S2 Transmission
Contents
Transmission
MF70B22(5MT)
I、Outline................................................1-1
（
I
）
Structure Summary................................1-1
（
II
）
System Principle...................................1-2
（
III
）
Technical parameters, maintenance
parameters........................................................1-4
（
IV
）
Torque parameters a×..........................1-6
（
V
）
Maintenance Considerations.....................1-7
（
VI
）
Special tools............................................1-7
II、Troubleshooting......................................1-10
（
I
）
Vibration, noise......................................1-10
III、Transmission fluid discharge and
filling.................1-11
（
I
）
Transmission fluid discharge..........1-11
（
II
）
Transmission fluid filling.................1-11
IV、Shift lever shroud assembly...................1-12
（
I
）
Disassembly............................................1-12
（
II
）
Installation...............................................1-13
V、Shifting operation mechanism assembly1-13
（
I
）
Disassembly............................................1-13
（
II
）
Installation...........................................1-14
VI、The shifting drawing assembly..............1-15
（
I
）
Disassembly...........................................1-15
（
II
）
Installation..............................................1-16
VII、Neutral position sensor.........................1-17
（
I
）
Disassembly............................................1-17
（
II
）
Installation...............................................1-18
VIII、Transmission assembly........................1-19
（
I
）
Disassembly.............................................1-19
（
II
）
Installation................................................1-21
IX、Reversing light switch............................1-23
（
I
）
Special tool..............................................1-23
（
II
）
Disassembly..........................................1-23
（
III
）
Installation...............................................1-24
X、Transmission oil drain plug.....................1-25
（
I
）
Disassembly..........................................1-25
（
II
）
Installation............................................1-25
XI、Transmission breather plug................1-25
（
I
）
Disassembly...........................................1-25
（
II
）
Installation............................................1-26
XII、Transmission refueling bolt...............1-26
（
I
）
Disassembly............................................1-26
（
II
）
Installation.............................................1-26
XIII、Release Bearing..................................1-27
（
I
）
Disassembly............................................1-27
（
II
）
Installation...............................................1-27
XIV、Clutch fork assembly.........................1-27
（
I
）
Disassembly............................................1-27
（
II
）
Installation.............................................1-28
XV、 Rocker Arm...................................1-29
（
I
）
Disassembly............................................1-29
（
II
）
Installation..............................................1-29
XVI、Rear engaging member.......................1-30
（
I
）
Disassembly.............................................1-30
（
II
）
Installation...............................................1-30
S2 Transmission
XVII、Input shaft, output shaft, differential
assembly.......1-31
（
I
）
Special tool..........................................1-31
（
II
）
Disassembly.................................................1-31
（
III
）
Installation..............................................1-34
XVIII、Input shaft....................................1-36
（
I
）
Special tool........................................1-36
（
II
）
Disassembly.............................................1-38
（
III
）
Check................................................1-38
（
IV
）
Installation..............................................1-39
XIX、differential assembly...........................1-40
（
I
）
Special tool........................................1-40
（
II
）
Disassembly.............................................1-41
（
III
）
Check................................................1-42
（
IV
）
Installation............................................1-43
XX、Transmission case............................1-44
（
I
）
Special tool..........................................1-44
（
II
）
Disassembly............................................1-44
（
III
）
Installation.............................................1-46
XXI、Clutch housing................................1-48
（
I
）
Special tool..........................................1-48
（
II
）
Disassembly...........................................1-48
（
III
）
Installation............................................1-50
XXII、Input five gear engaging member, 5 / R
gear synchronizer assembly
1-51
（
I
）
Special tool..........................................1-51
（
II
）
Disassembly............................................1-52
（
III
）
Installation.............................................1-52
XXIII、Input five gear liner.......................1-53
（
I
）
Special tool..........................................1-53
（
II
）
Disassembly...........................................1-53
（
III
）
Installation.............................................1-54
XXIV、3/4 gear fork shaft engaging member, 1/2
shift fork shaft engaging member, 5 / R shift fork
shaft engaging member.............................1-54
（
I
）
Special tool..........................................1-54
（
II
）
Disassembly.............................................1-55
（
III
）
Installation.............................................1-57
XXV、Reverse ratcheting member............1-59
（
I
）
Special tool..........................................1-59
（
II
）
Disassembly.............................................1-60
（
III
）
Installation............................................1-61
XXVI、Reverse gear shift mechanism engaging
member and gear shift shaft engaging member
1-63
（
I
）
Special tool..........................................1-63
（
II
）
Disassembly...........................................1-63
（
III
）
Installation...........................................1-65
XXVII、Input three gear ratcheting member, Input
four gear engaging member, 3/4 gear synchronizer
assembly..................................1-68
（
I
）
Special tool..........................................1-68
（
II
）
Disassembly.............................................1-68
（
III
）
Installation............................................1-69
S2 Transmission
Transmission
（CVT）
I、Outline...................................................2-1
（
I
）
Structure Summary...................................2-1
（
II
）
System principle........................................2-4
(III
）
Technical parameters, maintenance
parameters..................2-12
（
IV
）
Torque parameters.................................2-12
（
V
）
Maintenance Considerations...................2-12
（
VI
）
Special tools.........................................2-12
II、Troubleshooting.....................................2-14
（
I
）
Diagnostics table......................................2-14
（
II
）
Noise Description....................................2-15
（
III
）
Noise inspection and maintenance..........2-16
（
IV
）
Fault codes and measures...................2-19
III、Driving Strategies...................................2-29
（
I
）
Reverse gear and neutral gear functional
properties..............2-29
（
II
）
D or R gear function.............................2-30
（
III
）
Failure default mode...........................2-31
IV、Adaptive update.....................................2-31
（
I
）
directions.............................................2-31
（
II
）
Conditions required.............................2-31
（
III
）
program.............................................2-31
（
IV
）
common problem.....................................2-34
V、Transmission oil.....................................2-35
（
I
）
Special tools......................................2-35
（
II
）
Description for checking the oil level.....2-35
(III
）
Check the oil level..................................2-35
VI、The shift lever assembly........................2-36
（
I
）
Special tool.........................................2-36
（
II
）
Disassembly............................................2-36
（
III
）
Installation.............................................2-36
（
IV
）
Check..............................................2-37
VII、Shift rocker and bushing......................2-37
（
I
）
Special tool..........................................2-37
S2 Transmission
（
II
）
Disassembly............................................2-37
(III
）
Installation.............................................2-38
（
IV
）
Check................................................2-38
VIII、The shifting drawing assembly............2-38
（
I
）
Special tool..........................................2-38
（
II
）
Disassembly...........................................2-38
（
III
）
Installation...............................................2-39
（
IV
）
Check................................................2-39
IX、Variable speed control mechanism
assembly...2-40
（
I
）
Special tool..........................................2-40
（
II
）
Disassembly............................................2-40
（
III
）
Installation.............................................2-40
（
IV
）
Check...............................................2-41
X、Differential Seal.....................................2-41
（
I
）
Special tool..........................................2-41
（
II
）
Disassembly...........................................2-41
（
III
）
Installation..............................................2-42
XI、The input shaft seal............................2-42
（
I
）
Special tool..........................................2-42
（
II
）
Disassembly............................................2-42
（
III
）
Installation...............................................2-43
XII、Gear selection shaft oil seal................2-43
（
I
）
Special tool..........................................2-43
（
II
）
Disassembly...........................................2-44
（
III
）
Installation..............................................2-45
XIII、Driving bevel gear cover....................2-45
（
I
）
Special tool..........................................2-45
（
II
）
Disassembly............................................2-45
（
III
）
Installation...............................................2-46
XIV、Pump.........................................2-46
（
I
）
Special tool..........................................2-46
（
II
）
Disassembly............................................2-46
（
III
）
Installation...............................................2-47
XV、Driving bevel shaft ball bearing.........2-47
（
I
）
Special tool..........................................2-47
（
II
）
Disassembly...........................................2-48
（
III
）
Installation..............................................2-49
XVI、Driven bevel shaft cover...................2-50
（
I
）
Special tool..........................................2-50
（
II
）
Disassembly...........................................2-50
（
III
）
Installation...............................................2-50
XVII、Sump......................................2-50
（
I
）
Special tool..........................................2-50
（
II
）
Disassembly...........................................2-51
（
III
）
Installation...............................................2-51
XVIII、Oil filters.......................................2-51
（
I
）
Special tool..........................................2-51
（
II
）
Check................................................2-51
（
III
）
Installation.............................................2-51
XIX、Driving mode sensor.........................2-52
（
I
）
Special tool..........................................2-52
（
II
）
Disassembly...........................................2-52
（
III
）
Installation..............................................2-53
XX、Hydraulic control block.....................2-53
（
I
）
Special tool..........................................2-53
（
II
）
Disassembly............................................2-53
（
III
）
Installation..............................................2-54
S2 Transmission
XXI、Driven bevel wheel speed sensor and
bracket....2-55
（
I
）
Special tool..........................................2-55
（
II
）
Disassembly...........................................2-55
（
III
）
Installation................................................2-56
二十二、Driving bevel wheel speed
sensor...........2-56
（
I
）
Special tool..........................................2-56
（
II
）
Disassembly...........................................2-57
（
III
）
Installation..............................................2-57
XXIII、Main interface and internal wiring
harness....................2-57
（
I
）
Special tool..........................................2-57
（
II
）
Disassembly..........................................2-57
（
III
）
Installation...............................................2-58
XXIV、Respirator tube................................2-59
（
I
）
Special tool..........................................2-59
（
II
）
Disassembly...........................................2-59
（
III
）
Installation...............................................2-60
XXV、Electrical Schematic......................2-60
（
I
）
TCU Interface Figure................................
2-61
（
II
）
Electronic Components Checklist...........
2-66
（
III
）
Transmission system circuit diagram.....
2-68
S2 Transmission
Transmission MF70B22(5MT)
I、Outline
（I）Structure summary
Type and description of the transmission
M
F 70
B
2 2
Variable Model
Two drive
Center
distance
Front
Manuel
Structure type
Fully synchronized manually shifted mechanical transmission with shift flexibility, good sense, low noise and compact structure
has large carrying capacity and good sealing performance. It has five forward gears and one reverse gear. Reverse gear is straight teeth
with a small inverted cone angle, and the rest are helical gears.The first gear and the second gear are the double cone synchronizer, and
the rest is a single cone synchronizer. The shift cable-type gear mechanism is remotely operated.
Gear Schematic
1
3 5
2
4
R
S2 Transmission
Transmission control system
2
3
1
1. Shifting operation
mechanism assembly
2. Shift lever shroud assembly
3. The shifting
drawing assembly
s2-4691b
（II）System Principle
System principle
Since the range of variation of the engine output torque and speed is narrow, it is unable to meet the complex conditions that require
the use of the vehicle considerable traction and vehicle speed range. The role of the transmission is to adapt the engine output torque and
speed to constantly changing conditions by changing the transmission ratio, expanding the range of torque and speed of the drive wheels.
