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Dismantlement and Assembling Transmission
Dismantlement and Assembling Transmission
Dismantlement and Assembling Transmission
第十一章 变速箱的拆卸与安装
Chapter 11 The Dismantlement and Assembling of the Transmission
11.1 变速箱的拆卸
11.1 Dismantle the transmission
11.1.1 变矩器拆卸
将变矩器从变速箱上拉出,放尽变矩器内剩余的油,放置一边(图 11-1)。
11.1.1 The dismantle of the torque converter
Pull out the torqueconverter from the transmission,
drain the remaining oil, then put it aside.(Fig.11-1)
图(Fig.)11-1
11.1.2 操纵阀拆卸
a、用 M8 内六角扳手将操纵阀上 10-M8×45、6-M8×75
内六角螺栓分别取下。
b、取操纵阀时注意阀垫完整。
C、取下操纵阀小隔板与纸垫。
(图 11-2)。
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
11.1.3 输油板拆卸
a、将输油板上六根油管依次拆下,六根油管从上往下分别为 K2、K1、K3、K4、KR、KV,其中 KV、
KR 二根油管按不同主机厂后桥转向改变。
b、将输油板与箱体连接的 3-M8*45、6-M8*35 内六角螺栓取下,拆下输油板、隔板后放置一边(图 11-3)。
图(Fig.)11-3
11.1.4 连接外壳拆卸
将连接外壳与变速箱连接的 12-M10×35、2-M10×50 螺栓拆下,用二只螺栓将连接外壳顶出,
放一边(图 11-4)。
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
图(Fig.)11-4
11.1.5 取力器组件与配油法兰、油泵组件拆卸。
a、将输出箱体轮毂与箱体连接的 11-M8×20 螺栓取下,
用二只 M8×20 螺栓将取力器组件顶出(图 11-5)。
铜棒顶住部位
The bar copper
withstands the
spot
b、左手持一根φ30×400mm 左右铜棒顶住油泵端盖,
右手用另一根铜棒将配油发兰与油泵组件敲出并放置
在一边(图 11-6)
b. Prop the pump cover with a copper stick of φ30×400mm
or so in your left hand, and knock the distribution flange and
pump assembly out, then put them aside. (Fig.11-6)
图(Fig.)11-6
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
11.1.6 润滑油管与手制动器组件拆卸
a、分别将二根变速箱润滑油管二端 M18 螺栓拧下,取出油管(图 11-7)
。
润滑油管组件
Lubrication oil pipe assembly
空心螺栓 A18
Hollow bolt A18
图 11-7
图(Fig.)11-7
b. Take the safety plates 2-M10×30 off the output shaft on the hand brake end, screw off the two boltsand
remove the hand brake and the hand brake flange assembly together with a bob crowbar.(Fig. 11-8)
螺栓锁片、2-M10×30 螺栓
Locking plates of the bolt、
bolt 2-M10×30
图(Fig.)11-8
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
11.1.7 三组离合器部件拆卸
a、依此将三根离合器轴与箱体连接的螺栓拆下(图 11-9)。
K1+KV 离合器
图(Fig.)11-9
K3+K4 离合器轴 轴位置
Clutch shaftK3+K4 Location of
clutch shaft
b、用轴端 2-M16 空心螺栓分别固定 K1、K2、K3 轴,
分别用专用拉摸依此拉出。
b. Fasten the K1, K2 and K3 shaft respectively with the hollow bolts on their ends, and pull them out one by
one by a special drawing die.
c、每组离合器拉出后,分别将离合器调整垫片套在轴端,以便今后总装(图 11-10)。
c. Put the cluth adjusting plate under the shaft end after pulling out each set of clutch for generalassembly.
(Fig. 11-10)
11.2 变速箱部件组装
图(Fig.)11-10
11.2 The assembling of the transmission parts
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
11.2.1 变矩器组装
a、把 25*3O 型圈装入垫圈槽中,压入罩法兰孔中,用 30×1.2 孔用卡簧固定(图 11-11)。
罩法兰
Cover flange
罩 轮
Cover wheel
图(Fig.)11-11
b. Fix the cover flange assembly and paper mat with bolt 12-M10×25.
c、将涡轮法兰用 16 只φ8mm 铆钉固定在涡轮上(图 11-12)。
c. Fix the turbine flange with sixteen rivetsonto the turbine.(Fig. 11-12)
涡轮法兰
Turbine flange
滚柱推力轴承
Roller thrust bearing
涡 轮
Turbine
图(Fig.)11-12
d. Fix the pump flange onto the pump wheel by bolts 12-M8×20. (Fig.11-13)
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
泵 轮
Pump wheel
泵法兰
Pump flange
图(Fig.)11-13
e. Knock the ball bearing 6010c3/j into turbine assembly before install them into the bearing hole of the wheel
casing. (Fig. 11-14)
图(Fig.)11-14
f、测量轴承深度,保证涡轮组件平面轴承间隙(图 11-15)
。
f. Measure he bearing depth and keep the suitable flat bearing clearance of the turbine assembly.(Fig.11-15)
g、测量轴承深度,保证导轮处平面轴承间隙(图 11-16)。
g. Measure the bearing depth and keep the suitable flat bearing clearance of the guide pulley.
