Juke F15 (2012 year). Service Repair Manual

TM-48

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

TRANSAXLE ASSEMBLY

30. Install mainshaft rear bearing inner race to mainshaft.

CAUTION:

Replace mainshaft rear bearing inner race and mainshaft rear bearing outer race as a set.

31. Press 3rd-4th shift fork down and then shift 3rd-4th coupling sleeve to 3rd gear side.

32. Turn the shifter lever A (1) fully clockwise to position (A) and

move back the lever 10 degrees to position (B).
NOTE:
This position allows the transaxle case to be properly installed to
the clutch housing.

33. Apply recommended sealant to transaxle case mounting surface

of clutch housing.
• Use Genuine Liquid Gasket, Three Bond 1215 or an equiv-

alent.

CAUTION:

• Never allow old liquid gasket, moisture, oil, or foreign

matter to remain on mounting surface.

• Check that mounting surface is not damaged.
• Apply a continuous bead of liquid gasket to the mounting surface.

34. Install transaxle case to clutch housing. If it is difficult to install,

slightly rotate shifter lever A counterclockwise, and then install.

CAUTION:

• Never disrupt liquid gasket bead with transaxle case or

other objects during installation.

• Be careful to align the lever of 5th-reverse fork rod with

reverse gear groove.

35. Rotate input shaft so that bearing and shaft fit each other, and

then tighten transaxle mounting bolts (

) to the specified

torque.

36. Apply recommended sealant to position switch thread and check

ball plug thread. Tighten them to transaxle case and them to the
specified torque.
• Use Genuine Liquid Gasket, Three Bond 1215 or an equiv-

alent.

CAUTION:

Never allow old liquid gasket, moisture, oil, or foreign mat-
ter to remain on thread.

37. Apply thread locking sealant to 5th main gear spline.

• Use Thread Locking Sealant, Loctite Frenbloc or an equivalent.

38. Install 5th main gear (1) to mainshaft, using a suitable bolt (A)

[M10 x 1.0] and a suitable nut (B).

JPDIC0842ZZ

: Selector

: Shift fork

PCIB1553E

JPDIC0610ZZ

PCIB1554E

TRANSAXLE ASSEMBLY

TM-49

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

39. Install adapter plate (1), bushing (2), and 5th input gear (3) to

input shaft.

CAUTION:

Be careful with the orientation of adapter plate.

40. Apply gear oil to 5th-reverse baulk ring (1).
41. Install 5th-reverse baulk ring, synchronizer levers (2), and 5th-

reverse synchronizer hub (3) to 5th input gear.

CAUTION:

• Be careful with the orientation of 5th-reverse baulk ring.
• Replace 5th-reverse synchronizer hub and 5th-reverse

coupling sleeve as a set.

• Be careful with the orientation of synchronizer lever.

• Be careful with the orientation of 5th-reverse synchro-

nizer hub.

• Never allow synchronizer lever (1) to mount on to 5th-

reverse baulk ring (2) protrusion (A).

42. Install washer to input shaft.

43. Set 5th-reverse shift fork (1) to 5th-reverse coupling sleeve, and

then install them to 5th-reverse fork rod and input shaft.

: Transaxle case side

PCIB1555E

: 5th-reverse synchronizer hub side

JPDIC0421ZZ

: 5th input gear side

PCIB1556E

: 5th-reverse synchronizer hub

JPDIC0408ZZ

: Pin punch

: Mounting bolt

: Mounting nut

JPDIC0532ZZ

TM-50

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

TRANSAXLE ASSEMBLY

CAUTION:

• Be careful with the orientation of 5th-reverse coupling

sleeve.

• Replace 5th-reverse synchronizer hub and 5th-reverse

coupling sleeve as a set.

• Replace 5th-reverse shift fork and 5th-reverse fork rod as

a set.

44. Check that the gear position is in the 3rd gear position. Press

5th-reverse shift fork and shift to 5th gear.

45. Tighten mounting bolt (B) to the specified torque.
46. Tighten mounting nut (C) to the specified torque.

47. Install retaining pin to 5th-reverse shift fork (1), using a pin

punch (A).

CAUTION:

Never reuse retaining pin.

48. Shift the shifter lever A (1) to the neutral position.

49. Install O-ring to rear housing.

50. Install rear housing to transaxle case, and tighten bolts (

) to

the specified torque.

CAUTION:

Never pinch O-ring when installing rear housing.

51. Install drain plug, as per the following procedure.

Install gasket to drain plug.

