· Web viewIt is likely that the tightening torque of plug screw is less than the specified value. Check the tightening torque. If it is not the specified value, fasten it. II. It

5T 19H-B Transmission Service Manual

Transmission

Chapter I Overview....................................................2Chapter II Fault Diagnosis and Maintenance..............4Section I Fault diagnosis.............................................4

1. Disengagement...............................................42. Loud noise or abnormal sound of the transmission........................................................43. Gearshift difficulty..........................................44. Oil leakage......................................................4

Section II On-board repair..........................................41. Replacement of gear oil..................................42. Replacement of front and rear differential oil seals....................................................................5

Section III Disassembly of transmission assembly.....51. Disassembly of release bearing.......................52. Disassembly of cable bracket.........................63. Disassembly of gear selection and gearshift mechanism..........................................................64. Rear shell and fifth gear..................................65. Transmission housing assembly......................76. Reversing fork mechanism.............................87. Disassembly of five shafts and differential.....8

Section IV Disassembly, overhaul and closing assembly of transmission assembly............................9

1. Input shaft assembly.......................................92. Output shaft assembly...................................113. Differential assembly....................................124. Fork assembly...............................................135. Gearshift mechanism....................................146. Clutch shell...................................................147. Transmission housing...................................158. Rear shell assembly......................................159. Closing assembly..........................................15

Attached: special tools .............................................18

1 / 21


Chapter I Overview

Through 3 synchronizers and 3 shafts, the transmission, under the action of input shaft, output shaft and reverse gear shaft, can provide five forward gears and one reverse gear. All the forward gears are constant mesh gears. The reverse gear is the sliding idler gear.

The low speed synchronizer is assembled onto the output shaft and interacts with the first driven gear or second driven gear of the output shaft. However, the high speed synchronizer is assembled onto the input shaft and engages with the third gear or fourth gear of the input shaft. The 5th-gear synchronizer on the input shaft engages with the fifth gear on the input shaft.

The output shaft drives the main reduction gear and the differential device, thus enabling the front drive shaft connected to the front wheel to rotate.

With respect to the service and maintenance, the sealant must be applied on the corresponding part of the transmission housing surface. The housing is made of aluminum. The fastening bolt of the housing must be fastened to the specified torque by the torque wrench. In addition, before the reassembly, all the parts should be thoroughly cleaned with the cleaner or cleaning solution and the dry air.

Figure 1-1 Transmission assembly

Figure 1-2 Gear transmission mechanism

Figure 1-3 Gearshift mechanism assembly

Figure 1-4 Gear selection and gearshift mechanism assembly

Gear selection and gearshift mechanism:Motion of gear selection and gearshift operating

lever: it is transmitted to the transmission shaft and gearshift shaft through the transmission control shaft and then to the transmission, shift lever, shaft, fork or rocker through the transmission cross arm and yoke.

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Input shaft assembly

Output shaft assembly

Differential assembly

Third/fourth/fifth reverse shift fork

First/second gear fork assembly

Reversing fork mechanism assembly

Gearshift rocker assembly

Gear selection rocker assemblyGear shift


The transmission interlocking plate is provided to prevent two pairs of gears engage at the same time. The mechanism has the fifth gear/reverse gear locking mechanism that achieves the locking of fifth gear and reverse gear through the return spring and locking plate, so as to prevent the gear from directly shifting to the reverse gear from the fifth gear.1) When the transmission is shifted to the fifth gear, the pull pin on the gear shift rotates to drive the locking plate of fifth gear/reverse gear interlocking mechanism to rotate and cross the locking plate. When the fifth gear is planned to directly engage the reverse gear, the locking plate prevents the motion of the gear shift and the reverse gear cannot be engaged.2) The fifth gear can be shifted to the neutral gear, but after that, it cannot be shifted to the reverse gear immediately.3) The gearshift mechanism is in the neutral gear of the fifth gear-reverse gear. As shown in Figure 1-4, when the gearshift shaft is moving to the left, it facilitates the shift lever to shift to the fifth gear or reverse gear. The gear shift pull pin is located in the center of the locking plate.4) At this time, the system can be shifted to the reverse gear without the interference of the locking plate.

