Manual of Assembling and Test of Transmission

Part 1 Assembling of Transmission

Assembling of Transmission shall be conducted according to the assembly drawing and
the requirements in General manual of Jie Fang Automotive Component and
Assembling
(JQ-00-1).
A.Assembling of transmission body
1.The transmission case must be cleaned completely ,no residual sand and dust, etc
.in oil groove is permitted, no burrs and parting line flashes in oil groove and die
parting line are permitted, flatten them by grinding wheel and wash to clean if
necessary.
2.The items for the 2nd gear assembly shall be conducted according to the
requirements in its assembly drawing, and inspected carefully.
3.When assembling the synchronizer cones of the 3rd,4th,5th ,and 6 th gear with their
corresponding gears, by changing the meshing phase of spline ,make the total run-
out of synchronizer cone surface in relation to the central lines of each gear hole not
more than 0.1mm, make the roundness tolerance of synchronizer cone not more
than 0.012mm.
4.When pressing the synchronizer rings of the 3 rd,4th,5th,and 6th gear against closely
their corresponding synchronizer cone, the back travels of synchronizers are listed in
Table 1
Table 1 (mm)
Gear shift Back travel

3rd gear 2(2.35,1.80)

4th gear 2(2.35,1.80)
5th gear 2(2.35,1.80)
6th gear 2(2.35,1.80)
5.The contact area between synchronizer ring and synchronizer cone shall be not less
than 90%.
6.Assembling of output shaft assembly
6.1 The gear bushes of the 1st gear and the back-up gear are interference fitted with
the corresponding shaft diameter of the output shaft. The bushes are heated
before assembling, then mounted in corresponding position of the output shaft and
be care that bushes must be in place.
6.2 Select a clip ring with a proper thickness, make the axial clearance between the
bush of 4th gear and the synchronizer gear seats of 5 th and 6th gears keep a
minimum, be sure that clip ring inserted in its groove.
6.3 When mounting the synchronizer gear seats of the 1 st gear and 2nd gear, the one
end of outer spline with a thickness for which can be reduced must be faced
against the 1st gear.
6.4 When mounting the gears and needle bearings of each gear shifting, a small
amount of gear oil should be painted on their moving surfaces.
 6.5 If the output shaft assembly is assembled properly, the gears for each gear shifting
shall be rotated freely.
7.Assembling of countershaft assembly
7.1 The reduction gear of countershaft and the 6 th gear are interference fitted with the
6th gear are interference fitted with the corresponding shaft diameters of
countershaft, before assembling, the gears be heated, then mount them in their
corresponding positions of countershaft, be sure that they are in their places.
7.2 Press the inner race assemblies of front and rear bearing of countershaft to the
front and rear ends of countershaft respectively, then touch closely with the
shoulder.
8. Assembling of input shaft assembly
8.1. The rear bearing of input shaft should be mounted in a set, mixing assembling is
not permitted . a small amount of gear oil should printed on the inner and outer
rolling tracks first, when pressing in the inner race, pressing in the outer race is not
allowed, the impact load is not allowed strictly. The side for which a larger circular
fillet in the bearing is existed should face against the gear, after the bearing is in its
place, select a proper thickness of clip ring and mount it in its groove and keep a
minimum clearance.
8.2. When the roller in the front end of output shaft shall be mounted in the hole of
input shaft, besides a small amount of gear oil should be painted on the roller track
first, also be care the rolling track surface should not be scratched at the time of
mounting, 15 rollers must be in the same size group, no mixing mounting of
different size roller group is permitted.
9. Assembling of rear bearing cap of countershaft
9.1 After the countershaft assembly is mounted in the case, press in the outer races of
front and rear bearing, put the clip ring in its groove.
