Nissan Juke F15. Manual - part 278

TRANSFER CASE

DLN-117

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

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Disassembly

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1. Remove transfer cover mounting bolts.
2. Lightly tap position (A) of transfer cover with a plastic hammer to

remove transfer cover.

CAUTION:

When tapping of transfer cover, be sure to tap the back of

cover.

3. Remove transfer case oil seal (right and left).
4. Remove ring gear shaft assembly. Refer to 

DLN-97, "Disassem-

bly"

.

NOTE:

When the ring gear shaft removed, the following parts are simul-

taneously removed:

• Spacer (right and left)

• Ring gear bearing adjusting shim (right and left)

• Outer race of ring gear bearing (right and left)

5. Remove drive pinion assembly from transfer case. Refer to 

DLN-112, "Disassembly"

.

6. Tap the outer races of pinion bearing (front and rear) from trans-

fer case with a brass rod to remove outer races of pinion bearing

(front and rear).

CAUTION:

Never damage transfer case.

7. Remove drive pinion adjusting shim.
8. Remove dowel pin.

CAUTION:

Never remove dowel pin, if it is not necessary to replace.

9. Remove the filler plug and drain plug from the transfer case, and

then remove each gasket.

10. Remove oil defense from transfer cover.
11. Perform inspection after disassembly. Refer to 

DLN-119,

"Inspection"

.

Assembly

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1. Install the oil defense to transfer cover.
2. Install gaskets onto filler plug and drain plug and install them into transfer case.

CAUTION:

• Never reuse gasket.

• Install filler plug after oil is filled.

3. Install the dowel pin to transfer case.

CAUTION:

Never reuse the dowel pin.

4. Select drive pinion adjusting shim, and install it to transfer case. Refer to 

DLN-99, "Adjustment"

.

: Apply anti-corrosive oil.

: Apply Genuine Silicone RTV or equivalent. Refer to 

GI-22, "Recommended Chemical Products and Sealants"

.

JSDIA2199ZZ

JSDIA2200ZZ

DLN-118

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

TRANSFER CASE

5. Install outer race of pinion bearing (front) to the transfer case

with the drift (A) [SST: ST37830000 (

—

)].

CAUTION:

• Never reuse pinion bearing.

• Apply gear oil to the pinion bearing.

6. Install outer race of pinion bearing (rear) to transfer case with

the drift (A) [SST: ST33230000 (J-25805-01)].

CAUTION:

• Never reuse pinion bearing.

• Apply gear oil to the pinion bearing.

7. Install drive pinion assembly to transfer case. Refer to 

DLN-113,

"Assembly"

.

8. Install ring gear shaft assembly to transfer case. Refer to 

DLN-

98, "Assembly"

.

9. Set the drifts (A and B) to right and left side spacers individually.

Compress ring gear shaft assembly with ring gear bearing to

install transfer cover to transfer case.

CAUTION:

• Never apply gasket fluid on the mounting surface.

• Clean the mounting surface of transfer case and transfer

cover to degrease sufficiently.

• 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 tapping, the transfer cover may be damaged.

Avoid tapping.

10. Check backlash, tooth contact, and  total preload. Refer to 

DLN-99, "Adjustment"

.

CAUTION:

Measure the total preload without the transfer case oil seals.

11. Remove transfer cover. Refer to 

DLN-117, "Disassembly"

.

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

• Use Genuine Silicone RTV or equivalent. Refer to 

GI-22,

"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 2 – 3 mm (0.08 – 0.012 in).

• Overlap both ends of the bead for at least 3 mm (0.012 in).

• Immediately install transfer cover after installing applying

gasket.

JSDIA2201ZZ

JSDIA2202ZZ

A

: Drift (Commercial service tool)

B

: Drift (Commercial service tool)

JSDIA1105ZZ

JSDIA2203ZZ

TRANSFER CASE

DLN-119

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

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13. Set the drifts (A and B) to right and left side spacers individually.

Compress ring gear shaft assembly with ring gear bearing to

install transfer cover to transfer case.

CAUTION:

• Immediately install after applying gasket.

• 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 tapping, the transfer cover may be damaged.

Avoid tapping.

14. Tighten transfer cover mounting bolts to the specified torque.
15. Using the drifts (A and B), install transfer case oil seal (left) (1)

within the dimension (L) shown as follows.

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.

• Immediately install after installing transfer cover.

• After installing oil seal, immediately wipe out gasket squeezed out inward of transfer case.

16. Using the drifts (A) [SST: ST35271000 (J-26091)], install transfer

case oil seal (right) (1) within the dimension (L) shown as fol-

lows.

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.

• Immediately install after installing transfer cover.

• After installing oil seal, immediately wipe out gasket

squeezed out inward of transfer case.

Inspection

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INSPECTION AFTER DISASSEMBLY

Check items below. If necessary, replace them with new ones.

Case and Cover

Check the cracks, damages, and bearing mounting surface for wear.

CAUTION:

Replace transfer case and transfer cover as a set if any malfunction is detected on transfer case or

transfer cover.

A

: Drift (Commercial service tool)

B

: Drift (Commercial service tool)

A

: Drift (Commercial service tool)

B

: Drift [SST: ST27863000 (

—

)]

L

: 1.0 – 1.6 mm (0.040 – 0.063 in)

JSDIA1105ZZ

JSDIA2511ZZ

L

: 0 – 0.6 mm (0 – 0.024 in)

JSDIA2512ZZ

DLN-120

< SERVICE DATA AND SPECIFICATIONS (SDS) 

[TRANSFER: TY21B]

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

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Preload Torque

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Unit: N·m (kg-m, in-lb)

Backlash

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Unit: mm (in)

Companion Flange Runout

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Unit: mm (in)

Applied model

MR16DDT

Transfer model

TY21B

Oil capacity (Approx.)

 (US pt, lmp pt)

0.37 (3/4, 5/8)

Gear ratio

0.404

Number of teeth

Ring gear

42

Drive pinion

17

Item

Standard

Drive pinion bearing preload

0.30 – 0.80 (0.03 – 0.08, 3.0 – 7.0)

Total preload

With all oil seals

P

1

 + 0.55 – 0.80 (0.06 – 0.08, 5.0 – 7.0)

Without transfer case oil seal

P

1

 + 0.35 – 0.60 (0.04 – 0.06, 3.0 – 5.0)

Item

Standard

Ring gear to drive pinion

0.13 – 0.18 (0.0051 – 0.0071)

Item

Limit

Companion flange face (inner side of the propeller shaft bolt holes)

0.15 (0.0059)

Inside of companion flange (socket diameter)

0.2 (0.008)