clutch tube from CSC (Concentric Slave Cylinder) and
then temporarily secure it to a position where it will not inhibit
work. 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 fender protector LH. Refer to
EXT-22, "Removal and Installation"
12. Disconnect ground cable.
13. Disconnect position switch connector. Refer to
TM-24, "Removal and Installation"
.
14. Remove the harness clamp from rear housing.
15. Remove the engine harness clamp and then temporarily secure it to a position where it will not inhibit
work.
16. Remove starter motor. Refer to
STR-22, "HR16DE : Removal and Installation"
.
17. Remove front drive shafts. Refer to
FAX-53, "Removal and Installation"
.
NOTE:
Insert a suitable plug into differential side oil seal after removing front drive shaft.
18. 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.
19. Remove engine mounting frame support (LH) (TBD) mounting bolts, as per the following procedure.
a.
Remove bolt (A).
b.
Release clutch damper (1) from bracket. Refer to
c.
Remove bolt (B).
d.
Remove engine mounting frame support (LH) mounting bolts
from vehicle. Refer to
EM-215, "Removal and Installation"
.
20. Remove rear engine mounting bracket and rear torque rod.
EM-215, "Removal and Installation"
21. Remove transaxle assembly mounting bolts.
22. 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.
23. Remove engine mounting bracket (LH) (TBD) and engine mounting frame support (LH) (TBD) from tran-
saxle assembly. Refer to
EM-215, "Removal and Installation"
24. 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.
: Vehicle front
: Vehicle front
JPDIC0846ZZ
JPDIC0819ZZ
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