Contents

1. Checking and measuring basic parameters of transmission ......... 3

1.1. Determining working principle and torque transmitting line . 3
1.2. Identify specific parameters ........................................................ 4
2. Disassembly and assembly procedures ............................................ 6
2.1. Disassembly procedure ................................................................ 6
2.2. Assembly procedure ................................................................... 16

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1. Checking and measuring basic parameters of transmission
1.1. Determining working principle and torque transmitting line
• Draw the structure diagram and torque transmitting line for each gear

STRUCTURE DIAGRAM

33 37
27 26 27
out in
24

counter
13
14 21 31
47 45

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TORQUE TRANSMIT
1st gear: LINE

2nd gear:

3rd gear:

4th gear:

5th gear:

Reverse gear:

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 • Draw the gear shift diagram

1.2. Identify specific parameters

• Type of transmission
Serial Parameter Value Note
1 Transmission type Synchronized / constant mesh
gearbox
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2 Number of gear ratio
3 Number of shafts 3
4 Synchronizer type Blocker ring

• Pair of gears which is always engaging and gear ratio

- Which pair of gears is always engaging?

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 - Gear ratio
Speed 1st 2nd 3rd 4th 5th Reverse gear
Ratio 3.92 2.14 1.39 1 0.85 4.75

• Gear
For the helix angle is a = 30 degrees, module of gear is calculated:
Speed 1st 2nd 3rd 4th 5th
Module 3.43 3.43 2.74 2.31 2.34

• Transmission shaft
- Shaft diameter at bearing journals
- Shaft overall length
Serial Shaft Diameter (mm) Length (mm)
1 Input 32.08 211.02
2 Counter-shaft 31.10 25.10 323.12
3 Output 30.02 521.20

• Bearing parameters
Identify the type of bearing
Serial Shaft Bearings
Type Size (inner / outer diameter)
1 Input Roller 32.18 / 80.20
2 Counter-shaft Roller 24.52 / 52.16
3 Output Roller 30.04 / 75.14

𝑚(𝑧1 +𝑧2 ) 3.43(33+14)

• Shaft distance a = = 93.07 (mm)
2𝑐𝑜𝑠𝛼 2𝑐𝑜𝑠30°

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2. Disassembly and assembly procedures
2.1. Disassembly procedure
Step 1: Drain oil

Drain the transmission oil

Step 2: Remove the transmission case cover sub-assy

Use socket wrench #12 to remove bolts at the case cover sub-assy

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Use hammer to tap gently and remove the case cover sub-assy

Step 3: Remove the reversing light switch and selector lever, Disassembly the transmission
from the holder

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Disassembly the transmission from the holder

Remove the reversing light switch (no pic)

Remove selecting bellcrank-assy (no pic)

Step 4: Remove the shift fork and synchronizer No.5

Use socket wrench #12 to remove shift fork’s bolt.

Remove the shift fork, shift fork shaft and synchronizer No.5

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Step 5: Remove snap ring

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Remove the bearing retainer rear: use socket wrench 12

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Remove circlip.

Step 6: Remove main case: use socket wrench #12

Remove reverse gear’s bolt.

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Remove 5 bolts No.1 between main case and clutch housing. (No Pic)
Remove 3 bolts No.2 between main case and clutch housing. (No Pic)

Step 7: Remove shift detent ball and idle gear sub-assy and idle gear shaft
Remove 3 seats, 3 springs and 3 shift detent balls from manual transmission case.

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Step 8: Remove the input shaft, layshaft and shift fork shaft
Use pliers to remove circlip laying on input shaft

Remove shaft assembly with hand

Step 9: Disassembly counter shaft

Disassemble counter shaft with disc gear puller.

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Use pliers to tap out snap ring at the end of shaft, then disassemble layshaft.

Disassemble output shaft at transmission case cover sub-assy.

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 2.2. Assembly procedure
Step 1: Assembly gear, synchronizer

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Step 2: Assembly input shaft, layshaft, and gearshift

Step 3: Assembly shift detent ball, idle gear sub-assay and idle gear shaft

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Step 4: Assembly the snap ring

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Step 5: Assembly the gearshift fork and synchronizer 5

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Step 6: Assembly the body

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