Nissan Juke (2012 year). Service Repair Manual - part 223

 

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Nissan Juke (2012 year). Service Repair Manual - part 223

 

 

TM-44

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

INPUT SHAFT AND GEAR

INPUT SHAFT AND GEAR

Exploded View

INFOID:0000000007576369

Disassembly

INFOID:0000000007576370

CAUTION:

1.

Input shaft front bearing

2.

Input shaft

3.

3rd input gear

4.

Spacer

5.

Snap ring

6.

3rd baulk ring

7.

3rd-4th coupling sleeve

8.

3rd-4th synchronizer hub

9.

Insert key

10. 4th baulk ring

11. 4th input gear

12. 5th input gear

13. 5th baulk ring

14. 5th-6th coupling sleeve

15. 5th-6th synchronizer hub

16. 6th baulk ring

17. Needle bearing 

18. 6th input gear

19. Input shaft rear bearing

A.

First step

B.

Final step

 : Apply gear oil.

 : Replace the parts as a set.

 : Always replace after every disassembly.

 : N·m (kg-m, ft-lb)

JPDIC0407GB

Revision: 2011 October

2012 JUKE

INPUT SHAFT AND GEAR

TM-45

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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• Fix input shaft 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 do not affect any functions.

1.

Remove input shaft rear bearing mounting bolt (1), using the
drift (A) [SST: KV32300QAM ( - )].

2.

Remove input shaft rear bearing (1), as per the following proce-
dure.

a.

Set a puller [Commercial service tool] to input shaft rear bearing.

b.

Remove input shaft rear bearing, using a drift (A) [Commercial
service tool].

3.

Remove spacer (1), 6th input gear (2), needle bearing, 6th baulk
ring, and 5th-6th synchronizer hub assembly (3).

4.

Remove insert keys and 5th-6th coupling sleeve from 5th-6th
synchronizer hub.

SCIA1755J

JPDIC0449ZZ

JPDIC0111ZZ

PCIB1750E

Revision: 2011 October

2012 JUKE

TM-46

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

INPUT SHAFT AND GEAR

5.

Remove snap ring (1).

6.

Remove spacer, 5th baulk ring, 5th input gear (2), and spacer.

7.

Remove snap ring (1).

8.

Remove spacer, 4th input gear (2), 4th baulk ring, and 3rd-4th
synchronizer hub assembly (3).

9.

Remove insert keys and 3rd-4th coupling sleeve from 3rd-4th
synchronizer hub.

10. Remove snap ring (1).

11. Remove spacer, 3rd baulk ring, and 3rd input gear (2).

12. Set a puller [Commercial service tool] to input shaft front bearing

(1), and then remove input shaft front bearing.

Assembly

INFOID:0000000007576371

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

CAUTION:

• Replace transaxle assembly when replacing input shaft.

PCIB1754E

PCIB1753E

PCIB1752E

PCIB1751E

Revision: 2011 October

2012 JUKE

INPUT SHAFT AND GEAR

TM-47

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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• 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.

• Never reuse snap ring.
• Check that snap ring is securely installed in a groove.
• Replace 3rd-4th coupling sleeve and 3rd-4th synchronizer

hub as a set.

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

as a set.

• Be careful to install 3rd-4th synchronizer hub according to the

specified direction.

• Be careful to install 5th-6th synchronizer hub according to the

specified direction.

• Install input shaft front bearing (1), using a drift (A) [Commercial

service tool].

SCIA1755J

A : 3rd input gear side

B : 4th input gear side

PCIB1748E

A : 5th input gear side

B : 6th input gear side

PCIB1749E

JPDIC0112ZZ

Revision: 2011 October

2012 JUKE

TM-48

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

INPUT SHAFT AND GEAR

• Install input shaft rear bearing (1), using a drift (A) [Commercial

service tool] and the drift (B) [SST: ST36720030 ( - )].

• Apply gear oil to 3rd baulk ring, 4th baulk ring, 5th baulk ring, and

6th baulk ring.

• Install input shaft rear bearing mounting bolt (1), as per the follow-

ing procedure.

CAUTION:

Follow the procedures. Otherwise it may cause a transaxle
malfunction.

1.

Fix the drift (A) [SST: KV32300QAM ( - )] in a vise, and then set
input shaft assembly.

2.

