Juke F15 (2012 year). Service Repair Manual

RING GEAR SHAFT

DLN-101

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

DLN

• Measure thickness (G) of spacer (right side) with a pair of ver-

nier calipers. Refer to “Measuring point”.

Calculate dimension “B” by the formula below.

Calculate dimension “D” by the formula below.

Calculate the thickness of the ring gear bearing adjusting shim (right side) “T

” by the formula below.

NOTE:
Calculate dimension “C” as 56.0 mm (2.20 in)

Select ring gear bearing adjusting shim (right side).

CAUTION:

• Only one adjusting shim can be selected.
• Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with

the calculated value is available.

Ring gear bearing adjusting shim (right side)

Measure the dimensions of each measuring point with the following procedure:

Dimension “X” measurement

• Measure the diameter (X) of transfer case with a pair of vernier

calipers. Refer to “Measuring point”.

Dimension “Y” measurement

• Measure dimension (Y) of transfer case with a pair of vernier

calipers. Refer to “Measuring point”.

JSDIA2179ZZ

B = Z

−

0.5)

D = E

−

V + W

= A

−

B + C + D

−

G + 0.045 mm (0.0018 in)

JSDIA2171ZZ

JSDIA2173ZZ

DLN-102

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

RING GEAR SHAFT

Dimension “Z” measurement

• Measure dimension (Z) of transfer case with a pair of vernier

calipers and straightedge. Refer to “Measuring point”.

Dimension “H” measurement

• Measure dimension (H) from outer race edge surface of ring

gear shaft bearing (left side) to inner race edge surface with a
pair of vernier calipers and straightedge. Refer to “Measuring
point”.

Dimension “I” measurement

• Measure thickness (I) of spacer (left side) with a pair of vernier

calipers. Refer to “Measuring point”.

Calculate dimension “B” by the formula below.

Calculate dimension “D” by the formula below.

Calculate the thickness of the ring gear bearing adjusting shim (left side) “T

” by the formula below.

NOTE:
Calculate dimension “C” as 56.0 mm (2.20 in)

Select ring gear bearing adjusting shim (left side).

CAUTION:

• Only one adjusting shim can be selected.
• Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with

the calculated value is available.

JSDIA2174ZZ

JSDIA2180ZZ

JSDIA2181ZZ

B = Z

−

0.5)

D = E

−

V + W

= B

−

I + 0.045 mm (0.0018 in)

RING GEAR SHAFT

DLN-103

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

DLN

Drive pinion adjusting shim

Measure the dimensions of each measuring point with the following procedure:

Dimension “L” measurement

• Measure dimension (L) from outer race edge surface of pinion

rear bearing to inner race edge surface with a pair of vernier
calipers and straightedge. Refer to “Measuring point”.

Dimension “Q” measurement

• Measure dimension (Q) of transfer case with a pair of vernier

calipers and straightedge. Refer to “Measuring point”.

Dimension “R” measurement

• Measure dimension (R) of transfer case with a pair of vernier

calipers and straightedge. Refer to “Measuring point”.

Dimension “S” measurement

• Measure the diameter (S) of transfer case with a pair of vernier

calipers. Refer to “Measuring point”.

Calculate dimension “J” by the formula below.

JSDIA2182ZZ

JSDIA2183ZZ

JSDIA2184ZZ

JSDIA2185ZZ

DLN-104

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

RING GEAR SHAFT

Calculate the thickness of the drive pinion adjusting shim “T

” by the formula below.

NOTE:
Calculate dimension “K” as 70.85 mm (2.7894 in)

Select drive pinion adjusting shim.

CAUTION:

• Only one adjusting shim can be selected.
• Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with

the calculated value is available.

DRIVE PINION BEARING PRELOAD

Remove ring gear shaft assembly from the transfer case. Refer to

DLN-96, "Disassembly"

Rotate the companion flange back and forth from 2 to 3 times to check for unusual noise, binding, sticking,
and so on.

