FAST GEAR BOX 12J系列变速箱维修手册-en

Maintenance Manual of Shaanxi Fast Gear 12J transmission
Table of contents
I. General..................................................................................................................................................1
II. Structural general and technical parameter..........................................................................................4
III. Replacement of neutral switch ..........................................................................................................29
IV. Replacement of reverse switch .........................................................................................................30
V. Replacement of single H assembly ....................................................................................................31
VI. Maintenance of single H assembly ...................................................................................................33
VII. Dismounting and mounting of upper cover assembly ......................................................................40
VIII. Replacement of upper cover housing .............................................................................................43
IX. Replacement of flange assembly ......................................................................................................48
X. Dismounting and mounting of auxiliary gearbox assembly ................................................................50
XI. Replacement of auxiliary gearbox housing .......................................................................................54
XII. Dismounting and mounting of auxiliary gearbox high/low gear synchronizer ...................................68
XIII. Output shaft and gear .....................................................................................................................77
XIV. Replacement of output shaft rear bearing seat...............................................................................80
XV. Replacement of auxiliary gearbox shifting cylinder ..........................................................................81
XVI. Replacement of gearbox assembly.................................................................................................85
XVII. 1st shaft assembly..........................................................................................................................87
XVIII. Replacement of 2nd shaft assembly ..............................................................................................92
XIX. Dismounting and mounting of 2nd shaft...........................................................................................99
XX. Replacement of Intermediate shaft Assembly ...............................................................................117
XXI. Intermediate shaft and gear..........................................................................................................125
XXII. Replacement of main gearbox housing .......................................................................................130
I. General
Single rod controlled 12-gear transmission
General 1
(I) Operating requirements

In order to ensure the running safety and reliability of vehicle and prolong the service life of transmission,
it is very important to correctly and reasonably operate the transmission and conduct regular
maintenance for the transmission. Please observe the following requirements:
Lubricating oil number
Fill GL-5(85W/90) vehicle gear oil to the transmission.
Correct oil level
Be sure to keep the oil level flush with the lower edge of oil drain port. Check the oil level through the
conical oil filler port at the side of housing. Fill oil till the oil overflows from the oil filler port.
Operating temperature
Be sure to keep the maximum operating temperature not greater than 120 ℃ when the transmission
operates continuously. Otherwise, the lubricating oil will be decomposed to shorten the service life of
transmission. When the transmission starts at -40 ℃ below, the oil seal and rubber sealing element will
be damaged, thus causing the leakage.
Oil change cycle
Be sure to change the lubricating oil of a new transmission after the vehicle runs for 2,000~5,000 km.
When the vehicle runs for 10,000 km, check the lubricating oil for oil level and leakage and refill the
lubricating oil if necessary. When the vehicle runs for 50,000 km, change the lubricating oil.
It is necessary to appropriately shorten the oil change cycle after continuous operation with a heavy load
in seriously-contaminated environment or on a steep slope.
Towing or coasting
The main shaft gear and intermediate shaft of transmission must rotate continuously to provide
adequate lubrication for transmission when the transmission operates. However, the above gear cannot
rotate when the vehicle is towed with rear wheels on the ground and the drive system connected, but the
main shaft is driven by rear wheels to rotate at high speed and the main shaft adjusting washer also
rotates at high speed under the action of main shaft. The tremendous rotation speed difference and
shortage of lubrication will cause the severe damage on transmission.
Warning: The transmission coasting at neutral position will cause the early damage on
transmission interior component to shorten the service life of transmission. Never conduct
coasting at neutral position. When a vehicle is towed, it is necessary to draw out the axle shaft or
relieve the drive shaft or leave the driving wheels above the ground. It is forbidden to take no
measure to tow the vehicle.
2 General
(II) Precautions
1. It is necessary to release the parking brake before starting vehicle. For the vehicle with
air-cut brake, after the brake valve is connected, the vehicle cannot be started until the air
pressure rises to the value necessary for releasing brake.
2. The vehicle can be started at 3rd gear or 4th gear upon the road condition.
3. When the gear lever is in high gear range, the neutral position is between 9th gear and 10th
gear; when the gear lever is in low gear range, the neutral position is between 3rd gear and 4th
gear. When parking a vehicle, the transmission shall be at the neutral position of low speed, that
is to say, the changeover switch on control handle is at its lower position.
4. When shifting gear, the clutch must be disengaged thoroughly and the gear lever must be
engaged in place. Otherwise, the service life of main gearbox synchronizer will be affected
adversely.
5. When the reverse gear is engaged, it is necessary to first stop the vehicle and then engage
the reverse gear in order to avoid the damage on the transmission interior components. To
engage the reverse gear, the operating force shall be large enough to conquer the resistance of
reverse lock.
6. To shift from 6th gear to 7th gear (or from 7th gear to 6th gear), it is necessary to consciously
wait for a moment so that the auxiliary gearbox can complete the switchover between high and
low speed ranges. Before disengaging gear, it is necessary to first pull the control handler to the
target range and then conduct the speed range switchover.
7. When the transmission changes speed from low speed range to high speed range (or vice
versa), it is not allowed to skip gear. Otherwise, the service life of auxiliary gearbox synchronizer
will be affected adversely.
8. Frequently check the air plug and clean the dirt at any moment.
9. Every 20,000 km, check the filter screen of air cleaner, clean the filter screen and air cleaner
inner wall with soapy water and dry them with compressed air.
10. It is necessary to avoid the switchover between high speed range and low speed range as
possible when the vehicle goes downhill.
11. If the transmission is found with abnormal noise, obviously heavy operation and other
abnormal phenomena during operation, it is necessary to stop the vehicle immediately for
troubleshooting. The vehicle is allowed to move again only after the fault is eliminated.
12. It is necessary to strictly follow the operation specification to operate the power take-off.
Otherwise, the auxiliary gearbox synchronizer will be damaged quickly.
Notice: the transmission within warranty period is forbidden to be dismounted and remounted
without approval.
General 3
II. Structural general and technical parameter

(I) Structural general
Main sectional view of twin-intermediate shaft full-synchronizer transmission assembly
Control handle gear

position diagram
high gear
low gear
4 Structural General and Technical Parameter

Typical structure of twin-intermediate shaft full-synchronizer transmission

The main and auxiliary gearboxes of 12-gear full-synchronizer series transmission are fitted with two
same intermediate shafts with 180° spaced. The power from input shaft is distributed on the two
intermediate shafts and then is collected on main shaft for output, and so does the auxiliary gearbox.
Theoretically, each intermediate shaft transmits 1/2 of torque only, so the twin-intermediate shaft is
adopted to reduce the center distance of transmission, decrease the gear thickness, shorten the axial
dimension and reduce the weight. Because the twin-intermediate shaft is adopted, each gear on main
shaft must engage with the gear of two intermediate shafts simultaneously.
In order to realize correct engagement and load average distribution as possible, the main shaft gear
shall represent radial floating state on the main shaft and the main shaft shall be of hinged floating
structure. Insert the main shaft journal into the hole on input shaft, press the oily guide sleeve in the hole,
keep enough radial clearance between main shaft journal and guide sleeve, insert the main shaft rear
end into the driving gear hole of auxiliary gearbox through involute spline and support the auxiliary
gearbox driving gear shaft journal on ball bearing.
The main shaft gears are floating on the main shaft so that the traditional needle bearing is cancelled to
simplify the main shaft assembly structurally. During operation, the radial force applied onto main shaft
gear by two intermediate shaft gears are of equality but of reverse direction, so they offset each other to
make the main shaft bear only torque but bending moment. This changes the force on main shaft and
bearing and largely improves the reliability and durability of transmission. To mount 12-gear
transmission, it is necessary to conduct tooth alignment. Refer to “Tooth alignment and alignment
procedure” in Chapter 1 for the tooth alignment procedure.
Shifting mechanism
Main gearbox double-conical-surface synchronizer assembly
1. Synchronizer gear 3. Spring; 5. Synchronizer outer cone; 7. Synchronizer conjunction

sleeve; 4. Synchronizer gear 6. Synchronizer double gear;
2. Locating block; hub; cone; 8, Synchronizer inner cone
The vehicle gearbox interior is fitted with synchronizer to make the shifting operation of transmission
become portable and rapid without impact and noise as well as to prolong the gear life and improve the
acceleration performance and oil conservation of vehicle, so the synchronizer is often fitted for the
transmission gear except for reverse gear. The synchronizer is required to be provided with such
characteristics as large torque capacity, stability and durability. The inertial synchronizer is stable and
reliable to ensure the transmission engagement and gearshift. It includes inertial lock-up type
synchronizer and inertial-servo type synchronizer, of which the inertial lock-up type synchronizers such
as locking ring type synchronizer and locking pin type synchronizer are the most popular.
Currently, the locking ring type synchronizer is most popular due to its compact structure, good
performance, reliable operation and low cost, but its disadvantage is relatively small frictional moment.
The double-conical-surface locking ring type synchronizer is a new-style synchronizer with operating
principle and structural arrangement similar with the locking ring type synchronizer, which continues the
advantages of locking ring type synchronizer and eliminates its disadvantage in terms of frictional
moment.
Structural General and Technical Parameter 5

