AUTOMATED MANUALTRANSMISSIONJH 1 - OVERHAUL

JH1 019 GEARBOX SPECIFICATIONSDRY WEIGHT : 42.5 KgGEARBOX RATIOS:1 : 11/372 : 22/413 : 28/374 : 34/355 : 39/32R: 11/39Final drive : 14/59

GEARBOX OIL:

OIL TYPE: 75 W 80APPROVED GEARBOX OILS: ELF XT4447 TEXACO ETL8681GEARBOX OIL CAPACITY: 3.5 lREPLACEMENT INTERVAL: 40 000Km LEVEL CHECKING: TOP-UP (NO DIPSTICK)

GENERAL SPECIFICATION

TRANSMISSION FEATURES* 5 Forward speed and 1 Reverse speed* Transmission output torque : 125 Nm* Shiftronic type Fitted with BORG WARNER synchronizersReverse gear control reverse gear brake.* Transverse mount

TRANSMISSION MODEL CODEA = Gearbox type.B = Gearbox suffixC = Manufacturing factory ( C = Clon)D = Production numberE = Letter preceding production numbers greater than 999 999.Engrave on the transmission

TRANSMISSION OIL CAPACITY & LUBRICANTS 3.4 LitersOil filler plug made ofplastic base materialTrans ELF TRJ 75W/80

MAINTENANCETransmission oil change :

Every 40,000km

CLUTCH SYSTEM* Mechanical operating mechanism ( cable linkage clutch )* Single dry plateSST~Clutch disccenter guide

SPECIAL TOOLS

ToolNumberName/UseB.Vi 31-01Set of 3 pins for fitting the 5mm diameter roll pins

ToolNumberName/UseB.Vi 945Mandrel for fitting the sun wheel seal

SPECIAL TOOLS

ToolNumberName/UseB.Vi 946Mandrel for fitting the snap ring on the sun wheel

ToolNumberName/UseB.Vi 949Fork roll pins fitting and removal tool

SPECIAL TOOLS

ToolNumberName/Use

B.Vi 1000Extractor for the 5th fixed gear on the output shaft,use with B.Vi 22-01

ToolNumberName/UseB.Vi 1059 Ring for fitting differential bearing

SPECIAL TOOLS

ToolNumberName/Use

B.Vi 1170Extractor for the 5th gear hub on the input shaft

ToolNumberName/Use

B.Vi 1576Mandrel for fitting bearings in the mechanism housing

SPECIAL TOOLS

ToolNumberName/UseB.Vi 1570Tool for fitting ball indentation

TORQUE SPECIFICATION

DISASSEMBLY PROCEDURE Note: Part must be removed and handled on a work bench with covering which protects against impact ( rubber or thick plastic )1st Step : Remove the rear housing. This must be remove in horizontal centerline of the transmission as it has a lubricating nozzle located in the input shaft. ( 3 bolts size 13mm)

DISASSEMBLY PROCEDURE 2nd Step : Engage 1st gear with the gear lever and 5th gear by sliding the 5th gear fork on the shaft.1st gear with the gear lever5th gear fork on the shaft

DISASSEMBLY PROCEDURE 3rd Step : Remove the input shaft nut 27mm and loosen the output shaft bolt.

DISASSEMBLY PROCEDURE 4th Step :Using the B.Vi.31-01 remove the 5th gear fork pin placing a piece of wood behind the shaft to support it.

DISASSEMBLY PROCEDURE 5th Step :Remove the 5th gear fork and sliding gear.Note: Place the transmission in neutral again.

DISASSEMBLY PROCEDURE 6th Step :Extract the 5th gear synchronizer hub using toolB.Vi. 1170.Note: Fit the special tool onto the 5th gear Grooves and the hub grooves opposite each other.

DISASSEMBLY PROCEDURE 7th Step :Remove the 5th gear assembly

DISASSEMBLY PROCEDURE 8th Step :Remove the 5th gear bolt at output shaft.

DISASSEMBLY PROCEDURE 9th Step :Extract the 5th gear at output shaft.Note: Using tools B.Vi.22-01 and B.Vi 1000 remove the output shaft gear.

DISASSEMBLY PROCEDURE 10th Step :Remove the reverse gear plunger lock. 11st Step : Remove the primary shaft speed sensor ( B )

DISASSEMBLY PROCEDURE 12nd. Step :Remove the mechanism housing bolts. ( 16pcs bolts size E12 )

DISASSEMBLY PROCEDURE Note: Before pull out the mechanism housing it is advisable to fit two magnets or to close the opening in order to retrieve the 1/2 and 3/4 shaft locking ball and springs.13rd Step : Turn the 5th and Rev. gear selector shaft to clockwise direction.Gap

DISASSEMBLY PROCEDURE 14th Step : Press the control shaft and turn downward.

