Juke F15 (2012 year). Service Repair Manual — part 109

FRONT OIL SEAL

DLN-133

< REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: RTVS]

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REMOVAL AND INSTALLATION

FRONT OIL SEAL

Exploded View

INFOID:0000000006361778

Removal and Installation

INFOID:0000000006361779

REMOVAL

CAUTION:

Verify identification stamp of replacement frequency put in the lower part of gear carrier to determine
replacement for collapsible spacer when replacing front oil seal. Refer to “Identification stamp of
replacement frequency of front oil seal”. If collapsible spacer replacement is necessary, remove final
drive assembly and disassemble it to replace front oil seal and collapsible spacer. Refer to

DLN-144,

"Removal and Installation"

and

DLN-160, "Disassembly"

.

NOTE:
The reuse of collapsible spacer is prohibited in principle. However, it is reusable on a one-time basis
only in cases when replacing front oil seal.

Identification stamp of replacement frequency of front oil seal

1.

Rear final drive assembly

2.

Front oil seal

3.

Companion flange

4.

Companion flange lock nut

A.

Oil seal lip

: Vehicle front

: N·m (kg-m, ft-lb)

: Never reuse parts

: Apply multi purpose grease

: Apply gear oil.

JSDIA2115GB

DLN-134

< REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: RTVS]

FRONT OIL SEAL

• The diagonally shaded area in the figure shows stamping point for

replacement frequency of front oil seal.

• The following table shows if collapsible spacer replacement is

needed before replacing front oil seal.
When collapsible spacer replacement is required, disassemble
final drive assembly to replace collapsible spacer and front oil seal.
Refer to

DLN-160, "Disassembly"

.

CAUTION:

Make a stamping after replacing front oil seal.

• After replacing front oil seal, make a stamping on the stamping point in accordance with the table below in

order to identify replacement frequency.

CAUTION:

Make a stamping from left to right.

1.

Make a judgment if a collapsible spacer replacement is required.

2.

Remove rear propeller shaft. Refer to

DLN-121, "Removal and Installation"

.

3.

Measure the total preload with the preload gauge (A) (SST:
ST3127S000).
NOTE:
Record the preload measurement.

4.

Put matching mark (B) on the end of the drive pinion. The
matching mark (B) should be in line with the matching mark (A)
on companion flange (1).

CAUTION:

For matching mark, use paint. Never damage companion
flange and drive pinion.

Stamp

collapsible spacer replacement

No stamp

Not required

“0” or “0” on the far right of stamp

Required

“01” or “1” on the far right of stamp

Not required

JSDIA2116ZZ

Stamp before stamping

Stamping on the far right

Stamping

No stamp

0

0

“0”
(Front oil seal was replaced once.)

1

01

“01”
(Collapsible spacer and front oil seal were replaced last time.)

0

010

“0” is on the far right.
(Only front oil seal was replaced last time.)

1

...01

“1” is on the far right.
(Collapsible spacer and front oil seal were replaced last time.)

0

...010

JSDIA2117ZZ

JSDIA2118ZZ

FRONT OIL SEAL

DLN-135

< REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: RTVS]

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5.

Remove companion flange lock nut using the flange wrench (A)
(commercial service tool).

6.

Remove companion flange using pullers (A) (commercial ser-
vice tool).

7.

Remove front oil seal using a suitable tool.

CAUTION:

Never damage carrier case.

INSTALLATION

1.

Apply multi-purpose grease to front oil seal lips.

2.

Install front oil seal using the drift (A) (commercial service tool)
as shown in figure.

CAUTION:

• Never reuse oil seal.
• Never incline oil seal when installing.

3.

Align the matching mark (B) of drive pinion with the matching
mark (A) of companion flange (1), and then install the compan-
ion flange (1).

JSDIA2119ZZ

JSDIA2120ZZ

JSDIA2122ZZ

JSDIA2118ZZ

DLN-136

< REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: RTVS]

FRONT OIL SEAL

4.

Temporarily tighten drive pinion lock nut to drive pinion, using
flange wrench (commercial service tool).

CAUTION:

• Never reuse drive pinion lock nut.
• Apply anti-corrosion oil to the thread and seat of new

drive pinion lock nut.

5.

Tighten drive pinion lock nut within the limits of specified torque
so as to keep the pinion bearing preload within a standard val-
ues, using preload gauge (A) (SST: ST3127S000).

CAUTION:

• Adjust to the lower limit of the drive pinion lock nut tight-

ening torque first.