Profile drawing of transmission:

1. Gearshift rocker; 2. Gear selection rocker; 3. Oil delivery

pipe; 4. Housing engraving area; 5. Hydraulic release bearing;

6. Cable bracket; 7. Reversing lamp switch

1. Bar-code paste area; 2. Neutral switch

Transmission engraving information:

Transmission bar-code information:

Figure 1-5 Profile drawingSchematic diagram of transmission:

1. Engine; 2. Clutch; 3. Transmission; 4. Input shaft;

5. Output shaft; 6. Output assembly; I-1 gear, II-2 gear, III-3

gear, IV-4 gear, V-5 gear, R-reverse gear; A. Main

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①

②

③

④

⑤

⑦

⑥

Model

Serial number

Code

②

Bar code that can be scanned


transmission;

● Arrow is the forward direction of the vehicle

Figure 1-6: Schematic diagram of transmission system

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Chapter II Failure Diagnosis and Maintenance

Section I Failure diagnosisMain faults and troubleshooting of transmission:1. Disengagement

Cause and solution for disengagement:a. Cause: severely worn and deformed shift lever

Solution: manually straightened shift lever; in case of bending or severe wear, timely have it replaced.b. Cause: severely worn and deformed gearshift

rockerSolution: timely replace the gearshift rocker.

c. Cause: the fork shaft or gearshift positioning seat is less elasticSolution: timely replace the gearshift positioning

seat.d. Cause: worn and deformed fork

Solution: when the fork is bent and deformed, it can be manually straightened; however, in case of severe wear, it should be timely replaced.e. Cause: worn gear synchronic cone, synchronizer

sleeve or ring gearSolution: in case of disengagement, replace the

worn parts.2. Loud noise or abnormal sound of the transmission

Cause and solution for loud noise or abnormal sound of the geara. Cause: insufficient or degenerative transmission

oil Solution: refill sufficient oil or replace with new

oil.b. Cause: excessively large axial clearance of gears

Solution: replace the gear or worn parts.c. Cause: worn gear or broken gear tooth

Solution: replace the damaged parts.d. Cause: worn synchronizer ring gear or broken gear

Solution: replace the ring gear.e. Damaged or worn bearing

Solution: replace the bearing.3. Gearshift difficulty

Cause and solution for gearshift difficulty:a. Deformed or unevenly worn gearshift fork shaft or

gearshift fork

Solution: replace the parts.b. Worn fork shaft positioning seat and gearshift fork

shaft grooveSolution: replace the parts.

c. Locking of synchronizer ring gear and gear synchronic coneSolution: replace the ring gear.

d. Damaged synchronizer sliding block or springSolution: replace the synchronizer.e. Worn gear sleeve and gear end or worn and

broadened ring gear grooveSolution: replace the corresponding parts.

4. Oil leakagea. Leakage of drain plug

Solution: I. It is likely that the tightening torque of plug screw is less than the specified value. Check the tightening torque. If it is not the specified value, fasten it. II. It is likely that the matching deviation or the thread tooth is damaged. In such case, replace the corresponding parts or fasten the drain plug after applied with the sealant.b. Oil leakage of input or output oil seal

Solution: replace the seals and pay attention to the operation standardization.c. Oil leakage of matching surface of box

Solution: Check and ensure that the tightening torque of each connecting bolt conforms to the specification; check whether the housing sealant is properly applied and apply the sealant again as required.d. Oil leakage of housing

Solution: it is likely that the housing has sand hole or crack. Find out the crack position and repair it with the aluminum repair agent, or directly replace the damaged parts.

Section II On-board repair1. Replacement of oil1) During the replacement and visual inspection of lubricating oil, be sure to stop the engine and stably lift the vehicle.2) Check for the oil level and leakage situation after lifting the vehicle. In case of leakage, conduct timely remedies.

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3) Drain away the old lubricating oil and refill the specified new lubricating oil.4) The torque specifications of the oil drain plug and oil filler plug are as follows. Before the assembly, apply a certain amount of sealant on the thread of the oil drain plug.