Rotate the companion flange at least 20 times to check for smooth operation of the bearing.

Measure the drive pinion bearing preload with a preload gauge
(A) (SST: ST3127S000).

CAUTION:

• Each rotational part should rotate smoothly with the spec-

ified gear oil.

• Disassemble the drive pinion assembly to check and

adjust each part if outside the standard.

TOTAL PRELOAD

Measure drive pinion bearing preload (P

). Refer to

DLN-117, "Preload Torque"

CAUTION:

Check that the drive pinion bearing preload is within the standard.

Assemble the ring gear shaft assembly to the transfer case. Refer to

DLN-97, "Assembly"

Install transfer cover. Refer to

DLN-114, "Assembly"

Rotate the companion flange at least 20 times to check for smooth operation of the bearing.

Measure the total preload with a preload gauge (A) (SST:
ST3127S000).

CAUTION:

• Each rotational part should rotate smoothly with the spec-

ified gear oil.

• Disassemble the transfer assembly to check and adjust

each part if outside the standard. Measure it with the
transfer case oil seals removed when measuring total pre-
load after disassembly. Then install transfer case oil
seals.

BACKLASH

J = Q

−

0.5)

= J

−

Drive pinion bearing preload

: Refer to

DLN-117, "Pre-

load Torque"

JSDIA2186ZZ

Total preload

:Refer to

DLN-117, "Preload

Torque"

JSDIA2186ZZ

RING GEAR SHAFT

DLN-105

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

DLN

Install the bolt (A) to the companion flange.

Fit a dial indicator onto the bolt.

Measure the circumference backlash of the companion flange.

If outside the standard, disassemble the transfer assembly to
check and adjust each part.

TOOTH CONTACT

Remove transfer cover. Refer to

DLN-114, "Disassembly"

Remove ring gear shaft assembly from transfer case. Then
apply red lead onto the ring gear. Refer to

DLN-96, "Disassem-

bly"

CAUTION:

Apply red lead to both faces of 3 to 4 gears at 4 locations
evenly spaced on the ring gear.

Assemble the ring gear shaft assembly to the transfer case.
Refer to

DLN-97, "Assembly"

Install transfer cover. Refer to

DLN-114, "Assembly"

Rotate the companion flange back and forth several times.

Remove ring gear shaft assembly from transfer case. Then
check drive pinion to ring gear tooth contact

Tooth Contact Judgment Guide

Backlash

: Refer to

DLN-117, "Backlash"

JSDIA2187ZZ

JSDIA2188ZZ

JSDIA2189GB

DLN-106

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

RING GEAR SHAFT

Follow the procedure below to adjust pinion height (dimension
X) if tooth contact is improper.

CAUTION:

If no adjusting shim with the calculated value is available,
select the thicker and closest one.

• Thicken the drive pinion adjusting shim to move the drive pin-

ion closer to the ring gear in case of face contact or heel con-
tact.

CAUTION:

Only one adjusting shim can be selected.

• Thin the drive pinion adjusting shim to move the drive pinion

farther from the ring gear in case of flank contact or toe con-
tact.

CAUTION:

Only one adjusting shim can be selected.

Assemble the plug to the transfer case.

CAUTION:

• Remove old gasket on mounting surface, then remove

any moisture, oil, and foreign material on the application
and mounting surfaces.

• Apply liquid gasket to the thread, and tighten to the speci-

fied torque when installing plug.

COMPANION FLANGE RUNOUT

Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft bolt holes).

Rotate the companion flange to check for runout.

SDIA3158J

PDIA0440E

PDIA0441E

Companion flange runout

: Refer to

DLN-117, "Com-

panion Flange Runout"

JSDIA2190ZZ

RING GEAR SHAFT

DLN-107

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

DLN

Fit a test indicator to the inner side of the companion flange
(socket diameter).

Rotate the companion flange to check for runout.

Follow the procedure below to adjust if runout value is outside
the repair limit.