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
图(Fig.)11-15 图(Fig.)11-16
h、将调整好间隙并配好平面轴承的导轮装入涡轮内(图 11-17)。
h. Install the guide pulley whose clearance adjusted and flat bearing equipped into the turbine.
变矩器平面轴承
Flat bearing of the
torque converter
变矩器合箱纸垫
Paper mat of the
torque converter
图(Fig.)11-17
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
油 泵
Oil pump
6206RS/J 球轴承
Ballbearing
辅助驱动轴
Stand-by drive shaft 图(Fig.)11-19
e. Knock the needle bearing HK75×83×16 into the bearing hole on the bearing bracket of the pump
wheel, then fit in an oil seal of Ø75. (Fig. 11-20)
HK75×83×16 滚针轴承
Needle bearing
Ø75 油封
Oil seal Ø75
泵轮轴承座
Bearing bracket of
the pump wheel
图(Fig.)11-20
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
f. Clean the distribution flange before fit the roller bearing NJ209E/C3 into the bearing hole of the flange.
g. Fit the input gear into the distribution flange and adjust the gear clearance to a suitable value.
h. Insert in a turbine shaft and amount the ball bearing 6308C3.
i. Fit the snap ring of 40×1.75 and ring seal 252 for hasp. (Fig. 11-21)
图 11-21
j、将油泵纸垫放在配油法兰油泵面,
涂上黄油。
k、将φ20mm 钢球,2.5×16.95×57.2 压力弹簧装入配油法兰变矩器旁通阀孔中。
l、将油泵组件插入配油法兰组件孔中,拧紧 4-M8×85、4-M8×115 内六角螺栓(图 11-22)。
j. Place the paper mat of the oil pump on the pump side
of the distribution flange and butter it.
k. Fit the steel ball of φ20mm, pressure spring of 2.5×
16.95×57.2 into the bypass valve port on the torque
converter of the distribution flange.
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
11.2.3 离合器部件组装
a、将单向阀钢球朝上装入离合器阀孔中(图 11-23)。
107 单向阀
107One-way valve
图(Fig.)11-23
b、异形密封环(140、141)分别装入活塞槽中。
b. Fit the shaped sealing rings (140,141) into the washer groove respectively.
c、将活塞组件装入离合器油缸内,装上 083 导向环、183 压力弹簧、083 导向环、346 挡圈、084 导向
环后用专用工装将挡圈装入离合器油缸卡簧槽中。
c. Fit the piston assembly into the cylinder of the clutch, then amount the guide ring 083, the pressure spring
183, the guide ring 083, the baffle ring 346 and the guide ring 084 before fit the baffle ring into the circlip
groove of the clutch cylinder with a special tool set-up.
d、将 203、205 滚针轴承分别敲入离合器轴承孔中并装上挡圈(图 11-24)。
d. Knock the needle bearing 203 and 205 respectively into the bearing hole of the clutch and amount the
baffle.( Fig. 11-24)
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
140 异形密封环
346 挡 圈
183 弹簧 the shaped 活 塞 组 件 the
the baffle 离合器外器
sealing rings
ring spring piston
`
141 异形密封环 the 203 轴承 The 205 轴承 The
084 导向环 083 导向环
shaped sealing rings
needle bearing needle bearing
图(Fig.)11-24
e、将粉片、钢片分别装入 离合器中,K1+KV、K2+KR 离合器二端粉片分别为 9 片、8 片,钢片分别
为 8 片、7 片, K3+K4 离 合器二端粉片分别为 10 片、9 片,钢片分别为 9 片、8 片(图 11-25)
e. Fit in sintered pieces and steel pieces respectively. Number of the sintered piece at the two ends of each
clutch: K1+KV, K2+KR:9,8;K3+K4: 10,9; :that of the steel piece for each clutch: K1+KV, K2+KR:8,7,
K3+K4: 9,8(Fig. 11-25)
钢片 粉片
steel piece 图(Fig.)11-25 sintered
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
f. Amount the pressure-bearing plate and the snap ring, and adjust the thickness of the steel pieces to make sure
that the piston path is between 1.9-2.2mm. (Fig. 11-26)
