Juke F15 (2012 year). Service Repair Manual — part 354

TM-96

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

TRANSAXLE ASSEMBLY

18. Remove differential side bearing outer race (1) from transaxle

case, using a brass rod.

CAUTION:

Never damage transaxle case.

19. Remove shim (2) from transaxle case.

20. Remove shifter lever A (1) retaining pin, using a pin punch.
21. Remove shifter lever A from transaxle case.

22. Remove shifter lever B (1) from transaxle case.

23. Remove oil gutter (1) from transaxle case.

24. Remove bushings (1) from transaxle case, using a remover

[Commercial service tool].

PCIB1705E

JPDIC0106ZZ

PCIB1712E

PCIB1707E

PCIB1710E

TRANSAXLE ASSEMBLY

TM-97

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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

using a remover [Commercial service tool].

26. Remove mainshaft rear bearing adjusting shim from transaxle

case.

27. Remove snap ring (1) and oil channel (2) from transaxle case.

28. Remove input shaft oil seal (1) from clutch housing, using an oil

seal remover.

CAUTION:

Never damage clutch housing.

29. Remove mainshaft front bearing outer race (1) from clutch hous-

ing, using the puller (A) [SST: KV381054S0] and a spacer (B)
[Commercial service tool].

30. Remove oil channel (2) from clutch housing.

31. Remove bushing (1) from clutch housing, using a remover

[Commercial service tool].

PCIB1706E

PCIB1708E

PCIB1714E

JPDIC0107ZZ

PCIB1717E

TM-98

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

TRANSAXLE ASSEMBLY

32. Remove 2 way connector (1) from clutch housing.

33. Remove plug from clutch housing.

34. Remove pinion gear (1) and pinion shaft (2) from clutch housing.

Assembly

INFOID:0000000006415756

1.

Install pinion gear (1) and pinion shaft (2) to clutch housing.

CAUTION:

Replace transaxle assembly when replacing clutch hous-
ing.

2.

Install plug to clutch housing.

3.

Install 2 way connector (1) to clutch housing.

PCIB1720E

PCIB1719E

PCIB1719E

PCIB1720E

TRANSAXLE ASSEMBLY

TM-99

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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4.

Install bushings (1) so that they becomes even to clutch housing
edge surface, using a drift (A) [Commercial service tool].

5.

Install oil channel to clutch housing.

CAUTION:

Never reuse oil channel.

6.

Install mainshaft front bearing outer race to clutch housing,
using the drift (A) [SST: KV38100200].

CAUTION:

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

7.

Install input shaft oil seal (1) to clutch housing, using the drift (A)
[SST: ST33220000].

8.

Install snap ring (1) and oil channel (2) to transaxle case.

CAUTION:

• Select and install snap ring that has the same thickness

as previous one.

• Replace transaxle assembly when replacing transaxle

case.

9.

Install mainshaft rear bearing adjusting shim to transaxle case.

CAUTION:

Select mainshaft rear bearing adjusting shim, as per the fol-
lowing procedure when replacing mainshaft adjusting
shim, 6th main gear, 5th main gear, or 4th main gear.
• Replace mainshaft adjusting shim.
- If new mainshaft adjusting shim is thinner than previous one, offset the thickness difference by

selecting thicker mainshaft rear bearing adjusting shim.

- If new mainshaft adjusting shim is thicker than previous one, offset the thickness difference by

selecting thinner mainshaft rear bearing adjusting shim.

• Replace 6th main gear, 5th main gear, or 4th main gear.
- Measure the thickness of the main gear used before and the new main gear
- Increase the thickness of the mainshaft rear bearing adjusting shim, if the difference is smaller

than 0.025 mm (0.0010 in).

- Decrease the thickness of the mainshaft rear bearing adjusting shim, if the difference is greater

than 0.025 mm (0.0010 in).

JPDIC0108ZZ

PCIB1724E

PCIB1721E

PCIB1729E

TM-100

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

TRANSAXLE ASSEMBLY

10. Install mainshaft rear bearing outer race to transaxle case, using

the drift (A) [SST: KV38100200].

CAUTION:

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

11. Install bushings (1) to transaxle case, using a drift (A) [Commer-

cial service tool].

12. Install oil gutter (1) to transaxle case.

13. Install shifter lever B (1) to transaxle case.

CAUTION:

Replace shifter lever A and shifter lever B as a set.

14. Install shifter lever A to transaxle case.

CAUTION:

Replace shifter lever A and shifter lever B as a set.

15. Install retaining pin to shifter lever A (1), using a pin punch.

CAUTION:

Never reuse retaining pin.

16. Install shim to transaxle case.

PCIB1728E

JPDIC0109ZZ

PCIB1730E

PCIB1712E

BCIA0047E

TRANSAXLE ASSEMBLY

TM-101

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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17. Install differential side bearing outer race (transaxle case side)

to transaxle case, using the drift (A) [SST: ST33400001].