S2 Transmission
12
11 10
9 8
7
6
5 4
3 2
1
13 14 15 16 17 18 19
1 gear work status：
engine→ clutch → input shaft splines 1 →input first gear 3→ output first gear 18 → 1/2 gear synchronizer 17 →output shaft 2 →
differential 19
2 gear work status：
engine→ clutch → input shaft splines 1 →input second gear 6→ output second gear 16 → 1/2 gear synchronizer 17 →output shaft 2 →
differential 19
3 gear work status：
engine→ clutch → input shaft splines 1 →3/4 gear synchronizer 8→ input third gear 7→ output third gear 15 →output shaft 2 →
differential 19
4 gear work status：
engine→ clutch → input shaft splines 1 →3/4 gear synchronizer 8→ input forth gear 9→ output forth gear 14 →output shaft 2 →
differential 19
5 gear work status：
engine→ clutch → input shaft splines 1 →5/R gear synchronizer 11→ input fifth gear 10→ output fifth gear 13 →output shaft 2 →
differential 19
Reverse gear work status：
engine→ clutch → input shaft splines 1 →5/R gear synchronizer 10， reverse gear 12→ reverse gear 5 →input reverse gear 4→1/2 gear
synchronizer 17 → output shaft 2 → differential 19
S2 Transmission
Manipulation principle
By controlling the lever in the cab, the driver can make the shift operation by controlling selector lever and shift lever. Different gear
selection and shift position display according to different directions of lever handle ball. After each picking gear,the lever will
automatically return to the neutral position; only if the lever returns to the neutral gear can start the gear selection.
1，The separated pedal should be fully depressed in shfting gear, so that the engine torque is disengaging to the transmission and shift
lever should be manipulated quickly. Slow gear should be used to start.
2，Slow gear should be used in uphill, downhill and cornering.Do not separate clutch to slide
3，When it has difficulties in the shift lever operating, you should stop and check the reason, do not subject to excessive force.
S2 Transmission
The appropriate Km/h number for each gear in forward gears in transmission as below：
Gears
First
gear
Second
gear
Third
gear
Forth
gear
Fifth
gear
（km/h）
0~15 20~30 35~45 50~60 65~75
△Attention 1, Transmission shift operation should be carried out within the scope of the number of kilometers.
2, Km number is different for each different gear when the transmission matches the different vehicle.
Shift principle
In the vehicle forward state, transmission shift principle requirements are as follows: the speedup should be progressively shifted
from 1 to 5 gear; speed reduction should be shifted from 5 to 1 gear gradually; upside-down block is ban under advances state. In the
vehicle shift condition, in order to avoid misuse, the transmission has a locking device that 5 gear is not allowed to shift to reverse gear.
In principle, the requirements linked to reverse gear in the vehicle stationary depress the clutch after a pause of three seconds; do not link
to reverse gear in the advance state; at the same time the gear can not be shift to forward in reverse gear.
△Attention The vehicle is running, in case of emergency, may not comply with the principle of transmission shifting.
（III）Technical
parameters,maintenance
parameters
Technical parameters
Drive
mode
Two front
wheel drive
Transmission gears
5 forward gears，1 reverse gear
Clutch control Hydraulic pressure
Assembly quality (kg) Around 36.5
Transmission lubricant specifications Gear Oil 75W/90 GL-4
Transmission lubricant filling method Add a predetermined amount of oil from the
side oil hole
Transmission lubricant filling quantity 2L
Transmission ratio
Manipulation mode Remotely operated
Rated input torque 200 N·m
Type
MF70B22
Ratio
1Gear 3.769
2Gear 2.053
3Gear 1.393
4Gear 1.031
5Gear 0.778
Reverse Gear 3.25
Main reduction ratio 4.056
Dimensions specifications
Dimensions specifications
Specification
Metric system（mm)
1 gear axial clearance
0.08~0.19
2 gear axial clearance
0.08~0.19
S2 Transmission
3 gear axial clearance
0.08~0.19
4 gear axial clearance
0.08~0.19
S2 Transmission
5 gear axial clearance
0.08~0.19
1gear synchronous ring backup
1.2±0.15
2 gear synchronous ring backup
1.2±0.15
3 gear synchronous ring backup
1.2±0.15
4 gear synchronous ring backup
1.2±0.15
5 gear synchronous ring backup
1±0.22
The output shaft adjustment shim thickness specifications
Mark Thickness specification
37 1.37
40 1.40
43 1.43
46 1.46
49 1.49
52 1.52
55 1.55
58 1.58
61 1.61
64 1.64
67 1.67
70 1.70
73 1.73
76 1.76
79 1.79
82 1.82
85 1.85
88 1.88
91 1.91
94 1.94
97 1.97
00 2.00
03 2.03
06 2.06
09 2.09
12 2.12
15 2.15
18 2.18
21 2.21
24 2.24
S2 Transmission
27 2.27
Differential adjustment shim thickness specifications
Mark Thickness specification
77 0.77
80 0.80
83 0.83
86 0.86
89 0.89
92 0.92
95 0.95
98 0.98
01 1.01
04 1.04
07 1.07
10 1.10
13 1.13
16 1.16
19 1.19
22 1.22
25 1.25
28 1.28
31 1.31
（IV）Torque parameters a×
No.
Item
Torque（N·m）
Remarks
1 Reverse gear shifting mechanism connecting
bolts and the clutch body
14.7~21.6 M8×1.25
2 Oil drain plug 40~60 M18×1.5
3 The pressure plate and the clutch housing bolts
14.7~21.6 M8×1.25
4 Clutch and housing connection bolt 34.3~41.2 M10×1.25
5 Reverse gear shaft bolt 42.2~53.9 M10×1.25
6 Cover bolt 14.7~21.6 M8×1.25
7 Ball lock spring engaging member 29.4~41.2 M14×1.5
8 Fasten screw nut 137.2~156.8 M22×1.5
9 Refueling plug 30~40 M16×1.5
10 The shifting positioning pins 40~50 M18×1.5
11 Reversing light switch 29.4~34.3 M14×1.5
12 Clutch slave cylinder mounting bolts 14.7~21.6 M8×1.25
13 Main reduction gear mounting bolts 75~85 M12×1.25
S2 Transmission
No.
Item
Torque（N·m）
Remarks
14 The shifting clutch bracket and bolts 14.7~21.6 M8×1.25
15 Ball support 32~40 M12×1.75
16 Guide seat bolts 6~8 M6
17 Reversing light switch bracket mounting bolts
14.7~21.6 M8×1.25
（V）Maintenance considerations
1. The safety and operating standards must be strictly followed in diagnosis and repair process, in order to prevent personal injury and
damage to vehicles.
2. In the
repair of decomposition transmission, please prevent mixing of slag dust and a special tool must be used in transmission repair,
which not only improve efficiency and service quality, but also prevent unnecessary damage to the vehicle.
3.
Do not reuse the drained transmission gear oil.
4.
Checking or replacing the transmission gear oil, oil change has nothing to do with the cleaning parts; the vehicle should be kept
horizontal.
5.
Removing and installing the transmission, the interior should be kept clean.
6.
Before removing or decomposition, please check the correct position. If you do need to install the tags, make sure the mark will not
affect the other functions.
7.
According to regulations, multiple steps shall be taken and please follow a diagonal sequence to tighten the middle, and then tighten
the outside bolt and nut. If the special tightening sequence is required, please tighten according to the requirements.
8. Do not damage the sliding surface and the mating surface.
9.
Before the needle bearing assembly grease should be applied in its circumferential surface.
10. Grease should be applied before the seal assembly at its lip portion.
11.
When press-fit synchronizer component, first align synchronizer slider to synchronizer ring slider groove and then press-fit.
（VI）Special tool
No.
Tool
Outline drawing
Discription
1
Differential oil seal
installation tool
JAC-T6B025
2
Fork shaft fixing pin
punches
JAC-T6B026
3
Reversing light
switch sleeve
JAC-T6B027
S2 Transmission
No.
Tool
Outline drawing
Discription
4
Input shaft seal
installation tool
JAC-T6B028
5
Differential
bearing
block removable pads
JAC-T6B029
6
Differential bearing
installation tool
JAC-T6B030
7
Input shaft removable
pad
JAC-T6B031
8
I
nput shaft bushing
installation tool
JAC-T6B032
9
The input shaft
4
gear,5 gear bushing
installation tool
JAC-T6B033
10
Input shaft front
bearing installation
tool
JAC-T6B034
S2 Transmission
No.
Tool
Outline drawing
Discription
11
Front output shaft
bearing outer ring
installation tool
JAC-T6B035
12
Rear output shaft
bearing outer ring
installation tool
JAC-T6B036
13
Differential bearing
outer ring mounting
tool
JAC-T6B037
14
G
ear shaft oil seal
installation tool
JAC-T6B038
15
Gear axis linear
bearing mounted tool
JAC-T6B039
16
Output shaft
disassembly pad
JAC-T6B040
17
G
ear shaft oil seal
disassembly tool
JAC-T6B041
S2 Transmission
No.
Tool
Outline drawing
Discription
18
Inner pin punching
tool of shifting fork
shaft
JAC-T6B042
19
Rama
JAC-T6B043
20
Differential bearing
outer race puller
JAC-T6B044
II、Troubleshooting
（I）Vibration, noise
No. Indication Failure Analysis
Solution
Remarks
1
Vibration, noise
Engine and transmission loose connections Screw
Gear axial clearance is too large Adjust the gap
Gear wears Replace
Deterioration of grease Replace gear oil
Insufficient oil volume Fill oil
Engine idle speed instability Adjust the idle speed size
2 Oil spill Seal damage Repalce seal
3
Shifting
difficulties
Manipulation drawing damage Change the drawing
Bad meshing of synchronizer ring with gear
cone or worn
Change or repair
Synchronizer slider fail Replace the synchronizer slide
S2 Transmission
III、Transmission fluid discharge and filling
（I）Transmission lubricants discharge
1. Preparations
1). Keep the vehicle horizontally and pull the hand brake.
2).
Until the internal transmission oil cooling.
2.
Transmission lubricants discharge
1). Removing the gearbox oil drain plug.
2).
Discharge all the gear oil in transmission.
3).
Remove promptly if the surface has iron drain plug.
4).
Install the transmission oil drain plug.
Tighten torque 40~60N·m
S2-w1001b
（II）Transmission lubricants filling
1. Fill transmission lubricants
1). Removing the fuel bolts.
2).
Add new gear oil until the oil level reaches the limits of the
provisions of the mounting hole near vicinity.
3).Install the fuel bolts.
Tighten torque 30~40N·m
2. Check the transmission oil level
1).
Confirm whether manual transmission around gear
oil leak or not.
2). Removing the fuel bolts.
S2-w1001b
S2-w1001b
S2 Transmission
3).
Check whether the transmission gear oil level flushes with the lower edge of the filling hole.
4).
If the transmission gear oil level is lower than the lower edge of
filling hole, adding a dedicated manual transmission gear oil
through the filler plug hole until the oil begins to flow.
5). Removing the fuel bolts.
Tighten torque 30~40N·m
△Attention Check whether the transmission gear oil is
deteriorated, replace the transmission gear oil if it is
deteriorated.
S2-w1001b
IV、Shift lever shroud assembly
（I）Disassembly
1. Open the engine hatch
2. Disconnect the negative battery cable
3. Remove the shifting lever assembly with the shield
1). Keep the shift lever in neutral.
2).
Pry the shifting lever cover assembly with a crowbar.
3). Remove the retaining ring that connects the shifting lever cover
assembly with and the shifting operation mechanism. Disengage
the shifting lever cover assembly with the shifting operation
mechanism.
4). Remove the shifting lever cover assembly.
S2-w1001b
S2-w1001b
S2 Transmission
（II）Installation
1. Install the shifting lever cover assembly
1). Install the retaining ring that connects the shifting lever cover
assembly with and the shifting operation mechanism. Disengage the
shifting lever cover assembly with the shifting operation mechanism.
2). Install the shift lever cover assembly to the body of the
instrument panel.
