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Nissan Juke (2016 year). Service Repair Manual - part 616

TM-120

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F52H]

INPUT SHAFT AND GEARS

Push baulk ring on the cone and measure the clearance between

baulk ring and cone. If measurement is below limit, replace it with a

new one.

•

Double-cone synchronizer (3rd)

Check the clearance between outer baulk ring, synchronizer cone,

and inner baulk ring as follows.

CAUTION:

The clearances (A) and (B) are controlled with outer baulk

ring, synchronizer cone, and inner baulk ring as a set.

Replace them as a set if the clearances are outside the limit

value.

1. Measure the clearance (A) at 2 points or more diagonally oppo-

site using a dial indicator. And then calculate mean value.

2. Measure the clearance (B) at 2 points or more diagonally oppo-

site using a feeler gauge. And then calculate mean value.

Bearing

Clearance

Standard value : Refer to

TM-144, "Baulk Ring Clear-

ance"

Limit value

: Refer to

TM-144, "Baulk Ring Clear-

ance"

SMT140

SCIA0950E

Tool number

: ST30031000 (J-22912-01)

Clearance (A)

Standard value : Refer to

TM-144, "Baulk Ring Clear-

ance"

Limit value

: Refer to

TM-144, "Baulk Ring Clear-

ance"

PCIB0945E

Clearance (B)

Standard value : Refer to

TM-144, "Baulk Ring

Clearance"

Limit value

: Refer to

TM-144, "Baulk Ring

Clearance"

SCIA1084E

Revision: November 2015

2016 JUKE

INPUT SHAFT AND GEARS

TM-121

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F52H]

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

• Damage and rough rotation of bearing

ASSEMBLY

1. Install 3rd needle bearing to input shaft.
2. Install 3rd input gear, 3rd inner baulk ring, 3rd synchronizer cone, and 3rd outer baulk ring to input shaft.

CAUTION:

Replace 3rd inner baulk ring, 3rd synchronizer cone, and 3rd outer baulk ring as a set.

3. Install 3rd-4th spread springs, 3rd-4th shifting inserts, and 3rd-4th synchronizer hub onto 3rd-4th coupling

sleeve.

CAUTION:

• Be careful with orientation of 3rd-4th synchronizer hub.

• Do not reuse 3rd-4th synchronizer hub and 3rd-4th cou-

pling sleeve.

• Replace 3rd-4th synchronizer hub and 3rd-4th coupling

sleeve as a set.

• Be careful with orientation of 3rd-4th coupling sleeve.

• Be sure not to hook center projection of 2 spread springs

on same shifting insert.

MTF0041D

SCIA0921E

PCIB0799E

SCIA1083E

Revision: November 2015

2016 JUKE

TM-122

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F52H]

INPUT SHAFT AND GEARS

4. Press in 3rd-4th synchronizer hub assembly using Tool.

CAUTION:

Align grooves of 3rd-4th shifting insert and 3rd outer baulk

ring.

5. Press in 4th input gear bushing using Tool.

6. Install 4th baulk ring.
7. Install 4th needle bearing and 4th input gear to input shaft.

8. Select thrust washer so that dimension "C2" satisfies the stan-

dard value below. Then install thrust washer onto input shaft.

Refer to

TM-145, "Available Thrust Washer"

CAUTION:

Only one thrust washer can be selected.

9. Press in 5th input gear bushing using Tool.

CAUTION:

Do not reuse 5th input gear bushing.

10. Install 5th needle bearing and 5th input gear to input shaft.
11. Install 5th baulk ring.

Tool number

: KV40105710 ( — )

SCIA1031E

Tool number

: KV40105710 ( — )

PCIB0922E

Standard value for dimension "C2”

: Refer to

TM-145, "Available Thrust Washer"

SCIA0925E

Tool number

: KV40105710 ( — )

SCIA1033E

Revision: November 2015

2016 JUKE

INPUT SHAFT AND GEARS

TM-123

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F52H]

12. Install 5th-6th synchronizer hub, 5th-6th spread springs, and 5th-6th shifting inserts onto 5th-6th coupling

sleeve.

CAUTION:

• Be careful with orientation of 5th-6th synchronizer hub.

• Do not reuse 5th-6th synchronizer hub and 5th-6th cou-

pling sleeve.

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

sleeve as a set.

• Be careful with orientation of 5th-6th coupling sleeve.

• Be sure not to hook center projection of 2 spread springs

on same shifting insert.

13. Press in 5th-6th synchronizer hub assembly using Tool.

CAUTION:

Align grooves of 5th-6th shifting insert and 5th baulk ring.