弹性挡圈 承压板
the snap ring the pressure-bearing
图(Fig.)11-26
g、 K1 部件组装:将 029 挡圈、6009 球轴承(专用)、556 调整圈装入 K1 齿轮孔中,卡上 75×2.5 挡
圈,保证轴承轴向间隙在 0.1-0.3mm,掉头装入 109 滚针轴承、779 杜帮片并用黄油固定待用(图 11-27)。
g. The assembling of the K1 assembly: fit the baffle 029, ball bearing 6009(special),adjusting loop 556 into the
hole of the gear K1 and wedge a baffle of 75×2.5 to make sure that the axile clearance of the bearing is
between 0.1-0.3mm. Then, amount the needle bearing 109 and the 779 Dupond shim at the other end and
fix them with butter. (Fig. 11-27)
图(Fig.)11-27
h、 KV 齿轮组装:将 111 滚柱轴承装入 KV 齿轮内,用黄油固定住 777 杜帮片待用(图 11-28)。
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
h. The assembling of gear KV: fit the roller bearing 111 into the gear KV and fix the Dupond shim 777 with
butter.(Fig. 11-28)
111 滚柱轴承
the roller bearing
777 杜帮片
Dupond shim
KV 齿 轮
gear
图(Fig.)11-28
i. The assembling of the KR gear: Fit the roller bearing 028 into the KR gear, and fix the 777 Dupond shim
with butter. (Fig. 11-29)
028 滚柱轴承
the roller bearing
777 杜帮
Dupond shim
Kr 齿轮
gear
图(Fig.)11-29
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
j. The assembling of the K2 gear: amount a baffle ring 830 in the bearing orifice groove of the K2 gear with its
small end downward and put a 211 roller bearing with the small end surface upward, then wedge in a 830
baffle with its small surface downward to fix the bearing. After that, amount another 830 baffle ring with
its small surface downward and another 211 roller bearing with its small surface upward. At last, fit in a
Dupond shim 779 at the other end and fix it by butter. (Fig. 11-30)
830 挡圈
the baffle
K2 齿轮
gear
211 滚柱轴承
777 杜帮片
Dupond shim the roller bearing
图(Fig)11-30
K、将 109 滚针轴承装入 K3 齿轮轴承孔后,再装入 048 滚柱用黄油分别固定,调头装入 779 杜帮片用
黄油固定待用(图 11-31)。
k. Fit a 109 needle bearing into the bearing hole of the gear K3 before fitting the 048 roller bearing and fix
them respectively with butter. Fit 779 Dupond shim at the other end and fix it with butter. (Fig. 11-31)
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
K3 齿轮
gear
图(Fig.)11-31
i. The assembling of the K4 gear: Amount the roller bearing 069 into the hole of K4 gear, and fix the Dupond
shim 777 with butter. (Fig. 11-32)
069 滚柱轴承
K4 齿轮 777 杜帮片
gear Dupond shim
图(Fig.)11-32
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
m. Cover the washer grooves of K1, K2, K3 with 49×3“O”rings then amount three 106 ring seals for tab for
each shaft and fix them with butter. (Fig. 11-33)
49×3“O”型圈
“O”rings
图(Fig.)11-33
11.2.4 主取力器部件组装
a、将 HK4516 滚针轴承装入输出箱体轮毂内。
b、将 068 挡圈装入 002 传动齿轮孔内,再将齿轮装入 806 输出箱体轮毂内。
c、将 011 取力器轴插入齿轮孔内,敲入 6209N/C3 球轴承,卡入二只 011H 弹性
挡圈、一只 45×1.75 挡圈(图 11-34)
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
6209N/C3 球轴承
输出箱体轮毂 the ball bearing
the wheel hub
of the output
housing.
068 挡圈
002 传动齿轮
the transmission gear 002
图(Fig.)11-34
11.3 变速箱总装
11.3 The general assembly of the transmission
11.3.1 装输出部件
a、装入挡油盘、挡板并用 M8 螺栓定(图 11-35)。
b. Knock the NJ213E bearing onto the end of the output gear shaft, then fit the whole into the oil deflector and
insert the output shaft.