2. Connect the negative battery cable
3. Close the engine hatch
S2-w1001b
S2-w1001b
V、Shifting operation mechanism assembly
（I）Disassembly
1. Open the engine hatch
2. Disconnect the negative battery cable
3. Remove the rear section of deputy dashboard, checking deputy dashboard
4. Remove the shifting lever cover assembly, checking shifting lever cover assembly
5.
Removing the shifting control mechanism assembly
1).
Remove two lock pins connecting the shifting control
mechanism assembly and the shift drawing assembly.
Disengage the shifting control mechanism assembly with the
shifting drawing assembly.
S2-w1001b
S2 Transmission
2).
Remove 4 mounting bolts connecting the shifting control mechanism
assembly with the body.
3). Remove the shifting control mechanism assembly.
（II）Installation
1. Install the shifting control mechanism assembly
1). Install 4 mounting bolts connecting the shifting control
mechanism assembly with the body.
2). Install two lock pins connecting the shifting control
mechanism assembly and the shift drawing assembly.
Disengage the shifting control mechanism assembly with
the shifting drawing assembly.
2. Install the shifting lever cover assembly
3. Install the rear section of deputy dashboard
4. Connect the negative battery cable
5. Close the engine hatch
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
VI、The shifting drawing assembly
（I）Disassembly
1.
Open the engine hatch
2. Disconnect the negative battery cable
3. Remove the deputy dashboard body assembly, checking deputy dashboard body assembly
4. Remove the neutral position sensor, checking the neutral position sensor
5. Removing the shifting drawing assembly
1). Put the shift lever in neutral.
2). Remove two retainers that connect the shifting control
mechanism assembly and the shift drawing assembly,
disengage the shifting control mechanism assembly with the
shifting drawing assembly.
3). Remove two locking pins and washers connecting the
transmission side shifting drawing and the transmission
rocker cradle.
4
). Disengage the shifting assembly drawing from the transmission arm bracket.
△Attention Pull up the shifting drawing with force.
S2-w2009b
S2-w2011b
S2-w2012b
S2 Transmission
5).
Remove four nuts connecting the shifting drawing assembly and body.
6). Remove the shifting
drawing assembly.
S2-w1001b
（II）Installation
1. Install the shifting drawing assembly
1).
Install the shifting drawing assembly to the
mounting position.
2). Install four nuts connecting the shifting drawing
assembly and body.
Tighten torque 20~28N·m
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
3). Install the shifting assembly drawing to the transmission arm bracket.
4). Install two locking pins and washers connecting the
transmission side shifting drawing and the transmission
rocker cradle.
5). Install two retainers that connect the shifting control
mechanism assembly and the shift drawing assembly,
disengage the shifting control mechanism assembly with
the shifting drawing assembly.
2. Install the neutral position sensor, checking the neutral position
sensor
3. Remove the deputy dashboard body assembly
4. Connect the negative battery cable
5.Close the engine hatch
S2-w1001b
S2-w1001b
S2-w1001b
VII、Neutral position sensor
（I）Disassembly
1. Open the engine hatch
2. Disconnect the negative battery cable
3. Remove the rear section of deputy dashboard, checking deputy dashboard
4. Remove the neutral position sensor
S2 Transmission
1).
Disconnect the neutral position sensor wiring harness connector.
2). Remove the neutral position sensor from the
shifting drawing assembly.
S2-w1001b
（II）Installation
1. Install the neutral position sensor
1). Install the neutral position sensor to the shifting
drawing assembly.
2). Connect the neutral position sensor wiring harness
connector.
2. Install the rear section of deputy dashboard
3. Connect the negative battery cable
4. Close the engine hatch
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
VIII、Transmission assembly
（I）Disassembly
1. Open the engine hatch
2. Disconnect the negative battery cable
3.
Discharge clutch hydraulic oil, checking Drain and Refill Clutch Hydraulic oil
4.
Discharge transmission gearbox lubricant, checking Drain and Refill Lubricants
5. Remove the battery, checking Battery
6.
Remove the battery tray, checking Battery Tray
7.
Remove the reversing light switch, checking Reversing Light Switch
8.
Remove the clutch cylinder, checking clutch cylinder inlet pipe assembly
9. Remove starter, checking starter
10.
Remove the front left wheel, checking Wheels
11. Remove the front right wheel, checking Wheels
12.
Remove the left drive shaft assembly, checking Drive Shaft Assembly
13. Remove the right drive shaft assembly, checking Drive Shaft Assembly
14.Remove the trnasimission assemebly
1).
Disconnect the connection of power harness and transmission assembly.
2). Remove two locking pins and washers connecting the
transmission side shifting drawing and the transmission
rocker cradle.
3). Disengage the shifting assembly drawing from the
transmission arm bracket.
4). Remove two bolts connecting the transmission and the
transmission arm bracket.
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S2-w1001b
S2-w1001b
S2 Transmission
5).
Remove the 4 bolts connecting the transmission and gearbox fender,
then remove the fender.
6). Remove the three bolts connecting transmission assembly and the
rear suspension bracket and disengage the connection of
transmission assembly with the left mount bracket.
7). Remove the 3 bolts connecting the transmission assembly and
upper side of engine assembly.
8). Remove the 3 bolts connecting the transmission assembly and
down side of engine assembly.
9). Remove the transmission assembly
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S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
（II）Installation
1. Install the transmission assembly
1). Install the transmission assembly.
2). Install the 3 bolts connecting the transmission assembly
and upper side of engine assembly.
3). Install the 3 bolts connecting the transmission assembly and
down side of engine assembly.
4). Remove the three bolts connecting transmission assembly
and the rear suspension bracket.
5). Install the 4 bolts connecting the transmission and gearbox
fender.
S2-w1001b
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
6). Install the fixing nut, spring washer and washer assemblies.
7). Install two bolts connecting the transmission and the transmission
arm bracket.
Tighten torque 14.7~21.6N·m
8). Install the shifting assembly drawing to the transmission
arm bracket.
9). Install two locking pins and washers connecting the
transmission side shifting drawing and the transmission
rocker cradle.
10). Connect the connection of power harness and transmission
assembly.
2. Install the right drive shaft assembly
3. Install the left drive shaft assembly
4. Install the front right whee
5. Install the front left whee
6. Install the starter
7. Install the clutch cylinder
8. Install the reversing light switch
9. Install the battery tray
10. Install the battery
11. Refill transmission gearbox lubricant, checking Drain and Refill
Lubricants
12.
Refill clutch hydraulic oil, checking Drain and Refill Clutch
Hydraulic oil
13. Connect the negative battery cable
14. Close the engine hatch
S2-w3023b S2-
w1001bS2-
w1001b S2-
w1001b
S2 Transmission
IX、Reversing light switch
（I）Special tool
No.
Tool
Outline drawing
Discription
1
Reversing light switch
sleeve
JAC-T6B027
（II）Disassembly
1. Open the engine hatch
2. Disconnect the negative battery cable
3.
Remove the battery, checking Battery
4.
Remove the battery tray, checking Battery Tray
5.
Remove the reversing light switch
1).
Disconnect reverse lamp switch harness connector.
2). Disassembly Reversing light switch fixed nut with a special
tool reversing light switch sleeve.
S2-w1001b
S2-w1001b
S2 Transmission
3).Remove the reversing light switch.
（III）Installation
1. Install the reversing light switch.
1).
Install reversing light switch fixed
nut.
Tighten torque 29.4~34.3N·m
2). Connect reverse lamp switch harness
connector
2. Install the battery tray
3. Install the battery
4. Connect the negative battery cable
5. Close the engine hatch
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
X、Transmission oil drain plug
（I）Disassembly
1. Lift the car
2. Remove the front left engine cover, checking Front Engine Cover
3.
Remove the gearbox oil drain plug
1). Remove the gearbox oil drain plug
△Attention Prepare a container for transmission lubricant before removing
S2-w1001b
（II）Installation
1. Install the transmission oil drain plug
1). Install the transmission oil drain plug
Tighten torque 40~60N·m
2. Refill transmission gearbox lubricant, checking Drain and Refill Lubricants
S2-w1001b
XI、Transmission breather plug
（I）Disassembly
1. Open the engine hatch
2.
Removing the gearbox breather plug
1). Remove the gearbox breather plug
S2-w1001b
S2 Transmission
（II）Installation
1. Install the transmission breath plug
1). Install the transmission breath plug
2. Close the engine hatch
S2-w1001b
XII、Transmission refueling bolt
（I）Disassembly
1. Open the engine hatch
2. Remove the transmission refueling bolt
1). Remove the transmission refueling bolt
S2-w1001b
（II）Installation
1. Install the transmission refueling bolt
1). Install the transmission refueling bolt
Tighten torque 30~40N·m
2. Close the engine hatch
S2-w1001b
S2 Transmission
XIII、Release bearing
（I）Disassembly
1. Remove transmission assembly, checking transmission assembly
2. Clean the transmission assembly
3. Remove the clutch fork, checking clutch fork
4. Remove release bearing
1). Remove release bearing
S2-w1001b
（II）Installation
1. Install release bearing
1). Install release bearing
2. Install the clutch fork
3. Install transmission assembly
S2-w1001b
XIV、Clutch fork assembly
（I）Disassembly
1. Remove transmission assembly, checking transmission assembly
2. Clean the transmission assembly
3. Remove the clutch fork assembly
1).
Remove the nuts and washersconnecting clutch fork and
separation rocker
S2-w1001b
S2 Transmission
2).Remove clutch fork assembly
（II）Installation
1. Install clutch fork assembly
1). Install clutch fork assembly
2). Install the nuts and washersconnecting clutch fork and
separation rocker
Tighten torque 44N·m
2. Install transmission assembly
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
XV、Rocker arm
（I）Disassembly
1. Open the engine hatch
2. Remove rocker arm
1).
Remove the latch and rivets connecting clutch cylinder and rocker arm.
2). Remove the nuts and washers connecting clutch fork and
rocker arm.
3). Remove rocker arm
S2-w3023b
S2-w1001b
（II）Installation
1. Install rocker arm
1). Remove the latch and rivets connecting clutch cylinder and rocker arm
S2-w3023b
S2 Transmission
2). Remove the nuts and washers connecting clutch fork and rocker arm.
Tighten torque 44N·m
2. Close the engine hatch
S2-w1001b
XVI、Rear engaging member
（I）Disassembly
1. Remove the transmission assembly and install the transmission assembly
2. Remove the transmission assembly
3. Remove the rear engaging member
1).
Remove the 8 bolts connecting rear engaging member and the
transmission housing.
2).Remove the rear engaging member
△Attention If the engaging member and the transmission
housing are tightly fit, please loosen them with a rubber hammer
or a copper bar to gently tap the edge of the casing.
S2-w1001b
（II）Installation
1. Install the rear engaging member
1). Eradicate the colloidal on the joint surface of rear engaging member
and the transmission housing.
2).Gumming on the joint surface of rear engaging member
and the transmission housing.
△Attention Gumming must be uniform without unglue or broken glue.
3).
Install the 8 bolts connecting the rear engaging member with the
transmission housing.
S2-w1001b
Tighten torque 14.7~21.6N·m
2. Install the transmission assembly
S2 Transmission
XVII、Input shaft, output shaft, differential assembly
（I）Special tool
NO.
Tool
Outline drawing
Discription
1
Fork shaft fixing pin
punches
JAC-T6B026
2
Fork shaft inside pin
punches
JAC-T6B042
（II）Disassembly
1. Remove the transmission assembly, checking transmission assembly
2. Remove the transmission assembly
3. Remove the rear engaging member
4.
Remove the reverse gear mechanism engaging member and shift shaft engaging member
5.