CAUTION:

Replace collapsible spacer to check and adjust each part
when companion flange is adjusted or replaced.

Check for runout while changing the phase between companion flange and drive pinion in 90

steps. Then

search for the minimum point.

Replace companion flange if runout value is still outside the limit after the phase has been changed.

Adjust assembly status of the drive pinion bearings and drive pinion, or replace drive pinion bearings if
runout is outside the standard after the companion flange is replaced.

Inspection

INFOID:0000000006359789

INSPECTION AFTER DISASSEMBLY

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

Gear and Shaft

Check gear face and shaft for wear, cracks, damage, and seizure.

CAUTION:

Replace ring gear and drive pinion as a set (hypoid gear set) if any malfunction is detected on the ring
gear or drive pinion.

Bearing

Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other
damage.

CAUTION:

Always replace inner race and outer race as a pair when replacing the bearing.

Shim

Check for seizure, damage, and unusual wear.

Case

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

CAUTION:

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

Companion flange runout

: Refer to

DLN-117, "Com-

panion Flange Runout"

JSDIA2191ZZ

DLN-108

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

DRIVE PINION

DRIVE PINION

Exploded View

INFOID:0000000006359780

Pinion lock nut

Companion flange

Drive pion oil seal

Pinon rear bearing

Transfer case

Gasket

Filler plug

Collapsible spacer

Drive pinion adjust shim

10. Drive pinion

11.

Pinion front bearing

12. Ring gear

13. Ring gear shaft

14. Ring gear bearing (right)

15. Ring gear bearing adjust shim (right)

16. Spacer (right)

17. Transfer case oil seal (right)

18. Drive shaft oil seal

19. Transfer cover

20. Oil defense

21. Ring gear bearing (left)

22. Ring gear bearing adjust shim (left)

23. Spacer (left)

24. Transfer case oil seal (left)

25. Drain plug

26. Dowel pin

Oil seal lip

Transfer case mounting face

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

: Apply gear oil.

: Apply anti-corrosive oil.

: Apply multi purpose grease

: Apply Genuine Liquid Gasket 1215 or equivalent.

: Select with proper thickness.

JSDIA2087GB

DRIVE PINION

DLN-109

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

DLN

Disassembly

INFOID:0000000006359781

Remove transfer cover. Refer to

DLN-114, "Disassembly"

Remove ring gear shaft assembly. Refer to

DLN-96, "Disassembly"

Remove lock nut from the drive pinion.

Put matching marks (A) on screw ends of companion flange (1)
and drive pinion.

CAUTION:

Use paint to avoid scratching the surface.

Remove companion flange from drive pinion with a puller (A).

Remove drive pinion oil seal from the transfer case with a puller
(A) (SST: KV381054S0).

CAUTION:

Never damage transfer case.

Remove drive pinion assembly (1) from transfer case while tap-
ping the drive pinion lightly with a plastic hammer.

CAUTION:

Never drop the drive pinion assembly.

Remove collapsible spacer from the drive pinion.

Remove inner race of drive pinion bearing (rear side) from trans-
fer case.

JSDIA2192ZZ

JSDIA2193ZZ

JSDIA2194ZZ

JSDIA2195ZZ

DLN-110

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

DRIVE PINION

10. Remove inner race of drive pinion bearing (front side) from drive

pinion with a replacer (A) (commercial service tool).

11. Remove drive pinion adjusting shim from the drive pinion.

12. Perform inspection after disassembly. Refer to

DLN-111,

"Inspection"

Assembly

INFOID:0000000006359782

Select drive pinion adjusting shim. Refer to

DLN-98, "Adjustment"

Install selected drive pinion adjusting shim to drive pinion.

Install inner race of drive pinion bearing (front side) to drive pin-
ion with a drift (A) (SST: ST35272000).

CAUTION:

• Never reuse drive pinion bearing (front side).
• Apply gear oil to the drive pinion bearing (front side).