Sealant: TONSAN 1569FTightening torque: 28-35N·mGear oil: designation SAE 75W-90 (GL-4)Oiling amount: 2.7-2.9L

Attention: When the vehicle is jacked up for the maintenance work other than the replacement of lubricating oil, it is also required to check for the leakage of lubricating oil.

2. Replacement of front and rear differential oil seals1) Jack up the vehicle and drain away the transmission lubricating oil.2) Remove the transmission shaft from the differential.3) Disassemble the oil seal with the special tool and hammer and assemble one new part

Special tool (A): oil seal installer (right);The installation surface of oil seal is flush with the

end face of the oil seal seat hole4) Apply the lubricating grease at the 1/3 depth of outer and inner lips of the oil seal; and check the part where the transmission shaft contacts the oil seal and ensure its smoothness.

Lubricating grease: Omega lithium-based lubricating grease 85#

2-1 Replacement of differential oil seal

5) Assemble the transmission shaft into the differential.

Attention: 1. When inserting the transmission shaft, do not scratch the oil seal edge.

2. Ensure that the transmission shaft is fully inserted and the elastic retainer ring is fixed as it was.

3. During the disassembly of transmission shaft, prevent the oil seal mounting hole of transmission housing from being damaged. Before the reassembly, check whether the mounting hole edge of housing oil seal is damaged

6) Fill the transmission oil as specified and ensure that the oil has been tightly sealed by the oil seal.

Section III Disassembly of transmission assembly1. Disassembly of release bearing1) Release it according to the arrow direction; ① After the release bearing is connected to the oil pipe clip, pull it out in the direction as shown; The oil② delivery pipe of release bearing.

Figure 3-1-1 Disassembly of oil delivery pipe of release bearing

2) Release the hydraulic release bearing bolt① (tightening torque: 10-12N•m), and remove the bolt, gasket and hydraulic release bearing;②

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（A）

Differential oil seal

Housing

①

②


Figure 3-1-2 Disassembly of release bearing

2. Disassembly of cable bracketDisassemble the fastening bolt and cable① ②

clip above the cable bracket, and remove cable③ bracket assembly;

Installation torque of bolt: 18-22N•m①

Figure 3-2 Disassembly of cable bracket assembly

3. Disassembly of gear selection and gearshift mechanism assembly

Remove limiting screw. Remove gearshift③ ② housing bolt and bracket and taken down gear① selection and gearshift mechanism assembly.Tightening torque for the installation of limiting screw: 22-27N•m

Figure 3-3 Disassembly of gear selection and gearshift mechanism assembly

Attention: Be sure to remove the gear selection and gearshift mechanism assembly when the transmission is in neutral (the gear selection and gearshift mechanism can move up and down).

4. Disassembly of rear cover, fifth reverse synchronizer, fifth gear assembly and rear bearing baffle1) See Figure 3-4-1 for the removal of rear cover② bolt and rear cover and accessories;①Tightening torque of rear shell bolt: 18-22N•m

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①

②

③

①

②

②

①

①②

③


Figure 3-4-1 Disassembly of rear shell2) Two gears are engaged at the same time. The fastening screw thread is unscrewed with the hexagon wrench (10mm);The tightening torque for the installation of fastening screw thread is 145-155N•m3) See Figure 3-4-2 for the disassembly of spring③ pin of the fifth reverse shift fork shaft, fifth reverse④ shift fork, fifth reverse synchronizer, fastening⑥ screw threads of synchronizer and output shaft① ② and spring washer;⑤

Figure 3-4-2 Disassembly of fifth reverse synchronizer

4) See Figure 3-4-3 for the removal of ① synchronizer lever, fifth reverse synchronizing② ring, fifth drive gear; fifth gear needle bearing③ ⑤ and 5th-gear driven gear;④

Figure 3-4-3 Disassembly of fifth gear5) See Figure 3-4-4 for the disassembly of rear bearing baffle screw and rear bearing baffle.① ②

The tightening torque is 16-20N•m during the assembly (applied with thread sealant)6) Take out the rear bearing retainer rings of the input shaft and output shaft with the circlip pliers.

