Nissan Juke (2012 year). Service Repair Manual — part 72
ELECTRIC CONTROLLED COUPLING
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4.
Install electric controlled coupling (1) to spline of center stem
with grommet of harness facing upward, temporarily tighten
reamer bolts (2) to the positions shown in the figure.
CAUTION:
Never damage side oil seal.
5.
Tighten reamer bolts and coupling cover mounting bolts to the
specified torque.
CAUTION:
Never allow harness to get caught in the bolt.
6.
Replace connector clip from electric controlled coupling connec-
tor, and then insert it to final drive assembly.
CAUTION:
• Never reuse connector clip.
• When inserting connector clip to final drive assembly,
never tug harness.
7.
Connect electric controlled coupling connector (1) to sub-har-
ness (2).
8.
When oil leaks while removing, check oil level after the installa-
tion. Refer to
.
9.
When replacing electric controlled coupling, perform writing unit
characteristics after installing rear final drive assembly to the
vehicle. Refer to
CAUTION:
Always perform writing unit characteristics of both side
electric controlled couplings.
A: Left side
B: Right side
: Vehicle front
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CENTER STEM ASSEMBLY
CENTER STEM ASSEMBLY
Exploded View
INFOID:0000000007580305
1.
Filler plug
2.
Gasket
3.
Drain plug
4.
Breather tube
5.
Hose clamp
6.
Breather hose
7.
Breather
8.
Band 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 bearing (rear)
22. Collapsible spacer
23. Breather
24. Gear carrier
25. Carrier bracket (right)
26. Pinion bearing (front)
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. Side oil seal (left)
35. Electric controlled coupling (left)
A.
Oil seal lip
B.
Gear carrier mounting face
: Always replace after every disassembly.
: Select with proper thickness.
: N·m (kg-m, ft-lb)
: Apply multi purpose grease
: Apply gear oil.
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CENTER STEM ASSEMBLY
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Disassembly
INFOID:0000000007580306
1.
Remove carrier brackets.
2.
Remove electric controlled couplings. Refer to
.
3.
Remove breather tube and breathers.
CAUTION:
Remove breather tube and breathers only when necessary.
4.
Remove side oil seal with the suitable oil seal remover.
CAUTION:
Never damage gear carrier and rear cover.
5.
Remove rear cover mounting bolts.
6.
Set the drifts (A and B) to the right and left side bearing adjusting
shims individually. Press center stem assembly with side bear-
ing to remove gear carrier assembly and rear cover assembly.
CAUTION:
The pressure shall be as low as possible to remove gear
carrier assembly and rear cover assembly. The maximum
pressure shall be 10 kN (1 ton, 1.0 Imp ton).
NOTE:
Center stem assembly, side bearings, and adjusting shims are
compressed and integrated in gear carrier and rear cover.
7.
Remove drain plug and filler plug, if necessary.
8.
Remove side bearing adjusting shims and outer races of side bearing .
CAUTION:
Mark the side bearing adjusting shims so that the original mounting positions (right/left) can be
identified later.
9.
Remove inner race of side bearing (right), using the puller (A),
the replacer (B) and the drift (C).
: Apply anti-corrosive oil.
: Apply Genuine Silicone RTV or equivalent. Refer to
GI-22, "Recommended Chemical Products and Sealants"
.
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A
: Drift [SST: KV38109820 (
—
)]
B
: Drift [SST: KV38109810 (
—
)]
A
: Puller (Commercial service tool)
B
: Replacer (Commercial service tool)
C
: Drift [SST: ST33052000 (
—
)]
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CENTER STEM ASSEMBLY
10. Remove inner race of side bearing (left), using the puller (A), the
replacer (B) and the drift (C).
11. Remove center stem from drive gear, using the drift (A) [SST:
ST33220000 (J-25804-01)].
12. Perform inspection after disassembly. Refer to
Assembly
INFOID:0000000007580307
1.
Press center stem to drive gear, using the drift (A) [SST:
ST33052000 (
—
)].
2.
Press inner race of side bearing (right) to center stem assembly,
using the drift (A) (Commercial service tool).
CAUTION:
• Never reuse side bearing.
• Apply gear oil to side bearing.
A
: Puller (Commercial service tool)
B
: Replacer (Commercial service tool)
C
: Drift [SST: ST02371000 (
—
)]
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CENTER STEM ASSEMBLY
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3.
Press inner race of side bearing (left) to center stem assembly,
using the drift (A) (Commercial service tool).
CAUTION:
• Never reuse side bearing.
• Apply gear oil to side bearing.
4.
Install side bearing adjusting shims (2 pieces for right side) with
the same thickness as the ones installed prior to disassembly or
re-install the old ones, with outer race of side bearing to center
stem assembly.