CAUTION:

Replace differential side bearing outer race (transaxle case
side) and differential side bearing inner race (transaxle case
side) as a set.

18. Install differential side bearing outer race (clutch housing side) to

clutch housing, using the drift (A) [SST: KV38100200].

CAUTION:

Replace differential side bearing outer race (clutch housing
side) and differential side bearing inner race (clutch hous-
ing side) as a set.

19. 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.

20. Install magnet to clutch housing.

21. Install final drive assembly to clutch housing.

22. Set fork rod (1) to input shaft assembly (2), and then install them

to clutch housing.

PCIB1726E

PCIB1722E

A

: Transaxle case side

B

: Clutch housing side

Dimension “L

1

”

: 1.2 – 1.8 mm (0.047 – 0.071 in)

Dimension “L

2

”

: 2.7 – 3.3 mm (0.106 – 0.130 in)

JPDIC0454ZZ

JPDIC0608ZZ

TM-102

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

TRANSAXLE ASSEMBLY

23. Install mainshaft assembly (1), as per the following procedure.

a.

Pull up input shaft assembly (2) and fork rod (3).

b.

Set 1st-2nd fork rod (4) to mainshaft assembly, and then install
them to clutch housing.

24. Install reverse idler shaft assembly (1), as per the following pro-

cedure.

a.

Install spring washer to clutch housing.

b.

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.

c.

Set reverse fork rod (6) to reverse idler shaft assembly, and then
install them to clutch housing.

25. Shift 1st-2nd fork rod (1), fork rod (2), and reverse fork rod (3) to

the neutral position.

26. Install selector (4) to clutch housing.

CAUTION:

Replace selector lever and selector as a set.

27. Install selector spring (1) to return bushing (A).

28. Apply recommended sealant to mounting surface of transaxle

case.
• Use Genuine Liquid Gasket, Three Bond 1215 or an equiv-

alent.

CAUTION:

• Never allow old liquid gasket, moisture, oil, or foreign

matter to remain on mounting surface.

• Check that mounting surface is not damaged.
• Apply sealant bead continuously.

29. Install transaxle case to clutch housing while rotating shifter

lever A (1) in the direction as shown in the figure.

JPDIC0609ZZ

JPDIC0606ZZ

SCIA7782E

JPDIC0445ZZ

JPDIC0110ZZ

TRANSAXLE ASSEMBLY

TM-103

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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30. Install reverse idler shaft mounting bolt (

), as per the following

procedure.

a.

Install seal washer to reverse idler shaft mounting bolt, and
install reverse idler shaft mounting bolt to transaxle case.

CAUTION:

Never reuse seal washer.

b.

Tighten reverse idler shaft mounting bolt to the specified torque.

31. Tighten transaxle case mounting bolts (

) to the specified

torque.

32. Install position switch (1), as per the following procedure.

a.

Apply recommended sealant to threads of position switch.
• Use Genuine Liquid Gasket, Three Bond 1215 or an equiv-

alent.

CAUTION:

Never allow old liquid gasket, moisture, oil, or foreign mat-
ter to remain on thread.

b.

Install position switch to transaxle case, and tighten it to the
specified torque.

33. Install bracket (2) to transaxle case, and tighten mounting bolt to

the specified torque.

34. Install selector lever (3), as per the following procedure.
a.

Install selector lever to transaxle case.

CAUTION:

Replace selector lever and selector as a set.

b.

Install retaining pin to selector lever, using a pin punch.

CAUTION:

Never reuse retaining pin.

35. Install drain plug, as per the following procedure.

a.

Install gasket to drain plug.

CAUTION:

Never reuse gasket.

b.

Install drain plug to clutch housing, using a socket [Commercial service tool].

c.

Tighten drain plug to the specified torque.

36. Install filler plug, as per the following procedure.
a.

Install gasket to filler plug, and then install them to transaxle case.

CAUTION:

Never reuse gasket.

b.

Tighten filler plug to the specified torque.

CAUTION:

Fill with gear oil before tighten filler plug to the specified torque.

PCIB1695E

PCIB1694E

SCIA7784E

TM-104

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

TRANSAXLE ASSEMBLY

Inspection

INFOID:0000000006641535

INSPECTION AFTER DISASSEMBLY

Check contact surface and sliding surface for excessive wear,
uneven wear, bend, and damage. Replace if necessary.

SCIA7785E

INPUT SHAFT AND GEAR

TM-105

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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INPUT SHAFT AND GEAR

Exploded View

INFOID:0000000006415757

Disassembly

INFOID:0000000006415758

CAUTION:

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-106

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

INPUT SHAFT AND GEAR

• Fix input shaft in a vise with back plate, and then remove gears and snap rings.
• For removal of snap ring, set snap ring pliers and flat pliers at

both sides of snap ring. While expanding snap ring with snap
ring pliers, move snap ring with flat pliers.

