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Nissan Juke (2016 year). Service Repair Manual - part 608

TM-56

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

MAINSHAFT AND GEAR

Disassembly

INFOID:0000000012200784

CAUTION:

• Fix mainshaft 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 never affect any functions.

1. Remove snap ring (1).

2. Remove 6th main gear (1) and mainshaft rear bearing inner race

(2), as per the following procedure.

a. Set a puller [Commercial service tool] to 6th main gear.
b. Remove mainshaft rear bearing inner race and 6th main gear,

using the drift (A) [SST: ST33052000 ( - )].

3. Remove 4th main gear (1) and 5th main gear (2), as per the fol-

lowing procedure.

a. Set a puller [Commercial service tool] to 4th main gear.
b. Remove 5th main gear and 4th main gear, using the drift (A)

[SST: ST33052000 ( - )].

4. Remove mainshaft adjusting shim.

SCIA1755J

PCIB1745E

PCIB1744E

PCIB1743E

Revision: November 2015

2016 JUKE

MAINSHAFT AND GEAR

TM-57

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

5. Remove 1st main gear (1), 1st-2nd synchronizer hub assembly

(2), 2nd main gear (3), and 3rd main gear (4), as per the follow-

ing procedure.

a. Set a puller [Commercial service tool] to 1st main gear.
b. Remove 3rd main gear, busing, 2nd main gear, 2nd inner baulk

ring, 2nd synchronizer cone, 2nd outer baulk ring, 1st-2nd syn-

chronizer hub assembly, 1st outer baulk ring, 1st synchronizer

cone, 1st inner baulk ring, and 1st main gear, using the drift (A)

[SST: ST33052000 ( - )].

c. Remove insert keys and 1st-2nd coupling sleeve from 1st-2nd

synchronizer hub.

6. Remove mainshaft front bearing inner race (1), as per the fol-

lowing procedure.

a. Set a puller [Commercial service tool] to mainshaft front bearing

inner race.

b. Remove mainshaft front bearing inner race, using the drift (A)

[SST: ST33052000 ( - )].

Assembly

INFOID:0000000012200785

CAUTION:

• Select mainshaft rear bearing adjusting shim, as per the following procedure when replacing main-

shaft 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).

• Replace transaxle assembly when replacing mainshaft.

• 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.

PCIB1742E

PCIB1741E

SCIA1755J

Revision: November 2015

2016 JUKE

TM-58

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

MAINSHAFT AND GEAR

1. Install mainshaft front bearing inner race (1), using the drift (A)

[SST: ST36720030 ( - )].

CAUTION:

Replace mainshaft front bearing outer race and mainshaft

front bearing inner race as a set.

2. Apply gear oil to 1st inner baulk ring, 1st synchronizer cone, 1st

outer baulk ring, 2nd inner baulk ring, 2nd synchronizer cone,

and 2nd outer baulk ring.

CAUTION:

• Replace 1st inner baulk ring, 1st synchronizer cone, and

1st outer baulk ring as a set.

• Replace 2nd inner baulk ring, 2nd synchronizer cone, and

2nd outer baulk ring as a set.

3. Install insert keys and 1st-2nd coupling sleeve to 1st-2nd synchronizer hub.

CAUTION:

Replace 1st-2nd synchronizer hub and 1st-2nd coupling sleeve as a set.

4. Install 1st main gear (1), 1st inner baulk ring, 1st synchronizer

cone, 1st outer baulk ring, 1st-2nd synchronizer hub assembly

(2), 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer

baulk ring.

5. Install bushing (3), using the drift (A) [SST: KV32102700 ( - )].

6. Install 3rd main gear (1) and 2nd main gear (2), using the drift

(A) [SST: KV32102700 ( - )].

7. Measure dimension “L” as shown in the figure. Select mainshaft

adjusting shim (1) according to the following list, and then install

it to mainshaft.