Remove the input shaft, an output shaft, differential assembly
1).
Remove the input shaft output shaft
lock nut.
2). Disassembly 5 / R shift fork spring pins with a special tool
3).
Remove the 5 / R shift fork, 5 / R gear synchronizer sets,
gear lever and the hub.
4). Remove the 5 / R gear synchronizer ring and the fifth speed
input gear assembly.
5). Remove the five-speed output gear.
S2-w1001b
S2 Transmission
6).
Remove the reverse gear shaft bolt.
7). Remove 3 mounting bolts in the lock ball spring engaging
member.
8). Remove 14 retaining bolts connecting the clutch housing and the
transmission case.
9). Remove the transmission housing.
△Attention If the engaging member and the transmission
housing are tightly fit, please loosen them with a
rubber hammer or a copper bar to gently tap the
edge of the casing.
10). Remove the reverse gear and reverse gear shaft teeth.
S2-w1001b
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
11).
Remove the guide seat assembly.
12). Disassembly block 1/2, 3/4 shift fork spring pins with a special
tool.
13). Remove the fork shaft engaging member and the yoke.
△Attention Rotate shifting block before removing the front
fork shaft engaging member and the fork so that
shifting block can be away from the opening
interlocking boards.
14). Remove the 3 screws in input shaft bearing plate.
15). Remove the input shaft assembly, output shaft assembly and
differential assembly.
16). Remove the reverse gear shift mechanism engaging member
fixing bolts.
17).
Remove open ring, torsion, cotter pin in the reverse gear shifting
mechanism assembly, then remove the reverse gear shifting
mechanism assembly.
S2-w1001b
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
（III）Installation
1. Install the input shaft assembly, output shaft assembly and differential assembly
1). Remove the input shaft assembly, output shaft assembly and
differential assembly
2). Glue onto the threaded of the bearing plate bolts.
3).
Install the bearing plate and three plate bolts.
Tighten torque 14.7~21.6N·m
4). Glue on the two mounting bolts thread on guide
seating member.
5). Install the guide member and the seating mounting
bolts.
6). Install the reverse gear selection mechanism
engaging member and the fixing bolts.
Tighten torque 14.7~21.6N·m
S2-w1001b
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
7).
Install 1/2 shift fork shaft assembly.
8).
Install 1/2 shift fork shaft spring pins.
9).
Install 3/4 shift fork shaft assembly.
10). Install 3/4 shift fork shaft spring pins.
11). Install 5 / R shift fork shaft assembly.
12). Install 5/R shift fork shaft spring pins.
△Attention Spring pins must be replaced with new pins.
13).Install reverse gear and reverse gear shaft teeth.
14).Install magnet, sump.
△Attention Gumming must be uniform without unglue or
broken glue.
△Attention Reverse gear shaft bolt alignment.
15).
Eradicate colloid on mating surface of the clutch and
transmission case.
16). Gumming on mating surface of the clutch and transmission
case.
△Ateention Gumming must be uniform without unglue or
broken glue.
17). Co-box the clutch housing and transmission housing
18). Install 14 retaining bolts on joint surface of the transmission
housing and the clutch housing.
Tighten torque 34.3~41.2N·m
19).）Install 3 locking ball spring assembly.
Tighten torque 29.4~41.2N·m
S2-w1001b
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
20).
Install reverse gear shaft bolt.
Tighten torque 42.2~53.9N·m
21).
Install output five-speed gear. Install the five-speed needle bearing
mounted, five-speed input gear assembly. Install 5 / R gear
synchronizer assembly and 5 / R gear synchronizer ring.
22). Install 5 / R shift fork.
23). Install 5 / R shift fork spring pins
24). Install 5 / R gear synchronizer assembly, lever, 5 / R gear
synchronizer ring and 5 / R block dial fork.
△Attention Lever head must falls into 5 / R gear synchronizer
assembly recess.
25).Install the input and output shaft lock nut.
△Attention locking nut must be mattered to be riveted.
2.
Install reverse gear mechanism engaging member and shift shaft
engaging member
3. Install the rear engaging member
4. Install the transmission assembly
S2-w1001b
S2-w1001b
S2-w1001b
XVIII、Input Shaft Assembly
（I）Special tool
NO.
Tool
Outline drawing
Discription
1
I
nput shaft removable
pad
JAC-T6B031
S2 Transmission
NO.
Tool
Outline drawing
Discription
2
Input shaft bushing
installation tool
JAC-T6B032
3
I
nput shaft 4 gear, 5
gear
bushing
installation tool
JAC-T6B033
4
Input shaft front
bearing installation
tool
JAC-T6B034
5
Front output shaft
bearing outer ring
installation tool
JAC-T6B035
6
Rama
JAC-T6B043
S2 Transmission
（II）Disassembly
1. Remove transmission assembly, checking transmission assembly
2. Clean transmission assembly
3.
Remove the rear engaging member, checking the rear engaging member
4.
Remove the input shaft, output shaft, differential assembly, checking
the input shaft, output shaft, and differential assembly
5. Remove
input shaft assembly
△Attention The front input shaft bearing can not be dismantled.
Ball bearings in the input shaft and the front input
shaft shall be replaced at the same time.
1). Remove the snap ring (rear input shaft end).
2).
Remove five gear input liner with Rama JAC-T6B043.
3).
Disassembly the 3/4 gear synchronizer assembly and input 4 gear
bushing with Rama JAC-T6B043.
4). Remove ball bearings and snap ring by Rama
JAC-T6B043.
5).
Remove the three-block synchronization ring,
input three-block gear assembly.
S2-w1001b
S2-w1001b
（III）Check
1. Check the appearance of the output shaft
1). Check whether the input shaft has gear teeth broken, tooth surface
pitting, severe tooth wear and tooth bonding phenomenon.If it has
either case, you must replace the input shaft.
2). Check whether the input shaft splines have severe wear and
damage.you must replace the input shaft if the splines are damage.
3).
Hand touch the bearing rotation whether it is flexible or whether it
has catching phenomenon. If the bearing rotation is not flexible or
has catching phenomenon, you must replace the bearings.
S2 Transmission
B
A
2.
Check the size of the input shaft
1).
Input Shaft runout ≤0.03mm.
2).
A point wears a minimum diameter of Φ32.981 and B point wears a
minimum diameter Φ27.995.
（IV）Installation
1. Install input shaft assembly
1).
Install the three gear loaded needle roller bearings, three gear
input gear engaging member, spring and three gear
synchronization synchronizer ring.
2).Install 3/4 gear synchronizer assembly.
△Attention Input 3 gear axial clearance is 0.08 ~ 0.19mm.
Attention When installing the 3/4 gear synchronizer hub,
three grooves should face toward the 3gear and
the four slots should face toward the 4 gear
Attention When you install the synchronizer sleeve, you
should confirm two deep gullet synchronizer hub
properly comply with two sets of teeth of high
rack.
3).
Install 4 gear bushing with special tool JAC-T6B033.
4). Install synchronous spring, four gear synchronous ring, needle
roller bearings, input four gear engaging member and the input
4 gear thrust pad.
5).
Install the input shaft ball bearings with special tools JAC-
T6B034
6). Install the rear input shaft snap ring.
Attention Select the snap ring thickness, so that the input
shaft bearing axial clearance in line with
standards.
S2-w1001b
S2-w1001b
S2 Transmission
7).
Install input five gear bushing with a special tool JAC-T6B033.
2.
Install the input shaft, output shaft, differential assembly
3.
Install rear engaging member
4.
Install transmission assembly
S2-w1001b
XIX、Differential Assembly
（I）Special tool
NO.
Tool
Outline drawing
Discription
1
Differential oil seal
installation tool
JAC-T6B025
2
Differential bearing
block removable
pads
JAC-T6B029
3
Differential bearing
installation tool
JAC-T6B030
4
Differential bearing
outer ring mounting
tool
JAC-T6B037
S2 Transmission
NO.
Tool
Outline drawing
Discription
5
Rama
JAC-T6B043
6
Differential bearing
outer race puller
JAC-T6B044
7
Fork shaft fixing pin
punches
JAC-T6B042
（II）Disassembly
1. Remove transmission assembly, checking transmission assembly
2. Clean transmission assembly
3. Remove the rear engaging member, checking the rear engaging member
4.
Remove the input shaft, an output shaft, differential assembly see the
input shaft, output shaft, differential assembly
5. Remove the differential assembly
1).
Remove differential two tapered roller bearings with Rama JAC-
T6B043 and differential bearing removable pads JAC-T6B029.
S2-w1001b
S2 Transmission
2). Remove 8 fixing bolts in the main reduction assembly.
3).
Remove the differential gear.
4). Disassembly groove pin with a special tool holder pin punches
JAC-T6B042.
5). Remove the planetary gear shaft, the planetary gear, the planetary
gear thrust pad, gear axle, the side gear thrust ring.
S2-w1001b
（III）Check
1. Check the differential appearance
1). Check whether the main reduction gear teeth have broken tooth,
surface pitting, severe tooth wear and tooth bonding
phenomenon. If there is either case, you must replace the main
reduction gear.
2). Check whether the planetary gears and the side gears and splines
have severe wear and damage, if there are any cases,they must
be replaced.
3). Check tapered roller bearing outer ring and roller wearing
situation, must be replaced if bearings are badly worn.
2. Inspect the synchronizer ring
1). Inspect whether the synchronizer ring teeth surface has injury or
damage.
2).
Check whether the tapered portion is damage or wear and
whether thread is crushed.
S2-w1001b
S2 Transmission
3).
In the synchronizer ring to gear pressed state, check clearance "A".
If "A" is smaller than the limit, it should be replaced.
A
Limit：0.5mm
¼҄½
÷
3. Check the synchronizer sleeve and hub gear
1). Install the synchronizer sleeve and hub gear together to
check whether they are smooth sliding or stuck.
2).
Check whether the surface of the tooth kit front and rear ends
have injury.
△Attention When replacing synchronizer sleeve or gear hub,
they should be replaced as a set.
（IV）Installation
1. Install the differential assembly
1). First install the side gear thrust ring gear in the back axle, and
then install the side gear in the differential. Placed in the back of
the planetary gear planetary gear thrust after the two planetary
gears simultaneously meshing with the side gears, then rotate the
planetary gear so that it fits in the correct position.
2).
Insert the pinion shaft.
3). Mounting groove pin.
4). Fit main reduction gear to the installation location.
5). Install main reduction gear 8 fixing bolts.
Tighten torque 75~85N·m
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
6).
Install bearing differential assembly with special tool JAC-T6B037.
2.
Install the input shaft, output shaft, differential assembly, checking the
input shaft, output shaft, and differential assembly
3. Install rear engaging member
4.
Install transmission assembly
S2-w1001b
XX、Transmission case
（I）Special tool
NO.
Tool
Outline drawing
Discription
1
Fork shaft fixing pin
punches
JAC-T6B026
（II）Disassembly
1. Remove transmission assembly, checking transmission assembly
2. Clean transmission assembly
3.
Remove the rear engaging member, checking the rear engaging member
4. Remove the drive shaft seal, checking the shaft seal
5.
Remove the transmission case
1).
Remove the input shaft output shaft lock nut.
S2-w1001b
S2 Transmission
2).
Disassembly 5 / R shift fork spring pins with a special tool.
3).
Remove the 5 / R shift fork, 5 / R gear synchronizer sets, gear lever and the hub.
4).
Remove the 5 / R gear synchronizer ring and the fifth gear input gear assembly.
5).
Remove the fifth gear output gear.
