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Items: N125

Transmission System Service Manual

No. N125-NAM-PV-DP- G9-18

Version: 1.0

Edition:

Proof:

Revision:

Standardization:

Countersignature:

Approval:

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Clutch

1. Overview ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …….3

2. Main data and specification…………………………………………………………5

3. Clutch assembly check and repair ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5

4. Clutch control device check and repair ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ........10

5. Clutch master cylinder check and repair ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 14

6. Clutch wheel cylinder check and repair ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16

7. Fault diagnosis………………………………………………………………………...22

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1. Review

Clutch Assembly

Clutch Pressure Plate Clutch Driven Disc Assemblies

Clutch Master Cylinder

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Clutch wheel Cylinder

Clutch Circuit Diagram

1、Clutch wheel cylinder assembly 2、Clutch hose assembly 3、Clutch buffer valve assembly 4、Clutch pipe assembly Ⅰ

5、Clutch pipe assembly Ⅱ 6、Clutch master cylinder assembly 7、Clutch brake pedal assembly 8、clutch master cylinder oil inlet hose

9、oil reservoir assembly

W5000 series mini-truck uses single-chip dry diaphragm spring clutch. This includes clutch pressure plate and

clutch driven disc. Clutch driven disc is equipped with corrugated gaskets to offer a buffer to driven disc when the clutch

is engaged. Shock absorber is installed onto the drive hub to relieve the Engine and Drive Train vibration. Diaphragm

spring from clutch pressure plate provides with contact pressure. Diaphragm spring tip offers the effect of separation.

Clutch separation mechanism includes split bearings, split sleeves, split rocker arms, and so on. Split bearings are

roller bearing to reduce friction. Inside of split sleeve needs grease lubrication for that it glides on gearbox input shaft

when clutch is separated or engaged. Split Sleeve of some types of vehicles is equipped with grease tube. Split bearings

are lubricated bearings which do not require additional lubrication.

Clutch control device adopts hydraulic remote control, including the oil reservoir, the oil hose, and clutch pedal,

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clutch master cylinder, hydraulic hard way, buffer valve, hoses, and clutch wheel cylinder. The master cylinder is

controlled by the clutch pedal, and the hydraulic oil pushes the rod of clutch wheel cylinder to push forward the rocker to

disengage the clutch.

2. Main data and specification

Types of clutch Single-chip dry diaphragm spring clutch

Driven disc diameter Ф250mm

Clutch master cylinder

diameter

Ф15.87mm

Clutch wheel cylinder

diameter

Ф 20.64 mm

Clutch pedal stroke 155 mm ～165mm

Clutch pedal free stoke 5mm～15mm

3. Clutch assembly inspection and repair

Disassembling

Disassembly Order

1、Transmission assembly 2、Clutch mounting bolt assembly 3、Clutch pressure plate assembly 4、Clutch driven

disc assembly 5、Engine assembly

Disassembling steps (in order)

Jack up the car and prop up it.

1． Remove the transmission. (Reference to the operation of the transmission in the manual )

2． Pressure plate assembly

3. Driven plate assembly

Use a guide shaft to prevent the free falling of driven disc assembly.

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Mark on the flywheel and pressure plate so as to make them aligned when reassembled.

Note: Make sure the brake fluid is wiped off immediately so as not to flow to the paint surface.

Inspection and repair.

If in the course of the inspection, excessive wear, damage, or other failures are found, necessary

actions should be made to adjust 、repair or replace the appropriate parts.

Pressure plate assembly

Visually inspect if there are wear-and-tear, hot cracks and bending

deformation on the pressure plate. If there is an excessive worn, bent or dark hot crack,

replace the disk. (Pressure plate deformation - measure the pressure plate friction surface

flatness, change the pressure plate assembly if the limit is exceed. Operation limit: 0.3

mm)

Pressure plate assembly

Visually inspect if there are wear-and-tear, hot cracks, bending deformation

and other damage on the pressure plate. Clutch pressure plate assembly with

excessive wear, cracks and other damage must be replaced.

Clutch installation contact pressure

1) Upside down clutch pressure plate

2) Put a metal block of which the thickness is 7.4 MM (8) on

the pressure plate.

3) Push down the tray until the distance "B" reaches 0

Metal blocks

Measurement

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4) Record the pressure numerical reading.

Standard pressure: 6100 N ~6700 N

Diaphragm spring separation height

1) Put a metal block of which the thickness is 7.4 MM (8) below

the pressure plate.

2) Push down the tray until the distance "B" reaches 0 mm.

Two ways can be adopted:

a: Press down from the top of the tray .

b: Tighten the mounting bolts.

3) Measure from the base panel to disengagement end.

Standard Height: 40 mm± 1mm

Driven plate assembly

Visually check if torsion spring is loose, soft or broken. If one

of the situations is detected, drive plate assembly should be

replaced.

Visually check friction surface if there are cracks, grease or

over-burned. If one of the situations is detected, drive plate

assembly should be cleared or replaced Check if the driven disc

assembly can move smoothly on the transmission shaft splines.

Driven plate deformation

Insert pilot shaft into the splined hub. Keep the pilot shaft

Straight, fix a scale onto the driven disc outer annulus, and then slowly turn the

driven disc assembly to read out the scale readings. If the measured value

exceeds the limit, the driven disc assembly should be replaced. Limit value

≤1.0mm.

Clean the inner of splined hub

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Install the driven disk to transmission shaft splines; mount on the outer circle of the driven disk with a surface

measurement meter; slowly turn the driven disk, measure the changes of outer circle ; if the measured value exceeds

the limit, you should replace driven disc assembly; driven disc splined hub wear limit ≤1.0mm.

The rivet head depth of the driven disc

Measure the distance between the rivet head and the friction

surface with a depth gauge measurements. Both sides should be

measured.

If the measured value is less than the limit value, the driven

disc assembly should be replaced.

The driven disc rivet head depth limit is 0.2 mm.

Warning: release bearing is filled with the lubricant so do not clean it in any solvent, in case

that the lubricant is dissolved. Note if no problem occurs, do not disassemble split sleeve. Visually

check if the spring is broken or soft. If it is, parts must be replaced.

Re-installation

Orders of re-installation

1、engine assembly 2、clutch driven disc assembly 3、clutch pressure plate assembly 4、clutch mounting bolt

assembly 5、transmission assembly

Steps of re-installation

1、 Driven plate assembly

Daub molybdenum disulfide in the inner of the driven

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disc splined hub; install the driven disc assembly with a guide shaft.