CAUTION:

Never reuse gasket.

Install drain plug to clutch housing, using a socket [Commercial
service tool].

Tighten drain plug to the specified torque.

52. Install filler plug, as per the following procedure.

Install gasket to filler plug, and then install them to transaxle case.

CAUTION:

Never reuse gasket.

Tighten filler plug to the specified torque.

CAUTION:

Fill with gear oil before tightening filler plug to the specified torque.

: 5th input gear side

JPDIC0409ZZ

JPDIC0532ZZ

JPDIC0843ZZ

PCIB1558E

TRANSAXLE ASSEMBLY

TM-51

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

Inspection and Adjustment

INFOID:0000000006415703

INSPECTION AFTER DISASSEMBLY

Check contact surface and sliding surface for excessive wear,
uneven wear, bend, and damage. Replace if necessary.

ADJUSTMENT

Mainshaft Rear Bearing Preload

NOTE:
An adequate adjusting shim must be selected after replacing mainshaft, mainshaft front bearing inner race,
mainshaft front bearing outer race, mainshaft rear bearing inner race, mainshaft rear bearing outer race, clutch
housing, or transaxle case.

Install mainshaft assembly to clutch housing, as per the following procedure.

Install oil channel to clutch housing.

CAUTION:

Never reuse oil channel.

Install mainshaft front bearing outer race to clutch housing,
using a drift [Commercial service tool].

CAUTION:

• Never reuse mainshaft front bearing outer race.
• Replace mainshaft front bearing outer race and mainshaft

front bearing inner race as a set.

Install mainshaft front bearing inner race to mainshaft, using a
drift [Commercial service tool].

CAUTION:

• Never reuse mainshaft front bearing inner race.
• Replace mainshaft front bearing inner race and mainshaft

front bearing outer race as a set.

PCIB1571E

MCIB0080E

TM-52

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

TRANSAXLE ASSEMBLY

Install mainshaft assembly (1) to clutch housing (2).

Install the dummy shim [1.60 mm (0.0630 in) thickness] (A) of
dummy shim set [SST: KV32300QAN] to the mainshaft.

Install mainshaft rear bearing inner race (1) to mainshaft (2).

CAUTION:

Replace mainshaft rear bearing inner race and mainshaft
rear bearing outer race as a set.

Install mainshaft rear bearing outer race to transaxle case, using
a drift [Commercial service tool].

CAUTION:

Replace mainshaft rear bearing inner race and mainshaft
rear bearing outer race as a set.

Install transaxle case to clutch housing and then tighten mount-
ing bolts (

) to the specified torque.

Install adjusting plate (A) [SST: KV32300QAP], suitable washer,
and suitable bolt (C) [M10 x 1.0] to mainshaft.

JPDIC0671ZZ

JPDIC0672ZZ

MCIB0078E

JPDIC0610ZZ

MCIB0081E

TRANSAXLE ASSEMBLY

TM-53

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

Install dial indicator to the transaxle case.

After rotating the mainshaft several turns for conforming the
bearing, bring the dial indicator meter to zero.

Pull up the mainshaft, using two suitable tools.

Read the meter on the dial indicator.

Repeat Step 6 to 8 three times and calculate the average value
of the readings.

10. Calculate and select the thickness of adjusting shim.

Specified value [0.26 mm (0.0102 in)] + Dummy shim [1.60 mm (0.0630 in)] + Average value of dial
indicator readings = Adjusting shim thickness

Example

NOTE:
Adjusting shim is configured for a thickness between 2.15 mm (0.0846 in) and 2.43 mm (0.0957 in) [0.04
mm (0.0016 in) intervals].

MCIB0082E

Specified value

Dummy shim

Average value of dial indicator readings

Adjusting shim thickness

0.26 mm (0.0102 in)

1.60 mm (0.0630 in)

0.49 mm (0.0193 in)

2.35 mm (0.0925 in)

TM-54

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

INPUT SHAFT AND GEAR

INPUT SHAFT AND GEAR

Exploded View

INFOID:0000000006417972

Disassembly

INFOID:0000000006417973

Refer to

TM-37, "Disassembly"

for disassembly procedure.

Assembly

INFOID:0000000006417974

Refer to

TM-43, "Assembly"

for assembly procedure.