Figure 3-4-4 Disassembly of fifth gear5. Disassembly of transmission housing assembly1) Disassemble idler shaft bolt with the hexagon① wrench; The tightening torque is 30-35N•m2) Disassemble third/fourth/fifth gear fork shaft② positioning seat, first/second gear fork shaft③ positioning seat, reversing lamp switch and gasket;④

Figure 3-5-1 Disassembly of idler bolt and reversing lamp switch

3) Remove closing bolt and accessories (8 Nos.)① above the transmission housing;

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④

①

③⑤

⑥

①

②

③

④

⑤

①②

③④

②

①③

④

②


Figure 3-5-2 Closing bolt-1

4) Disassemble closing bolt (7 Nos.) in the clutch① shell; in which, the tightening torque of closing bolt is 22-27N•m

Figure 3-5-3 Closing bolt-25) Remove transmission housing assembly (knock① the left cabinet edge with the rubber hammer)

Figure 3-5-4 Disassembly of transmission housing assembly

6. Disassembly of reversing fork and idler1) Release fastening bolt of reversing fork and① disassemble reversing fork mechanism;②Tightening torque of reversing fork bolt: 22-27N•m (applied with thread fastener adhesive)

2) Take down reverse idle gear shaft, reserve③ ④ idler assembly, idler gasket and magnet;⑤ ⑥

Figure 3-6-1 Reversing fork and idler

7. Disassembly of five shafts and differential assemblyIntegrally take out input shaft assembly, output① ② shaft assembly and first/second gear fork assembly③ and third/fourth/fifth reverse shift fork assembly④ from the cabinet. Gently knock the housing with the plastic hammer and then remove differential⑤ assembly from clutch shell;⑥

Figure 3-7-1 Disassembly of shaft assembly

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①

①

①

②

③

④

⑤

⑥

①

②

③

④

⑤

①

⑥


10 / 21


Section IV Disassembly, overhaul and closing assembly of transmission assembly

1. Input shaft assembly(1) Disassembly

Figure 4-1-1 Disassembly of input shaft assembly1) Place the input shaft assembly on the flat place. Press out the fifth gear shaft sleeve, input shaft rear bearing, fourth gear shaft sleeve, fourth gear drive gear and third/fourth-gear synchronizer with the pressure device at one time;Attention: Be sure to use flat pad to avoid the damage to the gear tooth.2) Press out the input shaft front bearing after reversely placing the input shaft;

1. Input shaft; 2. Input shaft front bearing; 3. Third

gear drive gear assembly; 4. third/fourth-gear synchronizing ring; 5. Third gear needle bearing; 6. Third/fourth-gear synchronizer assembly; 7. Same parts ; 8. Fourth gear drive gear; 9. Fourth gear④ needle bearing; 10. Fourth gear shaft sleeve; 11. Input shaft rear bearing; 12. Fifth gear shaft sleeve

Figure 4-1-2 Decomposition diagram of input shaft assembly

(2) Assembly instructions:(1) Clean each part.(2) Check each partInput shaft: 1) Check whether the outer diameter surface of the installation part of the needle bearing has damage, abnormal wear or indentation, etc.; 2) check whether the spline is damaged or worn; 3) check whether the oil hole is blocked;Needle bearing: 1) Check whether the needle bearing is worn; 2) check whether the rolling needle is missing; 3) check whether the input shaft and gear are correct, whether they can flexibly rotate and have noise, etc.Third/fourth gear drive gear: 1) check whether the tooth surface of oblique gear is damaged or worn; 2) check whether the synchronic cone is roughened, damaged or worn. 3) Check for damage or wear of gear inner hole and front and rear end faces.Synchronizing ring: 1) check for injury or damage of synchronizing ring lock angle; 2) check for compression failure and rubdown of the tapered thread inner diameter; 3) press the synchronizing ring against the conical surface of respective gear and check the clearance A of shifting gear. See Table 4-1-1 for the inspection standard of clearance ACheck clearance A. Standard value: (unit: mm)