2、Pressure plate assembly

Press and tighten the mounting bolts in numerical sequence. Mount bolts by 2 steps: step1, the pre-tensioner (10 - 19)

N.M, in the shape of a star: step 2, (17 - 26) N.M, in the shape of a star; mark the bolts to make sure they are tightened.

Warning: after tighten the mounting bolts; remove the protective steel wire of the film leaf-spring

4. Clutch control device inspection and repair

Disassembling

Disassembly Order

1、clutch wheel cylinder assembly 2、clutch hose assembly 3、clutch buffer valve assembly 4、clutch steel tube

assembly I

5、clutch steel tube assembly II 6、clutch master cylinder assembly 7、 clutch brake pedal body assembly

8、clutch master cylinder inlet hose 9、oil reservoir assembly

Disassembling procedures of the clutch control device

Drain the brake fluid in clutch hydraulic line.

Note: Do not keep the fluid retention on the paint surface; wipe it off immediately if any.

1、clutch wheel cylinder assembly

2、clutch hose assembly

3、clutch buffer valve assembly

4、clutch steel tube assembly I

5、clutch steel tube assembly II

6、clutch master cylinder assembly

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7、clutch brake pedal body assembly

8、clutch master cylinder inlet hose

9、oil reservoir assembly

Inspection and repair

If in the course of the inspection, excessive wear, damage, or other failures are found, necessary actions should be

made to adjust, repair or replace the appropriate parts.Pressure plate assembly

Re-installation

Orders of re-installation

1、oil reservoir assembly 2、clutch master cylinder inlet hose 3、clutch brake pedal body assembly 4、clutch master

cylinder assembly

5、clutch steel tube assembly I 6、clutch steel tube assembly II 7、clutch buffer valve assembly

8、clutch hose assembly 9、clutch hose assembly

The clutch pedal assembling

a) Pre-installation spot inspection: check the number of all parts and see if there is any defect in the

pedal, slide back and forth the pedal to see if there is abnormal sound. Remove the master cylinder seal

plug; check the pump body and parts for cracks, scratches. Make sure the joint of pumps is clean and

clear of objects. Make sure the steel tube and inlet hose are mounted with a dust plug.

b) Install the main pump inlet hose: First, mount 1 (Q673B155) onto two ends of the inlet hose, and fit

the right end of inlet hose 2 (1607110W5000) right-side into 4 (1605010W5000) the oil hole. And then

lock it tightly with 1 (QB673155).

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c) Install the main pump: fix the pump with 3(Q1460830) onto the pedal, the torque is (23 ~ 28) N·m.

Connect 4 (1605010W5000) and 8 (1635010W5000) with pedal pivot shaft, and lock it with pivot shaft

lock.

d) Installation of pipeline stationary barrier and oil pipe: level the connector of 7 (1607120W5000) at

the pump outlet threaded hole, pre-tension it first, and mount the onto the tube and fix them with

the pipeline stationary barrier. Then tighten the connector with power（16～20）N·m.

The clutch circuit assembling

a) The spot inspection before pre-installation: check the clutch pipe, hose, and valve, pump surface for

Brake pipe clamp

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dust plug

、

scratches, burrs and cracks. Make sure the joint and the connectors are clean and clear of

objects.

b) Buffer valve installation: fix the buffer valve 12 (1607600W5000) on the vehicle chassis through 11

(Q1420616). Tightening torque: (6

～

10) N·m

c) The clutch tube and hose installation: connect the clutch steel tube 10 (1607010 W5000) with brake

hose clips, align the front connector of steel tube with brake 3-way bracket threaded holes to tighten

them with torque (16 to 20) N·m. Align the other end of steel pipe and the center of valve threaded

holes, and tighten them in same way. Pad the top and bottom of the clutch hose with copper backings

17 (3506016R001), then fix the hose 13 (1607020W5000) to valve body with piercing bolt 16

(1607013W5000), and the tighten torque is (20 to 25) N·m.

d) The clutch wheel cylinder assembling

Fix the sub-pump 15(1609010W5000) with two bolts 14 (Q1421030) onto the transmission, and

tighten it with torque (20 to 30) N·m. Let piercing bolt 16 (1607013W5000) go through the central

hole of hose 13(1607020W5000), and pad the top and bottom of the hose with copper backings 17

(3506016 R001), then fix it onto the clutch wheel cylinder 15 (1609010W5000) with tighten torque

(20to25)N·m.

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After the above assembly, the clutch control mechanism needs

adjustments

Clutch pedal height and stroke

1. Loosen the clutch master cylinder push rod and lock the nuts.

2. Rotate rod to adjust the pedal.

Clutch pedal height: 155 - 165 mm

Clutch pedal stroke: 155 - 165 mm

3. Clutch master cylinder push rod lock nut torque 1.3N·m.

4. Re-install meters and adjust clutch pedal free stroke

Loosen the clutch switch or pedal spacing bolt. Adjust clutch switch or pedal spacing bolt to offer free

stroke of clutch pedal.

Clutch pipeline deflating

Follow the steps below

1. Strain the parking brake.

2. Pour the brake fluid into the oil reservoir, to the

maximu

level. See if there is brake fluid in the oil reservoir

during the deflating.

3. Remove bleed screw rubber cap from the clutch

booster, connect the cap with a plastic pipe to bleed screw, and insert the other end of the plastic tube

into a transparent container of brake fluid. Step on the clutch pedal after press it down several times,.

4. Keep the pedals down then loosen the bleed screw to let out the air, and then tighten the bleed screw.

5. Repeat the above steps until the air has been completely expelled. Add the brake fluid to the mark

"MAX” in the oil reservoir after deflating.

7. Fault diagnosis

Clutch dragging (gear grinding sounds when shifting)

Inspect the hydraulic circuit

Normal Hydraulic circuit failure Fluid leakage Air in the circuit

Replace Repair or replace

Nuts clearance 1—2mm

Stroke

Idle stroke 15-25mm

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Check the master cylinder and wheel cylinder

Normal Abnormal

Check free clearance Repair or replace

Normal Excessive clearance

Check the clutch disk Adjustment

Normal Disk warped

Check diaphragm spring Replace clutch disk

Normal Diaphragm spring force weakened or pointer tip worn Diaphragm spring clip fault

Replace pressure plate assembly Replace pressure plate assembly

Check shaft splines

Normal Inflexible sliding

Clean, repair, coat grease

Check pilot bearing

Pilot bearing is worn or damaged

Replace pilot bearing

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Clutch skidding

Check the master cylinder and wheel cylinder

Normal Abnormal

Check the clutch pedal Repair or replace

Normal Hold the clutch pedal down

Adjust the clutch switch settings

Check the clutch pedal and pump free clearance

Normal No clearance

Check clutch disk Adjust

Friction surface hardened Clutch disk worn Oil or grease on the disk

Normal

Repair or replace clutch disk assembly Replace clutch disk assembly Replace clutch disk assembly