• If the preload torque exceeds the specified value, replace

collapsible spacer and tighten it again to adjust. Never
loosen drive pinion lock nut to adjust the preload torque.

6.

Fit a dial indicator onto the companion flange face (inner side of
the rear propeller shaft mounting bolt holes).

7.

Rotate companion flange to check for runout.

8.

Fit a test indicator to the inner side of companion flange (socket
diameter).

9.

Rotate companion flange to check for runout.

10. If the runout value is outside the runout limit, follow the procedure below to adjust.
a.

Check for runout while changing the phase between companion flange and drive pinion by 90

°

step, and

search for the position where the runout is the minimum.

b.

If the runout value is still outside of the limit after the phase has been changed, replace companion flange.

c.

If the runout value is still outside of the limit after companion flange has been replaced, possible cause will
be an assembly malfunction of drive pinion and electric controlled coupling, malfunctioning coupling bear-
ing, or malfunctioning of electric controlled coupling.

11. Make a stamping for identification of front oil seal replacement frequency. Refer to “Identification stamp of

replacement frequency of front oil seal”.

CAUTION:

Make a stamping after replacing front oil seal.

12. Install rear propeller shaft. Refer to

DLN-121, "Removal and Installation"

.

13. Check the final drive for oil leakage. Refer to

DLN-132, "Inspection"

.

Total preload torque

: A value that add 0.1 – 0.4
N·m (0.01 – 0.04 kg-m, 0.1 –
0.3 in-lb) to the measured
value before removing.

JSDIA2123ZZ

Companion flange runout

: Refer to

DLN-167, "Com-

panion Flange Runout"

.

Companion flange runout

: Refer to

DLN-167, "Com-

panion Flange Runout"

.

PDIA0439E

SIDE OIL SEAL

DLN-137

< REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: RTVS]

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SIDE OIL SEAL

Exploded View

INFOID:0000000006361780

Removal and Installation

INFOID:0000000006361781

REMOVAL

1.

Remove electric controlled couplings. Refer to

DLN-139, "Removal and Installation"

.

2.

Remove side oil seals with a suitable tool.

CAUTION:

Never damage gear carrier and rear cover.

INSTALLATION

1.

Rear final drive assembly

2.

Side oil seal (right)

3.

Electric controlled coupling (right)

4.

Reamer bolt

5.

Side oil seal (left)

6.

Electric controlled coupling (left)

A.

Oil seal lip

B.

Gear carrier mouting face

: Vehicle front

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

: Apply multi purpose grease

: Apply gear oil.

: Apply Genuine Liquid Gasket 1217 or equivalent.

JSDIA2233GB

JSDIA2234ZZ

DLN-138

< REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: RTVS]

SIDE OIL SEAL

1.

Install side oil seal (right side) until it becomes flush with the car-
rier end, using the drift (A) (SST: KV38100200).

CAUTION:

• Never reuse oil seals.
• When installing, never incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference of oil seal.

2.

Install side oil seal (left side) until it becomes flush with the car-
rier end, using the drift (A) (SST: KV38100500).

CAUTION:

• Never reuse oil seals.
• When installing, never incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference of oil seal.

3.

Install electric controlled couplings. Refer to

DLN-139, "Removal

and Installation"

.

4.

When oil leaks while removing, check oil level after the installa-
tion. Refer to

DLN-132, "Inspection"

.

JSDIA2235ZZ

JSDIA2236ZZ

ELECTRIC CONTROLLED COUPLING

DLN-139

< REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: RTVS]

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ELECTRIC CONTROLLED COUPLING

Exploded View

INFOID:0000000006361782

Removal and Installation

INFOID:0000000006361783

REMOVAL

1.

Remove rear drive shaft. Refer to

RAX-17, "Removal and Installation"

.

2.

Disconnect electric controlled coupling connector (1) from sub-
harness (2).

3.

Remove connector clip (

) from final drive assembly.

1.

Sub-harness

2.

Rear final drive assembly

3.

Electric controlled coupling (right)

4.

Reamer bolt

5.

Electric controlled coupling (left)

A.

Gear carrier mouting face

: Vehicle front

: N·m (kg-m, ft-lb)

: Apply Genuine Liquid Gasket 1217 or equivalent.

JSDIA2237GB

JSDIA2238ZZ

JSDIA2239ZZ

DLN-140

< REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: RTVS]

ELECTRIC CONTROLLED COUPLING

4.

Remove electric controlled coupling from final drive assembly.

5.

Remove sub-harness from final drive assembly.

CAUTION:

Remove sub-harness only when necessary.