Table 4-1-1 Inspection standard for clearance ASynchronizing

ringA value

Limits after wear

First/second gear outer ring

1.25-1.5 0.5

First/second gear inner ring

0.6-1.1 0.3

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Third gear assembly


Third/fourth gear 1.1-1.5 0.5Gear 5 1.1-1.5 0.5

Figure 4-1-3 Inspection of synchronizing ring clearance

Third/fourth-gear synchronizer:1) Assemble the gear sleeve and gear hub. Check for clamping; 2) check for damage and wear of lock angles at both ends of the gear sleeve;Attention: If the synchronizer gear sleeve or gear hub should be replaced, they should be replaced as a complete set.

1. Steel ball; 2. Synchronizer sliding block; 3. Synchronizer spring; 4. Synchronizer gear hub; 5. Synchronizer gear sleeve

Figure 4-1-4 Third/fourth-gear synchronizer

(3) Assembly of input shaft assembly1) Set third gear needle bearing and third gear⑤ ③ sleeve onto the input shaft and apply the gear oil on the gear conical surface and needle bearing according to Figure 4-1-2;2) Assemble 3 sliding blocks and springs and set the third/fourth-gear synchronizer gear sleeve onto the gear hub as shown in Figure 4-1-4.3) Set third/fourth gear needle bearing onto the④ gear conical surface;4) Assemble the third/fourth-gear synchronizer with the special sleeve and pressure deviceAttention:1. When press fitting the synchronizer, ensure that the synchronizing ring groove and synchronizer sliding block are well aligned, as shown in 4-1-5 B;2. After properly press fitting the synchronizer assembly, check whether the third gear rotates flexibly;

Figure 4-1-5 Assembly of synchronizer5) Place third/fourth synchronizing ring into the⑦ square synchronizer groove and apply gear oil on the inner conical surface of the synchronizing ring;6) Assemble fourth gear drive gear onto the input⑧ shaft. Apply gear oil on needle bearing and place it⑨ onto fourth gear shaft sleeve. Press in with sleeve⑩ and pressure device and rotate fourth gear drive⑧ gear;7) Press in the front and rear bearings of input shaft and the fifth gear shaft sleeve in the same way;

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①

②

③

④

⑤

B


Figure 4-1-6 Input shaft assembly

2. Output shaft assembly(1) Disassembly1) Press out the output shaft rear bearing and fourth gear driven gear with the bracket and pressure device. See Figure 4-2-1 "Working procedure I";2) Take out the third and fourth gear driven shaft sleeve;3) Press out the third gear driven gear with the bracket and pressure device. See Figure 4-2-1 "Working procedure II" for the removal of second gear driven gear, first and second gear conical ring, outer ring and inner ring, and second gear needle bearing

Figure 4-2-1 Disassembly of output shaft assemblyAttention: To prevent the gear tooth from being damaged, place the parts on the bracket plane.4) Take out first and second gear synchronizer gear hub snap ring with the circlip pliers;5) Press out the first and second gear synchronizer assembly with the bracket and pressure device, and remove the first gear driven gear and first gear needle bearing in the same way;

1. Output shaft; 2. Shaft sleeve of input shaft rear bearing; 3. Snap ring of output shaft bearing; 4. First gear; 5. First and second gear needle bearing; 6. First and second gear inner ring; 7. First and second gear intermediate ring; 8. First and second gear outer ring; 9. First-/second -gear synchronizer assembly; 10. First-/second -gear synchronizer snap ring; 11. Second gear assembly; 12. Third gear driven gear; 13. Third/fourth gear spacer bush; 14. Fourth gear; 15. Output shaft rear bearing

Figure 4-2-2 Decomposition diagram of input shaft assembly

Notes: ② Inner ring of output shaft front bearing and ①

output shaft are in interference assemble at one time and they cannot be disassembled; in case of part replacement, replace parts , and .① ② ③

(2) Assembly of output shaft assembly

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Input shaft assembly

Working procedure I

Working procedure II


Refer to Figure 4-2-2 Parts assembly in order for the assembly instructions of input shaft assembly.Notes:1) First-/second -gear synchronizer snap ring of part

and output shaft front bearing snap ring of part ⑩ ③ are assembled as a whole. It is recommended to assembly after replacing with a new snap ring;2) In assembling the snap ring, it is required to ensure that the snap ring is assembled into the corresponding the groove. The axial clearance of snap ring should be<0.1mm.