Check diaphragm spring

Normal Diaphragm spring force weakened

Replace pressure plate assembly

Check pressure plate and flywheel

Flywheel warped Pressure plate warped

Repair or replace Repair or replace pressure plate assembly

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Clutch vibration (the body will vibrate when the clutch is partially engaged)

Check clutch disk

Poor contact of clutch friction disc Clutch disk warped or worn Clutch disk surface harden

Replace clutch disk assembly Replace clutch disk assembly Repair or replace

No oil on clutch disk surface Clutch disk damping spring Clutch disk loosen rivet

or no grease weakened or broken

Normal

Replace clutch disk assembly Replace clutch disk assembly Replace clutch disk assembly

Check pressure plate and flywheel

Pressure plate warped or worn Flywheel warped or worn

Normal Repair or replace Repair or replace

Check diaphragm spring

Normal Diaphragm spring force weakened

Replace pressure plate assembly

Check the engine mount or rubber pad

Engine support loosen Rubber deterioration

Tighten Replace the rubber pad assembly

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Clutch noise (check to see if clutch noises when it is engaged and disengaged thus to determine the reason for this

noise.

Check the release fork or the rod

Abormal

Normal repair or replace

Check the clutch pedal

Clutch disc cracks or damping Vibration damper spring weaken Rivet head out

spring housing cracked or broken

Normal

Replace clutch disk assembly Replace clutch disk assembly Replace clutch disk assembly

Normal Release bearings poor lubrication Release bearing worn

Replace release bearing Replace release bearing

Check pilot bearing

Pilot bearing worn

Replace pilot bearing

Check release bearing

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Transmission Assembly Device

1. Repair and Maintenance Data ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .19

2. Instructions for Use ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..21

3. Transmission Structure ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22

4.Transmission Disassembling ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23

5. Wearing Parts Catalog ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... 30

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1、Repair and Maintenance Data

1. Technical parameters

Type 5-gear overspeed

Control mode Long-distance control

Rated input torque 240 N·M.

Center distance 79mm

Assembly mass About 41 kg

Gear ratio

First gear (1st) 4.271

Second gear (2nd) 2.283

Third gear (3rd) 1.414

Forth gear (4th) 1.000

Fifth gear (5th) 0.813

Reverse (Rev) 3.814

Lubricant oil

mode

South of the Yangtze River 85 W/90 GL - 4

North of the Yangtze River 85 W/90 GL - 4

Cold region 80 W/90 GL - 4

Bitter region 75 W GL - 4

Lubricant amount Approximately 2.5 L

2. Meaning of Transmission Name

LC5 T 80

Center distance (mm)

Tape synchronizer

5 drive gears

The manufacturer logo: 6 gears

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3. Transmission identification location:

The ex-factory date, serial number and identification of the transmission are pasted on its side.

4. Repair and Maintenance Data:

Unit: mm

Items Standard

Operating

limit

Remarks

Gear head and striker gap 0.213～-0.422 0.6

Shaft rail and housing clearance 0.05～-0.11 0.4

1/2 gear, 5/R gear fork shaft locking ball

spring pressure

33. 6

Compressed

to 16.2 mm

3/4gear gearforkshaftlockingball

spring pressure

51.6

Compressed

to 16.2 mm

Shift fork and synchronizer gear shift fork

slot clearance

0.1～-0.4 1.0

Gear wheel side clearance 0.05～-0.12 0.30

Ball bearing axial runout 0.50

Reverse gear shaft axial clearance 0.20～-0.35 0.50

Jackshaft axial clearance 0.04～-0.07

Axial clearance of each

shaft of the second shaft

The first

(1st)

0.20～-0.33 0.45

The second

(2nd)

0.20～-0.33 0.45

The third

(3rd)

0.20～-0.33 0.45

The fifth

(5th)

0.20～-0.33 0.45

The

Reverse

(Rev)

0.20～-0.33 0.45

gear spline and gear hub spline clearance 0.033～-0.116

Clearance of the simultaneous ring and

each gear clearance

1.4～-2.2 0.5

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5. Tightening torque

Items Torque

Connecting bolts of transmission and engine 43-55N·m

Clutch release cable bracket bolts 20～-27 N·m

Exhaust shaft bracket bolts 20～-27 N·m

Front cover bolts of the first shaft 10～12 N·m

Clutch wheel cylinder bolt 30～42 N·m

Release fork ball bearing 30～42 N·m

The second shaft lock nut 250～270 N·m

The middle shaft lock nut 160～190 N·m

Reverse shaft lock nut 20～60 N·m

Reverse shaft screw 15～22 N·m

Eccentric pin nut 30～42 N·m

Oil drain plug 35～45 N·m

Refueling plug 30～35 N·m

The bed bolt 8～10 N·m

Odometer shaft sleeve bolt 3～5N·m

Reversing light switch assembly 30 N·m

The chassis body mounting bolt 10～12 N·m

Starter installation bolts 43～55 N·m

Ball lock plug 10～12 N·m

2. Instructions for Use

1. Each gear of LC5T80 transmission is equipped with a synchronizer. To reduce the wear of gear wheel and

synchronizer, and avoid gear broken, make sure to shift moderately so as that synchronize and gear wheel can

successfully engaged and disengaged. Car can only be switched from forward gear to reverse gear or from reverse gear

to forward gear when it is stopped.

2. Particular attention should be given to: the 5th gear of the transmission is overdrive. To avoid any damage to gear

wheel caused by excessive speed, the 5th gear can only be adopted by 3 terms: with no overload, under good road

conditions and speed reaches 50 km/h or more. At the 5th gear, in a case that the vehicle speed drops below 50 km/h, a

lower gear should be adopted. If keep no change, the 5th gear is easy to be broken.

3. The transmission can use 85W/90 GL - 4 gear oil, and change the oil after 6000 km. After draining the oil , keep the

car at reverse gear , jack up the rear axle , fill in with kerosene, keep the transmission gear rotate 2 ~3 minutes, then drain

the dirty oil and fill in clean gear oil.

4. It is forbidden to shut off It is not allowed to shut off the engine, the engine when the car is coasting on the downhill.

It is also forbidden to start the engine by inertia of this coasting when the engine is stopped, so as not to damage the

gear.