Assemble the inner race of drive pinion bearing (rear side) into
the transfer case.

CAUTION:

• Never reuse drive pinion bearing (rear side).
• Apply gear oil to the drive pinion bearing (rear side).

Install drive pinion oil seal to transfer case with drifts so that it
becomes flush with case end surface with the drifts (A and B).

CAUTION:

• Never reuse oil seal.
• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference.

Assemble a collapsible spacer onto the drive pinion.

CAUTION:

Never reuse the collapsible spacer.

Assemble drive pinion assembly into the transfer case, and then
install companion flange (1) to drive pinion.
NOTE:
Align matching marks (A) on the thread edge of companion
flange and drive pinion and install companion flange if drive pin-
ion is reused.

JPDIE0028ZZ

JSDIA2196ZZ

: Drift (SST: KV38102510)

: Drift (SST: ST30720000)

JSDIA2197ZZ

JSDIA2192ZZ

DRIVE PINION

DLN-111

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

DLN

Tap the companion flange (1) with a plastic hammer as far as
the lock nut can be tightened.

CAUTION:

Never damage drive pinion oil seal.

Apply anti-corrosive oil to the thread and seat of the lock nut,
and temporarily tighten lock nut to the drive pinion.

CAUTION:

Never reuse lock nut.

10. Tighten lock nut within the specified torque range with a preload

gauge (A) (SST: ST3127S000) so that the drive pinion bearing
preload is within standard.

CAUTION:

• Start the tightening of lock nut from lower limit of the

specified torque. Check the preload every 5

to 10

while

tightening the lock nut.

• Replace the collapsible spacer and tighten it again to

adjust if preload exceeds the specified value. Never
loosen lock nut to adjust preload.

• After adjustment, rotate the drive pinion back and forth from 2 to 3 times to check for unusual

noise, sticking, binding, and so on.

11. Install ring gear shaft assembly. Refer to

DLN-97, "Assembly"

12. Install transfer cover. Refer to

DLN-114, "Assembly"

13. Check backlash, tooth contact, total preload and companion flange runout. Refer to

DLN-98, "Adjust-

ment"

CAUTION:

Measure the total preload without the transfer case oil seal.

Adjustment

INFOID:0000000006359783

About adjusting of drive pinion, refer to

DLN-98, "Adjustment"

Inspection

INFOID:0000000006359784

INSPECTION AFTER DISASSEMBLY

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

Gear and Shaft

Check gear face and shaft for wear, cracks, damage, and seizure.

CAUTION:

Replace ring gear and drive pinion as a set (hypoid gear set) if any malfunction is detected on the ring
gear or drive pinion.

Bearing

Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other
damage.

CAUTION:

Always replace inner race and outer race as a pair when replacing the bearing.

Shim

Check for seizure, damage, and unusual wear.

Case

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

CAUTION:

JSDIA2198ZZ

Drive pinion bearing preload

: Refer to

DLN-117, "Pre-

load Torque"

JSDIA2186ZZ

TRANSFER CASE

DLN-113

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

DLN

TRANSFER CASE

Exploded View

INFOID:0000000006359790

Pinion lock nut

Companion flange

Drive pion oil seal

Pinon rear bearing

Transfer case

Gasket

Filler plug

Collapsible spacer

Drive pinion adjust shim

10. Drive pinion

11.

Pinion front bearing

12. Ring gear

13. Ring gear shaft

14. Ring gear bearing (right)

15. Ring gear bearing adjust shim (right)

16. Spacer (right)

17. Transfer case oil seal (right)

18. Drive shaft oil seal

19. Transfer cover

20. Oil defense

21. Ring gear bearing (left)

22. Ring gear bearing adjust shim (left)

23. Spacer (left)

24. Transfer case oil seal (left)

25. Drain plug

26. Dowel pin

Oil seal lip

Transfer case mounting face

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

: Apply gear oil.

: Apply anti-corrosive oil.