The above drawing shows 5-6 gear synchronizer. The gear 5 and 6 are of double conical surface and
they share the synchronizer gear sleeve, gear hub, sliding block and spring. They have three (5, 6 and 8)
conical components respectively. The synchronizer combines six single keys on outer cone (5) to
connect with six key grooves on inner cone (8), so the outer cone (5) and inner cone (8) rotate with the
transmission 2nd shaft. The synchronizer double cone (6) is connected to six holes on conjunction gear
(7) through its six lugs, so the double cone (6) rotates with 5th-speed gear. Consequently, when the
transmission changes from 4th gear to 5th gear or from 6th gear to 5th gear, a relative angular velocity
difference will be caused between 5th-speed gear and 2nd shaft. In such a case, two pairs of sliding
friction conical surfaces start operating in the synchronizer double cone. Therefore, when same overall
dimension, the synchronous frictional moment caused on the friction conical surface by the axial thrust
applied to the synchronizer gear sleeve is the sum of frictional moment applied between two pairs of
conical surfaces, that is to say, the synchronous frictional moment caused when changing to 5th gear is
about twice than that of single conical surface synchronizer so as to reduce the shifting force by about
50%.
Working process: when putting into gear, the shitting sleeve drives the sliding block to move the outer
cone. Due to the mounting clearance of synchronizer, the outer cone is pressed to push the cone body
and the cone body pushes the conjunction gear towards the gear, the frictional moment caused by
speed difference makes that the outer cone rotates by an angle against the shitting sleeve and sliding
block and is located by sliding block. Under the action of shifting force, the sliding block moves so that
the locking angular surface of shitting sleeve integrates closely with that of outer spline and the shifting
force is applied onto the locking angular surface to further presses the outer cone. In such a case, the
conical surface starts friction so that the righting moment caused on the locking angular surface under
the action of shifting force to return and align the outer cone is lower than the frictional moment between
conical surfaces so as to prevent putting into gear before synchronization. After the frictional moment on
conical surface conquers the inertial moment of connected part, the speed difference and frictional
moment will disappear. At that time, the righting moment compels the outer cone to return, the locking
angular surface disengages and the shitting sleeve conquers the spring force of sliding block and skips
over the locking ring to connect with the conjunction gear synchronously so as to ensure the gear shifting
operation without impact.
The shifting process is briefly described below:
When the vehicle moves and after the driver disengages gear, the position of transmission components
is shown in Fig.4. In such a case, the power is transmitted to the 1st shaft via engine and clutch and then
to the 1st shaft gear via involute spline. Because the 1st shaft gear engages with the intermediate shaft
driving gear, the power is transmitted to the intermediate shaft to cause that the gears of various speeds
on intermediate shaft rotate together due to their fixation with intermediate shaft. The gears of various
speeds on intermediate shaft drive the gears of various speeds on 2nd shaft to rotate together. Because
various synchronizers are at their neutral position, the gears of various speeds on 2nd are of idling
operation to cause no power output on 2nd shaft.
To put into the 5th gear, the driver shall control the control lever in cab. The gear lever transmission
mechanism drives the 5th/6th gear declutch shift shaft to move rightwards and the shifting fork feet
pushes the synchronizer to move axially. In such a case, two pairs of sliding friction conical surfaces in
the 5th gear synchronizer cone body starts operation. When the relative angular speed between the gear
of 5th speed and the 2nd shaft is about zero, the spline in shitting sleeve flexibly engages with the 5th gear
external spline. So far the operation to put into gear is completed smoothly. In this way, the power is
transmitted to the 1st shaft via engine and clutch, to the 1st shaft gear via spline, to two symmetrical
intermediate shaft driving gears, to the 2nd shaft 5th-speed gear via two symmetrical intermediate shaft
5th-speed gears, to the shitting sleeve and 2nd shaft under the action of spline engagement and to the
auxiliary gearbox through auxiliary gearbox driving gear. Finally, the power is transmitted from the
auxiliary gearbox to the transmission output flange disk for output.
The auxiliary transmission is fitted with locking pin type inertial synchronizer which is same with the
shafting mechanism of 9-gear twin-intermediate shaft transmission in terms of structure and operating
principle.
Analysis on the damage of inertial synchronizer
The locking ring type synchronizer includes ordinary single-conical-surface synchronizer,
multiple-conical-surface or multiple-piece type synchronizer.
1. Early failure: it mainly means under the normal operation the locking and synchronization
failure of synchronizer gear ring and the shifting gear collision of synchronizer caused by the

disappearance of wear allowance, the clearance between the synchronizer gear ring and the
synchronizer cone body or conjunction gear, within warranty period. There are many reasons for
the early failure of synchronizer. For example:
1) Check whether the clutch is separated thoroughly. When shifting, otherwise, the synchronizer will
have to conquer excessive torque and the synchronizer ring conical surface will have to be worn out for
long so as to result in the failure of synchronizer ring.
2) Check whether the transmission interior is lubricated properly and whether the conical surface of
synchronizer gear ring is lubricated properly. If the conical surface is short of oil, its screw thread will
wear out quickly and at the same time produce high temperature to quicken the abrasion of screw thread
so as to cause failure.
3) Check whether the lubricating oil in transmission is clean. If the oil is contaminated, the impurities
will cause the damage on screw thread of synchronizer gear ring and affect the synchronization and the
useful of synchronizer gear ring so as to cause early failure.
4) The mismachining tolerance of synchronizer interior conical surface such as its roundness,
straightness and runout will cause the abnormal abrasion of conical surface of synchronizer gear ring so
as to result in early failure.
2. Teeth breakage and rupture of synchronizer: it means the design problem of synchronizer or
machining problem of single component such as too small round angle, too thin wall thickness
as so on. They will cause the heat treatment through hardening, centralized stress and crack.
3. The conical surfaces of double-conical-surface synchronizer are locked and the inner cone
is burnt off: firstly check whether the mounting space of synchronizer is appropriate. Too large
space will affect its effect and life while too small space will cause the conical surface fails to be
lubricated properly and even the conical surface is burnt off.
Control mechanism
12-gear full synchronizer series transmission is of single H remote control mechanism which is
characterized by compact structure, clear gear position and good feel to touch. R1, 2nd, 3rd, 4th, 5th and
6th gears are in low gear range while R2, 7th, 8th, 9th, 10th, 11th and 12th gears are in high gear range. The
neutral position of low gear range is at the 3rd/4th gear while that of high gear range is at 9th/10th gear.
Control handle position diagram
Vacancy
The single H remote control mechanism is composed of control device housing, external shifting arm,
transverse gear lever, reverse gear switch control block, shifting block, compression spring, air plug,
indicator lamp switch, starting pin and other components. It is used to complete the gear selecting,
disengaging and engaging operation of transmission. The external shifting arm, reverse gear switch
control block, shifting block, spring seat, spring and snap ring are mounted on the transverse gear lever
which can be controlled by the external shifting arm to move transversely and rotate so as to realize gear
selection, disengagement and engagement. One fan-shaped dummy club is set respectively at two sides
of shifting block and its groove are used to control the neutral position indicator lamp switch and air
passage control valve. The reverse gear indicator switch is controlled with the displacement and rotation
of reverse gear switch control block.

Single H control device diagram
1. Low reverse switch 7. Spring seat; 13. Transverse gear lever 19. LRC external shifting
control block; 8. Transverse gear lever; liner; arm;
2. Air pipe assembly; 9. Side plate; 14. Shifting block; 20. Reverse gear switch;
3. 90° quick change 10. Limit sleeve; 15. Air plug; 21. Neutral switch
coupler; 16. Oil seal;
11. Compression spring;
4. Three-way union; 17. Sleeve;
12. Control device housing;
5. Air passage control valve; 18. Spring-type straight pin;
6. Straight pin;
Air passage operating principle of 12-gear transmission

0.7-0.8Mpa of compressed air from complete vehicle is adjusted to 0.57-0.6Mpa by the air cleaner
regulator and then flows to the main air pipe and control air pipe. When the main gearbox is at neutral
position, the air passage control valve is so connected that the compressed air flows into the air passage
reversing valve. In such a case, when the preselector switch handle is placed at low gear, the handle
shifting block is at its lower position to control the air in the air outlet pipe to push the air passage
reversing valve so as to connect the low gear air passage. The compressed air enters the low gear air
inlet of shifting cylinder via the low gear air pipe so that the shifting cylinder piston drives the auxiliary
gearbox synchronizer sliding sleeve to engage with the conjunction gear of auxiliary gearbox reduction
gear. At this time, the transmission represents low gears including R1, 1st, 2nd, 3rd, 4th, 5th and 6th gears.
When the preselector switch handle is placed at high gear, the handle is at its high position to control
that there is no air in air outlet pipe, so the compressed air enters the high gear air inlet from high gear
air pipe to auxiliary shifting cylinder via the high gear air outlet of air passage reversing valve so that the
shifting cylinder piston drives the auxiliary gearbox synchronizer sliding sleeve to engage with the
conjunction gear of auxiliary gearbox reduction gear. At this time, the transmission represents high gears
including R2, 7th, 8th, 9th, 10th, 11th and 12th gears. The neutral position for low gear range is at 3rd/4th
gear while that of high gear range is at 9th/10th gear.

Single H shifting mechanism pneumatic circuit schematic diagram
High gear
range
Low gear
range
Connected
to port P Compressed air inlet
Connected to
port S
1. Air cleaner regulator; 5. Shifting handle (preselector valve); 9. Air passage control valve;
2. Main air pipe; 6. Control air outlet pipe; 10. Air passage reversing valve
3. Transition air pipe; 7. High gear air pipe;
4. Control air inlet pipe; 8. Low gear air pipe;
Notice:
1. The air passage control valve is connected only at neutral position. When putting into gear, the air
passage is cut as the air passage control valve, that is to say, the switchover between high gear and low
gear is allowed only at neutral position.
2. There is air in the air outlet pipe of control air passage (preselector valve) at low gear while there is no
air at high gear.
Operating principle of parking power take-off
For the demand by some special vehicles, the transmission is allowed to be fitted with power take-off at
its rear lower part or between clutch housing and transmission. The power is taken from the auxiliary
gearbox extended intermediate shaft at the rear right lower part of transmission, known as “rear power
take-off”. This power taking mode is mostly popular. The power is taken between clutch housing and
transmission, known as “front power take-off” or “full power take-off”.
When the rear power take-off is used for taking power when parking, it is necessary to place the rear
auxiliary gearbox synchronizer at its neutral position. To solve this problem, remove the range gear
cylinder cover of transmission and additionally mount a neutral position cylinder.
In the diagram, the ports A and B are connected to transmission double H air valve respectively through
low gear and high gear air pipes of transmission and their air pressures are 0.57-0.6Mpa. The port C is
the compressed air inlet when the transmission is at neutral position (middle) and its air pressure is
0.7-0.8Mpa. To take power when parking, firstly separate the clutch, place the transmission control
handle at neutral position in low gear range, make the range gear cylinder piston 15 firmly press the
locating ring, and control the neutral position cylinder control valve to make the compressed air of
0.7-0.8Mpa pass through the port C to the neutral position cylinder 7. Due to its boosting action, the
neutral position cylinder pistons 10 and 13 will move leftwards and will stop moving when they touch the
locating ring. In this way, the transmission range gear cylinder piston 15 will be at neutral position. In
such a case, the power take-off can take power at parking when the transmission is engaged in an
appropriate gear, the power take-off air passage is connected and the clutch is activated.

Neutral position cylinder structural diagram
1. Range gear declutch shift 5. Hexagon nylon lock nut; 9. Cylinder cover; 13. Middle position cylinder
shaft; 6. Air plug; 10. Middle position cylinder piston;
2. Range gear cylinder; 7. Middle position cylinder; piston; 14. Bolt;
3. Rear cover housing body; 8.Shafting retainer ring; 11. O-ring; 15. Range gear cylinder
4. O-ring; 12. Hollow shaft; piston
If the boosting cylinder is not selected when reconstruction but the ordinary middle position cylinder is
adopted, it is impossible to take power when parking by conventional means because of relatively small
pressure difference between operating air pressure of transmission and air pressure of complete vehicle.
However, it can be realized by changing the operating method.
1) Firstly place the transmission handle switch at its higher position to make the transmission in high
gear range;
2) Connect the working air passage of power take-off, realize air intake at middle position cylinder air
inlet and push the middle position cylinder piston to locating ring;
3) Place the preselector handle at lower position. In such a case, the shifting cylinder piston cannot
return to low gear position and retain at middle position under the action of pressure;
4) Put into gear to take power when parking.