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、

The Transmission Structure

3/4gear

synchronizer

assembl

First shaft

1/2gear

synchronizer

assembly

R/5gear

synchronizer

assembly

Main reverse

gear

Intermediate

shaft

Reverse gear

Middle

reverse

gear

Middle

gear

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4、The Transmission Disassembly (Disassembly)

1、Dismantling



Key points for disassembly :

1) Put the start switch in the position "OFF” before remove the transmission assembly from the vehicle. Pad the

wheels with a wedge to ensure that the vehicle will not slip.

2) Unscrew the oil drain plug to drain all the gear oil from the transmission box.

3) Remove (loosen) drive shaft, manipulate stringing, wire, clutch parts, etc. .

4) Demount the transmission assembly from the engine flywheel housing. Prop the transmission from the bottom

with a jack so as to avoid a sudden fall, and then demount the transmission assembly from the engine flywheel

housing.

、

Disassembly

No. Code Name

Quanti

Remark

H - 1702211 - 79 -

Oil seal (selecting, shifting shaft) 2

H - 1702215 - 79 -

O-ring seal 1

3 H-1702214-79-00 Gear selection adjustment pin 1

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H - 1702216 - 79 -

Flat washer 1

5 Q341B12 Nut 1

H - 1701519 - 79 -

Washer (oil filler plug) 1

H - 1701518 - 79 -

Refueling plug 1

H - 1702213 - 79 -

Needle roller bearings (shifting shaft) 2

H - 1702240 - 79 -

Push rod assembly 1

H - 1702410 - 79 -

Director plate fitting unit 1

H - 1702230 - 79 -

Grip ring - 2 2

H - 1702225 - 79 -

Selecting shaft resistance arm assembly 1

H - 1702223 - 79 -

Setting bolt spring 1

H - 1702224 - 79 -

Torsion Spring 1

H - 1702222 - 79 -

flat pad (Selecting shaft ) 2

H - 1702218 - 79 -

Selecting shaft assembly 1

H - 1702229 - 79 -

Grip ring - 1 1

H - 1702239 - 79 -

Grooved pin 1

H - 1702310 - 79 -

Shifting shaft assembly 1

20 Q 5280532 Elastic cylindrical pin ( 2

H - 1702124 - 79 -

Bolt (ball nut) 3

H - 1702122 - 79 -

Ball-lock spring - 2 1

23 7.9375 - GB 308 Steel ball 3

H - 1702121 - 79 -

Ball-lock spring - 1 2

H - 1702212 - 79 -

Blank cap 2

H - 1701611 - 79 -

Bolt and elastic pad assembly (base plate) 12

H - 1701513 - 79 -

Magnet 1

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H - 1701516 - 79 -

Washer (drain plug) 1

H - 1701515 - 79 -

Oil drain plug assembly 1

H - 1701517 - 79 -

Gasket (base plate) 1

H - 1701510 - 79 -

Base plate assembly 1

H - 1701110 - 79 -

The first axle shaft assembly 1

H - 1701001 - 61 -

The front box 1

H - 1602240 - 79 -

Dust shield 1

H - 1701114 - 79 -

The first axle shaft bearing 1

H - 1701113 - 79 -

The first axle shaft washer 1

H - 1701116 - 79 -

Snap ring 1

H - 1601311 - 79 -

Oilseal(1staxle) 1

H - 1601310 - 79 -

The first axle front cover 1

40 1602050 1 Z A Release bearing 1

H - 1602200 - 61 -

Release fork assembly 1

H - 1701612 - 79 -

Bolt and elastic pad assembly 6

H - 1602230 - 79 -

Ball fulcrum bearing 1

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No. Code Name

Quanti

Remark

H - 1701614 - 79 -

Bolt and flat pad assembly 6

H - 1702118 - 79 -

1/2 gear fork 1

3 Q5280526 Spring pin 6

H - 1702119 - 79 -

1 / 2 gear striker 1

H - 1702123 - 79 -

Interlock pin 2

H - 1702117 - 79 -

1/2 gear fork shaft 1

H - 1702111 - 79 -

R/5 gear fork shaft 1

H - 1702112 - 79 -

R/5 gear fork 1

H - 1702113 - 79 -

R/5 gear striker 1

H - 1701330 - 79 -

Oil seal (rear box) 1

H - 1702114 - 79 -

3/4 gear fork shaft 1

H - 1702116 - 79 -

3 / 4 gear striker 1

H - 1701650 - 79 -

Bracket assembly 1

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H - 1702115 - 79 -

3/4 gear fork 1

H - 1701630 - 79 -

Null line 1

H - 1702125 - 79 -

Reversing light switch assembly 1

H - 1701642 - 79 -

Wire clamps - 2 1

H - 1701641 - 79 -

Wire clamps - 1 1

H - 1701613 - 79 -

Bolt and flat pad assembly 2

20 7.9375 - GB 308 Steel ball 1

H - 1701360 - 79 -

Locating pin 2

H - 1701350 - 79 -

Oil sump 1

H - 1701620 - 79 -

Stud bolt 4

H - 1701340 - 79 -

Vent plug 1

H - 1701002 - 79 -

Rear box 1

H - 1701311 - 79 -

Speedometer driven gear 1

H - 1701313 - 79 -

Oil seal (guide bushing) 1

H - 1701312 - 79 -

O-ring (guide bushing) 1

H - 1701310 - 79 -

Guide bushing 1

30 Q 1860616 Screw bolt 1

31 Q 5280316 Spring pin 1

H - 1701380 - 79 -

Shield 1

H - 1702216 - 79 -

Flat washer 1

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No. Code Name Quantity Remark

H - 1701211 - 79 -

Needle roller bearings (2nd axle head 1

H - 1701225 - 79 -

3/4, R/5 gear synchronization rings 4

H - 1701226 - 79 -

Snap ring (3/ 4 gear ) 1

H - 1701223 - 79 -

3/4gearspring 4

H - 1701222 - 79 -

3 / 4 gear hub 1

H - 1701224 - 79 -

3/4gearslider 6

H - 1701221 - 79 -

3/4, R/5 gear sleeve 1

H - 1701230 - 79 -

The drive shaft third gear assembly 1

H - 1701233 - 79 -

Needle roller bearings (drive shaft third and

fifth gears)