Install input shaft rear bearing mounting bolt, and then tighten it
to the specified torque of the first step.

3.

Loosen input shaft rear bearing mounting bolt by a half turn.

4.

Tighten input shaft rear bearing mounting bolt to the specified
torque of the final step.

Inspection

INFOID:0000000007576372

INSPECTION AFTER DISASSEMBLY

Input Shaft 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

JPDIC0113ZZ

JPDIC0449ZZ

SCIA7736E

SCIA1753J

Revision: 2011 October

2012 JUKE

INPUT SHAFT AND GEAR

TM-49

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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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.

SCIA0608J

MTF0041D

Revision: 2011 October

2012 JUKE

TM-50

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

MAINSHAFT AND GEAR

MAINSHAFT AND GEAR

Exploded View

INFOID:0000000007576373

1.

Mainshaft front bearing outer 
race

2.

Mainshaft front bearing inner race

3.

Mainshaft

4.

1st main gear

5.

1st inner baulk ring

6.

1st synchronizer cone

7.

1st outer baulk ring

8.

1st-2nd coupling sleeve

9.

Insert key

10.

1st-2nd synchronizer hub

11. 2nd outer baulk ring

12. 2nd synchronizer cone

13.

2nd inner baulk ring

14. 2nd main gear

15. Bushing

16.

3rd main gear

17. Mainshaft adjusting shim

18. 4th main gear

19.

5th main gear

20. 6th main gear

21. Mainshaft rear bearing inner race

22.

Mainshaft rear bearing outer race 23. Snap ring

24. Mainshaft rear bearing adjusting 

shim

 : Apply gear oil.

 : Replace the parts as a set.

 : Select with proper thickness.

 : Always replace after every disassembly.

SFIA3293E

Revision: 2011 October

2012 JUKE

MAINSHAFT AND GEAR

TM-51

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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Disassembly

INFOID:0000000007576374

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: 2011 October

2012 JUKE

TM-52

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

MAINSHAFT AND GEAR

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:0000000007576375

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: 2011 October

2012 JUKE

MAINSHAFT AND GEAR

TM-53

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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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: 2011 October

2012 JUKE

TM-54

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

MAINSHAFT AND GEAR

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:0000000007576376

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: 2011 October

2012 JUKE

MAINSHAFT AND GEAR

TM-55

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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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: 2011 October

2012 JUKE

TM-56

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

REVERSE IDLER SHAFT AND GEAR

REVERSE IDLER SHAFT AND GEAR

Exploded View

INFOID:0000000007576377

Disassembly

INFOID:0000000007576378

1.

Remove reverse output gear (1).

1.

Reverse output gear

2.

Snap ring

3.

Reverse baulk ring

4.

Return spring

5.

Needle bearing

6.

Seal washer

7.

Reverse idler shaft

8.

Spacer

9.

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: 2011 October

2012 JUKE

REVERSE IDLER SHAFT AND GEAR

TM-57

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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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:0000000007576379

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:0000000007576380

INSPECTION AFTER DISASSEMBLY

PCIB1759E

PCIB1758E

PCIB1757E

PCIB1761E

Revision: 2011 October

2012 JUKE

TM-58

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

REVERSE IDLER SHAFT AND GEAR

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: 2011 October

2012 JUKE

FINAL DRIVE

TM-59

< UNIT DISASSEMBLY AND ASSEMBLY >

[6MT: RS6F94R]

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FINAL DRIVE

Exploded View

INFOID:0000000007576381

Disassembly

INFOID:0000000007576382

1.

Remove differential side bearing inner race (clutch housing side)
(1), as per the following procedure.

a.

Set a puller [Commercial service tool] to differential side bearing
inner race (clutch housing side).

b.

Remove differential side bearing inner race (clutch housing
side), using the drift (A) [SST: ST33061000 (J-8107-2)].

1.

Shim

2.

Differential side bearing outer race 
(transaxle case side)

3.

Differential side bearing inner race 
(transaxle case side)

4.

Final gear

5.

Differential case

6.

Differential side bearing inner race 
(clutch housing side)

7.

Differential side bearing outer race 
(clutch housing side)

 : Replace the parts as a set.

 : N·m (kg-m, ft-lb)

JPDIC0424GB

PCIB1767E

Revision: 2011 October

2012 JUKE

 

 

 

 

 

 

 

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