If side bearing adjusting shims have been already selected, use
them.
CAUTION:
• Never reuse side bearing.
• Apply gear oil to side bearing.
5.
Set the drifts (A and B) to the right and left side bearing adjusting
shims individually. Press center stem assembly with side bear-
ing to install gear carrier assembly to center stem assembly.
CAUTION:
• The drift shall be placed on the center of the adjusting
shims.
• The pressure shall be as low as possible to install differ-
ential assembly into gear carrier assembly. The maximum
pressure shall be 10 kN (1 ton, 1.0 Imp ton).
• If the adjusting shims are installed by tapping, the gear carrier may be damaged. Avoid tapping.
6.
Install dummy cover set, check and adjust drive gear runout, tooth contact, backlash, and total preload
torque. Refer to
7.
Remove dummy cover set.
8.
Apply liquid gasket (1) to mating surface of rear cover.
• Use Genuine Silicone RTV or equivalent. Refer to
"Recommended Chemical Products and Sealants"
CAUTION:
• Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adher-
ing to the mounting surfaces.
• The width of sealant bend is approximately 3 mm (0.012
in). Apply sealant evenly.
9.
Set the drifts (A and B) to the right and left side bearing adjusting
shims individually. Compress center stem assembly with side
bearing to install rear cover.
CAUTION:
• The drift shall be placed on the center of the adjusting
shims.
• The pressure shall be as low as possible to install the rear
cover. The maximum pressure shall be 10 kN (1 ton, 1.0
Imp ton).
• If rear cover is forced in by tapping, rear cover may be damaged by adjusting shims. Avoid tap-
ping.
10. Tighten rear cover mounting bolts to the specified torque.
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A
: Drift [SST: KV38109820 (
—
)]
B
: Drift [SST: KV38109810 (
—
)]
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A
: Drift [SST: KV38109820 (
—
)]
B
: Drift [SST: KV38109810 (
—
)]
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CENTER STEM ASSEMBLY
11. Install side oil seal (right) until it becomes flush with the gear car-
rier end, using the drift (A) [SST: ST33400001 (J-26082)].
CAUTION:
• Never reuse oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal.
12. Install side oil seal (left) until it becomes flush with the gear car-
rier end, using the drift (A) [SST: KV38100500 (
—
)].
CAUTION:
• Never reuse oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal.
13. Set gasket to drain plug. Install it to gear carrier.
CAUTION:
Never reuse oil gasket.
14. Set gasket to filler plug. Install it to gear carrier.
CAUTION:
• Never reuse oil gasket.
• After oil is refilled, tighten filler plug to specified torque.
15. Install carrier brackets.
16. Install electric controlled coupling. Refer to
17. Check total preload torque. Refer to
.
18. Install breather tube (1) and breathers (2) with the paint mark (A)
facing vehicle rear within the angle (B) shown as follows.
Adjustment
INFOID:0000000007580308
TOTAL PRELOAD TORQUE
1.
Before inspection and adjustment, drain gear oil.
2.
Remove electric controlled couplings. Refer to
.
3.
Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
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Angle (B)
: 0 – 15
°
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CENTER STEM ASSEMBLY
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4.
Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
5.
Measure the total preload, using the preload gauge (A) [SST:
ST3127S000 (J-25765-A)].
NOTE:
Total preload torque = Pinion bearing torque + Side bearing
torque
• If measured value is out of the specification, disassemble it to
check and adjust each part. Adjust the pinion bearing preload and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bearing preload.
DRIVE GEAR RUNOUT
1.
Remove rear cover. Refer to
.
2.
Following the procedure below, install the dummy cover set [SST: KV381096S0 (
—
)] to gear car-
rier.
a.
Temporarily install the bearing guides [SST: KV38109610 (
—
), KV38109620 (
—
)] to
gear carrier.
b.
Position the dummy cap spacers [SST: KV38109630 (
—
), KV38109640 (
—
)] and the
angle [SST: KV38109650 (
—
)] to bearing guide.
c.
Use rear cover mounting bolts, tighten bolts to the specified torque. Refer to
.
d.
Tighten dummy cap spacer mounting bolts evenly to the specified torque.
3.
Fit a dial indicator to the drive gear back face.
4.
Rotate the drive gear to measure runout.
• If the runout is outside of the repair limit, check drive gear
assembly condition; foreign material may be caught between
drive gear and center stem, or center stem or drive gear may
be deformed, etc.
CAUTION:
Replace drive gear and drive pinion as a set.
TOOTH CONTACT
1.
Remove rear cover. Refer to
.
2.
Following the procedure below, install the dummy cover set [SST: KV381096S0 (
—
)] to gear car-
rier.
a.