H - 1701210 - 79 -

The second shaft 1

H - 1701243 - 79 -

Needle roller bearings (drive shaft second gear) 1

12 H-1701240-79-51 Drive shaft second gear assembly 1

H - 1701256 - 79 -

Inner ring 2

H - 1701255 - 79 -

Dual-cone ring 2

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H - 1701257 - 79 -

Outer ring 2

H - 1701252 - 79 -

1 / 2 gear hub 1

H - 1701254 - 79 -

1/2gearspring 3

H - 1701251 - 79 -

1/2 gear sleeve 1

H - 1701253 - 79 -

1/2gearslider 3

H - 1701262 - 79 -

Drive shaft first gear bushing 1

H - 1701263 - 79 -

needle roller bearings (drive shaft first gear) 1

H - 1701260 - 79 -

Drive shaft first gear assembly

H - 1701264 - 79 -

Dual row angular contact ball bearings 1

H - 1701425 - 79 -

Pressure plate 1

25 Q 2580820 The 6-point take-countersunk head screws 9

H - 1701274 - 79 -

Main reversing sleeve 1

H - 1701270 - 79 -

Main reversing gear assembly 1

H - 1701281 - 79 -

R/5 gear hub 1

H - 1701293 - 79 -

Drive shaft fifth gear sleeve 1

H - 1701273 - 79 -

Needle roller bearings (Main reversing gear) 1

H - 1701290 - 79 -

Drive shaft fifth gear assembly 1

H - 1701294 - 79 -

Thrust washer 1

33 4.7625 - GB 308 Steel ball 2

H - 1701295 - 79 -

The second shaft nut 1

H - 1701296 - 79 -

Snap ring 2

H - 1701297 - 79 -

The second shaft rear bearing 1

H - 1701298 - 79 -

Snap ring (speedometer driven gear ) 2

H - 1701299 - 79 -

Speedometer driven gear 1

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H - 1701410 - 79 -

Intermediate shaft front sleeve 1

H - 1701411 - 79 -

Tapered roller bearing 1

H - 1701412 - 79 -

Intermediate shaft 1

H - 1701413 - 79 -

Tapered roller bearing 1

H - 1701414 - 79 -

Washer adjustment (intermediate shaft) 1

H - 1701415 - 79 -

Intermediate shaft rear sleeve 1

H - 1701416 - 79 -

Intermediate shaft reversing gear 1

H - 1701417 - 79 -

Intermediate shaft fifth gear 1

47 6305C3Z2 Ball bearing 1

H - 1701419 - 79 -

Nut (intermediate shaft) 1

H - 1701420 - 79 -

Reverse gear shaft 1

H - 1701421 - 79 -

Needle roller bearings (reverse gear) 2

H - 1701422 - 79 -

Reverse gear 1

H - 1701423 - 79 -

Thrust washer (reverse gear) 1

H - 1701424 - 79 -

Nuts (reverse shaft) 1

 Installation

1、 Install the transmission onto the vehicle with a jack or ropes. Note to adjust the first shaft so that its splines can be

engaged with the clutch friction disc splines.

2、 Install in its original position the drive shaft, lever, wire drawing, clutch components, and so on.

5. Wearing Parts Catalog

No. Code Name Materials Quantity Remarks

H - 1701419 - 79 -

Nut (intermediate shaft) 1

H - 1701295 - 79 -

The second shaft nut 1

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H - 1701424 - 79 -

Nuts (reverse shaft) 1

H - 1601311 - 79 -

Oilseal(1staxle) 1

H - 1702211 - 79 -

Oil seal (selecting, shifting

shaft)

H - 1701330 - 79 -

Oil seal (rear box) 1

H - 1701312 - 79 -

O-ring (guide bushing) Nitrile rubber 1

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Selecting and Shifting Control Device

1. Overview

The transmission of this model is equipped in a short distance from the driver, it adopts the remote control mode,

the transmission operation system adopts mechanical mode, and the transmission mode between the transmission device

and shift operation system is cable transmission.

(1) handle body （2）decorative ring （3）dust cover hoop （4）hoop （5）transmission lever shield（6）

stroke adjustment block (7) lock pin (8) hexagon headed bolt、spring washer and flat washer assemblies（9）

Shifting operation base assembly （10）spring shim （11）rubber pad（12）fixed pipe clamp assembly （13）

hexagon head bolt and single coil spring lock washer assemblies (14) gear selecting cable (15)hexagon head

bolt and single coil spring lock washer assemblies （16）gear changing cable bracket（17）small flat washer

（18）gear changing cable pad （19）hexagon flange nuts （20）pipe clamp（￠12）（21）gear changing

cable assembly （22）bonnet（23）Cross recessed big cup-head tapping screw（24）dustproof cover seat

1312

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2. Specification

Number of gears 5 forward gear, 1 reverse gear

Operating mechanism

form

mechanical type

Transmissions type cable transmission

3. Disassembly and re-installation

Disassembly

Disassembly Order

（1） handle body（2）transmission lever shield （3）dustproof cover seat （4）Shifting operation base assembly

（5）rubber pad （6）fixed pipe clamp assembly （7）gear changing cable assembly （8）gear selecting cable （9）

gear changing cable bracket

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Preparations

Before installation clean the gear changing cable to

avoid greasy dirt and mud, pull the parking brake

control handle to the braking position.

Important operations - disassembly

1、Dust cover seat

(1) Open the 4 plug covers of the set screw, and then

remove the four mounting screws in order,

then remove dust cover.

2、Gear changing cable

(1) Split gear shifting cable assembly and gear

changing operation seat assembly

(2) Remove the lock pin and stroke adjustment

block to split gear shifting cable assembly.

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(4) Unscrew the lever body, and then remove trim

ring and the transmission lever cap.

(5) Remove 4 mounting bolts and 2 spring washers

of the gear changing operation seat, remove the

operation seat.

(6) Remove the 2 mounting bolts of fixed flexible

shaft.

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(7) Remove the screw bolts fixed on the gear

changing fixing bracket of the transmission box,

the fixed flexible shaft and 2 lock pins, remove

flexible shaft.

(8) Disassemble 2 spring washers, set bolts of fixing

clip assembly, split soft shaft.

Inspection and repair

In the course of the inspection, if excessive wear or

damage is found, it is necessary to repair or replace

parts.

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Visual check

Visually check to find the damage or failure and replace

them.

Re-installation

The order of re-installation is opposite to the disassembly order

No. Items Tightening torque (N·m)

(8) Hexagon bolt, spring washers and flat washer assembly

(Q146BB0830F62)

11.6

(13) Hexagon bolt and spring washers assembly

(Q1420616F71)

6.8

(19) Hexagon flange nuts (Q 32008 F62) 10.5

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Drive shaft

1. Overview ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ……….... 2

2. Technical parameters……………………………………………………………………2

3. Disassembling and re-installation…………………………………..... ... ... ... ... ... .....2

4. Re-installation . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …5

5. Fault diagnosis and maintenance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6

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1. Overview

Drive shaft consists of the shaft tube, telescopic sleeve and knuckle. Telescopic sleeve can automatically adjust the

distance change between the transmission and drive axle. Knuckle is to ensure two axles angle change of the

transmission output shaft and the drive axle input shaft, and the conformal speed drive of these 2 axles.