9.2Measure the value A of rear bearing cap of countershaft (see Fig.1)
9.3 press tightly the outer race of rear bearing of countershaft, make the axial clearance
of the bearing as zero(0), eliminate the axial blearance between clip ring and front
bearing and measure the value B(see Fig. 2)
9.4 Calculate the total thickness of the adjusting shim set T=A-B-h-0.05, here h is a
compression value of shims, taking the compression value as 0.1
9.5 A set of shims with a total thickness T should be formed with a minimum shims as
possible as you can, the thinnest one placed in the inside and the thickest one place in
the outside.
9.6 When assembling the shims, the sealing glue should be painted on both surfaces of a
shim, be care the return oil hole does not seal by the glue and the return oil hole must be
aligned with the return oil hole of transmission case.
9.7 Tighten the bolts for bearing caps a tightening torque specified in Table 2.
10. Assembling of bearing caps of input shaft and output shaft
10.1 Press vertically the rubber oil seal on bearing cap with a special tool, be sure the
rubber oil seal placed in its position and paint lubricating grease on its edge.
10.2 When mounting the bearing cap of the input shaft on transmission, in order to
pervert the oil seal edge from damaging, the rectangular spline of input shaft should be
covered with some thing and make the oil seal edge pass through. In order to prevent oil
seal edge from curling, insert the oil seal while rotate the bearing cap assembly at the
same time, after the oil seal in placed in its position, remove the coverings from
rectangular spline of input shaft.
10.3 When mounting the shims of bearing cap, the two sides of shim should be covered
with sealing glue, be care the return oil hole should not be blocked, make the return oil
hole align with the return oil hole of transmission case.
10.4 When mounting the driven gear and connector of speedometer in the rear bearing
cap, the O ring should be covered with lubrication grease and should e not damaged,
tighten it by bolts with a tightening torque specified in Table 2.
10.5 After the bolts of bearing cap are tightened evenly by a torque specified in Table 2,
the input shaft, output shaft and countershaft should be rotated by hand easily and
smoothly.
11 After mounting the flange assembly on the rear end of output shaft, the o ring shall be
inserted in the groove of flange, tighten the lock Nut with a tightening torque specified in
Table 2, rivet the two positions at the end of nut to the corresponding groove of output
shaft, the depth of riveting is not less than 1.5mm ,no tearing is permitted.
12.The bolt to threaded into the through hole must be covered with sealing glue when
assembling it.
13. Assembling of back-up idle wheel
13.1 Pay attention to the mounting direction of back-up idle wheel, make the one side
with protruded gear hub and larger end face against front direction, a small amount of
gear oil should be painted on the idle wheel shaft and needle bearing, the o ring should
be covered with the lubrication grease a little when mounting it in the shaft groove, no
scratch on o ring is permitted, if it is mounted correctly, the idle wheel shall be rotated
freely, then tighten the lock bolt with a torque specified in Table 2.
13.2 After the two sides of side cover shim are painted with sealing glue, tighten the side
cover bolts with a torque specified in Table 2.
14 After the two sides of shim used for power-take- off howl are covered with sealing
glue, tighten the blots used for cover plate of power-take-off hole with a torque specified
in Table 2.
Table 2
Bolt position Tightening torque
Fixing bolt, front and rear bearing caps 70-80
Fixing bolt, top cover and upper cover 37.0-49.0
Fixing bolt , power-take-off hole cover plate 19.6-31.4
Fixing bolt, back-up side cover 16-30
Fixing bolt, speedometer driven gear
8.0-10.5
connector
Lock nut, output shaft flange 588-784
Fixing bolt, back-up shaft lock plate 18.6-25.5
Fixing bolt, top cover pulling rod 24.5-37.2
 Ventilating cock 26.5-31.4
Switch, back-up warning 26.5-31.4
Filling and drain oil screw 100-120