6). Remove the reverse gear shaft bolt.
7). Remove 3 mounting bolts in the lock ball
spring engaging member.
8). Remove the gearbox oil drain plug.
S2-w1001b
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
9).
Remove 14 retaining bolts connecting the clutch housing and the transmission case.
10).
Remove the transmission housing.
△Attention If the engaging member and the transmission
housing are tightly fit, please loosen them with a
rubber hammer or a copper bar to gently tap the
edge of the casing.
11). Remove the bearing outer race (totally2, a differential and an output shaft).
12). Remove the fuel
transmission bolts.
S2-w1001b
（III）Installation
1. Install the transmission case
1).
Eradicate colloids on joint surface of the clutch and the
transmission housing.
2). Gumming on the binding surface of the clutch and the
transmission case.
△Attention Coating must be uniform without unglue or breaks.
3). Install the bearing outer race (totally2, a differential and an output
shaft)
4). install 14 retaining bolts connecting the clutch housing and the
transmission case.
Tighten torque 34.3~41.2N·m
5).）Remove 3 mounting bolts in the lock ball spring engaging
member.
Tighten torque 29.4~41.2N·m
S2-w1001b
S2-w1001b
S2 Transmission
6). Remove the reverse gear shaft bolt.
Tighten torque 42.2~53.9N·m
7). Install the fifth gear output gear.
8). Install the five gear needle mounted bearing, five gear input gear
assembly.
9). Install 5 / R gear synchronizer assembly, lever, 5 / R gear
synchronizer ring and 5 / R block dial fork.
△Attention Lever head should fall assembly 5 / R gear
synchronizer recess.
10). Install the input and output shaft lock nut.
△Attention lock nut must be mattered and riveted.
11). Install the transmission oil drain plug.
Tighten torque 40~60N·m
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S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
12).
Install refueling transmission bolt.
Tighten torque 30~40N·m
2. Install the rear engaging member
3. Install the drive shaft seal
4.
Install transmission assembly
S2-w1001b
XXI、Clutch housing
（I）Special tool
NO.
Tool
Outline drawing
Discription
1
Fork shaft fixing pin
punches
JAC-T6B026
（II）Disassembly
1. Remove transmission assembly, checking transmission assembly
2. Clean transmission assembly
3.
Remove the rear engaging member, checking the rear engaging member
4.
Remove release bearing, checking release bearing
5.
Remove the clutch fock engaging member, checking the clutch fock engaging member
6.
Remove rocker arm, checking rocker arm
7.
Remove the reverse gear shifting mechanism engaging member and gear
shift shaft engaging member, checking the reverse gear shifting
mechanism engaging member and gear shift shaft engaging member
8.
Remove the clutch housing
1). Remove the input shaft output shaft
lock nut.
S2-w1001b
S2 Transmission
2).
Disassembly 5 / R shift fork spring pins with a special tool.
3).
Remove the 5 / R shift fork, 5 / R gear synchronizer sets, gear lever and the hub.
4).
Remove the 5 / R gear synchronizer ring and the fifth gear input gear assembly.
5).
Remove the fifth gear output gear.
6). Remove the reverse gear shaft bolt.
7). Remove 3 mounting bolts in the lock ball spring engaging
member.
8). Remove 14 retaining bolts connecting the clutch housing and the
transmission case.
9). Remove the transmission housing.
△Attention If the engaging member and the transmission
housing are tightly fit, please loosen them with a rubber hammer
or a copper bar to gently tap the edge of the casing.
S
2
-
w
1
0
0
1
b
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
10).
Remove the shaft seal.
11).
Remove the shift shaft seal.
12).
Remove the input shaft oil seal.
13).
Remove the shifting axis linear bearings (two).
14). Remove the bearing outer race (totally2, a differential and an output shaft)
（III）Installation
1. Install the transmission case
1).
Eradicate colloids on joint surface of the clutch and the
transmission housing.
2).
Gumming on the binding surface of the clutch and the
transmission case.
△Attention Coating must be uniform without unglue or
breaks.
3). Install the bearing outer race (totally2, a differential and an
output shaft)
4). Install the shaft seal.
5).
Install the shift shaft seal.
6).
Install the input shaft oil seal.
7).
Install the shifting axis linear bearings.
8). Install 14 retaining bolts connecting the clutch housing and
the transmission case.
Tighten torque 34.3~41.2N·m
9). Install 3 mounting bolts in the lock ball spring engaging
member.
Tighten torque 29.4~41.2N·m
S
2
-
w
3
0
3
6
b
S2-w3036b
S2-w1001b
S2 Transmission
10). Install the reverse gear shaft bolt.
Tighten torque 42.2~53.9N·m
11). Install the fifth gear output gear.
12). Install the five gear needle mounted bearing, five gear input
gear assembly.
13).
Install 5 / R gear synchronizer assembly, lever, 5 / R gear
synchronizer ring and 5 / R gear dial fork.
△Attention Lever head should fall assembly 5 / R gear
synchronizer recess.
14). Install the input and output shaft lock nut.
△Attention lock nut must be mattered and riveted.
2. Remove the reverse gear shifting mechanism engaging member and
gear shift shaft engaging member
3.
Install separate rocker
4. Install separate fork engaging member
5. Install release bearing
6. Install rear engaging member
7.
Install release bearing
8. Install transmission assembly
S2-w1001b
S2-w1001b
S2-w1001b
XXII
、
Input five gear engaging member, 5 / R gear synchronizer assembly
（I）Special tool
NO.
Tool
Outline drawing
Discription
1
Fork shaft fixing pin
punches
JAC-T6B026
S2 Transmission
（II）Disassembly
1. Remove transmission assembly, checking transmission assembly
2. Clean transmission assembly
3.
Remove the rear engaging member, checking the rear engaging member
4. Remove five gear engaging member, 5 / R gear synchronizer assembly
1).
Remove the input shaft output shaft lock nut.
2). Disassembly 5 / R shift fork spring pins with a
special tool.
3).
Remove the 5 / R shift fork, 5 / R gear
synchronizer assembly.
4).
Remove the five-speed gear assembly.
S2-w1001b
S2-w1001b
（III）Installation
1. Install input five gear engaging member, 5 / R gear synchronizer assembly
1).
Install the input five-speed needle mounted bearing, input five-speed gear assembly.
2).
Install 5 / R gear synchronizer assembly, lever, 5 / R gear synchronizer
ring and 5 / R gear dial fork.
△Attention Lever head should fall assembly 5 / R gear synchronizer recess.
S2-w1001b
S2 Transmission
3).
Install the input and output shaft lock nut.
△Attention lock nut must be mattered and riveted.
2. Install rear engaging member
3. Install transmission assembly
S2-w1001b
XXIII、Input the five gear liner
（I）Special tool
NO.
Tool
Outline drawing
Discription
1
Rama
JAC-T6B043
2
The input shaft 4
gear, 5 gear bushing
installation tool
JAC-T6B033
（II）Disassembly
1. Remove transmission assembly, checking transmission assembly
2. Clean transmission assembly
3.
Remove the rear engaging member, checking the rear engaging member
4. Remove the input shaft, output shaft, differential assembly, chencking the input shaft, an output shaft, differential assembly
5. Remove the input 5 gear liner
△Attention Input shaft front bearing can not be dismantled. The
input shaft or the input shaft front ball bearings should
be replaced at the same time.
S2 Transmission
1).Disassembly the input five gear liner with Rama JAC-T6B043.
2).
Remove the input five gear bush.
（三）Installation
1. Install the input five gear bush
1). Install the input five gear liner with Rama JAC-
T6B043
2.
Install the input shaft, output shaft, differential assembly
3.
Install rear engaging member
4. Install transmission assembly
S2-w1001b
S2-w1001b
XXIV
、
3/4 gear fork shaft engaging member, 1/2 shift fork shaft engaging member, 5 / R
shift fork shaft engaging member
（I）Special tool
NO.
Tool
Outline drawing
Discription
1
Fork shaft fixing pin
punches
JAC-T6B026
2
The fork shaft inside
pin punches
JAC-T6B042
S2 Transmission
（II）Disassembly
1. Remove transmission assembly, checking transmission assembly
2. Clean transmission assembly
3.
Remove the rear engaging member, checking the rear engaging member
4.
Remove 3/4 gear fork shaft engaging member, 1/2 shift fork shaft engaging member, 5 / R shift fork shaft engaging member
1).
Remove the input shaft output shaft lock nut.
2). Disassembly 5 / R shift fork spring pins with a special tool.
3). Remove the 5 / R shift fork, 5 / R gear synchronizer sets,
gear lever and the hub.
4). Remove the 5 / R gear synchronizer ring and the input fifth
speed gear assembly.
5).
Remove the five-speed output gear.
6). Remove the reverse gear shaft bolt.
7). Remove 3 mounting bolts in the lock ball spring engaging
member
S2-w1001b
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
8). Remove 14 retaining bolts connecting the clutch housing and the transmission case.
9). Remove the transmission housing.
△Attention If the engaging member and the transmission
housing are tightly fit, please loosen them with a
rubber hammer or a copper bar to gently tap the
edge of the casing
10). Remove the reverse gear and reverse gear shaft teeth.
11). Remove the reverse gear shifting mechanism mounting bolts.
12). Remove the reverse gear shaft assembly.
13). Disassemble 1/2 gear, 3/4 gear shift fork spring pins with a
special tool.gear
14).
Remove the fork shaft engaging member and the yoke.
△Attention Before removing the front fork shaft engaging
member and the fork, rotate shifting block so
that shifting block away from the opening
interlocking boards.
S2-w1001b
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
（III）Installation
1. Remove 3/4 gear fork shaft engaging member, 1/2 shift fork shaft engaging member, 5 / R shift fork shaft engaging member
1).
Install the 1/2 shift fork shaft assembly, 3/4 shift fork shaft
assembly, 5 / R shift fork shaft assembly, 1/2 shift fork, 3/4 shift
fork and spring pins.
△Attention Spring pins must be replaced with new.
2). Mount plate and plate screws.
Tighten torque 14.7~21.6N·m
3). Install guide member and the seating
mounting bolts.
4).Install the reverse gear shift mechanism
engaging member and the fixing bolts.
Tighten torque 14.7~21.6N·m
S2-w1001b
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
5). Install the
reverse gear and reverse gear shaft teeth.
6). Install the magnet and sump.
△Attention Coating must be uniform without unglue or break.
7). Eradicate colloid on the mating surface of the clutch and
transmission case.
8). Coating on binding surface of the clutch and the transmission
case.
9). Co-box the clutch housing and transmission housing
10). Install 14 retaining bolts connecting the clutch housing and
the transmission case.
Tighten torque 34.3~41.2N·m
11).）Install 3 mounting bolts in the lock ball spring engaging
member.
Tighten torque 29.4~41.2N·m
12). Install the reverse gear shaft bolt.
Tighten torque
42.2~53.9N·m
S2-w1001b
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
13). Install the fifth gear output gear.
14). Install the five gear needle mounted bearing, five gear input
gear assembly.
15). Install 5 / R gear synchronizer assembly, lever, 5 / R gear
synchronizer ring and 5 / R gear dial fork.
△Attention Lever head should fall assembly 5 / R gear
synchronizer recess.
16). Install the input and output shaft lock nut.
△Attention lock nut must be mattered and riveted.
2. Install the rear engaging member
3. Install the transmission assembly
S2-w1001b
S2-w1001b
XXV、Reverse ratcheting member
（I）Special tool
NO.