Drive shaft, automotive drive train passes in the important parts, and its role is to the transmission, drive axle,

engine power is transmitted to the wheel, the cars drive.

N 125 drive shaft assembly

2. Technical parameters

Bearing fixed mode Outer spring clasp

External diameter of universal joint pin (mm) 29 Φ

Shaft Tube Size (mm) Φ76×2.5

Flange bolt size (mm) M10

Flange pitch size (mm) Φ 90

The largest residual unbalance value（g·cm/r/min） No more than 30 /3200

Distance between universal joint pins (mm) 813

3. Drive device disassembly

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3.1. Drive device disassembly

Disassembly Order

1. Type 1 hexagon nut 2. Spring washer 3. Hexagon flange bolts 4.hexagon bolts - close pitched tube 5. Spring washer

6. Flat washer 7. Shaft protection framework 8. Drive shaft assembly

Drive shaft device disassembly steps

1 Remove the drive shaft assembly mounting bolts,

nuts and spring washers

2 Take out the drive shaft assembly ;

3 Remove drive shaft protection rack mounting bolts

and spring washers;

4 Remove the shaft protection rack. It is not necessary

to remove the protection rack if it has no distortion or

damage.

Note: The shaft requires a good balance of

performance so when disassembling it please mark the

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knuckle (so you can refer to these markers during re-installation).

3.2. The joint fork, universal joint disassembly

Disassembly Order

1. Flange york 2. Universal joint bearing shield ring g 3. Needle bearing 4.Field axle

The joint fork, universal joint disassembly

steps

(1) Spring shield ring

Remove the spring shield ring of the transmission shaft

with a nipper plier

(2) Needle roller bearings

Use a brass rod to gently tap the flange fork

shoulder, remove the cross shaft and needle bearings.

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Visual check

Check the following parts for wear, damage and other

anomalies.

4. Re-installation

The order of re-installation is opposite to that of removal.

Please refer to the torque table for tightening torque

during reassembly.

Torque Reference Table (N·m)

No. Item

Drive shaft protection rack mounting bolts

Hexagon flange bolt

5. Fault diagnosis and maintenancee

5.1. Fault diagnosis

Cross shaft

Needle roller bearings

Flange fork

Link fork

1 2

cross axle

in diameter

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1) Cross shaft pin diameter (mm)

If wear or damage is found, it is necessary to repair or

replace the parts.

Size Limit

29 29.13

(2) Spline side clearance (mm)

(4) Check the balance solder for sealing off.

Frequently check the balance pad to ensure the

dynamic balance of the transmission shaft.

Standard Limit

0.1 0.3

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（4）Abnormal sounds

Damage, wear, distortions, and the lost of the balance of drive shaft parts may cause abnormal sounds and vibration

when the vehicle is running, which even results in damage of relevant parts. If the vehicle sounds when starting or

accelerating, and shows the looseness, it is probably the loose of drive axle gear or that of drive shaft parts. The loose

probably locates in the universal joint cross shaft or the steel bowl and flange yoke, and spline shaft and spline sleeve of

the telescopic sleeve. The space between cross shaft diameter and bearing should not exceed 0.13 MM, backlash between

telescopic spline shaft and spline sleeve should not exceed 0.3 mm. Parts should be repaired or replaced if the limit is

over.

If chassis has a humming sound, and the higher the speed is, the louder the sound shows. This is typically caused by

the looseness between the universal joint and the bearings, or by the wear of the intermediate bearing of the transmission

shaft, or by the loose hanging bracket, or by the wrong position of the hanging bracket.

(5) Vibration

The noise increases with the speed, and it is accompanied by a shaking, this is generally caused by the imbalance of

drive shaft. This vibration in the cab can be felt obviously. The largest remaining imbalance of the drive shaft dynamic

balance is not bigger than 30/3200 （ g·cm/r/min）. Invalidation of the drive shaft dynamic balance will result in the

damage of relevant parts, of which the most common is the clutch housing cracks.

Ways to Check:

Stuff up the front wheels with stow-wood, and jack up the drive axle from one side; start the engine, engage a high

speed to check the vibration of the drive shaft. If with the decrease of the speed the vibration is even significant, this

indicates that the drive is bent or flange is skew. It is often the axle tube that is bending, and this is mainly caused by

overload.

Replace drive shaft assembly, balance check should be carried out after the alignment, and the unbalanced volume

should be up to the required standard. The technical conditions of the universal joint and the transmission shaft also call

for detailed inspection. Undesirable installation may lead to looseness, vibration and damage of the cross shaft and roller,

which will also cause imbalance of the drive shaft.

5.2. Drive shaft maintenance

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To extend its service life, it should be noted.

1. Do not start a car in high gear.

2. Do not suddenly lift clutch pedal.

3. Do not overload or over speed.

4. Frequently check the drive shaft.

5. Frequently check the tightness of the drive shaft hanging bracket, check the connection of each parts for the looseness,

and check if the spindle is deformed.

6. Often add grease to the universal joint bearings. In summer, No.3 lithium grease should be filled in while in winter

No.2 lithium grease.

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Rear axle assembly

1. Overview ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2

2. Rear axle structure parameters... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 2

3. Disassembly, inspection and repair of rear axle assembly………………………………3

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1. Overview

The car is of unitary drive axle, axle housing adopts punch forming, the solder is of welding fabrication; the master

reducer box is casted formation, and to be connected by dual-head stud, nut and axle housing; rear axle assembly is

connected with rear brake.

2. Rear axle structure parameters

1 Brake drum 2 Axle shaft bolt 3

Heavy spring

washers ¢ 10

4Half-shaft

Wheel hub outer oil

seal

6 Bolt M5×12 7 Spring washer ￠5 8 Spring pad ￠5

Wheel hub nut

locking tab

10 Rear wheel lock nut 11 Bearing LM 102949 12 Wheel Hub

Wheel hub outer oil

seal

14 Wheel nut 15

Brake connecting bolt

(short)

Brake connecting

bolt (long)

Brake assembly

(left)

18 Copper washer 19 Refueling plug 20

Rear axle housing

assembly

21 Brake lock nut 22 Flange lock nut 23 Washer 24 Flange

25 Dust shield 26 Oil seal 27 Bearing M88043 28

Pre-tightening

washers

29 Spacer 30 Bearing HM89249 31

Mounting distance

adjusting washer

32 Driving bevel gear

33 Reduction shell 34 Screw bolt 35 Driven bevel gear 36 Bearing 17887

37 Thrust washer 38 Half-shaft gear 39 Differential Housing 40 Planetary Gear

41 Spherical washer 42 Planetary gear shaft 43 Pin 44 Bearing seat

45 Bearing cap bolts 46 spring washer 47 Adjusting nuts 48 Locking tab

Spring washer ￠

50 Bolt M8×16 51 Nut 52

Heavy spring

washers ¢ 10

53 Special bolt (long) 54 Special bolt (short) 55

Ventilator plug

assembly

Brake assembly

(right)

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Rear axle sealant and adhesive

Item Prescriptive sealant and adhesive

Rear axle housing assembly and the main gear

assembly mounting panel

YT598 silicone sealant.