Inspection

INFOID:0000000006415704

INSPECTION AFTER DISASSEMBLY

Input Shaft and Gear

Input shaft front bearing

Input shaft

Snap ring

Input shaft rear bearing

Adapter plate

Bushing

5th input gear

5th-reverse baulk ring

Synchronizer lever

10. 5th-reverse synchronizer hub

11. 5th-reverse coupling sleeve

12. Retaining pin

13. Reverse gear

: Apply gear oil.

: Replace the parts as a set.

: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

JPDIC0731GB

INPUT SHAFT AND GEAR

TM-55

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

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.

PCIB0987J

SCIA1753J

SCIA0608J

MTF0041D

TM-56

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

MAINSHAFT AND GEAR

MAINSHAFT AND GEAR

Exploded View

INFOID:0000000006415705

Disassembly

INFOID:0000000006415706

CAUTION:

Place a direction mark on the surface of gears, avoiding an effect on their functions.

Mainshaft front bearing outer
race

Mainshaft front bearing inner race

Mainshaft

1st main gear

1st inner baulk ring

1st synchronizer cone

1st outer baulk ring

Spread spring

1st-2nd synchronizer hub

10.

1st-2nd coupling sleeve

11. 2nd outer baulk ring

12. 2nd synchronizer cone

13.

2nd inner baulk ring

14. Mainshaft bushing

15. 2nd main gear

16.

Thrust washer

17. 3rd main gear

18. 3rd baulk ring

19.

3rd-4th synchronizer hub

20. 3rd-4th coupling sleeve

21. Spring

22.

Insert key

23. 4th baulk ring

24. 4th main gear

25.

Adjusting shim

26. Mainshaft rear bearing inner race

27. Mainshaft rear bearing outer race

28.

5th main gear

: Apply gear oil.

: Apply Thread Locking Sealant, Loctite Frenbloc or an equivalent.

: Replace the parts as a set.

: Always replace after every disassembly.

: Select with proper thickness.

: N·m (kg-m, ft-lb)

JPDIC0681GB

MAINSHAFT AND GEAR

TM-57

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

Set puller (A) at the area shown by (

) on the 3rd main gear

(1).

Remove the 3rd main gear, using a press. The following parts
become detached together at the same time:
• Mainshaft bushing
• 3rd-4th synchronizer hub
• 3rd baulk ring

CAUTION:

Never drop mainshaft.

Set puller (A) to 1st main gear (1).

Remove the 1st main gear, using a press. The following parts
become detached together at the same time:
• Mainshaft bushings
• Thrust washer
• 2nd main gear
• 2nd inner baulk ring
• 2nd synchronizer cone
• 2nd outer baulk ring
• 1st-2nd coupling sleeve
• 1st-2nd synchronizer hub
• 1st outer baulk ring
• 1st synchronizer cone
• 1st inner baulk ring

CAUTION:

Never drop mainshaft.

Remove spread springs from 1st-2nd synchronizer hub.

Remove mainshaft front bearing inner race, using a puller [Commercial service tool].

Assembly

INFOID:0000000006415707

CAUTION:

After replacing the following parts, adjust mainshaft rear bearing preload. Refer to

TM-51, "Inspection

and Adjustment"

• Mainshaft
• Mainshaft front bearing inner race
• Mainshaft front bearing outer race
• Mainshaft rear bearing inner race
• Mainshaft rear bearing outer race
• Clutch housing
• Transaxle case

Install 1st main gear to mainshaft.

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

CAUTION:

Replace 1st inner baulk ring, 1st synchronizer cone, and 1st outer baulk ring as a set.

Install 1st inner baulk ring (1), 1st synchronizer cone (2), and 1st
outer baulk ring (3) to 1st main gear (4).

CAUTION:

Align the pawl (A) of the 1st synchronizer cone with the
groove (B) of the 1st main gear.

Install spread spring to 1st-2nd synchronizer hub.

Install 1st-2nd synchronizer hub to mainshaft.

CAUTION:

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

: 3rd baulk ring side

JPDIC0673ZZ

JPDIC0674ZZ

JPDIC0675ZZ

TM-58

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

MAINSHAFT AND GEAR

Heat the mainshaft bushing for 15 minutes at a temperature of
150

C, using a heat plate or an equivalent.

CAUTION:

• Never reuse mainshaft bushing.
• Never touch the mainshaft bushing with bare hands.

Remove the mainshaft bushing from the heat plate to install to
the mainshaft, using pliers or an equivalent.

CAUTION:

Never touch the mainshaft bushing with bare hands.

Install mainshaft bushing (1) to mainshaft, using a drift (A) [Com-
mercial service tool] and a press.