(II) Main technical parameter of twin-intermediate shaft full-synchronizer transmission

Numbering rule of twin-intermediate shaft full synchronizer transmission
Number of forward Speed ratio code

gears
Mechanical type Full synchronizer
Twin-interm ×10=Nominal input torque （N.m）

ediate shaft
Number of forward gears Improved
Mechanical Full synchronizer
Number of forward gears ×10=Nominal input torque （N.m）
Main performance parameter of twin-intermediate shaft full-synchronizer transmission
Rated Rated
Maximum Fueling
input input Weight Length
Transmission series input speed charge
power torque (Kg) (mm)
(rpm) (L)
(KW) (Nm)
12JSl60T 285 1600 2600 350 983.5 17
12JSl60TA 285 1600 2600 350 983.5 17
12JSl80T 331 1800 2600 360 983.4 18.5
12JSl80TA 331 1800 2600 360 983.4 18.5
12JS200T 331 2000 2600 360 983.4 18.5
12JS200TA 331 2000 2600 360 983.4 18.5
12JS240T 400 2400 2600 380 983.4 18.5
12JS240TA 400 2400 2600 380 983.4 18.5

Speed ratio of each gear
Speed ratio of each (I)

Model
Climbing 1 2 3 4 5 6 7 8
12JS160T / 15.53 12.08 9.39 7.33 5.73 4.46 3.48 2.71
12JS160TA / 12.10 9.41 7.31 5.71 4.46 3.48 2.71 2.11
12JS180T / 15.53 12.08 9.39 7.33 5.73 4.46 3.48 2.71
12JS180TA / 12.10 9.41 7.31 5.71 4.46 3.48 2.71 2.11
12JS200T / 15.53 12.08 9.39 7.33 5.73 4.46 3.48 2.71
12JS200TA / 12.10 9.41 7.31 5.71 4.46 3.48 2.71 2.11
12JS240T / 15.53 12.08 9.39 7.33 5.73 4.46 3.48 2.71
12JS240TA / 12.10 9.41 7.31 5.71 4.46 3.48 2.71 2.11
Speed ratio of each gear (continued)
Speed ratio of each (II)
Model 倒1 倒2
9 10 11 12 13 14 15 16 Reverse Reverse
1 2
12JS160T 2.10 1.64 1.28 1.00 / / / / 14.86 3.33
12JS160TA 1.64 1.28 1.00 0.78 / / / / 11.56 2.59
12JS180T 2.10 1.64 1.28 1.00 / / / / 14.86 3.33
12JS180TA 1.64 1.28 1.00 0.78 / / / / 11.56 2.59
12JS200T 2.10 1.64 1.28 1.00 / / / / 14.86 3.33
12JS200TA 1.64 1.28 1.00 0.78 / / / / 11.56 2.59
12JS240T 2.10 1.64 1.28 1.00 / / / / 14.86 3.33
12JS240TA 1.64 1.28 1.00 0.78 / / / / 11.56 2.59
Tightening torque
Recommended tightening
No. Application position Bolt (nut)
torque (Nm)
1 Clutch housing 6M16×1.5 244～271Nm
2 Clutch housing 4M12 108～135Nm
3 1st shaft bearing cap 6M10 47.5～61Nm
4 1st shaft gear M54×1.5 left 338～406Nm

Recommended tightening
No. Application position Bolt (nut)
torque (Nm)
5 Double H control cover 8M10×1 47.5～61Nm
6 Upper cover 16M10 47.5～61Nm
7 Shifting fork locking screw 5M12～1.2S 67.5～88Nm
8 Auxiliary gearbox shifting fork 2M12×1.5 67.5～88Nm
9 Air filter stand 2M6 13.5～20.3Nm
10 Output shaft M50×1.5 609～677Nm
11 Auxiliary gearbox rear cover 19--M10 47.5～61Nm
12 Oil drain port Z3/4” 61～74.5Nm
13 Oil filler port 21 81～101.5Nm
Auxiliary gearbox driving

14 6M10 47.5～61Nm
gear locating plate
15 Reverse idler shaft 2M16×1.5 67.5～81Nm
Auxiliary gearbox
16 8M10 47.5～61Nm
intermediate shaft rear cover
17 Bottom power take-off cover 8M12 67.5～88Nm
18 Intermediate shaft brake 8M10 47.5～61Nm
Transmission side window

19 6M10 24.5～31Nm
cover
20 Main shaft rear bearing cap 6M10 47.5～61Nm
21 Shifting cylinder housing 4M10 47.5～61Nm
22 Cylinder cover 4M10 47.5～61Nm
23 Clutch housing bottom cover 4M8 20～27Nm
24 Intermediate shaft front end 2M16×1.5 122～162Nm

(III) Fault symptom diagnosis chart

Note: read each line of the chart from up to down, and follow the arrow to find out the solutions.
1. Spontaneous out-of-gear of auxiliary transmission in high/low gear range
Fault reason Solutions
The pressure value of pressure regulating …………

valve is not in the standard range or the
Replace the pressure regulating valve.
pressure regulating valve cannot adjust the
pressure effectively.
OK
The air pipe or joint is loose and the air ………… Tighten the component.
passage is of bad sealing performance.
OK
The air pipe or joint is pinched and the air ………… Eliminate the interference suffered by
passage has large air resistance. component.
OK
The gear deviates from its tooth alignment ………… Replace the component and find out the
position due to the shaft distortion. resulting damage.
OK
The soldered tooth is of bad taper. ………… Replace the component.
2. Spontaneous out-of-gear or skip gear of main transmission
The engine and supporting are damaged. ………… Replace the component.
OK
The engine and transmission fail to align. ………… Replace the component and readjust the
pressure value of pressure regulating valve
as required.
OK
The shifting fork or sleeve groove is severely ………… Replace the component.
worn out.

OK
The locking spring becomes poor or is ………… Replace the component and mount the
omitted. omitted component.
OK
The connecting rod motions difficultly. ………… Eliminate the interference suffered by
component.
OK
The connecting rod is adjusted improperly. ………… Adjust the connecting rod as required.
OK
The gear deviates from its tooth alignment ………… Replace the component and mount the
position due to the shaft distortion. omitted component.
OK
The soldered tooth is of bad taper. ………… Replace the component.
3. Gear shifting difficulty or failure in high/low gear range
The pressure value of pressure regulating …………

valve is not in the standard range or the
Replace the pressure regulating valve.
pressure regulating valve cannot adjust the
pressure effectively.
OK
The air pipe or joint is loose and the air ………… Tighten the component.
passage is of bad sealing performance.
OK
The air pipe or joint is pinched and the air ………… Eliminate the interference suffered by
passage has large air resistance. component.

OK
The double H air valve plunger is blocked. ………… Clean the component.
OK
The shifting cylinder O-ring is damaged. ………… Replace the component.
OK
The cylinder piston nut is loose. ………… Tighten the component.
OK
The cylinder piston is broken. ………… Replace the component.
OK
The synchronizer spring is damaged. ………… Replace the component.
OK
The synchronizer is damaged. ………… Replace the component.
OK
The cylinder O-ring is little lubricated. ………… Apply a thin layer of silicone oil.
OK
The cylinder O-ring is excessively lubricated. ………… Clean the O-ring and reapply a little
amount of lubricant.

4. Gear shifting difficulty or failure of main transmission
The engine supporting is damaged. ………… Replace the component and find out the
resulting damage.
OK
The clutch fails to be adjusted properly. ………… Readjust it as required.
OK
The clutch is not used. ………… Direct the driver to use the correct
method and find out the resulting
damage.
OK
The shifting mechanism housing is broken. ………… Replace the component.
OK
The declutch shift shaft has burrs. ………… Polish the surface with sand paper.
OK
………… Replace the component, screw off the

The declutch shift shaft bends. locking screw and retighten it with
appropriate torque.
OK
The locking spring is too hard. ………… Replace the component.
OK
component.
OK

The main shaft is distorted. ………… Replace the component.
OK
5. Failure to interlock
The interlocking structural ball is omitted. ………… Replace the component.
OK
The interlocking pin is omitted. ………… Replace the component.
6. The gear lever is pulled with squawk.
The shifting mechanism housing liner is worn ………… Replace the component.
out.
OK
The clutch fails to be adjusted properly. ………… Readjust the pressure value of pressure
regulating valve as required.
OK
The shifting fork is severely worn out. ………… Replace the component.
OK
OK
The intermediate shaft brake fails to operate. ………… Replace the component, tighten the
component and check the air pipe.

OK
component.
OK
The connecting fails to be adjusted properly. ………… Readjust the pressure value of pressure
7. The gear cannot be disengaged.
component.
OK
The connecting fails to be adjusted properly. ………… Readjust the pressure value of pressure
OK
The main shaft is distorted. ………… Replace the component.
8. Big noise
OK
The gear has crack or the teeth have burrs. ………… Polish the surface with sand paper and
replace the component.
OK
The main shaft gear has too large tolerance. ………… Check the air pipe.

OK
The auxiliary gearbox intermediate shaft front ………… Mount the omitted component.
bearing inner ring is fallen off.
OK
The bearing is damaged. ………… Replace the component.
OK
The oil level is too low. ………… Replace the component and find out the
resulting damage.
OK
The lubricating oil is of poor quality. ………… Replace the component and find out the
resulting damage.
OK
The oil cannot be changed timely. ………… Replace the component and find out the
resulting damage.
OK
The different oil products are mixed and used. ………… Replace the component.
9. The gear generates sound when running idle.
………… Readjust the pressure of pressure

The main shaft gear has too large tolerance. regulating valve to the permissible range
as required.
OK
………… Readjust the pressure value of pressure

The engine cannot operate stably.

10. Severe vibration
The engine support is damaged. ………… Replace the component.
OK
The tightening torque of output shaft nut is not ………… Readjust the pressure value of pressure
enough. regulating valve as required.
OK
The drive shaft cannot be mounted properly. ………… Readjust the pressure value of pressure
OK
………… Replace the component and readjust the

The suspension is worn out. pressure value of pressure regulating
valve as required.
11. The main shaft washer is burnt out.
………… Replace the component.

Find out the resulting damage.
The oil level is too low.
Readjust the pressure value of pressure
OK
………… Replace the component.

The vehicle towing or sliding method is Find out the resulting damage.
improper.