Driven gear cap screws Anaerobic Adhesive GY - 340

Half-shaft and wheel hub faying surface YT598 silicone sealant

Axle housing and reduction shell connecting

bolts straight thread

Anaerobic Adhesive GY - 340

Wheel hub bearing and hub cavity NO. 2 the base grease

Main gear oil seal YT598 silicone sealant

Rear axle wearing parts list

Item Quantity

Main gear oil seal 1

Rear wheel hub inner oil seal 2

Rear wheel hub outer oil seal 2

Rear wheel hub inner bearing 32010 X 2

Rear wheel hub outer bearing LM 102949/LM

102910

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Active gear large bearings HM 89249/HM

89210

Active gear small bearings M 88043/M 88010 1

Differential Bearing 17887 /17831 2

Main bolt torque list

Bolt (nut) name Tightening torque (N.m)

Flange lock nut 200～300

Bearing cap bolts 90～110

Bolt-driven gear 140～160

Main reduction and axle housing cap screws 60～75

Locking tab 4～8

Rear brake bottom plate nut 65～80

Half-shaft cap screw 50～65

Wheel hub inner nut

Lock washer hexagon head bolt 4～8

Refueling plug 130 to 150 after gear oil refilling

Oil drain plug 130～150

3. Rear axle disassembly, inspection and repair

Rear axle disassembly

1. Pad the wheels with wooden wedges.

2. Release the lug nuts of the outer side wheel.

3. Jack up the rear axle.

4. Remove drain plug and drain the gear oil.

Remove brake drum

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Remove half shaft

1. Release half-shaft cap screw

2. Remove half-shaft. If it is hard to remove the half shaft,

knock the shaft flange with a brass hammer until half

shaft is loosened.

Note: Lay the silicone sealant on the joint surface of half

shaft and the wheel hub when you assemble them.

Remove wheel hub outer oil seal

Remove the hub outer seal with a screwdriver

Disassemble wheel hub

1. Remove wheel hub lock tab.

2. Remove wheel hub lock nut.

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Caution:

Remove adjusting nut with wheel hub bearing adjust

lever

Remove wheel hub assembly

Note: Remove wheel hub with rear wheel hub expander

Remove the inner oil seal from wheel hub assembly

Remove the outer ring of the inner and outer bearings

Disassemble axle housing, main reduction gear.

1. Drain lubrication oil of main reduction gear.

2. Disassemble the connection of drive shaft and the main

reduction gear.

3. Remove main reduction gear assembly with a jack.

4. Remove the tube, steel pipe and wire harness.

5. Remove brake assembly.

6. Disassemble rear axle

Prop up the axle housing with a jack.

Remove U bolt and backing plates, put down the jack

then pull out the axle housing.

Disassemble main reduction gear assembly

1. Before disassembling, measure and record the gear

clearance between driving and driven gears;

Note：Check the mesh between gears after adjustment.

2. Remove locking plate

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3. Mark the bearing cover and housing

Caution:

Remove the bearing cap and the reduction gear then place

them separately by match number so as to avoid wrongly

assembly.

4. Loosen the bearing cap bolts, remove the nut with

differential wrench.

5. Remove the bearing cap and screws;

6. Remove the differential assembly;

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Disassemble the differential assembly

1. Remove driven bevel gear;

a. remove 10 screws and 5 lock plate.

b. tap the driven gear with a plastic hammer to separate it

from differential housing

2. Before disassembling, measure and record the side gear

clearance of planetary gear;

3. Get out planetary gear shaft

4. Remove the planetary gear and spherical washer and

half-shaft gears and thrust washers;

5. Remove the differential bearings from the differential

housing;

Driving gear disassembly

1. Inspect flange section run-out and port run-out

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2. Measure the driving bevel gear pretightening force

3. Remove the main gear flange nuts;

4. Take off the flange assemblies, pressure out the main

gear assembly

5. Remove adjusting washer and bearing sleeve;

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6. Remove the bearing from the driving gear,

7. Remove oil seal from the main reduction housing

8. Take out the bearing outer ring from the reduction

housing

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Rear axle service parameters table

Items Value

Gear clearance between

driving and driven gears

0.10～0.20

Planetary gear and half-shaft

gear clearance

0.12～0.20

Driving gear pre-tightening

force

18N ~25N

Rear axle gear oil GL-5 85W/90

Friction disks and brake drum

clearance

0.3～0.5mm

Item

Maintenance

standards

Abrasion limit Remarks

Rear axle steel spring seat positioning holes

wear

The left and right half shaft bushing outer

bearing journal radial run-out

Half shaft central undressed surface -

Wheel hub and axle flange faying surface face

run-out

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Driven gear tooth contact status Causes Adjustment methods:

A. circular tooth contact area

adjustment

B. backlash in circular tooth

adjustment

inclined to the top

Driving gear is too far to

driven gear.

1. Depart driven gear from

driving gear.

2. Move driving gear towards driven gear

to get proper backlash in circular tooth.

(add shim)

inclined to the bottom

Driving gear is too close to

driven gear.

1. Move driven gear towards

driving gear.

2. Depart driving gear from driven gear to

get proper backlash in circular

tooth.( remove shim)

inclined to the inner ring

Driven gear is too close to

driving gear.

1. Depart driven gear from

driving gear.

2. Depart driving gear from driven gear to

get proper backlash in circular

tooth.( remove shim)

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inclined to the outer ring

Driven gear is too far to

driving gear.

1. Move driven gear towards

driving gear.

2. Move driving gear towards driven gear

to get proper backlash in circular tooth.

(add shim)

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Wheel cover unit

1. Overview ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ................. 2

2.Technical parameters…………………………………………………………………….2

3.Disassembly……………………………………………………………………………...2

4.Re-installation…………………………………………………………………………....3

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1. Overview

Wheel cover unit is the decorative covers installed on the wheel rims which make the car even more pleasing. And it

prevents corrosions and scratches to wheel rims and wheel nuts from block liquid, dust, and debris.