: Front side

: Rear side

PCIB1883E

: 5th input gear side

: 6th input gear side

PCIB1884E

SCIA1083E

Tool number

: KV40105710 ( — )

SCIA1039E

Revision: November 2015

2016 JUKE

TM-124

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F52H]

INPUT SHAFT AND GEARS

14. Install 6th needle bearing, 6th input gear, 6th baulk ring onto 6th

input gear bushing and then press in 6th input gear bushing onto

input shaft using Tool.

15. Install snap ring onto input shaft and make sure that end play

(gap between snap ring and groove) of 6th input gear bushing

satisfies the standard value.

• If measurement is outside the standard range, select snap

ring. Refer to

TM-144, "Available Snap Rings"

CAUTION:

Do not reuse snap ring.

16. Press in input shaft rear bearing using Tool.

CAUTION:

Install input shaft rear bearing with its brown surface facing

the 6th input gear side.

17. Press in input shaft front bearing using Tools.

18. Install oil channel onto input shaft.

19. Check end play of 3rd, 4th, 5th, and 6th input gears.

Tool number

: ST33200000 (J-26082)

WCIA0309E

End play standard value

:Refer to

TM-144, "Available Snap Rings"

SCIA0970E

Tool number

: ST30901000 (J-26010-01)

WCIA0310E

Tool number

A: ST33052000 ( — )
B: ST30032000 (J-26010-01)

WCIA0311E

End play standard value

: Refer to

TM-144, "Gear End Play"

SCIA0966E

Revision: November 2015

2016 JUKE

MAINSHAFT AND GEARS

TM-125

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F52H]

MAINSHAFT AND GEARS

Exploded View

INFOID:0000000012200826

MAINSHAFT AND GEARS

Disassembly and Assembly

INFOID:0000000012200827

DISASSEMBLY

Mainshaft front bearing

Mainshaft bearing retainer

Mainshaft

Reverse main gear

1st main gear

1st main gear bushing

1st needle bearing

1st inner baulk ring

1st synchronizer cone

10. 1st outer baulk ring

11. 1st-2nd spread spring

12. 1st-2nd shifting insert

13. 1st-2nd synchronizer hub

14. 2nd outer baulk ring

15. 2nd synchronizer cone

16. 2nd inner baulk ring

17. 1st-2nd coupling sleeve

18. 2nd main gear bushing

19. 2nd needle bearing

20. 2nd main gear

21. 3rd main gear

22. 3rd-4th mainshaft spacer

23. 4th main gear adjusting shim

24. 4th main gear

25. 5th main gear

26. 5th-6th mainshaft spacer

27. 6th main gear

28. 6th main gear adjusting shim 29. Mainshaft rear bearing

30. Mainshaft C-ring

31. C-ring holder

32. Snap ring

33. Mainshaft rear bearing adjust-

ing shim

: Apply gear oil.

: Replace the parts as a set.

: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

PCIB1889E

Revision: November 2015

2016 JUKE

TM-126

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F52H]

MAINSHAFT AND GEARS

1. Before disassembling, measure the end play of 1st and 2nd

main gears.

2. Remove snap ring.
3. Remove C-ring holder and then remove mainshaft C-rings.

4. Press out mainshaft rear bearing, 6th main gear adjusting shim,

and 6th main gear using Tool and a puller.

5. Remove 5th-6th mainshaft spacer.

6. Press out 4th main gear and 5th main gear using Tool and a

puller.

7. Remove 4th main gear adjusting shim.
8. Remove 3rd-4th mainshaft spacer.

9. Press out 3rd main gear and 2nd main gear using Tool (A) and a

puller (B).

10. Remove 2nd needle bearing.

End play standard value

: Refer to

TM-144, "Gear End Play"

SCIA0973E

PCIB0805E

Tool number

: ST33052000 ( — )

SCIA1056E

Tool number

: ST33052000 ( — )

SCIA1044E

Tool number

A: KV40105020 ( — )

PCIB1885E

Revision: November 2015

2016 JUKE

MAINSHAFT AND GEARS

TM-127

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F52H]

11. Press out 2nd main gear bushing, 1st-2nd synchronizer hub

assembly, 1st main gear, 1st needle bearing, 1st main gear

bushing, and reverse main gear using Tool (A).

INSPECTION AFTER DISASSEMBLY

Mainshaft and Gears

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

• Damage, peeling, dent, uneven wear, bending, and other non-

standard conditions of the shaft.

• Excessive wear, damage, peeling, and other non-standard condi-

tions of the gears.

Synchronizer

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

• Damage and unusual wear on contact surfaces of coupling sleeve,

synchronizer hub and shifting insert.

• Coupling sleeve and synchronizer hub must move smoothly.

• If any crack, damage, or excessive wear is found on cam face of

baulk ring or working face of insert, replace it.

BAULK RING CLEARANCE

Triple-cone synchronizer (1st and 2nd)

Tool number

A: KV40105020 ( — )

PCIB1886E

SCIA1076J

SMT387A

SMT867D

Revision: November 2015

2016 JUKE

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