Temporarily install the bearing guides [SST: KV38109610 (
—
), KV38109620 (
—
)] to
gear carrier.
Total preload torque
: Refer to
When the preload torque is large
On pinion bearings:
Replace the collapsible spacer.
On side bearings:
Use thinner side bearing adjusting shims. For selecting adjusting
shim, refer to the latest parts information.
When the preload is small
On pinion bearings:
Tighten the drive pinion nut.
On side bearings:
Use thicker side bearing adjusting shims. For selecting adjusting
shim, refer to the latest parts information.
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Tightening torque
: 5.9 N·m (0.6 kg-m, 52 in-lb)
Drive gear back face
runout
: Refer to
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CENTER STEM ASSEMBLY
b.
Position the dummy cap spacers [SST: KV38109630 (
—
), KV38109640 (
—
)] and the
angle [SST: KV38109650 (
—
)] to bearing guide.
c.
Use rear cover mounting bolts, tighten bolts to the specified torque. Refer to
.
d.
Tighten dummy cap spacer mounting bolts evenly to the specified torque.
3.
Apply red lead to drive gear.
CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on drive gear.
4.
Rotate drive gear back and forth several times, check drive pin-
ion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side and reverse side.
Tightening torque
: 5.9 N·m (0.6 kg-m, 52 in-lb)
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CENTER STEM ASSEMBLY
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Tooth Contact Judgment Guide
5.
If tooth contact is improperly adjusted, follow the procedure
below to adjust the pinion height (dimension X). For selecting
adjusting shim, refer to the latest parts information.
• If the tooth contact is near the face (face contact), or near the
heel (heel contact), thicken drive pinion gear adjusting shim to
move drive pinion closer to drive gear.
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CENTER STEM ASSEMBLY
• If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thin drive pinion gear adjusting shim to move
drive pinion farther from drive gear.
BACKLASH
1.
Remove rear cover. Refer to
.
2.
Following the procedure below, install the dummy cover set [SST: KV381096S0 (
—
)] to gear car-
rier.
a.
Temporarily install the bearing guides [SST: KV38109610 (
—
), KV38109620 (
—
)] to
gear carrier.
b.
Position the dummy cap spacers [SST: KV38109630 (
—
), KV38109640 (
—
)] and the
angle [SST: KV38109650 (
—
)] to bearing guide.
c.
Use rear cover mounting bolts, and tighten bolts to the specified torque. Refer to
.
d.
Tighten dummy cap spacer mounting bolts evenly to the specified torque.
3.
Fit a dial indicator to the drive gear face to measure the back-
lash.
• If the backlash is outside of the specified value, change the
thickness of side bearing adjusting shims.
Inspection
INFOID:0000000007580309
INSPECTION AFTER DISASSEMBLY
Drive Gear and Drive Pinion
• Clean up the disassembled parts.
• If the gear teeth never mesh or line-up correctly, determine the cause and adjust or replace as necessary.
• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new drive
gear and drive pinion as a set.
Bearing
• Whenever disassembled, replace.
• Clean up the disassembled parts.
• If any chipped (by friction), pitted, worn, rusted or scratched marks, or unusual noise from the bearing is
observed, replace as a bearing assembly (as a new set).
PDIA0441E
Tightening torque
: 5.9 N·m (0.6 kg-m, 52 in-lb)
Backlash
: Refer to
.
When the backlash is large:
Make drive gear back adjusting shims thicker, and drive
gear front adjusting shims thinner. For selecting ad-
justing shim, refer to the latest parts information.
When the backlash is small:
Make drive gear back adjusting shims thinner, and
drive gear front adjusting shims thicker. For selecting
adjusting shim, refer to the latest parts information.
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CENTER STEM ASSEMBLY
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Oil Seal
• Whenever disassembled, replace.
• If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace them.
Gear Carrier and Rear Cover
• Check damage and cracks of gear carrier and rear cover.
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DRIVE PINION
DRIVE PINION
Exploded View
INFOID:0000000007580310
1.
Filler plug
2.
Gasket
3.
Drain plug
4.
Breather tube
5.
Hose clamp
6.
Breather hose
7.
Breather
8.
Band 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 bearing (rear)
22. Collapsible spacer
23. Breather
24. Gear carrier
25. Carrier bracket (right)
26. Pinion bearing (front)
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. Side oil seal (left)
35. Electric controlled coupling (left)
A.
Oil seal lip
B.
Gear carrier mounting face
: Always replace after every disassembly.
: Select with proper thickness.
: N·m (kg-m, ft-lb)
: Apply multi purpose grease
: Apply gear oil.