2. Technical parameters

Front wheel mounting

surface diameter 183mm

Rear wheel mounting

surface diameter 159mm

3. Disassembly

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Wheel cover unit disassembly

Level the cover with a screw driver then remove it.

Duiring disassembly, do not tear the wheel hub cover or wheel rim. Do not level too hard to breakdown the

wheel cover.

Inspection

Clean the wheels, the rims and wheel covers

surface, clear the dirt and keep the wheels, rims and

wheel covers clean and dry.

If the bayonet turns loose, then the trim cove

will be easily drop off, especially under high-speed. The

drop of it is dangerous for cars and pedestrians. Repair or

replace the wheel cover.

Keep the wheel cover and the rim at the same position,

and then gently push it in. If it is hard to match, point

the wheel cover at the location of rim gap valve, then

press the wheel cover in with with a screwdriver.

Notes for re-installation

(1) Fix the wheel covers on the wheels to ensure the security. Wheel cover is fixed with stainless steel wire snap ring and

the clip on the wheel rims; check the accepted products by removal stress test to ensure the security. Pay attention to the

wheel cover assembly during replacement. If the bayonet is loose then check if the spring tension is normal.

Clean the wheels and wheel covers clear the dirt and keep the wheels and covers clean and dry.

(3) If it is hard to install, do not slap with too much force in case the covers are destroyed. If the installation is failed, it is

recommended to turn to professionals.

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Spare tire lifter device

1. Overview ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ………..1

2.Technical parameters……………………………………………………………………..1

3.Disassembly……………………………………………………………………………...1

4. Re-installation . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4

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4. Overview

Because automobile spare tire is high from the ground and very heavy, manual removal will be quite difficult, a spare tire

lifter is necessary to raise or lower the spare tire so as to change tires. Generally, there are steel -wire -rope and chain

spare wheel lifters. N125 adopts chain spare tire lifter.

5. Disassembly

Spare tire lifter disassembly

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Disassembly Order

1. Cotter pin 2. Pin roll 3.hexagon headed bolts and spring washer assembly 4. Handle mounting bracket 5. Spare tire

lifter locks 6. Handle 7. Handle rubber base 8. Hexagon flange bolt 9. Spare tire lifter assembly 10. Hexagon headed

bolts - fine 11. Spare tire lifter right beam 12. Spare tire lifter left beam

Spare Tire lifter device disassembly steps

(1). Open the spare tire lifter lock, and shake the spare

tire off.

(2). Remove the spare tire.

(3). Disconnect cotter pin with a nipper plier, remove pin

rolls.

(4). Disassemble the handle mounting bracket bolts and

handle mounting bracket, take off handle rubber base.

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(5). Remove spare tire lifter assembly mounting bolts and

its left and right beam mounting bolts.

Visually inspect the parts on the left side to

ensure there is no damage, wear. To check if there is

corrosion and rust on spare tire lifter chains, if mounting

bolts of parts are in good condition, etc.

1. Pin roll

2. Spare tire lifter assembly

3. Handle

4. Chain

5. Bolts, etc.

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6. Re-installation

The order of re-installation is opposite to that of removal. Please refer to the torque table for tightening torque during

reassembly.

Tightening torque (N·m)

No. Item Torque

Rema

rks

① Spare tire lifter assembly mounting bolts 41～51

②

Spare tire lifter left and right beams mounting

bolts

41～51

③ Spare tire lifter handle mounting bracket bolts 7～9

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Wheels

1. Overview ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …..1

2. Wheel specification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ….2

3. Wheel inspection and repair ………………………………………………………3

4. Wheel installation torque ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5

5. Fault diagnosis.……………………………………………………………………..5

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1. Overview

The car adopts two types of tires, front wheel is a single tire （195/70R15LT）, and rear wheel is single side dual tire

(155R13LT). There are two spare tires (one front tire and the other rear tire), the spare tire beam and tray are fixed in

rear rack by the spare tire lifter. Front and rear wheel nuts can be employed universally; specifications are M14×1.5 and

are left-hand threads.

Front wheel Rear wheel

Wheel nut

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2. Front and rear wheels specifications

Front wheel Rear Wheel

Tire type 195/70R15LT-6PR 155R13LT-8PR

Rim specifications 5.5J×15

2/1

J×13

Standard inflation 350 kPa 450 kPa

Wheel nut M14×1.5，Left-wing

3. Wheel inspection and repair

1) Front wheels disassembly

Pull up the handbrake to stop the vehicle. Loosen the 5

nuts of the front wheel, back the sub-frame with a jack to let

the front wheels off the ground. Then remove the 5 nuts of

front wheels and take off the front wheels.

Visually check the front wheels

① Check the front wheel rim for deformation and

surface cracks, and replace the front wheels if necessary.

② Check if the front tire pressure is adequate, if not

please inflate tires.

③ Check the front tires for the wear limit, if the wear

marker is reached then replace the front wheels.

Wear marker■

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3）Front wheel installation

Align the wheel mounting bolts on front wheel rims to

install the front wheels, then screw in 5 nuts successively,

pre-tension then tighten them.

4）Rear wheel disassembly

Engage a gear and block front wheels with bits of wood,

loosen the 5 wheel nuts on one side, and then prop up the leaf

spring with a jack to keep the rear wheels off the ground, then

remove these 5 nuts and take off rear wheels.

5）Visually check the rear wheels

① Check the rear wheel rims for deformation and

surface cracks, and replace the rear wheels if necessary.

② Check if the rear tire pressure is adequate, if not

please inflate tires.

③ Check the rear tires for the wear limit, if the wear

marker is reached then replace the rear wheels.

Wear marker

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6) Rear wheels installation

Align the wheel mounting bolts on rear wheel rims to

install the front wheels, then screw in 5 nuts successively,

pre-tension then tighten them.

Note: Aim the inside rear tire valve stem to mounting

holes of the outside rear tire rims.

7) Spare tire disassembly

Open the spare tire lifter lock, cover the driver's tool on

the spare tire rocker lever, rotate counter-clockwise to remove

the spare tire.

8) Spare tire disassembly

Order of installation is opposite to that of disassembly, the

rear tires are on the above and front tires down.

4. Wheel installation torque

Front wheel nuts torque：180～220N·m

Rear wheel nuts torque：180～230N·m

5. Wheel fault diagnosis

1) Wheel abnormal wear

Possible causes: ① Tires didn't take dynamic balance test；

Driver’s tool

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② Problem occurs to front four-wheel alignment parameters adjustment, or suspension system parts are

deformed.

2） Under-inflation of tires

Possible causes: ① Valve stem encounters sealing leakage.

② Tires are broken.