: Apply multi purpose grease

: Apply Genuine Liquid Gasket 1215 or equivalent.

: Select with proper thickness.

JSDIA2087GB

DLN-114

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

TRANSFER CASE

Disassembly

INFOID:0000000006359791

Remove transfer cover mounting bolts.

Lightly tap (A) position of transfer cover with a plastic hammer to
remove transfer cover.

Remove ring gear shaft assembly. Refer to

DLN-96, "Disassem-

bly"

Tap the outer race of drive pinion bearing from transfer case with
a brass rod to remove outer race of drive pinion bearing (front
side and rear side).

CAUTION:

Never damage transfer case.

Remove dowel pin.

CAUTION:

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

Remove the filler plug and drain plug from the transfer case, and
then remove each gasket.

Remove oil defense from transfer cover.

Perform inspection after disassembly. Refer to

DLN-116,

"Inspection"

Assembly

INFOID:0000000006359792

Install the oil defense to transfer cover.

Install gaskets onto filler plug and drain plug and install them into transfer case.

CAUTION:

• Never reuse gaskets.
• Install filler plug after oil is filled.

Install the dowel pin to transfer case.

CAUTION:

Never reuse the dowel pin.

JSDIA2199ZZ

JSDIA2200ZZ

TRANSFER CASE

DLN-115

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

DLN

Install outer race of drive pinion bearing (front side) to the trans-
fer case with drift (A) (SST: ST17130000).

CAUTION:

• Never reuse drive pinion bearing (front side).
• Apply gear oil to the drive pinion bearing (front side)

Install outer race of drive pinion bearing (rear side) to transfer
case with a drift (A) (SST: ST33230000).

CAUTION:

• Never reuse drive pinion bearing (rear side).
• Apply gear oil to the drive pinion bearing (rear side).

Install drive pinion assembly to transfer case. Refer to

DLN-110,

"Assembly"

Install ring gear shaft assembly to transfer case. Refer to

DLN-

97, "Assembly"

Set the drifts (A and B) to right and left side spacers individually.
Compress ring gear shaft assembly and ring gear bearing to
install transfer cover to transfer case.

CAUTION:

• Clean the mounting surface of transfer case and transfer

cover to degrease sufficiently.

• Never apply gasket fluid on the mounting surface.
• 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.

Check backlash, tooth contact, total preload and companion flange runout. Refer to

DLN-98, "Adjust-

ment"

CAUTION:

Measure the total preload without the transfer case oil seals.

10. Remove transfer cover. Refer to

DLN-114, "Disassembly"

11. Apply liquid gasket (1) to mating surface of rear cover.

CAUTION:

• Remove old gasket adhering to the mounting surfaces.

Also remove any moisture, oil, or foreign material adher-
ing to the mounting surfaces.

• Overlap both ends of the bead for at least 3 mm (0.12 in).

JSDIA2201ZZ

JSDIA2202ZZ

: Drift (commercial service tool)

JSDIA1105ZZ

JSDIA2203ZZ

DLN-116

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21B]

TRANSFER CASE

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

Compress ring gear shaft assembly and 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.

13. Tighten rear cover mounting bolts to the specified torque.

14. Install transfer case oil seal (right side) until it becomes flush

with ring gear shaft end, using the drifts (A and B).

CAUTION:

• Never reuse oil seals.
• When installing, do not 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.

15. Install transfer case oil seal (left side) until it becomes flush with

ring gear shaft end, using the drift (A) (SST: KV40100620).

CAUTION:

• Never reuse oil seals.
• When installing, do not 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

INFOID:0000000006359793

INSPECTION AFTER DISASSEMBLY

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

Case

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

CAUTION:

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

: Drift (commercial service tool)

: Drift (SST: ST30720000)

: Drift (SST: ST19820000)

JSDIA1105ZZ

JSDIA2205ZZ

JSDIA2206ZZ

Juke F15 (2012 year). Service Repair Manual - part 107