Dongfeng DFA1101GZ5AD6J-907. Instruction - page 35
Transmission
MT-22
Transmission upper cover
1.Measure the clearance between gear shift fork and gear
slide sleeve slot;
Note:
Measure the gear slide sleeve slot, it has to be above
than 3 points or 5 points.
Repair standard: 0.10~0.18mm
Wear limit: 1.0mm
2.Measure the free length and stiffness of the gear shift
fork shaft self-locked spring.
Free length: 35mm
When press to 25mm:
Repair standard: 140~190N
Repair limit: 110N
Gear
1.If the measured backlash is over the wear limit value, check gear impression and working condition of the bear-
ing;
Repair standard: 0.15~0.25mm
Wear limit: 0.5mm
2.Measure the clearance between fixed gear seat and gear slide sleeve engaged tooth (including mainshaft);
Repair standard: 0.2~0.3mm
Wear limit: 0.5mm
3.Measure the radial clearance between slide sleeve and the upper engaged tooth of the gear.
Repair standard: 0.45~0.55mm
Wear limit: 1.0mm
Ball bearing
Measure the axial clearance of the ball bearing.
Wear limit: 0.5mm
Transmission
MT-23
Synchronizer
Lockpin type
Check the pretravel between synchronizer conical
ring and cone disc. (A)
Note:
Measure the average value between two points by
180°.
Repair standard: 0~0.5mm
Wear limit: 2.0mm
Slide block type
1.Measure clearance between baulk ring and synchro-
nizer conical ring;
Repair standard: 1.5~2.5mm
Wear limit: 0mm
2.Measure clearance between baulk ring and gear fixed
seat (C);
Repair standard: 5.3~5.7mm
3.Measure axial clearance between baulk ring and back-
ing block (D);
Repair standard: > 0.5mm
Transmission
MT-24
4.Measure radial clearance between fixed gear seat and
synchronizer backing block (E);
Repair standard: 0.05~0.35mm
5.Measure the free length and stiffness of the synchro-
nizer spring.
Free length: 15mm
When press to 12.5mm:
Stiffness repair standard: 0.6~1.0kg
Wear limit: 0.4kg
Reassembly
When assembling the parts, please make sure that the installing direction of the gear thrust washer needle
bearing and spacer sleeve.
All the surface of the turning part should be smeared with clean gear oil.
According to the requirement, all the self-locked nut, oil seal and O-ring should be replaced.
Mainshaft
1.Install the needle bearing and 2nd speed gear;
Note:
Install the 2nd speed gear in the correct direction.
2.Install the thrust spacer, and let the gap align to the
dowel;
3.Assemble the 3rd speed gear needle bearing;
4.Assemble the 3rd speed gear;
Transmission
MT-25
5.Assemble the 3rd and 4th speed fixed gear seat and
synchronizer assembly;
6.Press the needle bearing seat ring of the 4th speed gear,
then install the needle bearing and 4th speed gear;
7.Install the thrust spacer;
8.Install the 6th speed gear needle bearing seat ring and
needle bearing;
9.Install the 5th and 6th speed fixed gear seat;