Unit: mm (in)

PCIB1733E

PCIB1734E

PCIB1735E

2 : Mainshaft
3 : 3rd main gear

Dimension “L”

Mainshaft adjusting shim thickness

147.690 – 147.666 (5.8146 – 5.8136)

1.500 (0.0591)

147.665 – 147.641 (5.8136 – 5.8126)

1.525 (0.0600)

147.640 – 147.616 (5.8126 – 5.8116)

1.550 (0.0610)

147.615 – 147.591 (5.8116 – 5.8107)

1.575 (0.0620)

147.590 – 147.566 (5.8106 – 5.8097)

1.600 (0.0630)

147.565 – 147.541 (5.8096 – 5.8087)

1.625 (0.0640)

147.540 – 147.516 (5.8086 – 5.8077)

1.650 (0.0650)

147.515 – 147.491 (5.8077 – 5.8067)

1.675 (0.0659)

PCIB1736E

Revision: November 2015

2016 JUKE

MAINSHAFT AND GEAR

TM-59

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

8. Install 4th main gear (1), using the drift (A) [SST: KV32102700 ( -

)].

9. Install 5th main gear (1), using the drift (A) [SST: KV32102700 ( -

)].

10. Install 6th main gear (1), using the drift (A) [SST: KV32102700 ( -

)].

11. Install mainshaft rear bearing inner race (1), using the drift (A)

[SST: ST30901000 (J-26010-01)].

CAUTION:

Replace mainshaft rear bearing inner race and mainshaft

rear bearing outer race as a set.

12. Install snap ring.

CAUTION:

Never reuse snap ring.

Inspection

INFOID:0000000012200786

INSPECTION AFTER DISASSEMBLY

Mainshaft and Gear

147.490 – 147.466 (5.8067 – 5.8057)

1.700 (0.0669)

147.465 – 147.441 (5.8057 – 5.8048)

1.725 (0.0679)

147.440 – 147.416 (5.8047 – 5.8038)

1.750 (0.0689)

147.415 – 147.391 (5.8037 – 5.8028)

1.775 (0.0699)

Dimension “L”

Mainshaft adjusting shim thickness

PCIB1737E

PCIB1738E

PCIB1739E

PCIB1740E

Revision: November 2015

2016 JUKE

TM-60

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

MAINSHAFT 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

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.

CAUTION:

• Replace mainshaft front bearing outer race and mainshaft

front bearing inner race as a set.

• Replace mainshaft rear bearing inner race and mainshaft rear

bearing outer race as a set.

PCIB1775E

SCIA1753J

SCIA0608J

SPD715

Revision: November 2015

2016 JUKE

REVERSE IDLER SHAFT AND GEAR

TM-61

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

REVERSE IDLER SHAFT AND GEAR

Exploded View

INFOID:0000000012200787

Disassembly

INFOID:0000000012200788

1. Remove reverse output gear (1).

Reverse output gear

Snap ring

Reverse baulk ring

Return spring

Needle bearing

Seal washer

Reverse idler shaft

Spacer

Reverse input gear

10. Lock washer

11. Spring washer

: Replace the parts as a set.

: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

JPDIC0425GB

PCIB1760E

Revision: November 2015

2016 JUKE

TM-62

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

REVERSE IDLER SHAFT AND GEAR

2. Remove snap ring (1).

3. Remove reverse baulk ring (1) and return spring (2).

4. Remove snap ring (1), lock washer (2), and reverse input gear

(3).

5. Remove needle bearings (1) and washer.

Assembly

INFOID:0000000012200789

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

CAUTION:

• Never reuse snap ring.

• Check that snap ring is securely installed in a groove.

• Replace reverse output gear, snap ring, reverse baulk ring, return spring, needle bearing, reverse

idler shaft, spacer, reverse input gear, and lock washer as a set.

Inspection

INFOID:0000000012200790

INSPECTION AFTER DISASSEMBLY

PCIB1759E

PCIB1758E

PCIB1757E

PCIB1761E

Revision: November 2015

2016 JUKE

REVERSE IDLER SHAFT AND GEAR

TM-63

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

Shaft and Gear

Check the following items. Replace reverse output gear, snap ring, reverse baulk ring, return spring, needle

bearing, reverse idler shaft, spacer, reverse input gear, and lock washer as a set, if necessary.

• Damage, peeling, bend, uneven wear, and distortion of shaft

• Excessive wear, damage, and peeling of gear

Bearing

Check damage and rotation of bearing. Replace reverse output gear, snap ring, reverse baulk ring, return

spring, needle bearing, reverse idler shaft, spacer, reverse input gear, and lock washer as a set, if necessary.

Revision: November 2015

2016 JUKE

Content .. 606 607 608 609 ..