Tool
Outline drawing
Discription
1
Fork shaft fixing pin
punches
JAC-T6B026
S2 Transmission
（II）Disassembly
1. Remove transmission assembly, checking transmission assembly
2. Clean transmission assembly
3.
Remove the rear engaging member, checking the rear engaging member
4.
Remove the reverse ratcheting member
1).
Remove the input shaft output shaft lock nut.
2). Disassembly 5 / R shift fork spring pins with a special tool.
3). Remove the 5 / R shift fork, 5 / R gear synchronizer sets,
gear lever and the hub.
4). Remove the 5 / R gear synchronizer ring and the fifth speed
input gear assembly.
5).
Remove the fifth gear output gear.
6). Remove the reverse gear shaft bolt.
7). Remove 3 mounting bolts in the lock ball spring engaging
member.
S2-w1001b
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
8). Remove 14 retaining bolts connecting the clutch housing and the transmission case.
9). Remove the transmission housing.
△Attention If the engaging member and the transmission
housing are tightly fit, please loosen them with a
rubber hammer or a copper bar to gently tap the
edge of the casing
10). Remove the reverse gear and
reverse gear shaft teeth
S2-w1001b
（III）Installation
1. Install the reverse gear ratcheting member
1
). Install reverse gear and reverse gear shaft teeth.
2). Install 14 retaining bolts connecting the clutch housing and
the transmission case.
Tighten torque 34.3~41.2N·m
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
3).）Install 3 mounting bolts in the lock ball spring engaging member.
Tighten torque 29.4~41.2N·m
4). Install the reverse gear shaft bolt.
Tighten torque
42.2~53.9N·m
5). Install the fifth gear output gear.
6). Install the five gear needle mounted bearing, five gear input gear
assembly.
7). Install 5 / R gear synchronizer assembly, lever, 5 / R gear
synchronizer ring and 5 / R gear dial fork.
△Attention Lever head should fall assembly 5 / R gear
synchronizer recess.
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
8). Install
the input and output shaft lock nut.
△Attention lock nut must be mattered and riveted.
2. Install the rear engaging member
3. Install the transmission assembly
S2-w1001b
XXVI、Reverse gear shift mechanism engaging member and gear shift shaft engaging member
（I）Special tool
NO.
Tool
Outline drawing
Discription
1
Fork shaft fixing pin
punches
JAC-T6B026
（II）Disassembly
Remove transmission assembly, checking transmission assembly
2. Clean transmission assembly
3.
Remove the rear engaging member, checking the rear engaging member
4.
Remove the reverse gear shift mechanism engaging member and gear shift shaft engaging member
1). Remove the input shaft output shaft lock nut
S2-w1001b
S2 Transmission
2). Disassembly 5 / R shift fork spring pins with a special tool.
3).
Remove the 5 / R shift fork, 5 / R gear synchronizer sets, gear lever and the hub.
4).
Remove the 5 / R gear synchronizer ring and the fifth speed input gear assembly.
5). Remove the fifth gear output gear.
6). Remove the reverse gear shaft bolt.
7). Remove 3 mounting bolts in the lock ball spring engaging
member.
8). Remove 14 retaining bolts connecting the clutch housing and the
transmission case.
9). Remove the transmission housing.
△Attention If the engaging member and the transmission housing are
tightly fit, please loosen them with a rubber hammer or a copper bar to gently
tap the edge of the casing
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
10). Remove the reverse gear and reverse gear shaft teeth
11). Remove the two mounting bolts to the seating member, and
then remove the guide seat assembly.
12). Remove 2 mounting bolts from the reverse gear shift
mechanism engaging member.
13).
Removie the groove pin in reverse gear shift mechanism
engaging member.
14). Remove the open ring in reverse gear shifting mechanism
engaging member.
15).
Remove the torsion spring in reverse gear shift mechanism
engaging member
16). Remove the reverse gear shift mechanism engaging
member and gear shift shaft engaging member
S2-w1001b
S2-w1001b
（III）Installation
1. Install the reverse gear shift mechanism
engaging member and gear shift shaft engaging
member
1).
Install the reverse gear shift mechanism assembly.
2).Install the groove pin, open ring and torsion spring in reverse
gear shift mechanism engaging member
3). Install 2 mounting bolts into the reverse gear shift
mechanism engaging member.
Tighten torque 14.7~21.6N·m
S2-w1001b
S2 Transmission
4). Install the two mounting bolts to the seating member, and then remove the guide seat assembly
5). Install the reverse gear and reverse gear shaft teeth
6). Install 14 retaining bolts connecting the clutch housing and the
transmission case
Tighten torque 34.3~41.2N·m
7).）Remove 3 mounting bolts in the lock ball spring engaging
member.
Tighten torque 29.4~41.2N·m
S2-w1001b
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
8). Install the reverse gear shaft bolt.
Tighten torque
42.2~53.9N·m
9). Install the fifth gear output gear.
10). Install the five gear needle mounted bearing, five gear input
gear assembly.
11). Install 5 / R gear synchronizer assembly, lever, 5 / R gear
synchronizer ring and 5 / R gear dial fork.
△Attention Lever head should fall assembly 5 / R gear
synchronizer recess
12). Install the input and output shaft lock nut.
△Attention lock nut must be mattered and riveted.
2. Install the rear engaging member
3. Install the transmission assembly
S2-w1001b
S2-w1001b
S2-w1001b
S2 Transmission
XXVII
、
Input three gear ratcheting member, Input four gear engaging member, 3/4 gear synchronizer
assembly
（I）Special tool
NO.
Tool
Outline drawing
Discription
1
I
nput shaft removable
pad
JAC-T6B031
2
The input shaft
4
gear,5 gear
bushing
installation tool
JAC-T6B033
3
Rama
JAC-T6B043
（II）Disassembly
Remove transmission assembly, checking transmission assembly
2. Clean transmission assembly
3.
Remove the rear engaging member, checking the rear engaging
member
4.
Remove the input shaft, output shaft and differential assembly,
checking the input shaft, output shaft and differential assembly
5.
Remove the input three gear engaging member, input four gear engaging member and 3/4-speed synchronizer assembly
△Attention Input shaft front bearing can not be dismantled. The
input shaft or the input shaft front ball bearings should
be replaced at the same time.
1). Disassembly the input five gear liner with Rama JAC-T6B043.
2).
Remove the snap ring (input shaft rear end).
S2-w1001b
S2 Transmission
3).
Disassemble simultaneously 3/4 gear synchronizer assembly, input
4 gear bushings and ball bearings (input shaft rear) , then remove
the three-block synchronizing ring, three-block input gear
assembly with the tool Rama No. JAC-T6B043 for three gear
combination of upper teeth special tools
（III）Installation
1. Install the input three gear engaging member, input four gear
engaging member and 3/4 gear synchronizer assembly
1). Install the three gear needle roller bearings, input three gear
engaging member, spring and three gear synchronizer ring.
2).Install the
3/4 gear synchronizer assembly.
△Attention the input three gear axial clearance 0.08 ~
0.19mm.
Attention When installing 3/4 block synchronizer hub,please
apply three grooves facing toward the third gear, and
four slots facing toward the forth gear
Attention When installing the synchronizer sleeve, you
should confirm two deep gullet synchronizer hub
properly comply with two sets of teeth of high
rack.
3). Install input 4 gear bush with special tools JAC-T6B033.
4). Install the synchronous spring, 4 gear synchronous ring, input 4
gear needle roller bearings, input 4gear engaging member and
the input 4 gear thrust pad.
2.
Install the input shaft, output shaft, differential assembly
3.
Install rear engaging member
4.
Install transmission assembly
S2-w1001b
S2 Transmission
S2-w1001b
Transmission（CVT）
I、Summary
（I）Structure summary
Continuously variable transmission ratio can be achieved by means of a transmission, the device comprises two opposed a cone
wheel drive V-shaped strip and surrounded on two wheels. Transmission shifting device is transmitted through the intermediate shaft to
the ratio of the differential within the transmission.
This manual briefly describes the transmission, including the design and function of the various components of the transmission and
powertrain were elaborated and control devices. In addition, the manual also outlines the transmission oil cooling systems and external
shifting mechanism.
CVT shift patterns can make you more comfortable driving, and can improve vehicle performance.
CVT has following advantages：
- A lower vehicle speed at a constant engine speed;
- Improve emissions control / reduce fuel consumption;
-NVH (Noise, vibration, harshness) control;
- Smooth acceleration;
- Flexible Driving on mountain roads
The compassion between a traditional AT and a CVT
The below shows the compassion between a continuously variable transmission, a manual and a conventional automatic
transmission gear ratio change chart. Conventional automatic transmission (gear) gear ratio is a series of fixed values.
When the transmission is shifted into high gear, the gear ratio shown on the right will change with the throttle opening size along
the thick solid line or dotted line changes. The use of continuously variable transmission can be obtained as shown in the left throttle
opening gear ratio change chart, two transmission shift points and applied by the driver related.
When the throttle opening becomes large, the engine speed increases, the transmission shifted into high gear; traditional
transmission engine speed will fall significantly in such a condition, while the use of non-variable transmission the engine speed has
not decreased. CVT can be at constant engine speed by moving the cone rotation into high gear (see explanation below). In addition,
you can also use other policy shift that will help new users faster CVT accept it.
Throttle CloseCVT (left) and 4AT (right) ra
4 AT ratio change map
CVT ratio change map
Driven wheel
Driven whe
Throttle open
Overdrive
Throttle open
S2 Transmission
Ratio change map
Sectional view of the transmission
3
5
1
4
2
8
7
9
6
10
节气门全开
节气门关闭
超速档
C V T自动变速器的传动比变化图
常规4档自动变速器(传动装置)的传动比变化图
4
3
2
1
最大扭矩
最大扭矩
低档
节气门部分开启
加速度
节气门全开
加速度
主动轮速度(N prim )
主动轮速度(N prim )
从动轮速度（N sec）
从动轮速度（N sec）
S2 Transmission
1. Torsional damper /
flywheel
2. Pump
3.
Reverse clutch
4. Planetary mechanism
5. Forward clutch
6.
Strip
7. Driving bevel wheel
8.
Driven bevel wheel
9.
Countershaft
10. Differential
S2 Transmission
7
48
Transmission exploded view
29
30
31 32
33 34
35
36 24
39
38
37
40
43
S2 Transmission
1. Input shaft rubber boot 482235
2.
The input shaft seal 481274
3.
Differential oil blocks 481296
4.
Differential Seal 483329
5.
Refueling plug gasket 481247
6.
Refueling plug 481248
7.
Ventilator cap 483420
8.
Breathing pipe assembly 483114
9.
Driven axle cone end cap O-ring (small)
481254
10.
Driven bevel shaft seal cover 481877
11. Driven axle cone end cap O-ring (big)
481255
12.
Driven bevel wheel cover 482982
13.
Countersunk screws driven bevel wheel
cover 482208
14.
Active cone ball bearing axle 482294
15.
Driving bevel axle nut 481293
16.
Conical spring washer 481856
17.
Pump seals 481826
18.
Pump O-ring 481259
19.
Pump (including O-ring)483323
20.
Pump Bolts 481284
21.
Driving bevel axle end cap O-ring
481253
22.
Driving bevel wheel cover 481173
23.
Driving bevel wheel cover snaps 481189
24.
Driving bevel bolt axle cap 481283
24.
Oil pan bolt 481283
25.
Speed Sensor 482410
26.
Differential speed sensor bracket screw 481289
27. Differential speed sensor bracket 482468
28.
Speed sensor mounting bolts 481283
29.
Oil pan gasket 482504
30.
Valve assembly 482589
31.