• Disassemble gear components putting direction marks on the

parts that do not affect any functions.

1.

Remove input shaft rear bearing mounting bolt (1), using the
drift (A) [SST: KV32300QAM].

2.

Remove input shaft rear bearing (1), as per the following proce-
dure.

a.

Set a puller [Commercial service tool] to input shaft rear bearing.

b.

Remove input shaft rear bearing, using a drift (A) [Commercial
service tool].

3.

Remove spacer (1), 6th input gear (2), needle bearing, 6th baulk
ring, and 5th-6th synchronizer hub assembly (3).

4.

Remove insert keys and 5th-6th coupling sleeve from 5th-6th
synchronizer hub.

SCIA1755J

JPDIC0449ZZ

JPDIC0111ZZ

PCIB1750E

INPUT SHAFT AND GEAR

TM-107

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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5.

Remove snap ring (1).

6.

Remove spacer, 5th baulk ring, 5th input gear (2), and spacer.

7.

Remove snap ring (1).

8.

Remove spacer, 4th input gear (2), 4th baulk ring, and 3rd-4th
synchronizer hub assembly (3).

9.

Remove insert keys and 3rd-4th coupling sleeve from 3rd-4th
synchronizer hub.

10. Remove snap ring (1).

11. Remove spacer, 3rd baulk ring, and 3rd input gear (2).

12. Set a puller [Commercial service tool] to input shaft front bearing

(1), and then remove input shaft front bearing.

Assembly

INFOID:0000000006415759

Note the following procedures, and assemble in the reverse order of disassembly.

CAUTION:

• Replace transaxle assembly when replacing input shaft.

PCIB1754E

PCIB1753E

PCIB1752E

PCIB1751E

TM-108

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

INPUT SHAFT AND GEAR

• For installation of snap ring, set snap ring pliers and flat pliers

at both sides of snap ring. While expanding snap ring with
snap ring pliers, move snap ring with flat pliers.

• Never reuse snap ring.
• Check that snap ring is securely installed in a groove.
• Replace 3rd-4th coupling sleeve and 3rd-4th synchronizer

hub as a set.

• Replace 5th-6th coupling sleeve and 5th-6th synchronizer hub

as a set.

• Be careful to install 3rd-4th synchronizer hub according to the

specified direction.

• Be careful to install 5th-6th synchronizer hub according to the

specified direction.

• Install input shaft front bearing (1), using a drift (A) [Commercial

service tool].

SCIA1755J

A : 3rd input gear side

B : 4th input gear side

PCIB1748E

A : 5th input gear side

B : 6th input gear side

PCIB1749E

JPDIC0112ZZ

INPUT SHAFT AND GEAR

TM-109

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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• Install input shaft rear bearing (1), using a drift (A) [Commercial

service tool] and the drift (B) [SST: ST36720030].

• Apply gear oil to 3rd baulk ring, 4th baulk ring, 5th baulk ring, and

6th baulk ring.

• Install input shaft rear bearing mounting bolt (1), as per the follow-

ing procedure.

CAUTION:

Follow the procedures. Otherwise it may cause a transaxle
malfunction.

1.

Fix the drift (A) [SST: KV32300QAM] in a vise, and then set input
shaft assembly.

2.

Install input shaft rear bearing mounting bolt, and then tighten it
to the specified torque of the first step.

3.

Loosen input shaft rear bearing mounting bolt by a half turn.

4.

Tighten input shaft rear bearing mounting bolt to the specified
torque of the final step.

Inspection

INFOID:0000000006415760

INSPECTION AFTER DISASSEMBLY

Input Shaft and Gear

Check the following items and replace if necessary.
• Damage, peeling, bend, uneven wear, and distortion of shaft.
• Excessive wear, damage, and peeling of gear.

Synchronizer Hub and Coupling Sleeve

Check the following items and replace if necessary.
• Breakage, damage, and unusual wear on contact surface of cou-

pling sleeve, synchronizer hub, and insert key.

• Coupling sleeve and synchronizer hub move smoothly.

Baulk Ring

JPDIC0113ZZ

JPDIC0449ZZ

SCIA7736E

SCIA1753J

TM-110

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

INPUT SHAFT AND GEAR

Check contact surface of baulk ring cam and insert key for excessive
wear, uneven wear, bend, and damage. Replace if necessary.

Bearing

Check bearing for damage and unsmooth rotation. Replace if neces-
sary.

SCIA0608J

MTF0041D

MAINSHAFT AND GEAR

TM-111

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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MAINSHAFT AND GEAR

Exploded View

INFOID:0000000006415761

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