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