Body bolts 481311
32.
Plastic buckle 482253
33.
Oil filter assembly 483165
34.
Sump magnet 481870
35.
Sump assembly
36.
Oil drain plug 482442
37.
Driving mode sensor fixing screws 481090
38.
Driving mode sensor 482493
39.
Oil cooler drain plug O-ring 481258
40.
Oil cooler plug 482121
41.
Oil drain plug gasket 481249
42.
Oil level plug 481250
43. Main fitting closure 482104
44.
Main fitting snap 482105
45.
Main interface and internal wiring harness 482475
46.
Gear selection lever nut 481329
47.
Gear selection lever 483185
48.
Gear selection lever nut washer 482584
49.
Seal (election gear shaft)482099
50.
Locating Pins 483138
51.
Metal buckle 481456
（II）System Principle
These components of VT2 transmission can be divided into three groups according to the respective functions
·Group 1－Mechanical torque transfer. Function of this part is to provide mechanical transmission and torque transfer.
·Group 2－Control system. Components associated with the control system.
According to the load driving conditions and
requirements, the control system is to ensure the transmission and transfer power to change the transmission ratio at the
appropriate time.·
·Group 3－Externally connected device. Some components connected to the outside of the transmission.
Among these
components, some located or connected to the gearbox and transmission, as well as some of the components of the whole
system is composed of
Section, but they are distributed in other parts of the vehicle.
Group 1-
Mechanical torque transfer
Planetary mechanism
Planetary transmission mechanism provides forward and backward driving torque in both directions. The engine torque is
typically transmitted to the planet carrier offered by the transmission input shaft. Engaging the forward direction of the multiple disc
clutch can be directly connect the planet carrier to sun gear,and by the engagement of the planet carrier and sun wheel as a whole
rotation, the engine torque is transferred directly to the capstan. It does not transmit any torque planetary gear, the planetary
mechanism and therefore there is no mechanical loss, and the direction of rotation of the capstan in line with the direction of rotation
of the engine. This is the forward mode.
In reverse mode, engaging the reverse multiple disc clutch mechanism allows the planetary ring gear is held stationary, the planet carrier
drives three pairs of planetary gear sets so that the reverse rotation sun gear, then the gear transmission ratio is 1: 1.1, there will be slight
deceleration torque increases to compensate for friction losses in the planetary mechanism.
S2 Transmission
Planetary mechanism
1. Planetary gear
2. Input shaft 3
3. Sun gear
4. Ring gear
Multi-plate clutch
There are two sets of Wet Clutch: one is for forward and another is for reverse. Each group has three clutch friction discs a total of
six friction surface. Hydraulic clutch system controls the throttle opening to make any forward movement of the vehicle can be smooth,
the driving gear, the amount of clutch engagement control also allows the vehicle to stop. Cooling oil prevents friction clutch disk surface
from overheating.
Clutch in planetary mechanism
1. Forward clutch group 2.Reverse clutch group
Cone wheel and strips
The main design features of the CVT is a pair of "V" shaped cone round consists of a steel belt connection. Drive pulley and driven
pulley center distance of 155mm. Each cone wheel is divided into two halves: half fixed, half sliding axially, both inclination are 11 °.
The 24mm wide "Van Doorne" push belt for transmitting torque between the wheels (if you want to use a larger torque values, you can
use the 30mm belt). By way of jet injection lubricates and cools belt nozzle. In order to reduce the angle error of the belt when changing
gear, the two movable pulley halves is placed between the two diagonal positions, and then connect each of the movable pulley half to the
hydraulic cylinder / piston. By a hydraulic control system, see page 2-9, "The second group - the control system." Ball splines prevent the
movement of the wheel relative to their half of the semi-fixed wheel rotation.
Because the sun wheel is coupling on the active cone wheel by the spline, the torque effect of the planetary gear set can be directly
transferred to the drive bevel wheel. Steel belt transmits power from the drive bevel wheel to the driven cone wheel, power and from
then transferred to the intermediate wheel driven bevel gear shaft.
Torque and speed of the driven wheels is determined by the position of the belt. Two wheel sizes design can provide 2.416: 1 to
0.443: 1 gear ratio, the maximum transmission ratio is 5.45 times the minimum transmission ratio. Overdrive gear provides the lowest
fuel consumption.
Transmission 450 includes a steel sheet and 24 strips are secured together with each side 12 strips.
S2 Transmission
Transmission belt
1. Strip 2.Steel
Counter-shaft
Intermediate shaft (pinion shaft) reduces the speed of two engaging gear between the driven bevel wheels and the differential, so
you can ensure the correct direction of rotation of the shaft. Deceleration between driven bevel gear and drive shaft to a large extent
improves vehicle performances. Intermediate bearing shaft is fixed by two cone clutch housing and independent within the bearing.
Differential
Same as the manual transmission, the crown wheel torque transmitted through the differential to the wheels, the crown wheel 8 is bolted to
the differential housing, shaft fixed pads from the traditional Ball Basket universal joints and seals to differential Inside. Tapered Roller
Bearing is for fixing differential.
Mechanical operation
·Transmission ratio changing the traditional limited series planetary gear mechanism of the automatic transmission, usually is four, five or
six gears, but the continuously variable transmission is different, as its name suggests, a continuously variable transmission
The transmission ratio is continuously variable. Low gear (low gear ratio) makes it easier to start the vehicle stationary, a relatively small
diameter driving bevel wheel, but the wheel dynamic cone diameter is relatively large. Transmission belt for transmitting power and torque,
if selected high ratio by increasing the diameter of the driving bevel wheel, narrow way driven bevel wheel diameter, can produce
acceleration. By controlling the degree of change to ensure that the most appropriate ratio.
CVT with active cone wheel and driven bevel wheel has two wheels, each round consists of two half-cone compositions, half fixed
and half by the hydraulic control can be moved. Position the belt on the wheel can be determined ratios. If you move the wheel close to
half the corresponding fixed pulley halves, the outer periphery of the belt will move. When two separate half-cone wheel, the wheel rim
will become smaller, active and mobile cone wheel driven bevel wheel pulley halves in each diagonal position where the belt drive
bevel wheel radius is reduced, and the slave increase the radius of the cone belt wheel.
Vehicles need to start with lower gear ratio, for which separate drive bevel wheel so that the belt attached thereto, and so driven
bevel wheel drive closed zone around the outer periphery of the movement. Require high transmission ratio when the speed increase,
for moving pulley half drive bevel wheel fixed to the corresponding pulley halves gradually close, cone wheel rim wheel increases,
while the driven bevel wheel forced separation, radius decreases, so have higher ratios. Produce overdrive gear ratio when driving bevel
wheel completely closed, completely separate driven bevel wheel time. Driving bevel wheel and driven bevel wheel about 1: 2.5 ratio
of rotation.
S2 Transmission
The low-speed pulley position
1. Engine input
2. Output to wheels
3.
The minimum diameter of the drive wheel (low speed)
4.
The maximum diameter of the driven wheel (low speed)
The high-speed pulley position
1. Engine input
2. Output to wheels
3.
The minimum diameter of the drive wheel
4.
The maximum diameter of the driven wheel
S2 Transmission
·The selector lever is in neutral or the parking gear
In this state, the separation of reverse clutch (2) and
forward clutch (4) prevents the wheel from movement.
-Transmission input shaft (1) is the same with engine speed.
- Reverse clutch (2) separates.
- Forward clutch (4) separates.
- Planet wheel (3) bye turn around the sun wheel.
- The sun wheel does not move. The drive wheel (5), driven
wheel (7), and the vehicle also remain intact.
For All automatic transmission, the engine starts only when
in neutral or park gear. In park gear state, mechanical lock can
prevent the movement of the front and rear of the vehicle. To
avoid damage to the transmission, please use the parking gear
when vehicle is not moving.
Transmission torque mechanism is as right
1. Input shaft
2. Reverse clutch
3.
Planetary gear
4. Forward clutch
5. Driving wheel
6. Drive strip
7. Driven bevel wheel
·The selector lever is in forward gear
In this state, the forward clutch (4) engaging to move the wheel.
- Transmission input shaft (1) is the same with engine speed
- Reverse clutch (2) separates.
- Forward clutch (4) separates.
- Planet wheel (3) bye turn around the sun wheel
- The drive wheel (5) is the same with engine speed for
forward gear direction.
- The driven gear wheel (7) is the forward direction; its
speed depends on the ratio of the running state.
Transmission torque mechanism is as right
1. Input shaft
2. Reverse clutch
3.
Planetary gear
4. Forward clutch
5. Driving wheel
6. Drive strip
7. Driven bevel wheel
8. Driven bevel wheel
9. Input shaft
S2 Transmission
·The selector lever is in reverse gear
In this state, the reverse clutch (2) engages. The ring gear
(9) is locked in the transmission case. Planet wheel (3) makes
the sun wheel (10), capstan (5) and the driven wheel (7) in the
opposite direction of rotation of the transmission input shaft (1).
Now reverse gear is selected.
- Transmission input shaft (1) is the same with engine speed
- Reverse clutch (2) engages.
- Forward clutch (4) separates
- Ring (9) is connected with the transmission case via a reverse clutch (2)
-Transmission input shaft (1) direct drive planetary gear (3)
so that it surrounds the ring gear rotation, driving the sun wheel
(10), the pulley (5) and reverse rotation of the wheel from moving
cone (7).
Transmission torque mechanism is as right
1. Input shaft
2. Reverse clutch
3.
Planetary gear
4. Forward clutch
5. Driving wheel
6. Drive strip
7. Driven bevel wheel
8. Driven bevel wheel
9. Ring gear
10. Sun wheel
Group 2－Control system
Control system has following functions：
1. Adapt the steel belt tension clamping force to the engine torque to prevent belt slippage.
2. Control forward clutch and reverse clutch while driving.
3. Provide the best ratio.
4. Provide the necessary transmission lubricants and cooling oil.
Pump
The oil pump within the transmission is external gear pumps. Engine drives oil pump shaft, pump shaft reaches the pump inside
through active cone hollow shaft to. Splined shaft to the planet gear carrier, which has been the engine shaft rpm, fuel pump about 10 cm3
/ revolution. System pressure depends on the input torque of up to 40 ~ 50bar.
Full outline of the pump
Hydraulic is for transmission hydraulic control also for lubricates.
1
2
1. Oil pump drive shaft 2. Pump assembly
S2 Transmission
Pump inlet
1
Control devices
1. Pump inlet 2. Pump Seal
Transmission control keeps the minimum tension between belt the runner but not slipping, also provides the size of the transmission
ratio (according to the input of the transmission (active) and output (driven) speed calculation) given target value according to the driving
strategy. During the life of the control device performance degradation will remain within a certain range, without significantly affecting
the vehicle comfort and belt tension.
Tension control device Tension control devices can obtain the minimum tensioning force required for the belt does not slip, so that
the efficiency of the transmission gear with minimal impact, and thus the lowest fuel consumption. In addition to normal driving, the
tension control device takes into account the maximum torque of the transmission input, output of special circumstances, to the greatest
degree of protection transmission. Control means taking into account the anti-lock braking system (ABS) brakes, tire locking (without
ABS) as well as other driving force control system (such as ESP, anti-skid control device, etc.). In addition, the device also takes into
account the special circumstances and the road, as by potholes, curbs, low adhesion coefficient changes, tire slip (as in low adhesion
coefficient road surface).
Software can compare the performance of the transmission torque of the transmission and the expected transmission input torque.
When the tension control device finds insufficient tension, ECU receives the torque reducing command, so that the engine torque is
adjusted within an appropriate range. This function can also protect the transmission.