INSTALLATION

1.

Install new sub-harness clip to sub-harness.

CAUTION:

• Check original mounting dimensions to install clip to the original position.
• Baffle pin must be functioning normally.

2.

Install sub-harness to final drive assembly.

CAUTION:

Check the area around the rotating object to see that there is no interference.

3.

Apply liquid gasket (1) to mating surface of coupling cover.

CAUTION:

• Remove old gasket adhering to the mounting surfaces.

Also remove any moisture, oil, or foreign material adher-
ing to the mounting surfaces.

• Overlap both ends of the bead for at least 3 mm (0.12 in).

4.

Install electric controlled coupling (1) to spline of stem center
with grommet of harness facing upward, temporarily tighten
reamer bolts (2) to the positions shown in the figure.

5.

Tighten reamer bolts and coupling cover mounting bolts to the
specified torque.

CAUTION:

Never allow harness to get caught in the bolt.

JSDIA2240ZZ

JSDIA2241ZZ

: Vehicle front

JSDIA2242GB

ELECTRIC CONTROLLED COUPLING

DLN-141

< REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: RTVS]

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6.

Install the new connector clip (

) to final drive assembly.

CAUTION:

Never reuse connector clip.

7.

Connect electric controlled coupling connector (1) to sub-har-
ness (2).

8.

Install rear drive shaft. Refer to

RAX-17, "Removal and Installa-

tion"

.

9.

When oil leaks while removing, check oil level after the installa-
tion. Refer to

DLN-132, "Inspection"

.

10. When replacing electric controlled coupling, perform writing unit

parameter. Refer to

DLN-39, "Work Procedure"

.

JSDIA2239ZZ

JSDIA2238ZZ

DLN-142

< REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: RTVS]

ELECTRIC CONTROLLED COUPLING OIL SEAL

ELECTRIC CONTROLLED COUPLING OIL SEAL

Exploded View

INFOID:0000000006361896

Removal and Installation

INFOID:0000000006361897

REMOVAL

1.

Remove rear drive shafts. Refer to

RAX-17, "Removal and Installation"

.

2.

Remove electric controlled coupling oil seals from electric con-
trolled coupling, using a suitable tool.

CAUTION:

Never damage electric controlled coupling.

INSTALLATION

1.

Install electric controlled coupling oil seals to electric controlled
coupling, using the drift (A) (SST: KV38109700).
NOTE:
The use of the special service tool satisfies the mounting dimen-
sions.

CAUTION:

• Never reuse oil seals.
• When installing, never incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference of oil seal.

1.

Rear final drive assembly

2.

Electric controlled coupling oil seal

A.

Oil seal lip

: Vehicle front

: Always replace after every disassembly.

: Apply multi purpose grease

: Apply gear oil.

JSDIA2243ZZ

JSDIA2244ZZ

JSDIA2245ZZ

ELECTRIC CONTROLLED COUPLING OIL SEAL

DLN-143

< REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: RTVS]

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2.

Install rear drive shafts. Refer to

RAX-17, "Removal and Installation"

.

3.

When oil leaks while removing, check oil level after the installation. Refer to

DLN-132, "Inspection"

.

DLN-144

< UNIT REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: RTVS]

REAR FINAL DRIVE ASSEMBLY

UNIT REMOVAL AND INSTALLATION

REAR FINAL DRIVE ASSEMBLY

Exploded View

INFOID:0000000006361898

Removal and Installation

INFOID:0000000006361899

REMOVAL

1.

Remove rear propeller shaft assembly. Refer to

DLN-121, "Removal and Installation"

.

2.

Remove rear drive shaft. Refer to

RAX-17, "Removal and Installation"

.

3.

Disconnect sub-harness connector (1).

4.

Remove rear final drive breather hose.

5.

Support rear final drive assembly with a suitable jack.

1.

Final drive mounting bracket

2.

Washer

3.

Rear final drive assembly

: Vehicle front

: N·m (kg-m, ft-lb)

: Never reuse parts

: Apply multi purpose grease

: Apply gear oil.

JSDIA2134GB

JSDIA2135ZZ

REAR FINAL DRIVE ASSEMBLY

DLN-145

< UNIT REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: RTVS]

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6.

Remove rear final drive mounting bolt (

) at rear suspension

member.

7.

Remove final drive mounting bolts and nuts (

), and then

remove rear final drive assembly from final drive mounting
bracket.

CAUTION:

Secure final drive assembly to a suitable jack while remov-
ing it.

8.