12. The input shaft spline is worn out or damaged.
Direct the driver to use the correct driving

st
Start at above 1 gear. ………… method.
Replace the component.
OK

The impact load is too big. ………… method.
OK

The clutch fails to be adjusted properly. ………… Readjust the pressure value of pressure
OK
The clutch is in failure. ………… Check the belt and tensioner.
OK

The drive shaft cannot to be mounted properly. …………
13. Clutch housing is damaged
The engine supporting is damaged. ………… Replace the component.
OK
The engine and transmission fail to align. ………… Readjust it as required.
OK
The transmission auxiliary supporting is not ………… Mount the omitted component.
installed.

14. Too hot
Replace the component and readjust the

The transmission operates at too big tilt angle. ………… pressure value of pressure regulating
valve as required.
OK
Check the air pipe and find out the

The oil level is too low. …………
resulting damage.
OK
Check the air pipe and find out the

The oil level is too high. …………
resulting damage.
OK
Replace the component and readjust the

The oil is not changed timely or the lubricating
………… pressure value of pressure regulating
oil is of poor quality.
valve as required.
OK
The gear deviates from its tooth alignment Replace the component and find out the
…………
OK
The bearing is damaged. ………… Replace the component.
OK
The auxiliary gearbox intermediate shaft front Replace the component.

…………

15. The main shaft is distorted.

st
Start at above 1 gear. ………… method.
OK

The impact load is too big. ………… method.
16. The bearing is burnt out.

The oil level is too low. …………
OK

The oil is not changed timely or the lubricating Find out the resulting damage.
…………
oil is of poor quality.
OK
The auxiliary gearbox intermediate shaft front Replace the component.

…………
OK

The different oil products are mixed and used. …………

(IV) Special tools

The special tools of transmission mean the repair tools specially designed and manufactured for
dismounting and mounting the transmission. The special tools are composed of intermediate shaft front
bearing detacher, reverse gear intermediate shaft detacher, auxiliary gearbox intermediate shaft bearing
detacher, replacing bar, 2nd shaft rear nut replacing sleeve and other parts and components, which are
reasonable and convenient structurally and are necessary for dismounting and repairing the
transmission.
The use of special tools can make your work very efficient. To repair, dismount and mount transmission,
please use the special tools for transmission.
Special tools list
For the convenience of dismounting and repairing transmission, the following special tools are supplied
for the selection of user on demand.
Name of tool Diagram of tool Direction for use
Special hanger for auxiliary

gearbox assembly
Used for lifting the auxiliary
gearbox assembly
Combined shaft puller (BW-02)

Used for dismounting the auxiliary
gearbox intermediate shaft front
bearing
Used for dismounting the reverse
idler shaft
(Z05-01A)Output shaft nut

sleeve wrench (Z05-01A)
Replacing bar (Z04-10

Used for dismounting the
intermediate shaft rear bearing and
combination bearing outer ring

2nd shaft supporting tool

Used for supporting the 2nd shaft
1st shaft nut sleeve wrench

(Z06-01)
Used for dismounting the 1st shaft
nut
Front bearing detacher Z01A

Used for dismounting the main
gearbox intermediate shaft front
bearing
Extended hexagon spanner

(Z08/5#)
Used for dismounting and
mounting the air passage control
valve
Round-nose internal circlip

pliers (Z09/12")
mounting the 2nd shaft reverse gear
internal snap ring and where there
is snap ring on transmission
Flat-nose external circlip pliers

(Z10/12")
mounting the 1st shaft bearing
external snap ring, 2nd shaft
external snap ring, driving wheel
snap ring and where there is snap
ring on transmission

Ball headed screwdriver (Z14)

Used for mounting the snap ring
in transmission gear and stiring
the adjusting gasket or floriated
gasket till it turns by a tooth pitch
accordingly when mounting the
main shaft gear
(V) Dismounting and remounting precautions

Dismounting precautions
1. Carefully clean the bearing and check whether the raceway has pitting corrosion and whether the
rolling element is complete. It is necessary to use special tool for dismounting.
2. When dismounting various assemblies, it is necessary to follow the dismounting order to place all
the components at clean worktable to provide convenience for remounting and avoid the loss of
component.
3. The 1st shaft can be removed with intermediate shaft, 2nd shaft and 1st shaft gear.
4. The maintenance and repair shall be done at a clean site to protect the transmission interior from
dust and other impurities. Before dismounting, carefully clean the transmission exterior.
Inspection of wearing parts
Before remounting the transmission, carefully check all the components and avoid the unnecessary loss
due to the use of wearing parts.
The inspection procedure is recommended below:
1 Bearing
1) Clean all the bearings in clean solution, check steel ball, roller and bearing raceway for pockmark or
spalling.
2) Clean the undamaged bearing, check axial and radial clearance and replace the bearing with
excessive clearance.
3) Check the fit between bearing and housing hole. If the external ring can rotate freely in the hole,
replace the housing.
2. Gear
1) Check the gear tooth flank for pitting corrosion. If any, replace the gear in question.
2) Check all the engaging gears, replace the gear which wears out into cone or reduces its engaging
length due to shifting impact.
3) Check the axial clearance of gear. If too large, check the split ring, washer, adjusting gasket and the
flange of gear for excessive abrasion. The axial clearance shall be 0.13~0.30mm for the gear of 2nd shaft
forward gear and 0.30~0.90mm for the gear of reverse gear.

3. Spline
Check all the shaft splines for abrasion and replace it when the sliding gear sleeve and output flange
disk incline towards one side of spline due to abrasion.
4. Thrust washer
Check the appearance of thrust washer and replace the washer with scratch or reduced thickness.
5. Gray cast iron component
Check the gray cast iron component for crack or damage. A large-sized casting can be subject to melting
welding or copper welding, providing that the hot crack generated cannot extend to bearing hole or bolt
connecting surface.
6. Bearing cap
1) Check the seemfor abrasion.
2) Check the oil seal in 1st shaft bearing cap and odometer housing, replace the sealing element when
the lip has no sealing function.
7. Synchronizer
1) Check the high/low gear synchronizer for burr, check the uneven position and contacting surface for
excessive abrasion.
2) Check the locking pin for excessive abrasion.
3) Check the contacting surface of high/low gear synchronizer, replace it when the synchronizer or the
gear contacting surface is burnt out.
8. Sliding sleeve
1) Check the shifting fork and the shifting fork groove of sliding sleeve for excessive abrasion or
discolouration due to too hot.
2) Check whether the contact zone of conjunction gear of sliding sleeve is inclined.
9. O-ring
Check O-ring for rupture and deformation. If any, replace it.
Remounting precautions
The whole remounting process shall follow the precautions below:
1. It is necessary to use new gasket when remounting transmission.
2. In order to avoid oil leakage, all the screws shall be applied with screw sealant.
3. All the O-ring shall be lubricated by silicone grease.
4. All the thrust washers shall be applied with lubricant for initial lubricating purpose to avoid
the occurrence of scratch or abrasion.
5. The axial clearance shall be 0.13~0.30mm for the gear of 2nd shaft forward gear and
0.30~0.90mm for the gear of reverse gear.
6. Fasten the output shaft flange disk nut with the torque of 610~680 N·m. Otherwise, the
severe result will be caused.

III. Replacement of neutral switch

(I) Recommended tool
Tools and auxiliary materials Name and model
Common tool S30 open spanner
Special tool ——
Testing tool ——
Auxiliary materials ——
(II) Working procedure

Dismounting
1. Turn off the main power switch.
2. Dismount the neutral switch.
1) Disconnect the wiring harness joint of neutral switch.
2) Remove the neutral switch assembly from single H assembly.
3) Take off the straight pin.
Notice: Do not lose the interlocking steel ball at relevant position after the neutral switch is
removed.
Mounting
1. Mount the neutral switch.
1) Apply the thread sealant onto the screw
thread of neutral switch.
2) Put in the straight pin.
3) Mount the neutral switch.
Notice: Before mounting, be sure to check
whether the interlocking steel ball is installed
at relevant position.
4) Connect the wiring harness joint of neutral
switch.
Replacement of neutral switch 29

IV. Replacement of reverse switch

(I) Recommended tools
Common tool S30 open spanner
Special tool ——
Testing tool ——

Dismounting
2. Remove the reverse switch.
1) Disconnect the wiring harness joint of reverse switch.
2) Remove the reverse switch from single H assembly.
3) Take off the straight pin.
Notice: Do not lose the interlocking steel ball at relevant position after the reverse switch is
removed.
Mounting
1. Mount the reverse switch.
1) Apply the thread sealant onto the screw
thread of reverse switch.
2) Put in the straight pin.
3) Mount the reverse switch.
Notice: Before mounting, be sure to check
whether the interlocking steel ball is installed
at relevant position.
4) Connect the wiring harness joint of reverse
switch.
30 Replacement of neutral switch

V. Replacement of single H assembly

Tools and auxiliary

Name and model
materials
Inner hexagon spanner S5, open spanner S14 and S16, box spanner
Common tool
S12, S16 and S27, sleeve S14 and S16, ratchet spanner, circlip pliers
Special tool ——
Testing tool Torque spanner (0-300N·m)

Dismounting
1. Remove the neutral switch.

2. Remove the reverse switch.
3. Remove the air passage stop valve.
1) Remove the socket cap screw from stop
valve.
2) Take off the stop valve.
Notice: Check whether the valve pipeline is on
state.
4. Remove the upper cover right air passage

reversing valve.
1) Remove the single H valve air pipe assembly.
2) Remove the single H valve stand bolt.
3) Remove the single H valve stand.
Replacement of single H assembly 31

5. Remove the single H assembly.

1) Disconnect the shifting lever from the shifting
rocker arm.
2) Remove the four locking nuts from single H
assembly.
3) Knock and take off the single H assembly.

Notice: Use a copper bar or copper hammer to
slightly knock it out.
6. Remove the shifting rocker arm.
Mounting
1. Mount the shifting rocker arm.
2. Mount the single H assembly.
1) Mount the single H assembly.
2) Mount the four locking nuts.
3. Mount the upper cover right air passage
reversing valve.
1) Mount the reversing valve stand.
2) Mount the reversing valve stand bolt.
4. Mount the air passage stop valve on single
H assembly.
5. Mount the neutral switch.
6. Mount the reverse switch.
7. Connect the shifting lever and shifting
rocker arm.
32 Replacement of single H assembly

VI. Maintenance of single H assembly

Tools and auxiliary

Name and model
materials
Inner hexagon spanner S5, open spanner S14 and S16, box spanner
Common tool
S12, S16 and S27, sleeve S14 and S16, ratchet spanner, circlip pliers
Special tool ——

Dismounting
1. Remove the single H assembly.
Refer to the dismounting steps 1-7, Replacement of Single H Assembly.
2. Remove the dust cover and air plug.
3. Remove the reverse switch, neutral switch

and straight pin.
Maintenance of single H assembly 33

4. Remove the transverse shifting shaft.

1) Remove the two bolts from the single H
assembly side plate.
2) Take off the stop collar.
3) Remove the snap ring.
34 Maintenance of single H assembly

4) Take off the spring seat.
5) Take the spring out of the transverse shifting

shaft.
6) Screw off iron wire of shifting block.
7) Turn over the single H housing, remove the

bowl-shaped tabular plug.