B.Assembling of cover assembly of transmission

1. Assembling of cover assembly of transmission
1.1 Assembling of shifting guide block assembly used for back-up gear, 5 th and 6th gear
shall be conducted according to assembly drawings, and the avower-mentioned
requirements must be met.
1.2 When assembling the shifting fork, shifting guide block and their assembly, the
span directions of two elastic pins must be in 180, insert them from one direction
which has a protrusion in the guide block, until it is flattened and aligned.
1.3 Mount the shims with a special tool, coat an adhesive around the periphery after it
is riveted.
1.4 The upper cover assembly of transmission after it is assembled shall be checked
on a special inspection fixture for followings:
a. Distance from front end of shifting fork foot to the central line of front positioning
ring hole:
5th and 6th gear: 100.5mm
3rd and 4th gear: 1040.5mm
1st and 2nd gear: 2340.5mm
reverse gear: 308 (308.6~307.6)mm
b. Every fork notch should be flat and alignment, use a plug gauge with a width of
14.7~14.8mm and a length of 14mm to pass through in and out freely
c. The side clearance between each adjacent shifting guide block( or shifting fork
head):
Side clearance between reverse shifting guide block and 1 st and 2nd gear shifting guide
blocks: 1.2-5.0mm
Side clearance between 1st and 2nd gear shifting guide block and 3rd and 4th gear
shifting fork heads: 0.9-3.3mm
Side clearance between 3rd and 4th gear shifting guide block and 5th and 6th gear
shifting guide blocks: 1.7-4.5mm
1.5 The back-up warning switch should be tightened with a torque specified in table 2
1.6 The ventilating cock shall be tightened with a torque specified in table 2, the
sealing glue should be painted in the bottom end of ventilating cock.
2. Assembling of top cover assembly of transmission
2.1 The rubber oil seal for the top cover shall be pressed in vertically by a special tool,
the edge of rubber oil seal shall be covered with lubrication grease.
2.2 The connecting screw used for shifting lever and shifting shaft shall be tightened
with a torque specified in table 2, the steel lock wire shall be inserted into the hole,
be sure it is locked there.
2.3 After the end cover is tightened, the adhesive should be painted at the thread.
3. Clean the connecting surface between the upper cover assembly and top cover
 assembly of transmission, the two sides of shims should be covered with sealing
glue, tighten the 4 bolts with a torque specified in table 2.
C Final assembling of transmission
1. Clean the connecting surface between the transmission body and the cover
assembly of transmission, no dust and oil dirty are permitted.
2. The sealing glue should be painted on the transmission case, the 4-6 sealing
glue strip is positioned in the middle of surface width, the sealing glue shall be
painted in the inner side of screw hole, no interruption of sealing glue between front
and rear position is permitted, no sealing glue fallen in the inside of transmission
case is permitted.(see fig.3)
3. Put the every sliding gear sleeve and every shifting fork in neutral position, make
the cover assembly align with positioning ring hole and drop it down vertically.
4. Tighten evenly the bolts, make the tightening torque meet the requirements in table
2, then clean away the sealing glue that is excessively squeezed.
5. The name plate of transmission and the nameplate of speedometer shall be
stamped at the left or right side of transmission for where the nameplates are
stamped. Before stamp the nameplates, the oil dirty should be cleaned thoroughly,
the detail stamping positions see transmission assembly drawing.

Part break-in test of transmission

1. No load test shall be conducted for transmission on a special test bench under the
condition of 1450rpm input shaft rotation speed.
2. Before starting the transmission, fill enough break-in oil for transmission and the oil
temperature shall be not lower than 15C
3. The real test time shall be not less than 2.5 minutes
4. Inspection in test:
a. No abnormal sound, knocking voice and friction voice between shifting fork
and sliding gear sleeve are permitted
b. Shifting each gear shall be freely and exactly.
c. No marked impact noise from each shift gear is permitted.
d. When shifting for back-up gear, the back-up warning switch is turned on , and
it is turned off when shifting for neutral position.
e. No oil leakage or oil , to see page from each sealing position is permitted.
5. Rrepair or remedy should be performed when defects from transmission are found,
repeat the test after repair is done.
6. After the break-in test is finished and qualified, drain out the break-in oil completely,
put in the shims and tighten the filling oil cock and drain oil cock.
7. The tested and qualified transmission assembly shall be approved by inspection
department, the nameplate shall stamp on the upper position of speedometer gear
nameplate with production date and serial number.
8. Finally stamp the production date and production serial no. on the two protrusions
in front and back ends on the left side of upper surface of transmission.
Note: the lubrication oil used for transmission is 80w/90 common vehicle gear oil (GL-
3) SHO 0350-92, oil filling amount should be filled till the oil is overflowed from oil filling
hole.