Remove fuel tank. Refer to

FL-23, "4WD : Removal and Installa-

tion"

.

9.

Remove final drive mounting bracket.

INSTALLATION

Note the following, and install in the reverse order of removal.
• Install the breather hose (1) to breather tube until dimension (A)

shown as follows.

CAUTION:

• Never reuse hose clamps.
• Install the hose clamps, with the tab facing vehicle rear.

• If remove breather hose, install breather hose (1) as shown in the

figure.

- Install breather hose with paint mark (A) facing vehicle rear.
• When oil leaks while removing final drive assembly, check oil level

after the installation. Refer to

DLN-132, "Inspection"

.

• When replacing rear final drive assembly, perform writing unit

parameter. Refer to

DLN-39, "Work Procedure"

.

JSDIA2136ZZ

JSDIA2137ZZ

A:

Final drive side

: 20mm (0.79 in)

Breather side

: 20mm (0.79 in)

JPDID0020ZZ

: Vehicle front

JSDIA2138ZZ

DLN-146

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: RTVS]

ELECTRIC CONTROLLED COUPLING

UNIT DISASSEMBLY AND ASSEMBLY

ELECTRIC CONTROLLED COUPLING

Exploded View

INFOID:0000000006361900

1.

Filler plug

2.

Gasket

3.

Drain plug

4.

Breather tube

5.

Clip

6.

Breather hose

7.

Breather

8.

sub-harness clip

9.

sub-harness

10. Rear cover

11.

Center stem

12. Side bearing (right)

13. Side bearing adjusting shim (right)

14. Side oil seal (right)

15. Connector clip

16. Electric controlled coupling (right)

17. Electric controlled coupling oil seal

18. Reamer bolt

19. Drive pinion

20. Drive pinion adjusting shim

21. Pinion rear bearing

22. Collapsible spacer

23. Breather

24. Gear carrier

25. Carrier bracket (right)

26. Pinion front bearing

27. Front oil seal

28. Companion flange

29. Drive pinion lock nut

30. Carrier bracket (left)

31. Drive gear

32. Side bearing (left)

33. Side bearing adjusting shim (left)

34. Electric controlled coupling (left)

35. Side oil seal (left)

A.

Oil seal lip

B.

Gear carrier mounting face

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

: Apply gear oil.

: Apply anti-corrosive oil.

: Apply multi purpose grease

JSDIA2246GB

ELECTRIC CONTROLLED COUPLING

DLN-147

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: RTVS]

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Disassembly

INFOID:0000000006361901

1.

Disconnect electric controlled coupling connector (1) from sub-
harness (2).

2.

Remove connector clip (

) from final drive assembly.

3.

Remove electric controlled coupling from final drive assembly.

4.

Remove sub-harness from final drive assembly.

CAUTION:

Remove sub-harness only when necessary.

5.

Remove electric controlled coupling oil seals from electric con-
trolled coupling, using a suitable tool.

CAUTION:

Never damage electric controlled coupling.

: Apply Genuine Liquid Gasket 1217 or equivalent.

: Select with proper thickness.

JSDIA2238ZZ

JSDIA2239ZZ

JSDIA2240ZZ

JSDIA2297ZZ

DLN-148

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: RTVS]

ELECTRIC CONTROLLED COUPLING

6.

Remove side oil seals with a suitable tool.

CAUTION:

Never damage gear carrier and rear cover.

7.

Perform inspection after disassembly. Refer to

DLN-150,

"Inspection"

.

Assembly

INFOID:0000000006361902

1.

Install side oil seal (right side) until it becomes flush with the car-
rier end, using the drift (A) (SST: KV38100200).

CAUTION:

• Never reuse oil seals.
• When installing, never incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference of oil seal.

2.

Install side oil seal (left side) until it becomes flush with the car-
rier end, using the drift (A) (SST: KV38100500).

CAUTION:

• Never reuse oil seals.
• When installing, never incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference of oil seal.

3.

Install electric controlled coupling oil seals to electric controlled
coupling, using the drift (A) (SST: KV38109700).
NOTE:
The use of the special service tool satisfies the mounting dimen-
sions.

CAUTION:

• Never reuse oil seals.
• When installing, never incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference of oil seal.

4.

Install new sub-harness clip to sub-harness.

CAUTION:

• Check original mounting dimensions to install clip to the original position.
• Baffle pin must be functioning normally.

5.

Install sub-harness to final drive assembly.

JSDIA2298ZZ

JSDIA2299ZZ

JSDIA2300ZZ

JSDIA2301ZZ