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
图(Fig.)11-36 图(Fig.)11-37
c. Amount the spacer, bearing, adjusting washer and baffle one by one and make sure the bearing clearance lies
between 0.1-0.3mm. (Fig. 11-38)
图(Fig.)11-38 图(Fig.)11-39
d. Knock the oil seal on, amount the outputflange and pressure plate, and screw tight the bolts 2-M10×30
before lock the lockingplate. (Fig. 11-39, 11-40, 11-41)
图(Fig.)11-40 图(Fig.)11-41
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
e. Lock the locking plate after amounting the 819brake assembly, the parking brake flange, the brake drum
wheel, the pressure plate and screwing tight the bolts. (Fig. 11-42)
图(Fig.)11-42
11.3.2 装惰轮部件
a、将 216 滚柱轴承装入 560 惰轮轴承孔内用黄油固定待用。
b、将 57×3“O”型圈套入 618 惰轮轴槽内(图 11-43)。
216 滚柱轴承
惰 轮
the idle wheel
57×3“O”型圈
“O”ring
图(Fig.)11-43
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
c、将惰轮组件放入箱体惰轮槽中,插入惰轮轴,装上垫片后用螺栓固定(图 11-44、11-45、11-46)。
c. Put the idle wheel assembly into the idle wheel groove of the housing and insert the idle wheel shaft in.
Amount
the spacer and fix it with bolt. (Fig.11-44, Fig.11-45, Fig.11-46)
轴
shaft
11.3.3 装变矩器压力阀
a、将阀芯、压力弹簧、阀座装入阀套孔中。
b、将阀套组件装入箱体变矩器压力阀孔中(图 11-47)。
c、拧紧螺栓固定(图 11-48)。
阀套
图(Fig.)11-47 图(Fig.)11-48
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
11.3.4 装副取力器
a、将 6209N/C3 轴承装入箱体副取力器轴孔内并卡入二根弹性挡圈。
b、装入传动齿轮,插入副取力器轴并卡入弹性挡圈。
c、装上泵法兰并用螺栓固定(图 11-49)
6209N/C3 球轴承
the ball bearing
图(Fig.)11-49
11.3.5 装离合器部件
a、将 K3+K4 离合器部件先装入箱体 K3+K4 孔位上,调整轴承间隙,保证 0.1-0.3mm 后插入 K3 轴并用
2-M8×18 螺栓固定(图 11-50、11-51、11-52、11-53)。
图(Fig.)11-50 图(Fig.)11-51
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
图(Fig.)11-52 图(Fig.)11-53
b. Amount the clutch assemblies K2+KR and K1+KV onto their separate hole on the housing and adjust the
bearing clearance to be between 0.1-0.3mm. Then insert shafts K2 and K1and fix them with bolts 3-M8×18.
c. Amount steel balls and a pin into holes on both ends of the shaft K1, and screw the socket bolt tight to drive
steel balls into the external grrove on the baffle of the K1 gear.(Fig. 11-54, Fig. 11-55)
图(Fig.)11-54 图(Fig.)11-55
11.3.6 装输入部件
a、将配油法兰纸垫涂用黄油固定在箱体配油法兰孔上(图 11-56)。
b、将输入部件总成用二定位销固定位置后敲入箱体孔中(图 11-57)。
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
图(Fig.)11-56 图(Fig.)11-57
c、装上泵轮轴承座组件(图 11-58)
d、装上连接外壳并固定(图 11-59)
图(Fig.)11-58 图(Fig.)11-59
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
11.3.7 装取力器部件
a、将取力器部件用二根销定位后装入箱体取力器孔中。
b、用 11-M8×20 螺栓固定(图 11-60)
图(Fig.)11-60
11.3.8 装操纵部件
a、将纸垫、下隔板、纸垫、输油板分别放置在箱体阀板平面上,用 3-M8×30 螺栓、3-M8×45、6-M8
×35 内六角螺钉固定(图 11-61)。
b、将纸垫、上隔板、纸垫、操纵阀放置在输油板上,用 10-M8×45、6-M8×75 内六角螺钉固定(图
11-62)。
图(Fig.)11-61 图(Fig.)11-62
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
11.3.9 装油管、吸油管组件
a、从上往下数,输油板上六个油孔分别为 K2、K1、K3、K4、KR、KV(其中 KV、KR 油管根据各主
机后桥差速齿转向定)油管,分别与 K1、K2、K3 轴上各油道孔连接(图 11-63)。
b、将粗滤网塞入箱体粗滤孔中,用 4-M8×50 螺栓分别固定住吸油管组件(图 11-64)。
图(Fig.)11-63 图(Fig.)11-64
11.3.10 装变矩器
a、将变矩器总成套入配油法兰内, 并注意花键孔装配(图 11-65)
b、装膜片组件,并拧紧 12-M10×25 螺栓(图 11-66)。
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变速箱的拆卸与安装 The Dismantlement and Assembling of the Transmission
图(Fig.)11-65 图(Fig.)11-66
11.3.11 变速箱总成
WG180 变速箱总成(图(Fig.)11-67)机型号 4644 004 236.
11.3.11 transmission unit
WG180 transmission unit (Fig.11-67)Type number 4644 004 236
图(Fig.)11-67
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