3. Differential assembly(1) Disassembly1) Remove the front and rear bearings of differential with the special tool;2) Disassemble 10 differential bolts and then remove them by knocking the main reduction gear with the rubber rod;3) Knock out the planetary gear fixing pin with the hammer and fixing pin disassembly pin (Φ5mm).4) Remove the planetary gear shaft, planetary half shaft gear and gasket

1. Differential housing; 2. Differential bearing; 3. Main

reduction gear; 4. Differential bolt; 5. Half shaft gear gasket; 6.

Half shaft gear; 7. Planetary gear; 8. Planetary gear gasket; 9.

Fixing pin; 10. Planetary gear shaft (2.1 differential bearing

outer ring)

Figure 4-3-1 Decomposition diagram of differential assembly

Note:

1) The arrow direction is the assembly direction of the fixing pin. The fixing pin should be disassembled in the reverse direction;2) 2.1 is the differential bearing outer ring. During the

disassembly, the bearing outer ring is fixed on the housing;

(2) Assembly instructions:1) Clean each part;2) Check whether the half shaft gear gasket is worn.

If so, replace it;3) Check whether the planetary gear and half shaft

gear tooth are broken and worn. If so, replace them;

4) Check whether the planetary gear shaft surface is sintered. If so, replace it;

5) Check whether the joint of conical bearing and differential housing is loosened. If so, replace the conical bearing and differential housing;

6) Measure and adjust the half shaft gear clearance: fix the differential assembly as shown. Fix the magnetic stand on the differential assembly. Move the half shaft gear up and down with both hands. Read the change value of dial indicator pointer. Half shaft gear clearance: 0.05-0.20mm; wear limit: 0.4mm. If it is out of such range, re-select the adjusting gasket thickness of half shaft gear: 0.9, 0.95, 1.0, 1.05, 1.15 and 1.1mm

14 / 21


1. Measuring head; 2. Dial indicator holder and dial indicator;

3. Differential assembly; 4. Half shaft gear

Figure 4-3-2 Adjustment of half shaft gear clearance(3) Assembly of differential assembly:1) Place the half shaft gear, planetary gear and well selected gasket on the differential housing and rotate them to the correct position;2) Assemble the planetary gear shaft. Knock in the fixing pin of planetary gear shaft in the direction as shown in Figure 4-3-1 and rivet the inlet side of fixing pin mounting hole to deformation;Attention:

There are four slots (about 10mm) on one end of① the planetary gear fixing pin. The end with slot should be at the inlet side of the fixing pin mounting hole; otherwise, there will be looseness;

After properly assembling the planetary gear② shaft, check whether the half shaft gear rotates flexibly. If not, replace the half shaft gear gasket;3) Place the main reducer driven gear on the differential housing in the correct direction. Apply the thread fastener adhesive on the differential bolt. Fasten the differential bolt;Tightening torque of differential bolt: 110-120 N•m.4) Press fit the front and rear bearings of differential onto the differential housing with the special tooling.

4. Fork assemblyMaintenance instructions:1) Check the wear situation of each fork leg. If the

axial clearance of the fork and the corresponding gear sleeve is >1.0mm, the corresponding gearshift fork should be replaced;

2) The spring pin assembled on the fork assembly is assembled as a whole. In case of disassembly, the spring pin should be replaced;

3) In case of parts replacement, reassemble the parts as shown in Figure 4-4-1 and Figure 4-4-2;

1. First and second gear fork shaft; 2. Spring pin; 3. First and second gear fork

Figure 4-4-1 Decomposition diagram of first and second gear fork assembly

1. Fifth reverse gear fork shaft; 2. Third and fourth gear fork; 3. Third and fourth gear fork shaft; 4. Spring pin; 5. Third and fourth gear fork bracket; 6. Spring; 7. Reverse gear pull pin; 8. Interlock pin; 9. E-retainer ring

