Dongfeng DFA1063DJ10 (14)-301/303. Instruction - page 6

Clutch

CL-7

When install the clutch pressure plate and driven disc, insert the spe-

cial tool into the clutch driven disc spline (used to align and orient).

Screw down the fixing bolt of the clutch cover.

Screw down the bolt in an crossed sequence, following two steps.

1.Installation and adjustment

Check the type of the clutch to make sure if it is accord to the vehicle

model before installation, then find out if the size of installation screw
hole, locating pin hole or locating exicrcle match the flywheel.The thick-
ness of the driven disc also has to accord the requirements.

During the installation, first insert the locating mandrel into the

spline hole of the driven disc and set it on the flywheel end. Then install
the cover assembly to the flywheel and tighten the 8 installation bolts
equably. When tightening the bolts, do remember to make the locating pin
into the locating hole correctly.

When adjust the control mechanism, you have to make sure that the

travel of the release bearing is 2~3mm, and the efficient travel of the
release bearing should be not less than 10mm.

2.Notice

Pay attention to match the proper torque of the engine during using,

which is to assure the certain repertory coefficient.

The friction plate mustn't be contaminated with oil stain during using.

The vehicle should not be over loaded during using to avoid skid and

cause wear.

Never make the driven disc in a half engaging situation during using

to avoid too much wear earlier.

3.Maintenance

If the driven disc has been a little bit worn, you must adjust the con-

trol mechanism periodically to assure the proper free travel.

When the friction plate is worn too much like the distance between its

surface to the rivet head is not more than 0.5mm, you have to change a
new one.

When maintaining the engine, you must clean up the surrounding

place of the inner support disc and ring of the cover assembly.

If you need to disassemble the pressure plate to do the clean, do

remember to assemble it to its original place to assure its balance.

Transmission

MT

Table of Contents

Maintenance Standard ................................................................................... MT-1
Trouble Shooting ........................................................................................... MT-2
Construction................................................................................................... MT-4
Transmission Disassembly ............................................................................ MT-8
Check ........................................................................................................... MT-10
Assemble Point ............................................................................................ MT-11
Transmission Control System...................................................................... MT-14
Check and Adjustment................................................................................. MT-15

Transmission

MT-1

Maintenance Standard

Technical Parameter

Maintenance Standard

Assembly Name

DONGFENG 17G1A2-DJ10

Transmission Model

A121J

Transmission Type

Mechanical type, 5 forward gears, 1 reverse gear; 2nd~5th gear with

synchrinizer

Control System

Double flexible shaft cable, remote control

Center Distance (mm)

121.125

Output Torque (N.m)

1820

Gear Type

1st, reverse gear

Straight tooth

2nd~5th gear

Skewed tooth

Speed Ratio

1st gear

4.763

2nd gear

2.808

3rd gear

1.594

4th gear

1.00

5th gear

0.756

Reverse gear

4.99

Capacity of lubricant (L)

5.5

Lubricant type

Sulfur-phosphor middle loaded 85W/90 API GL-4 gear oil

Item

Nominal

Dimension

mm)

Sevice

Standard

mm)

Repair

Limit

mm)

Wear Limit

mm)

Trans-

mission

top cover

Clearance between gear select rocker block and
gear shift lever block slot

0.1~0.4

--

0.8

Tooth space between control shaft and gear
shift lever spline

0.05~0.11

--

0.5

Trans-

mission

upper

cover

Clearance between transmission fork shaft and
transmission fork hole

0.140~0.101

--

0.25

Clearance between end face of the reverse gear
fork and ring groove

0.5~0.8

--

Not drop

Clearance between end faces of other gears and
ring groove

0.2~0.5

--

Not drop

Trans-

mission

body

Axial clearance of output shaft 2nd gear

0.1~0.37

--

0.4

Axial clearance of output shaft 4th gear

0.1~0.35

--

0.4

Side play between output shaft and 1st, reverse
gear soline

0.055~0.175

--

0.3

meshing play of running gear

0.15~0.26

--

0.5

Synchro-

nizer

Max. turning quantity of balking ring end face

--

--

1.0

Max. wearing of balking ring bevel

--

--

0.1

Bevel groove

Clearance between balking ring end face and
cone disc end face

3

--

--

Single side

Transmission

MT-2

Tightening Torque

Trouble Shooting

Abnormal noise

Check the abnormal noise from transmission to determine if it happens during driving or gear shifting, which is
one of the factor to the trouble shooting. Also, find out this abnormal noise comes from gear or bearing.

Gear engagement is difficult

When gears of transmission are difficult or tend to disengaged, you must consider that is failure of control system
that the transmission inside mehanism is isolated from the gear shift lever to gear shift fork.

When there is failure of transmission engagement, the problem maybe caused by malfunctioning synchronizer
and this kind of problems normally occur at the certain speed, as 2

nd

speed or 3

rd

speed.

Item

Tightening Torque (Nm)

Clutch housing connecting bolt

137~167

Fasten nut of propeller shaft connecting flange

200~220

Transmission upper cover fixed bolt and nut

33~44

Transmission cover fasten bolt

20~26

Reversing lamp switch and neutral position switch

20

Countershaft rear bearing locking nut

200~300

Reverse gear shaft locking plate bolt

20~26

Oil drain scew and filler port screw

120~140

Propeller shaft connecting bolt and nut

215~245

Midship mounting bolt and nut

160~220

Trouble

Cause

Correction

Abnormal
sound or
noise

· Viscosity of lubricating oil too low
· Lubricating oil insufficient
· Gear teeth cracked or worn out (clearance too large)
· Bearing worn out or broken
· Engaging position of shift fork and gear incorrect
· Synchronizer worn out or damaged
· Some gears broken

· Use suitable lubricating oil
· Add it to required level
· Repair or replace the part
· Replace the bearing
· Check shift fork, replace it if its twist
· Replace
· Clean, replace

Trouble

Cause

Correction

Difficulty
in shifting

Control system
· Operating level deformed
· Gear select or shift flexible shaft length incorrect

· Adjust operating lever
· Adjust flexible shaft length

Transmission
· Bearing worn out or damaged
· Malfunctioning of synchronizer
· Gear select and shift rocker welding point loosened
· Fork deformed or damaged
· Shift lever come out from groove
· Malfunctioning of gear shift rocker bolt
· Fork stopping screw loosened

· Replace bearing
· Replace synchronizer
· Weld, repair
· Check, adjust or replace
· Assemble or replace parts
· Replace bolt
· Tighten, lock

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