8) Use a punch to impinge on the straight pin on

shifting block.
9) Pull the straight pin out of shifting block.
10) Remove the spring-type straight pin from

reverse gear control block.
11) Draw out the transverse shifting shaft.

5. Remove the oil seal of single H assembly.
Cleaning and inspection

1. Check whether the shifting block is worn
out;
2. Clean the shifting shaft.
Mounting
1. Mount the oil seal of single H assembly.
1) Put upright the single H assembly into the oil
seal.
Notice:
1. Apply the grease onto the oil seal lip
before the oil seal is mounted.
2. In order to avoid the damage on oil seal,
knock with copper bar or copper hammer when
the oil seal is mounted.
2. Mount the transverse shifting shaft.

1) Put in the transverse shifting shaft.
2) Mount the spring-type straight pin of reverse
gear control block.
Notice: The small head of spring-type straight
pin is upward.
3) Put in the straight pin of shifting block and fix it

with iron wire.

4) Mount the spring and spring seat.
5) Mount the snap ring.
6) Put in the stop collar and mount the side plate.
3. Mount the switch starting pin, reverse

switch and neutral switch.

4. Mount the dust cover and shifting rocker

arm.
Notice: Be sure to make the rocker arm and
shifting block at a straight line.
5. Mount the single H assembly.
Refer to the Replacement of Single H Assembly.

VII. Dismounting and mounting of upper cover assembly

Tools and auxiliary

Name and model
materials
Common tool Sleeve S14, box spanner S17, ratchet spanner, screwdriver, copper bar
Special tool ——

Dismounting
1. Dismount the single H assembly.
Refer to the dismounting steps 1-6, Replacement of Single H assembly.
2. Dismount the upper cover assembly.

1) Remove the bolts from upper cover housing.
2) Remove four stud bolts from upper cover

housing.
40 Dismounting and mounting of upper cover assembly

3) Use copper bar to knock at the upper cover to

separate it from liner.
Notice: When knocking cover the spring hole
with your hand to avoid the spring entering in
the main gearbox.
4) Take off the upper cover assembly and take

the spring and steel ball out of upper cover hole.
Notice: The thick spring shall be placed at
5th/6th gear shifting fork.

1. Check each declutch shift shaft and shifting fork for crack.
2. Clean the removed shifting fork and declutch shift shaft.
Mounting
1. Mount the upper cover assembly.
1) Mount the upper cover assembly in main
gearbox.
Notice: Before the upper cover assembly is
mounted, it is necessary to place the sleeve
and shifting fork of each gear at neutral
position for the convenience of correct
mounting.
2) Tighten the 16 fixing bolts.
Tightening torque: 47.5～61N·m
Dismounting and mounting of upper cover assembly 41

3) Mount the four stub bolts, locating spring and

steel ball on upper cover.
Notice: Pay attention to the spring sequence of
each gear. The spring in 5th/6th gear declutch
shift shaft hole is relatively thick.
42 Dismounting and mounting of upper cover assembly

VIII. Replacement of upper cover housing

Tools and auxiliary

Name and model
materials
Common tool Sleeve S14, box spanner S17, ratchet spanner, screwdriver, copper bar
Special tool ——

Dismounting
1. Dismount the single H assembly.
Refer to the dismounting steps 1-2, Dismounting and Mounting of Upper Cover Assembly.
2. Dismount the reverse gear shifting fork,

reverse gear declutch shift shaft and guide
block.
1) Turn over the upper cover assembly.
2) Remove the locking bolt of reverse gear
shifting fork, take off the shifting fork.
3) Screw off the locking bolt of reverse gear

guide block.
Replacement of upper cover housing 43

4) Take off the declutch shift shaft.
3. Dismount the 1st/2nd gear shifting fork and

declutch shift shaft.
1st/2nd gear shifting fork.
2) Take off the 1st/2nd gear shifting fork and

3) Take the interlocking pin out of shaft and the
interlocking steel ball out of hole.
4. Dismount the 3rd/4th gear shifting fork and

3rd/4th gear shifting fork.
2) Take off the 3rd/4th gear shifting fork and
44 Replacement of upper cover housing

3) Take the interlocking pin out of shaft and the

interlocking steel ball out of hole.
5. Dismount the 5th/6th gear shifting fork and

guide block.
1) Screw off the locking bolt from 5th/6th gear
2) Draw out the declutch shaft.
3) Take off the 5th/6th gear shifting fork and guide

block.

1. Check each declutch shift shaft and shifting fork for crack.
2. Clean the removed shifting fork and declutch shift shaft.

Mounting
1. Check the new upper cover housing.
2. Mount the 5th/6th gear declutch shift shaft.
1) Put in the 5th/6th gear declutch shift shaft.

2) Mount the 5th/6th gear guide block and shifting
and fix them with bolt, and tighten the fixing iron
wire.
Notice: The shifting fork shall be mounted in
turn. Otherwise, the fixing bolt cannot be
mounted.
3. Mount the 3rd/4th gear declutch shift shaft.

1) Put in the 3rd/4th gear declutch shift shaft.
2) Mount the spring-type straight pin on shifting
fork.
3) Mount the interlocking pin and interlocking
steel ball.
4. Mount the 1st/2nd gear declutch shift shaft.

1) Put in the 1st/2nd gear declutch shift shaft.
2) Mount the spring-type straight pin on shifting
fork.
Notice: Be sure to mount the interlocking pin
on 1st/2nd gear declutch shift shaft.
46 Replacement of upper cover housing

5. Mount the reverse gear declutch shift

shaft.
1) Put the reverse gear guide block and shifting
fork in turn onto reverse gear declutch shift shaft.
2) Fix them with tapered bolt and tighten the

fixing iron wire.
3) Put in an interlocking steel ball.
6. Mount the upper cover assembly.

1) Put the upper cover assembly into main
gearbox.
Notice: Notice: Before the upper cover
assembly is mounted, it is necessary to place
the sleeve and shifting fork of each gear at
neutral position for the convenience of correct
mounting.
2) Tighten the 16 fixing bolts.
3) Mount the four stub bolts, locating spring and

steel ball on upper cover.
Notice: Pay attention to the spring sequence of
each gear. The spring in 5th/6th gear declutch
shift shaft hole is relatively thick.

IX. Replacement of flange assembly

(I) Recommended tools and auxiliary materials
Tools and auxiliary

Name and model
materials
Common tool Open spanner S24/S21, box spanner S21
Special tool Special sleeve for flange
Testing tool Torque spanner (0~400N)
Auxiliary materials Lubricating grease

Dismounting
1. Disconnect the drive shaft belt sliding yoke assembly.
1) Remove the connecting bolt between drive shaft and gearbox flange.
2) Remove the drive shaft from gearbox flange.
2. Dismount the flange assembly.
1) Remove the flanged nut.
2) Pull out the flange assembly.
Inspection
1. Check the flange assembly.
1) Check the flange spline hole for damage. If severe damage, replace it.
Mounting
1. Mount the flange assembly.
1) Put the flange assembly onto the transmission rear end.
2) Mount the four belleville springs.
Notice: The concave side is forward.
3) Mount one hexagon slotted nut.
Tightening torque: 200~300N·m
2. Mount the intermediate drive shaft and support assembly.
1) Use four bolts to fix the intermediate drive shaft and support on transmission flange.
2) Use four bolts to fix the intermediate drive shaft and support assembly.
3. Connect the drive shaft and sliding yoke assembly.
1) Use four bolts to fix the drive shaft and sliding yoke assembly.
48 Replacement of flange assembly

Replacement of flange assembly 49

X. Dismounting and mounting of auxiliary gearbox assembly

Tools and auxiliary

Name and model
materials
Sleeve S10, S14, S16 and S17, open spanner S16, box spanner S24,
Common tool
ratchet spanner, monkey spanner
Special tool Special sleeve subassembly Z05-01A, circlip pliers Z10/12

Dismounting
1. Dismount the three air pipes from auxiliary

gearbox cylinder.
2. Dismount the air filter.
1) Remove the two bolts from air filter.
2) Take off the air filter assembly.
3. Dismount the output shaft flanged nut.

1) Engage the two synchronizers in main
gearbox with gears respectively.
Notice: If the sleeve is difficult to be prodded in
actual operation, it is allowed to use a copper
bar to limit the rotation of gear.
50 Dismounting and mounting of auxiliary gearbox assembly

2) Use a special spanner to loosen the output

shaft flanged nut.
4. Dismount the auxiliary gearbox assembly.

1) Dismount the connecting bolt between rear
cover housing and main gearbox.
2) Use three bolts to knock out the auxiliary

gearbox assembly backwards by about 10mm.
3) Take off the auxiliary gearbox assembly.

Notice: Be sure to slightly take off and place
the auxiliary gearbox.
Dismounting and mounting of auxiliary gearbox assembly 51

5. Dismount the flanged nut and flange plate.
Mounting
1. Mount the output shaft nut.
1) Place the auxiliary gearbox synchronizer in
low gear range.
2) Use a special sleeve to fix the flanged nut.

Tightening torque: 610～680N·m
Notice: Before mounting, be sure to firstly
engage the auxiliary gearbox at low gear and
then block the gear with copper bar.
2. Mount the auxiliary gearbox assembly.

1) Apply an even layer of lubricating grease onto
two bearing holes at the rear end of main gearbox.
Warning: This step is very important.
52 Dismounting and mounting of auxiliary gearbox assembly

2) Use a special hanger to mount the auxiliary

gearbox assembly.
3) Tighten the connecting bolt between rear cover

and main gearbox housing.
Dismounting and mounting of auxiliary gearbox assembly 53

XI. Replacement of auxiliary gearbox housing

Tools and auxiliary

Name and model
materials
Common tool
Dismounting
1. Dismount the engine assembly.
2. Dismount the three air pipes from auxiliary
gearbox cylinder.
3. Dismount the air filter.
1) Remove the two bolts from air filter.
2) Take off the air filter assembly.
4. Dismount the output shaft flanged nut.

gearbox with gears respectively.
Notice: If the sleeve is difficult to be prodded in
actual operation, it is allowed to use a copper
bar to limit the rotation of gear.
54 Replacement of auxiliary gearbox housing

2) Use a special spanner to loosen the output

shaft flanged nut.

1) Dismount the connecting bolt between rear
cover housing and main gearbox.
2) Use three bolts to knock out the auxiliary

gearbox assembly backwards by about 10mm.
3) Take off the auxiliary gearbox assembly.