Figure 4-3-3 Decomposition diagram of third/fourth/fifth gear fork assembly

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16 / 21


5. Gearshift mechanism assemblyMaintenance instructions:1) During the disassembly, it is required to pay attention to the assembly direction and order of each part;2) Tightening torque for bolt assembly: 18-②22N•m;3) During the assembly of neutral switch identification cam of 14# part, the spring pin should be pressed in after the insert is properly fixed. The direction of the side with magnet should be consistent with that of the notch of 13# part;Attention: Fragile magnet! Pay attention when press fitting the spring pin!

1. Gear selection and gearshift sliding block; 2. Bolt; 3. Gear selection arm assembly; 4. Spring pin; 5. Gearshift arm; 6. Shift shell assembly; 7. Gear shift; 8. Snap spring pin; 9. Spring pin; 10. E-retainer ring; 11. First and second gear return spring; 12. Gear selection and gearshift shaft; 13. Stop block; 14. Neutral switch identification cam; 15. Interlock plate

Figure 4-5-1 Decomposition diagram of gearshift mechanism

1. Gear selection and gearshift shell; 2. Linear bearing; 3. Gear selection and gearshift oil seal; 4. Dust cover5. Vent cap; 6. Breather pipe; 7. Bolt; 8. Fifth gear/reverse gear interlocking mechanism9. Fifth gear/reverse gear return spring

Figure 4-5-2 Decomposition diagram of gearshift shell assembly

Notes:Fifth gear/reverse gear return spring of 9# part and gear selection and gearshift shell of 1# part are riveted as a whole. In case of replacement, the complete set should be replaced;

6. Clutch shell assemblyMaintenance instructions:1) For assembly of part differential oil seal and part②

input shaft oil seal, the oil should be applied on the⑥ oil seal outer edge. After the assembly, check and ensure that the oil seal outer edge should not be turned up;2) During the assembly of output shaft of part , the⑤ cushion of corresponding height should be placed in the reverse cavity of the housing to prevent the housing from being compressed and damaged;3) Part is the blanking cap of differential oil seal. ①The assembly should be removed when placed into the complete vehicle;

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1. Blanking cap of differential oil seal; 2. Differential oil seal; 3. Locating pin of matching surface; 4. Differential bearing outer ring; 5. Output shaft front bearing; 6. Input shaft oil seal; 7. Clutch shell

Figure 4-6-1 Decomposition diagram of clutch shell assembly

7. Transmission housing assemblyMaintenance instructions:1) For assembly of part differential oil seal, the oil② should be applied on the oil seal outer edge. After the assembly, check and ensure that the oil seal outer edge should not be turned up;2) Tightening torque of bolt (N·m):

Part No. Torque Part No. Torque7 28-35 9 18-2212 28-35 15 28-3516 10-12

3) The oil delivery pipe of part is assembled as a④ whole;4) In case of no special circumstances of differential adjusting gasket of 18# part, it is not recommended for adjustment and replacement;

1. Blanking cap of differential oil seal; 2. Differential oil seal; 3. Transmission housing; 4. Oil delivery pipe; 5. Linear bearing; 6. Neutral switch; 7. Gearshift positioning seat; 8. Gearshift shell locating pin; 9. Bolt M10; 10. Hook; 11. Rear shell locating pin; 12. Drain plug; 13. Drain plug gasket; 14. Oil fill plug gasket; 15. Oil fill plug; 16. Bolt M6; 17. Differential bearing outer ring; 18. Differential adjusting gasketFigure 4-7-1 Decomposition diagram of transmission

housing assembly

8. Rear shell assembly Notes:Rear shell and oil conduit are riveted and assembled as a whole. In case of replacement, they should be replaced as a complete set;