Install 1st-2nd coupling sleeve and spread spring to 1st-2nd syn-
chronizer hub.

CAUTION:

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

10. Apply gear oil to 2nd inner baulk ring, 2nd synchronizer cone,

and 2nd outer baulk ring.

CAUTION:

Replace 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring as a set.

11. Install 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring to 1st-2nd synchronizer hub.

12. Install 2nd main gear and thrust washer to mainshaft.

CAUTION:

Align the pawl of the 2nd synchronizer cone with the groove of the 2nd main gear.

13. Heat the mainshaft bushing for 15 minutes at a temperature of

150

C, using a heat plate or an equivalent.

CAUTION:

• Never reuse mainshaft bushing.
• Never touch the mainshaft bushing with bare hands.

14. Remove the mainshaft bushing from the heat plate to install to

the mainshaft, using pliers or an equivalent.

CAUTION:

Never touch the mainshaft bushing with bare hands.

15. Install mainshaft bushing (1) to mainshaft, using a drift (A) [Com-

mercial service tool] and a press.

16. Install 3rd main gear to mainshaft.

17. Apply gear oil to 3rd baulk ring.
18. Install 3rd baulk ring to 3rd main gear.

19. Install 3rd-4th synchronizer hub to mainshaft.

CAUTION:

Replace 3rd-4th synchronizer hub and 3rd-4th coupling
sleeve as a set.

MCIB0074E

: 1st-2nd synchronizer hub

JPDIC0676ZZ

MCIB0074E

: Thrust washer

: 2nd main gear

JPDIC0677ZZ

MAINSHAFT AND GEAR

TM-59

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

20. Heat the mainshaft bushing for 15 minutes at a temperature of

150

C, using a heat plate or an equivalent.

CAUTION:

• Never reuse mainshaft bushing.
• Never touch the mainshaft bushing with bare hands.

21. Remove the mainshaft bushing from the heat plate to install to

the mainshaft, using pliers or an equivalent.

CAUTION:

Never touch the mainshaft bushing with bare hands.

22. Install mainshaft bushing (1) to mainshaft, using a drift (A) [Com-

mercial service tool] and a press.

23. Install mainshaft front bearing inner race, using a drift [Commer-

cial service tool].

CAUTION:

• Never reuse mainshaft front bearing inner race.
• Replace mainshaft front bearing inner race and mainshaft

front bearing outer race as a set.

Inspection

INFOID:0000000006415708

INSPECTION AFTER DISASSEMBLY

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

MCIB0074E

: 3rd-4th synchronizer hub

JPDIC0678ZZ

SCIA1762J

SCIA1753J

FINAL DRIVE

TM-61

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

FINAL DRIVE

Exploded View

INFOID:0000000006415709

Disassembly

INFOID:0000000006415710

Remove differential side bearings, using the drift (A) [SST:
ST33052000] and a puller [Commercial service tool].

Assembly

INFOID:0000000006415711

Install differential side bearings, using the drift [SST].

CAUTION:

Replace differential side bearing outer race and differential
side bearing as a set.

Inspection

INFOID:0000000006415712

INSPECTION AFTER DISASSEMBLY

Case

Differential side bearing outer race

Differential side bearing

Final drive

: Replace the parts as a set.

JPDIC0481ZZ

PCIB1568E

SCIA1765J

SERVICE DATA AND SPECIFICATIONS (SDS)

TM-63

< SERVICE DATA AND SPECIFICATIONS (SDS)

[5MT: RS5F92R]

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

INFOID:0000000006415714

Transaxle type

RS5F92R

Engine type

HR16DE

Model code number

1KA0A

1KA0C

Axle type

2WD

Number of speed

Synchromesh type

Warner

Shift pattern

Gear ratio

1st

3.7273

2nd

2.0476

3rd

1.3929

4th

1.0968

5th

0.8919

Reverse

3.5455

Final gear

4.5000

4.0667

Number of teeth

Input gear

1st

2nd

3rd

4th

5th

Reverse

Main gear

1st

2nd

3rd

4th

5th

Reverse

Reverse idler gear

Final gear

Final gear/Pinion

63/14

61/15

Side gear/Pinion mate gear

13/9

Oil capacity (Reference)

(Imp pt)

Approx. 2.3 (4)

Remarks

Reverse brake

Installed

Double-cone synchronizer

1st and 2nd

Speedometer drive gear

Not installed

SCIA0821E

Juke F15 (2012 year). Service Repair Manual - part 351