Notice: Be sure to slightly take off and place
the auxiliary gearbox.
Replacement of auxiliary gearbox housing 55

6. Dismount the flanged nut and flange plate.
7. Dismount the auxiliary gearbox shifting

cylinder (it is allowed to operate on vehicle)
1) Remove the four bolts from auxiliary gearbox
shifting cylinder cover.
2) Remove the fixing bolts from cylinder piston.

shifting cylinder.

4) Knock away the shifting cylinder assembly

and take off the piston.

fork and declutch shift shaft.
1) Remove the connecting bolts between
auxiliary gearbox shifting cylinder and auxiliary
gearbox shifting fork.
2) Take off the auxiliary gearbox shifting fork and
9. Dismount the left auxiliary gearbox

intermediate shaft bearing.
1) Remove the left auxiliary gearbox
intermediate shaft bearing cap.
2) Use circlip pliers to remove the snap ring from

auxiliary gearbox left intermediate shaft.

3) Knock at the auxiliary gearbox left

intermediate shaft backwards to make it separate
from bearing.
4) Knock away the left intermediate shaft

bearing.
10. Dismount the extended intermediate shaft

bearing.
auxiliary gearbox extended intermediate shaft.
2) Knock at the auxiliary gearbox extended

from bearing.

3) Knock away the extended intermediate shaft

bearing.
11. Dismount the auxiliary gearbox

intermediate shaft and bearing.
12. Dismount the auxiliary gearbox

intermediate shaft bearing inner ring.

13. Take the synchronizer assembly out of

output shaft.
14. Dismount the output shaft rear bearing

seat and odometer driven gear.
1) Remove the fixing bolts from output shaft rear
bearing seat and take off the output shaft rear
bearing seat.
2) Remove the odometer driven gear.
3) Knock away the output shaft rear bearing seat

oil seal.

15. Dismount the output shaft.

1) Knock at the output shaft backwards to make
it away from bearing hole.
Notice: Be sure to use copper bar to avoid the
damage on output shaft.
2) Knock away the bearing outer ring.

Notice: Be sure to use copper bar to avoid the
damage on bearing outer ring.
16. Dismount the auxiliary gearbox housing.

Mounting
1. Mount the output shaft.

1) Knock at the internal bearing outer ring into
auxiliary gearbox housing.
Notice: Be sure to use copper bar.
2) Put inside the spacer bush.
3) Knock at the external bearing outer ring into

auxiliary gearbox housing.
Notice: Be sure to use copper bar.

4) Mount the synchronizer assembly from lower

end of output shaft, and make a tooth alignment
mark at the direction of 180° of auxiliary gearbox
reduction gear.
5) Make tooth alignment mark on the marked

tooth top of auxiliary gearbox intermediate shaft.
6) Insert the marked teeth of two intermediate

shafts into the two marked grooves of reduction
gear respectively.

7) Put in the rear cover housing.

Notice: The extended shaft with power take-off
shall be mounted as the right lower part of rear
cover housing.
2. Mount the auxiliary gearbox intermediate

shaft.
1) Mount the two intermediate shaft bearings and
output shaft bearing on rear cover.
2) Mount the snap ring on auxiliary gearbox

3) Mount the two intermediate shaft caps.


3. Mount the output shaft bearing cap.

1) Mount the output shaft bearing oil seal.
Notice:
1. Before mounting, apply a few amount of
lubricating oil onto oil seal lip.
2. Slightly knock with copper bar to make the
oil seal in place.
2) Put in the odometer driven gear and joint.
3) Mount the odometer driving gear and output

shaft bearing cap, and tighten the output shaft
bearing cap bolt.
4. Mount the auxiliary gearbox shifting

cylinder assembly.
1) Insert the auxiliary gearbox shifting fork with
its surface outward into synchronizer.

2) Mount the connecting bolt between shifting

fork and shifting cylinder, and lock them with iron
wire.
Notice: The shifting fork surface engraved with
character shall face forward.
3) Tighten the bolts of auxiliary gearbox shifting

cylinder assembly.

low gear range.




gearbox assembly.
3) Tighten the connecting bolt between rear

cover and main gearbox housing.

XII. Dismounting and mounting of auxiliary gearbox high/low gear

synchronizer
Tools and auxiliary

Name and model
materials
Common tool

Dismounting
1. Disconnect the drive shaft from the transmission.
Refer to the dismounting steps 1-4, Dismounting and Mounting of Auxiliary Gearbox Assembly.
3. Dismount the auxiliary gearbox shifting cylinder (it is allowed to operate on vehicle).

shifting cylinder cover.
68 Dismounting and mounting of auxiliary gearbox high/low gear synchronizer

2) Remove the fixing bolts from cylinder piston.

shifting cylinder.
4) Knock away the range gear cylinder

assembly, and take off the piston.

fork and declutch shift shaft.
1) Remove the connecting bolts between
auxiliary gearbox shifting cylinder and auxiliary
gearbox shifting fork.
2) Take off the auxiliary gearbox shifting fork and
Dismounting and mounting of auxiliary gearbox high/low gear synchronizer 69

5. Dismount the left auxiliary gearbox

intermediate shaft.
1) Remove the left auxiliary gearbox
intermediate shaft bearing cap.

auxiliary gearbox left intermediate shaft.
3) Knock at the auxiliary gearbox left

from bearing.
6. Dismount the extended intermediate shaft.

auxiliary gearbox extended intermediate shaft.

2) Knock at the auxiliary gearbox extended

from bearing.
7. Take off the synchronizer from output

shaft.
Mounting
1. Make a tooth alignment mark on output
shaft.
1) Mount the synchronizer assembly from lower
end of output shaft, and make a tooth alignment
mark at the direction of 180° of auxiliary gearbox
reduction gear.

2) Insert the marked teeth of two intermediate

shafts into the two marked grooves of reduction
gear respectively.
3) Put in the rear cover housing.

Notice: The extended shaft with power take-off
shall be mounted as the right lower part of rear
cover housing.
2. Mount the auxiliary gearbox intermediate

shaft.
1) Mount the two intermediate shaft bearings and
output shaft bearing on rear cover.
2) Mount the snap ring on auxiliary gearbox


3) Mount the two intermediate shaft caps.

Tightening torque: 47.5～61N•m
3. Mount the output shaft bearing cap.

1) Mount the output shaft bearing oil seal.
Notice:
1. Before mounting, apply a few amount of
lubricating oil onto oil seal lip.
2. Slightly knock with copper bar to make the
oil seal in place.
2) Put in the odometer driven gear and joint.

3) Mount the odometer driving gear and output

shaft bearing cap, and tighten the output shaft
bearing cap bolt.
4. Mount the auxiliary gearbox shifting

cylinder assembly.
1) Insert the auxiliary gearbox shifting fork with
its surface outward into synchronizer.
2) Mount the connecting bolt between shifting

fork and shifting cylinder, and lock them with iron
wire.
Notice: The shifting fork surface engraved with
character shall face forward.
3) Tighten the bolts of auxiliary gearbox shifting

cylinder assembly.


low gear range.



gearbox assembly.

3) Tighten the connecting bolt between rear

cover and main gearbox housing.

XIII. Output shaft and gear

Common tool Copper bar
Special tool ——
Testing tool ——

Dismounting
Refer to the dismounting steps, Dismounting and Mounting of Auxiliary Gearbox Assembly.
2. Pad the output shaft assembly, and knock

at and dismount the bearing.
Notice: Be sure to knock with copper bar or
copper hammer to avoid the damage on output
shaft.
Output Shaft and Gear 77

3. Remove the various components from

output shaft.
Mounting
1. Put the gear pad onto the output shaft, and
rotate by one tooth pitch to make it cannot
move to the bottom end of shaft.
2. Mount the output gear.
3. Put the auxiliary gearbox reduction gear

with its surface upward onto the output shaft,
and put in the auxiliary gearbox main shaft
gear pressure plate.
Notice: Be sure to apply the lubricating grease
onto auxiliary gearbox main shaft gear
pressure plate.
78 Output Shaft and Gear

4. Knock at the one side of combination

bearing into output shaft.
Notice: Be sure to knock at the bearing inner
ring to avoid the damage on bearing.
Output Shaft and Gear 79

XIV. Replacement of output shaft rear bearing seat

(I) Recommended tools and auxiliary materials
Tools and auxiliary

Name and model
materials
Common tool Open spanner S24/S21, box spanner S21
Special tool Special sleeve for flanged nut
Auxiliary materials Lubricating grease

Dismounting
1. Dismount the flange assembly.
Refer to the dismounting steps 1-2, Replacement of Flange Assembly.
2. Dismount the output shaft rear bearing

seat.
Remove the fixing bolts from output shaft rear
bearing seat and take off the output shaft rear
bearing seat.
3. Remove the odometer driven gear.

4. Remove the odometer driving gear.
Mounting
1. Mount the odometer driving gear.
2. Mount the odometer driven gear.
3. Mount the output shaft rear bearing seat.
4. Mount the flange assembly.
Refer to the mounting steps 1-3, Replacement of
Flange Assembly.
80 Replacement of Output Shaft Rear Bearing Seat

XV. Replacement of auxiliary gearbox shifting cylinder

Tools and auxiliary

Name and model
materials
Sleeve S14, S16, S17 and S24, box spanner S14, S16 and S24, ratchet
Common tool
spanner
Special tool ——

Dismounting
1. Dismount the cylinder upper cover.
2. Dismount the self-locking nut from the

cylinder piston.
Replacement of auxiliary gearbox shifting cylinder 81

3. Dismount the bolt from the cylinder

housing side.
4. Take off the locating spring and steel ball,

and take the seal ring out of the piston.
5. Dismount the shifting cylinder piston and

seal ring.
82 Replacement of Auxiliary Gearbox Shifting Cylinder

Mounting
1. Mount the shifting cylinder seal ring.
Notice: Apply a few of butter onto seal ring.
2. Mount the piston internal/external seal

ring.
Notice: Apply a few of butter onto seal ring.
3. Insert the declutch shift shaft into cylinder,

mount the cylinder piston and tighten the
self-locking nut.
4. Mount the locking spring and steel ball,

and tighten the bolt on cylinder housing side.
Replacement of auxiliary gearbox shifting cylinder 83

5. Mount the cylinder upper cover.
84 Replacement of Auxiliary Gearbox Shifting Cylinder

XVI. Replacement of gearbox assembly

Tools and auxiliary

Name and model
materials
Common tool Sleeve S13 and S16, spanner S16X17
Special tool Circlip pliers Z04-01, Z04-01, Z01A

Dismounting
2. Discharge the gear oil from transmission.
3. Disconnect the drive shaft and sliding yoke assembly.
1) Remove the four bolts between drive shaft and gearbox flange.
2) Disconnect the drive shaft and sliding yoke assembly from the intermediate drive shaft.
4. Separate the clutch booster assembly.
1) Remove the four bolts between booster and clutch housing.
2) Separate the clutch booster assembly from the clutch housing.
5. Disconnect the neutral switch wiring harness joint.
6. Disconnect the reverse switch wiring harness joint.
7. Remove the odometer sensor.
1) Disconnect the odometer sensor wiring harness joint.
2) Remove the odometer sensor.
8. Dismount the shifting lever assembly.
1) Remove the bolts B2-B3 between control

pulling rod B and shifting pulling rod fulcrum
bracket.
2) Remove the bolts B2-B3 between control
pulling rod B and control rod.
3) Remove the bolt between shifting control lever
and top cover shifting rocker arm.
9. Dismount the transmission assembly.