Figure 4-8-1 Decomposition diagram of transmission housing assembly

9. Closing assemblyAfter properly assembling all the assemblies, refer to the order in "Section III Disassembly of transmission assembly" for the assembly of all parts. Pay attention to the following:1) During the assembly of reverse idle gear, the thread hole direction of idler shaft is consistent with that of the connection between the idler center and housing through-hole. See Figure 4-9-1 for details;

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Figure 4-9-1 Assembly of idler shaft2) Before closing, the sealant on the matching surface of the shell should be cleaned; after cleaning, refer to Figure 4-9-2 for gumming track. The sealant should be applied on the clutch shell. Then, do the closing operation;

Figure 4-9-2 Gluing track of clutch shell 3) After assembling the closing bolt, apply the sealant on first and second gear fork shaft positioning seat,①

third/fourth/fifth gear fork shaft positioning seat② and outer thread surface of reversing lamp switch③ (TONSAN). Then, assemble them into the corresponding thread holes. Tightening torques ① and : 28-35N•m; : 20-25② ③ N·m;

Figure 4-9-3 Assembly of fork shaft positioning seat and reversing lamp switch

4) During the assembly of fifth gear and synchronizer, area A of synchronizer lever should be flush with① area B of synchronizer gear hub. The end of ② ① synchronizer lever should be parallel to area C of ③ fifth gear synchronizing ring. See Figure 4-9-4 for details;

Figure 4-9-4 Assembly of Fifth gear/reverse gear synchronizer

5) After properly assembling the fifth gear and synchronizer gear hub, assemble the fifth reversing① fork into the gear sleeve and then set them onto the synchronizer gear hub together; press any two fork② shafts; apply thread fastener adhesive on the outer③ thread surface of the fastening screw thread and fasten it; then, assemble the fifth reverse shift fork spring④ pin. See Figure 4-9-5 for details.

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A

B

C


Figure 4-9-5 Assembly of fastening screw thread6) During the assembly of gear selection and gearshift mechanism, be sure to enable the three forks A to be flush with each other; after properly assembling the gear selection and gearshift mechanism, assemble the limiting screw;

Figure 4-9-6 Assembly of gear selection and gearshift mechanism

7) In assembling the hydraulic release bearing, first assemble the hydraulic release bearing as required, and then insert the oil delivery pipe into the corresponding oil pipe of hydraulic release bearing. After assembling the oil pipe, it is required to check whether the oil pipe is assembled in place according to the requirements of Figure 4-9-7: pulling-out force > 120N;

Figure 4-9-7 Detection of oil delivery pipe of hydraulic release bearing

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①

②

③

④

A

Limiting screw


Attached: Special tool

Oil seal

disassembler

Slide hammer Oil seal

installer

Bearing

installer

Snap ring

pliers

Dial indicator Magnetic

gauge stand

Bearing

installer

Box separator Bearing

bracket

Oil seal

installer

Bearing

installer

Bearing

installer

Stripping

attachment for

spring pin

5mm

Bearing

disassembler

Bearing

disassembler

Bearing

installation

Disassembly

of spring pin 6

Bearing

disassembler

Bearing

installer

Attached: List of quick-wear partsS. N.

Name Qty. Remarks

1Hydraulic release

bearing1

2Oil delivery pipe of

hydraulic release bearing

1

3 Spring pin Φ5×22 74 Spring pin Φ5×30 15 Spring pin Φ3×22 1

6Third/fourth gear

synchronizing ring2

7Fifth reverse

synchronizing ring1

8First/second gear

outer ring2

9First/second gear

inner ring2

10First/second gear intermediate ring

2

11 Input shaft oil seal 112 Differential oil seal 2

13First-/second -gear synchronizer snap

ring 4

4 kinds of specifications

14Adjusting gasket of

half shaft gear7

7 kinds of specifications

15Fixing pin of

planetary gear shaft1

16 Spherical washer 2

17Fastening screw

thread of 5th-gear synchronizer

1

18Fastening screw

thread of output shaft1

19 Disc washer 2

21 / 21

Documents

· Web viewIt is likely that the tightening torque of plug screw is less than the specified value. Check the tightening torque. If it is not the specified value, fasten it. II. It