DISASSEMBLY PROCEDURE 15th Step : Unpin the 3/4 fork using B.Vi 949. 16th Step : Remove the 3/4 shaft from the housing bore sliding in it fork and remove the shaft fork assembly. Note: Place the 1/2 shaft and the reverse gear in neutral.Selector shaft 1/2Selector shaft 3/4Reverse gear

DISASSEMBLY PROCEDURE 17th Step : Raise and separate the input and output shaft and remove the reverse gear shaft . 18th Step : Simultaneously pull the two shaft (input & output) and assembled 1/2 fork shaft and remove the assembly.

DISASSEMBLY PROCEDURE Note: Retrieve the interlock plunger located in the housing.NOTE : For assemble, reverse the procedure.

PARTS MUST BE REPLACE When they have been removed.Lip seals.O-Rings.Stop ring.Thrust pad guide tube.Differential ball bearing.Speedometer shaft and gear.Roll pins.Output shaft and differential nuts.Ring under the gear.Input and output shaft bearing circlips.

REPLACEMENT PROCEDURE 1st Step : Separate the circlips with circlip pliers and drive the bearing inside the housing using tool B.Vi.1576REPLACEMENT PROCEDURE 1. Removal and installation the bearings in the mechanism housing.

REPLACEMENT PROCEDURE 2nd Step : Place the new circlips in their respective housing3rd Step : Fit the bearing using tool B.Vi.1576 and knock the tool with the bearing using small hammer.

REPLACEMENT PROCEDURE 2. Removal and installation the bearings on the clutch housing.1st Step : Cut the base of the plastic hollow needle located at the centre of the bearing.2nd Step : Use the special tool to extract the bearing.

REPLACEMENT PROCEDURE 3rd Step : Fit the deflector and the bearing on the press flush with inner side of the housing..4th Step : Set the bearing with a mortise chisel.5th Step : Refit the bearing guide using tool B. Vi. 1601.

REPLACEMENT PROCEDURE3. Thrust Pad Guide Tube.

REPLACEMENT PROCEDURE

REPLACEMENT PROCEDURE

REPLACEMENT PROCEDURE

REPLACEMENT PROCEDURE

REPLACEMENT PROCEDURE

REPLACEMENT PROCEDURE

REPLACEMENT PROCEDURE

REPLACEMENT PROCEDURE

REPLACEMENT PROCEDURE

REPLACEMENT PROCEDURE4. Differential Ball Bearing.

REPLACEMENT PROCEDURE

REPLACEMENT PROCEDURE5. Removal and installation the speedometer gear.Note: The gear and the shaft must be changed whenever they are removed.Removed the shaft by pull out using the long nose plier

REPLACEMENT PROCEDURE

REPLACEMENT PROCEDURE6. Removal and installation the Control shaft.

INSPECTION PRIMARY SHAFT ( INPUT SHAFT).Note: 1. The primary shaft cannot be repaired. 2. There no adjustment to be carried out. 3. On the shaft which have a jet (B), this cannot be remove. 4. Clean the 5th gear lubrication hole. 5. Check the condition of the mating surface (A) . If there are any scratches or faults in appearance, change the primary shaft.1st2nd3rd4thRev

SECONDARY SHAFT ( OUTPUT SHAFT).INSPECTION Note: 1. The gear teeth and the clows should not be chipped or excessively worn. 2. Also ensure that there are no signs of grating or abnormal wear on the surfaces of the shafts or the inner walls of the gear. 3. It is advisable to mark the position of the sliding shafts in relation to the hub.

INSPECTION Secondary Shaft ( Output Shaft) Assembly.TOPBOTTOM1st2nd3rd4th5thRev

INSPECTION Output ShaftContinueBig cutting shape

INSPECTION Continue

INSPECTION ContinueSmall cutting shape

ContinueINSPECTION

DIFFERENTIALDisassembly and Assembly .Note: This operation is carried out after separating the housing.1st Step : Remove the O-Ring2nd Step : Strike the lip seal, using the pin extractor and small hammer in order to tilt it.3rd Step : Remove the seal, taking care not to damage the splines on the sun gear.

4th Step : Using the circlip pliers to free the circlip and extract it.5th Step : The differential is extracted by pushing on the shouldered sun wheel using a press..PressDIFFERENTIAL

DIFFERENTIAL

DIFFERENTIAL7th Step : Extract the tripod sun gear.

DIFFERENTIAL8th Step : Place the differential unit and press the housing.

DIFFERENTIALCirclip

DIFFERENTIALCoated with oil

Checking The Pre-Load1st Step : Turn the differential through several revolutions.2nd Step : Wind the string around the crown wheel.3rd Step : Pull the string using a spring balance.4th Step : The differential should turn under a load of between: Used bearing = 0 to 2 daN ( 0 ~ 204 gf ) New bearing = 1.6 to 3.2 daN ( 163 ~ 326 gf )INSPECTION