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DRIVE PINION
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Disassembly
INFOID:0000000007580311
1.
Remove electric controlled couplings. Refer to
.
2.
Remove center stem assembly. Refer to
3.
Remove drive pinion lock nut with the flange wrench (A) (Com-
mercial service tool).
4.
Put matching mark (A) on the end of drive pinion. The matching
mark should be in line with the matching mark (B) on companion
flange (1).
CAUTION:
For matching mark, use paint. Never damage companion
flange and drive pinion.
NOTE:
The matching mark on the final drive companion flange indicates
the maximum vertical runout position.
When replacing companion flange, matching mark is not neces-
sary.
5.
Remove companion flange using the puller (A) (Commercial ser-
vice tool).
6.
Press drive pinion assembly out of gear carrier.
CAUTION:
Never drop drive pinion assembly.
7.
Remove front oil seal.
8.
Remove inner race of pinion bearing (front).
9.
Remove collapsible spacer.
: Apply anti-corrosive oil.
: Apply Genuine Silicone RTV or equivalent. Refer to
GI-22, "Recommended Chemical Products and Sealants"
.
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[REAR FINAL DRIVE: RTVS]
DRIVE PINION
10. Remove inner race of pinion bearing (rear) and drive pinion
adjusting shim with the replacer (A) (Commercial service tool).
11. Remove drive pinion adjusting shim.
12. Tap the outer races of pinion bearing (front and rear) uniformly
using the brass rod or equivalent to remove them.
CAUTION:
Never damage gear carrier.
13. Perform inspection after disassembly. Refer to
Assembly
INFOID:0000000007580312
1.
Install outer race of pinion bearing (front) to the gear carrier with
the drift (A) [SST: ST33190000 (
—
)].
CAUTION:
• At first, using the hammer, tap outer race of bearing until
it becomes flat to gear carrier.
• Never reuse pinion bearing.
2.
Install outer race of pinion bearing (rear) to the gear carrier with
the drift (A) [SST: ST37830000 (
—
)].
CAUTION:
• At first, using the hammer, tap outer race of bearing until
it becomes flat to gear carrier.
• Never reuse pinion bearing.
PDIA0801J
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DRIVE PINION
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3.
Temporarily install drive pinion adjusting shim (1).
When hypoid gear set has been replaced
• Select drive pinion adjusting shim. Refer to
.
When hypoid gear set has been reused
• Temporarily install the removed drive pinion adjusting shim or
same thickness shim to drive pinion.
CAUTION:
Pay attention to the direction of drive pinion adjusting
shim. (Assemble as shown in the figure.)
4.
Install inner race of pinion bearing (rear) (1) to drive pinion with
the drift (A) [SST: ST33032000 (
—
)].
CAUTION:
Never reuse pinion bearing.
5.
Assemble collapsible spacer (1) to drive pinion (2).
CAUTION:
• Be careful of the mounting direction of collapsible spacer.
• Never reuse collapsible spacer.
6.
Assemble drive pinion into gear carrier.
CAUTION:
Apply gear oil to pinion bearing.
7.
Assemble inner race of pinion bearing (front) to drive pinion
assembly.
CAUTION:
• Never reuse pinion bearing.
• Apply gear oil to pinion bearing.
8.
Using the drift (A) [SST: KV37710000 (
—
)], press the
inner race of pinion bearing (front) to drive pinion as far as drive
pinion nut can be tightened.
9.
Using the drift (A) (Commercial service tool), drive front oil seal
until it becomes flush with the gear carrier end.
CAUTION:
• Never reuse oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal.
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DRIVE PINION
10. Install companion flange.
NOTE:
When reusing drive pinion, align the matching mark (A) of drive
pinion with the matching mark (B) of companion flange (1), and
then install companion flange.
11. Apply anti-corrosion oil to the thread and seat of drive pinion
lock nut, and temporarily tighten drive pinion lock nut to drive
pinion, using the flange wrench (Commercial service tool).
CAUTION:
Never reuse drive pinion lock nut.
12. Adjust to the drive pinion lock nut tightening torque and pinion
bearing preload torque, using the preload gauge (A) [SST:
ST3127S000 (J-25765-A)].
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.
• After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
13. Install center stem assembly. Refer to
.
CAUTION:
Never install rear cover at this timing.
14. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion
flange runout. Refer to
15. Check total preload torque. Refer to
.
16. Install rear cover. Refer to
17. Install electric controlled couplings. Refer to
Adjustment
INFOID:0000000007580313
PINION GEAR HEIGHT
If the hypoid gear set has been replaced, select the drive pinion adjusting shim.
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Pinion bearing preload
: Refer to
.
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Revision: 2011 October
2012 JUKE
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