1) Support the transmission assembly with transmission carrier.
2) Remove the ten bolts between clutch housing and flywheel housing.
Replacement of Gearbox Assembly 85

3) Use the carrier to pull out the transmission assembly.

Notice: Be sure to place the transmission stably.
Mounting
1. Mount the transmission assembly.
1) Use a carrier to hold the gearbox assembly.
2) Rotate the transmission flange till the 1st shaft spline fit with the clutch friction plate spline sleeve.
3) Tighten the ten bolts between clutch housing and flywheel housing.
Notice: First tighten by cross-angled force and then with torque spanner.
2. Mount the shifting flexible shaft and support.
1) Use two bolts to fix the flexible shaft on the clutch housing.
2) Use one nut and one bolt to fix two flexible shafts.
3. Mount the odometer sensor.
4. Connect the transmission wiring harness.
1) Use two bolts to fix wiring harness on transmission housing.
2) Connect the wiring harness joints of neutral switch, reverse switch and odometer sensor.
5. Mount the clutch booster support.
1) Use three bolts to fix the clutch booster support.
Tightening torque: 42±5N·m
6. Mount the clutch booster assembly.
1) Mount the booster push rod.
2) Use four bolts to fix the clutch booster assembly on the booster support.
Tightening torque: 22±2N·m
7. Mount the drive shaft and sliding yoke assembly.
1) Use four bolts to fix the drive shaft and sliding yoke assembly.
8. Fill the gear oil to transmission.
Gear oil: GL-485W/90
Filling amount: 6.5L
On-board inspection
Road test: put into each gear in turn, check whether the operation is clear and whether the gearbox
operates normally.
86 Replacement of Gearbox Assembly

XVII. 1st shaft assembly

Tools and auxiliary

Name and model
materials
Sleeve S14, S17, S24 and S30, ratchet spanner, flat-head screwdriver,
Common tool
copper bar
Circlip pliers Z06-01A, Circlip pliers Z10/12, pin puller subassembly

Special tool
BW-02, 1st shaft nut sleeve spanner Z06-01

Dismounting
1. Dismount the gearbox assembly.
Refer to the dismounting steps 1-9, Replacement of Gearbox Assembly.
2. Dismount the clutch housing.

1) Remove the bolts from clutch housing interior.
2) Take off the clutch housing assembly.
3. Dismount the 1st shaft cover.

1) Remove the bolts from 1st shaft cover.
2) Slightly knock at and take off the 1st shaft
cover.
1st Shaft Assembly 87

4. Dismount the 1st shaft nut.

gearbox with two groups of gears respectively.
2) Remove the front bearing pressure plate from

two main gearbox intermediate shafts, and use a
special tool to remove the 1st shaft nut.
Notice: Be sure that the 1st shaft nut is of left
handed screw thread when mounting.
5. Dismount the 1st shaft bearing.

1) Knock at the 1st shaft inwards.
2) Knock at the 1st shaft leftwards and rightwards

to make the bearing leave from the housing hole.
88 1st Shaft Assembly

6. Dismount the 1st shaft.

1) Take off the 1st shaft gear spacer.
2) Remove the snap ring from 1st shaft gear.
3) Use pressure plate and one bolt (M10×1) to

hold in 1st shaft gear.
Notice: In order to avoid the damage on 5th/6th
gear synchronizer when dismounting and
mounting, it is necessary to use pressure plate
and bolt to fix 1st shaft gear on 2nd shaft
assembly when dismounting main shaft
assembly. The pressure plate may be
manufactured upon the actual condition.

Mounting
1. Mount the 1st shaft.
1) Remove the pressure plate in front of 1st shaft
gear, apply the lubricating grease onto 1st shaft
hole, and put the 1st shaft in 1st shaft gear internal
spline.
2) Mount the snap ring of 1st shaft gear.
3) Mount the shock insulator of 1st shaft gear.
90 1st Shaft Assembly

2. Mount the 1st shaft bearing.

1) Knock at the bearing into housing.
2) Apply the sealant onto 1st shaft nut, and use a

special tool to tighten the 1st shaft nut.
Notice: Be sure that the 1st shaft nut is of left
handed screw thread when mounting.
3) Rivet the 1st shaft nut at thread groove.
4) Mount the front baffle of two intermediate

shafts and put in the 1st shaft cover.
3. Mount the gearbox assembly.
Gearbox Assembly.

XVIII. Replacement of 2nd shaft assembly

Tools and auxiliary

Name and model
materials
Common tool Monkey spanner
Special tool Circlip pliers Z04-01, Z04-01 and Z01A

Dismounting
Refer to the dismounting steps, Dismounting and Mounting of Upper Cover assembly.
3. Dismount the auxiliary gearbox.
4. Dismount the 1st shaft.
Refer to the dismounting steps, Dismounting and Mounting of 1st Shaft Assembly.
5. Dismount the left reverse idler gear.
Refer to the dismounting steps, Dismounting and Mounting of Reverse Idler Gear.
6. Dismount the rear snap ring of main

gearbox intermediate shaft.
92 Replacement of 2nd Shaft Assembly

7. Mount the driving gear bearing to locate

the rear end of 2nd shaft.
8. Dismount the rear bearing of two

intermediate shafts.
Notice: In order to realize a parallel movement
with shaft when knocking at the intermediate
shaft, do not dismount completely.
9. Use a copper bar to knock at the

intermediate shaft backwards by about 10mm.
10. Use a special tool to dismount the front

bearing of two intermediate shafts.
Replacement of 2nd Shaft Assembly 93

11. Dismount the driving gear bearing.
12. Use a crowbar to raise up the intermediate

shaft and take the 2nd shaft assembly out of
main gearbox.
Mounting
1. Mount the 2nd shaft assembly.
1) Make a tooth alignment mark on the opposite
teeth of two intermediate shaft key groove.
2) Respectively select a group of teeth at 180°
adjacent to 1st gear, put the 2nd shaft assembly in
main gearbox and mount the driving gear bearing
to locate the rear end of 2nd shaft.
3) Insert the marked tooth of intermediate

shaft into the marked groove of 1st shaft gear,
and then mount the intermediate shaft rear
bearing.

2. Mount the intermediate shaft front bearing

ring.
Notice: Use copper bar to knock at bearing
inner ring when mounting.
3. Use same method to make tooth alignment

and then mount the rear and front bearings of
intermediate shaft.
4. Mount the 1st shaft assembly.

spline.

4) Put in the 1st shaft bearing.


5. Mount the front baffle of two intermediate

6. Mount the reverse idler gear assembly,

dismount the driving gear bearing, and pull
backwards the 2nd shaft reverse gear to engage
with the reverse idler gear.
7. Mount the main shaft gear washer in 2nd

shaft reverse gear.
8. Mount the snap ring in 2nd shaft reverse

gear.

9. Put in the driving gear bearing, mount the

driving gear locating plate and fix them with
bolt and iron wire.
10. Mount the auxiliary gearbox driving gear,

and mount the rear snap ring.
11. Mount the front bearing of two auxiliary

gearbox intermediate shafts and the rear snap
ring of two main gearbox intermediate shafts.
12. Mount the clutch housing assembly.

• M12 bolt
• M16 bolt
Gearbox Assembly.

XIX. Dismounting and mounting of 2nd shaft

Tools and auxiliary

Name and model
materials
Common tool Long-nose pliers, flat-head screwdriver
Special tool Circlip pliers Z04-01
Testing tool ——

Dismounting
1. Dismount the 2nd shaft assembly.
Refer to the dismounting steps 1-12, Replacement of 2nd Shaft Assembly.
2. Dismount the gear subassembly of 5th/6th

gear.
1) Remove the front baffle from 2nd shaft
assembly, and take off the 1st shaft gear and 5th/6th
gear synchronizer upper subassembly.
2) Remove the upper snap ring used for fixing

5th/6th gear synchronizer on 2nd shaft.
Dismounting and Mounting of 2nd Shaft 99

3) Take off the 5th/6th gear synchronizer cone

hub.
4) Remove the snap ring from the other side of

5th/6th gear synchronizer, and take off the
synchronizer subassembly at the side.
5) Pull out the spring pin of 2nd shaft.
6) Draw out the long key.
100 Dismounting and Mounting of 2nd Shaft

7) Turn the gear spacer of 5th gear by one tooth

pitch, and take off the gear spacer of 5th gear.
8) Take off the gear of 5th gear.
3. Dismount the gear subassembly of 3rd/4th

gear.
1) Remove the gear shock insulator of 4th gear,
and take off the gear of 4th gear.
2) Remove the pad and take off the 3rd/4th gear

synchronizer upper subassembly.

3) Take off the 3rd/4th gear synchronizer gear hub

and sliding sleeve.
4) Remove the snap ring and take off the 3rd/4th

gear synchronizer lower subassembly.

5) Remove the floriated gasket from the gear of

3rd gear, and take off the gear of 3rd gear.
4. Dismount the gear subassembly of 1st/2nd

gear.
1) Turn the 2nd gear spacer by one tooth pitch,
remove the 2nd gear shock insulator and take off
the gear of 2nd gear.

2) Remove the floriated gasket, and take off the

1st/2nd gear synchronizer upper subassembly.
3) Remove the snap ring from gear hub, and

take off the gear hub and sliding sleeve.

4) Remove the snap ring and take off the 1st/2nd

gear synchronizer lower subassembly.
5) Turn the gear floriated gasket of 1st gear by

one tooth pitch, remove the floriated gasket and
take off the gear of 1st gear.

5. Dismount the reverse gear subassembly.
1) Turn the gear shock insulator of 1st gear by

one tooth pitch, remove the spacer and take off the
sliding sleeve of reverse gear.
2) Take off the reverse gear.

3) Turn the reverse gear pad by one pitch and

take off the reverse gear pad.

Mounting
1. Mount the 2nd shaft reverse gear
subassembly.
1) Place the 2nd shaft at working table with its
small end upright, put in the 2nd shaft reverse gear
pad, turn by one tooth pitch and insert in the long
key.
Notice: The long key shall be inserted in the 2nd
shaft groove with hole.
2) Mount the 2nd shaft reverse gear and sliding

sleeve.
Notice:
1. The reverse gear shall have its tooth loss
side toward the rear end of 2nd shaft.
2. The sliding sleeve shall have its tooth loss
side to align with the 2nd shaft groove with hole
and its short tooth side to face to the center.

2. Mount the gear subassembly of 1st/2nd

gear.
1) Mount the spacer of 2nd shaft gear, turn it by
one tooth pitch and then insert in the long key.
Notice: The gear spacer shall have its oil
groove side upward.
2) Put the 2nd shaft 1st gear conjunction gear

upwards in the 2nd shaft, put in the floriated gasket
with the convex side upwards, turn by one tooth
pitch and insert in the long key upwards.
Notice: The floriated gasket shall have its
convex side upward.
3) Put in the one side subassembly of 1st/2nd

gear synchronizer, and mount one snap ring with
its opening toward the 2nd shaft groove with hole.
Notice: The snap ring opening direction cannot
be wrong. Otherwise, the long key will not
move upwards.

4) Put in the 1st/2nd gear synchronizer gear hub,

and mount one snap ring.
Notice: The snap ring shall have its opening
toward the 2nd shaft groove with hole.
5) Put in the other side subassembly of 1st/2nd

gear synchronizer, mount the 2nd shaft floriated
gasket with its convex side downward, turn by one
tooth pitch and then insert in the long key upwards.
convex side downward.

6) Put in the 2nd shaft with 2nd shaft 2nd gear

conjunction gear downward, put in the 2nd shaft
gear spacer, turn by one tooth pitch and insert in
the long key upwards.
3. Mount the gear subassembly of 3rd/4th

gear.
1) Put in the 2nd shaft with 2nd shaft 3rd gear
conjunction gear upward, put in the floriated gasket
with its convex side upward, turn by one tooth pitch
and insert in the long key upwards.
convex side upward.

2) Put in the one side subassembly of 3rd/4th gear

synchronizer, and mount one snap ring.
3) Put in the 3rd/4th gear synchronizer gear hub,

and mount one snap ring.

4) Put in the other side subassembly of 3rd/4th

gear synchronizer, mount the 2nd shaft floriated
gasket with convex side downward, turn by one
tooth pitch and then insert in the long key upwards.
convex side downward.
5) Put in the 2nd shaft with 2nd shaft 4th gear

conjunction gear downward, put in the 2nd shaft
gear spacer, turn by one tooth pitch and insert in
the long key upwards.

4. Mount the gear subassembly of 5th/6th

gear.
1) Put in the 2nd shaft with 2nd shaft 5th gear
conjunction gear upward, put in the floriated gasket
with its convex side upward, turn by one tooth pitch
and insert in the long key upwards.
convex side upward.
2) Put in the one side subassembly of 5th/6th gear

synchronizer, and mount one snap ring.
Notice:
1. The snap ring shall have its opening toward
the 2nd shaft groove with hole.
2. The 5th/6th gear synchronizer is larger than
other two synchronizers.

3) Mount the spring pin on 2nd shaft, and push

the long key in place.
4) Put in the 5th/6th gear synchronizer gear hub,

and mount one snap ring
away from the 2nd shaft groove with hole.
5) Put in the other side subassembly of 5th/6th

gear synchronizer, and mount the 1st shaft gear.

5. Use pressure plate to fix 1st shaft gear on

2nd shaft.
Notice: This pressure plate is used to fix the
gear of 5th gear and the upper synchronizer
5th/6th gear for the convenience of the mounting
of 2nd shaft assembly.
2nd Shaft Assembly.

XX. Replacement of Intermediate shaft Assembly

Tools and auxiliary

Name and model
materials

Dismounting
4. Dismount the 1st shaft assembly.
Refer to the dismounting steps, Replacement of 1st Shaft Assembly.
Refer to the dismounting steps, Replacement of Left Reverse Idler Gear.

Replacement of Intermediate shaft Assembly 117





118 Replacement of Intermediate shaft Assembly


main gearbox.
13. Take two intermediate shafts assembly out

of main gearbox.

1. Check whether there are burrs at machined surface and hole of new gearbox housing.
2. Clean the gearbox housing interior.
Mounting
1. Mount the intermediate shaft assembly.


2) Put the two main gearbox intermediate shafts

in main gearbox housing.

2) Insert the marked tooth of intermediate shaft
into the marked groove of 1st shaft gear, and then
mount the intermediate shaft rear bearing.
3. Mount the intermediate shaft front bearing.



intermediate shaft.

spline.






shaft reverse gear.

gear.

bolt and iron wire.




• M12 bolt
• M16 bolt
Gearbox Assembly.

XXI. Intermediate shaft and gear

Tools and auxiliary

Name and model
materials
Common tool Long-nose pliers
Special tool Circlip pliers Z04-01, press machine
Testing tool ——

Dismounting
1. Dismount the intermediate shaft assembly.
Refer to the dismounting steps 1-13, Replacement of Intermediate shaft Assembly.
2. Dismount the intermediate shaft rear end snap ring.
3. Dismount the intermediate shaft driving

gear and spacer.
1) Dismount the intermediate shaft rear end snap
ring.
2) Press out the intermediate shaft driving gear.
Notice: Be sure to press slowly to avoid the
damage on intermediate shaft.
3) Take off the driving gear and spacer bush.
Intermediate shaftIntermediate shaftIntermediate shaftIntermediate shaft and Gear 125

4. Press out the intermediate shaft 5th gear.
5. Press out the intermediate shaft 4th gear.
6. Take off the intermediate shaft square key.
7. Press out the intermediate shaft 3rd gear,

take off the 3rd gear and woodruff key.
126 Intermediate shaftIntermediate shaftIntermediate shaftIntermediate shaft and Gear

Mounting
1. Mount the 3rd gear and woodruff key, press

in the intermediate shaft 3rd gear.
2. Mount the square key, press in the

intermediate shaft 4th gear.

3. Press in the intermediate shaft 5th gear.
4. Mount the driving gear and spacer bush.
128 Intermediate shaftIntermediate shaftIntermediate shaftIntermediate shaft and Gear

5. Press in the intermediate shaft driving

gear.
6. Mount the intermediate shaft rear snap
ring.
7. Mount the intermediate shaft assembly.
Intermediate shaft Assembly.

XXII. Replacement of main gearbox housing

Tools and auxiliary

Name and model
materials

Dismounting
3. Dismount the 1st shaft assembly.
Refer to the dismounting steps, Replacement of 1st Shaft Assembly.
Refer to the dismounting steps, Replacement of Left Reverse Idler Gear.

130 Replacement of Main Gearbox Housing





Replacement of Main Gearbox Housing 131


main gearbox.
12. Take two intermediate shafts assembly out

of main gearbox.
13. Dismount the right reverse idler gear
assembly.
The method is same as the dismounting and
mounting method of left reverse idler gear.

1. Check whether there are burrs at machined surface and hole of new gearbox housing.
2. Clean the gearbox housing interior.

Mounting
1. Mount the reverse idler shaft.

1) Make the convex side of reverse idler gear
forward.
2) Mount the reverse idler shaft.
3) Tighten the self-locking nut.



2) Put the two main gearbox intermediate shafts

in main gearbox housing.

4) Insert the marked tooth of intermediate shaft

into the marked groove of 1st shaft gear, and then
mount the intermediate shaft rear bearing.
3. Mount the intermediate shaft front bearing.



intermediate shaft.

spline.






shaft reverse gear.

gear.

bolt and iron wire.




• M12 bolt
• M16 bolt

FAST GEAR BOX 12J系列变速箱维修手册-en

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FAST GEAR BOX 12J系列变速箱维修手册-en

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Maintenance Manual of Shaanxi Fast Gear 12J transmission

Single rod controlled 12-gear transmission

(I) Operating requirements

II. Structural general and technical parameter

Control handle gear

4 Structural General and Technical Parameter

Typical structure of twin-intermediate shaft full-synchronizer transmission

1. Synchronizer gear 3. Spring; 5. Synchronizer outer cone; 7. Synchronizer conjunction

Structural General and Technical Parameter 5

6 Structural General and Technical Parameter

Control handle position diagram

Structural General and Technical Parameter 7

Single H control device diagram

Air passage operating principle of 12-gear transmission

8 Structural General and Technical Parameter

Single H shifting mechanism pneumatic circuit schematic diagram

Structural General and Technical Parameter 9

Neutral position cylinder structural diagram

10 Structural General and Technical Parameter

(II) Main technical parameter of twin-intermediate shaft full-synchronizer transmission

Number of forward Speed ratio code

Twin-interm ×10=Nominal input torque （N.m）

Number of forward gears Improved

Mechanical Full synchronizer

Number of forward gears ×10=Nominal input torque （N.m）

Main performance parameter of twin-intermediate shaft full-synchronizer transmission

12JSl60T 285 1600 2600 350 983.5 17

12JSl60TA 285 1600 2600 350 983.5 17

12JSl80T 331 1800 2600 360 983.4 18.5

12JSl80TA 331 1800 2600 360 983.4 18.5

12JS200T 331 2000 2600 360 983.4 18.5

12JS200TA 331 2000 2600 360 983.4 18.5

12JS240T 400 2400 2600 380 983.4 18.5

12JS240TA 400 2400 2600 380 983.4 18.5

Structural General and Technical Parameter 11

Speed ratio of each gear

Speed ratio of each (I)

Speed ratio of each gear (continued)

Speed ratio of each (II)

2 Clutch housing 4M12 108～135Nm

3 1st shaft bearing cap 6M10 47.5～61Nm

4 1st shaft gear M54×1.5 left 338～406Nm

12 Structural General and Technical Parameter

5 Double H control cover 8M10×1 47.5～61Nm

6 Upper cover 16M10 47.5～61Nm

7 Shifting fork locking screw 5M12～1.2S 67.5～88Nm

8 Auxiliary gearbox shifting fork 2M12×1.5 67.5～88Nm

9 Air filter stand 2M6 13.5～20.3Nm

10 Output shaft M50×1.5 609～677Nm

11 Auxiliary gearbox rear cover 19--M10 47.5～61Nm

12 Oil drain port Z3/4” 61～74.5Nm

13 Oil filler port 21 81～101.5Nm

Auxiliary gearbox driving

15 Reverse idler shaft 2M16×1.5 67.5～81Nm

17 Bottom power take-off cover 8M12 67.5～88Nm

18 Intermediate shaft brake 8M10 47.5～61Nm

Transmission side window

20 Main shaft rear bearing cap 6M10 47.5～61Nm

21 Shifting cylinder housing 4M10 47.5～61Nm

22 Cylinder cover 4M10 47.5～61Nm