If there is no electronic drive line systems in motor
vehicles, ECU transfers torque signal via CAN bus. If there is no CAN bus, the transmission control system (TCU) software itself is
generated a default torque signal.
Ratio control unit
Transmission balances the pressures driving bevel wheel and driven bevel wheel by controlling the input and output pressure to
control the transmission ratio. The active cone wheel and driven bevel rotation speed sensor signal can be calculated gear ratio, and
change the output pressure to give the desired ratio. The minimum pressure can be determined by methods tension. Physical model will
contribute to the rapid transmission of the pressure level is adjusted to a variable operating point. Control software also takes into
account the interference from other transmission components, and therefore also for the development of the software to minimize errors
and delays target ratio error and the like (in order to improve fuel consumption)
In order to ensure that requirements of mechanical transmission and durability limit state, we have developed a strategy to drive
some extreme state. In addition to the speed limit, the device also controls the transmission ratio change rate (set point) in the allowable
range by software. In addition the software also avoided due to the vehicle speed and engine speed gear lever status (POS) changes
beyond a certain limit. To achieve this constraint, the software required to reduce engine torque or the traveling car to change into high
gear.
Transmission control unit
Transmission control software integrated in the TCU (Transmission Control Unit) inside. TCU is installed in the cab.
Group 3－External device
Oil cooler fitting
In front of the transmission case is two oil cooler pipe joint. An oil cooler mounted next to the engine radiator imports, so that
the lubricating oil temperature is maintained at 120 ° C or less.
Gearbox oil flows from the right mouth which should be connected to the oil cooler in the following interface. Oil cooler oil from
entering the transmission from the gearbox to the left of the port, so the left side of the gearbox interface should be connected to the
above oil cooler interface
S2 Transmission
Oil cooler fittings
Shift lever
VVT2 transmission shift positions may include a parking gear (R), reverse gear (R), neutral (N), forward range (D) and sport mode
(S). Customers can configure their own custom selector lever. For security reasons, we recommend application of shift-lock device
as a starter protection. CVT can also be achieved in manual mode, which requires the TCU To add a new pin to receive the signal,
while the maximum speed of the engine to be calibrated within a certain range, all JAC CVT has a manual mode.
The main connector
The main connector is located on the transmission case, including 16 pins. Harness
connected via a circular connector.
The main connector in transmission
1
1.Wiring harness connector on the transmission
Torsional damper
Most conventional automatic transmission uses a torque converter connected to the engine and the input shaft of the transmission, but CVT
adopts a torsion damper.
出
进
油冷器
流向
流向
Output
Inout
Flowing
Flowing
Oil cooler
S2 Transmission
（III）Technical parameters, maintenance parameters
No.
Item
Parameters
1 Transmission VT2
2 Lubricating oil MOBIL(ESSO)EZL799(A)
（IV）Torque parameters
No.
Item
Torque（N·m）
Remarks
1 Refueling plug 21±3
2 Countersunk screws driven bevel wheel cover
9.5±0.95
3 Driving bevel axle nut 197.5±17.5
4 Pump Bolts 10±1
5 Driving bevel bolt axle cap 9.5±2.5
6 Oil pan bolt 9±1
7 Speed sensor mounting bolts 8,5±2
8 Differential speed sensor bracket screw 9.5±0.95
9 Body bolts 11±1
10 Oil drain plug 11±1
11 Driving mode sensor fixing screws 9.5±0.95
12 Oil level plug 15±2.25
13 Gear selection lever nut 14.5±1.5
（V）Maintenance Considerations
VT2 transmission equipped vehicle can not be directly dragged, because only when the engine is running can produce the hydraulic cone wheel to
drive belt to operate. Therefore, when the trailer you have to lift the front wheels before the trailer (floating hauling) from the ground.
（VI）Special tool
No.
Tool
Outline drawing
Description
1
Driving bevel wheel
bearing stopper
Remov
e the driving bevel wheel bearings
2
Shift gear shaft oil
seal installation tool
Install gear selection shaft seals
S2 Transmission
No.
Tool
Outline drawing
Description
3
Driving bevel wheel
bearing punch
Install active cone ball bearing shaft
4
Driving bevel wheel
bearing removal tool
Remov
e the active cone ball bearing shaft
5
Input shaft seal
installation tool
Install the input shaft oil seal
6
The input shaft seal
positioning bush
Install the input shaft oil seal
7
Gear shaft oil seal
disassembly tool
Remove the gear shaft oil seal
8
Hydraulic control
block locating pin
Install
hydraulic control block
9
Differential oil seal
installation tool
Install the differential oil seal
S2 Transmission
No.
Tool
Outline drawing
Description
10
Pump removal tool
Remove pump
11
Snorkel installation
tool
Install respirator tube
II、Troubleshooting
（I）Diagnostics table
No. Symptom Failure Analysis
Solution
Remarks
1
Transmission oil pan
gasket leak
Oil pan bolt damage Replace
Oil pan gasket Replace
Drain hole Replace
Sump assembly Replace
2
Transmission drain plug oil
leak
Screw not intact Tighten
Drain plug damage Replace
Damaged oil pan assembly Replace
3
Driving bevel wheel cap
oil leak
Closures stationary intact Tighten
O-ring damage Replace
Driving bevel wheel cover damage Replace
4
Driven bevel wheel cap oil
leak
Closures stationary intact Tighten
Sealing cap O-ring damage Replace
Driven bevel wheel cover assembly wear Replace
5
Selector lever spill Selector lever seal is damage Replace
Input rod spill The input shaft seal is damage Replace
Differential oil seal leakage Seal damage Replace
6
Oil cooling pipe joints leak
Fixed line not intact Tighten
Oil cooling pipe connector ring damage Replace
Pipeline damage Replace
S2 Transmission
No.
Symptom Failure Analysis
Solution
Remarks
7
In the D gear
driving
vehicle rushes, or
rushes
when in
rapid acceleration
of the vehicle
Self-learning not fully completed Re-learning
Filling the wrong gearbox oil or water Replace the gearbox oil
Driving bevel wheel speed sensor damage Replace
Hydraulic control block fault Re-learning
Driven bevel wheel speed sensor is damage Replace
8
Hanging D gear
, release
the brake and
the vehicle
is completely stationary
.
When the engine speed is
f
about 2000 rpm or so, the
vehicle suddenly go out
forward, with greater
impact
Check the cold car fault code Diagnosis by DTC
Check the self-learning Re-learning
Braking signal has a problem which will lead to
problems
Check the brake signal and
wiring harness
If the above checks have no problem, there
may be a problem for the body
Replace the valve body, and
self-learning
（II）Noise
Description
Sound of driven bevel gear wheel
Speed at the time of slow acceleration between 60kph to 90kph has obvious howling. When you release the accelerator pedal, the
sound becomes smaller, and when put the gas pedal, the sound is immediately restored. Sound like whistles and the sound rises with
increasing speed, and this sound is normal. Sound of gear and the intermediate shaft is driven bevel gear wheel engaging issued.
Sound of reverse gear
Hanging reverse gear, keep the vehicle stationary, relatively small audible whistle. This is the normal sound of the internal planetary
gear transmission generated when the work.
Low speed sound
When the vehicle speed is 40km / h, release the accelerator pedal when the speed is slow decline to hear a whistle. The sound whistles
than the driven bevel gear teeth sound described small and not easy to hear, this is a normal voice between the pinion and differential.
S2 Transmission
（III）Noise inspection and maintenance
No
Symptom Failure Analysis
Solution
Remarks
1
Driving bevel
wheel ball bearing
noise
Vehicle traveling in
the D block has
the
noise and
the sound
of buzz.
intensity
and sound vary
w
ith the increase of
the engine speed not
with the speed
In the D block at constant speeds (constant throttle
opening, vehicle speed at 60km / h or so), and then hang
to S mode, the engine speed will rise in about 1-
2
seconds
500 turn, this process is essentially the same vehicle
speed, engine speed increases if you follow the sound, is
in the active cone round ball
Sound emitted by the bearing
d
Replace the drive bevel
wheel ball bearing
In the 4-
speed manual transmission, a constant throttle
opening, vehicle speed to maintain a steady speed to
make about 60km / h, and then hang to manually block 3
when the engine speed will increase to about 800 rpm
and then from 3 to 4 block-for-block , the e
ngine speed
will drop to about 800 rpm, the speed remained
unchanged throughout the process, if the sound following
the engine speed increases, for the active cone bal
bearing wheels damaged by the sound
Replace the drive bevel
wheel ball bearing
2
Internal gearbox
bearing noise
Noise in the D
gear
lprocess
is
humming sound
sound volume and
frequency
is
associated with the
speed
Detection method according to driving bevel wheel
of the ball bearing noise, if the noise does not follow
the engine
speed increases and rises, but merely
follows the rise in the vehicle speed rises, it is
possible for the wheel axle bearing noise, the bearing
axle troubleshooting if, for the transmission internal
bearing noise
Correctly judge the noise
problem is very
difficult,
so before deciding to
replace the gearbox parts
or replace the entire
transmission, is required to
determine the noise
emitted from the gearbox
in the past. It can be
replace easily replaceable
parts on the car to
determine the source of
noise
Refer to
Internal
gearbox bearing
noise flowchart
3
Transmission water
noise. Hanging D
block or R gear,
slowly release the
brake, the wheel as
long as a move will
have a giggle sound,
if the fuel door,
between vehicle
speed from 10km / h
to 40km / h will
squeak ----- -
continuous sound,
more than 40km / h
sound disappears.
In the beginning of
the water, you may
only hear "Kaka Ka"
sound, not to listen to
the acceleration
"squeak ------
"
continuous sound.
Some cars at the
starting time may
be
Drain and remove sump and driving bevel wheel drive
bevel wheel cover if the cover is white matter, oil pan
has the same white matter is sufficient to prove there is
water in the gearbox or transmission, or mixed with
other oils liquid
Replace the filtration,
refill transmission oil
Driving at various speeds and acceleration and
deceleration for about 5 minutes. "Kaka Ka" sound
should disappear, "squeak ------
" sound should be
reduced
Put out The gearbox oil
and refill new gearbox oil
"Squeak"sound can make by doing experiments stall
clutch temperature rises to resolve. Linked to the D
block, step on the foot brake and fuel
If this process fails codes P2787 clutch and
disconnecting clutch temperature
is too high, this is only
the transmission of self-
protection, but not a
malfunction. When the fault lights automatically put out
After off, can continue to do experiments stall, until the
noise disappears too much water or mixed with other
oils too, the phenomenon does not solve the noise and
ran
Replace the gearbox
4
Neutral or P
gear
noise (noise with the
engine speed rises
rise
Analyzing sound sources whether transmission unit or
engine parts
If it is transmission, check for unusual noise pump
Check the oil pump
S2 Transmission
If it is confirmed
to be the noise of transmission, but
not the pump sound judgment, it is possible for the
input shaft bearing or the sound of the planetary gear
set
Replace the transmission
No. Symptom Failure Analysis
Solution
Remarks
5
Neutral or P
gear
noise (noise does
not
vary with
engine speed)
neutral or P block noise (noise of the engine
speed does not follow the rise and rise)
Correctly judge the noise problem
is
very difficult, so before deciding to
replace the gearbox parts or replace
the entire transmission, is required to
determine the noise emitted from the
gearbox in the past. It can be replace
easily replaceable parts on the car to
determine the source of noise
Refer to N or P
gear
noise
flowchart
6
In the D
gear
driving, vehicle
rushes, or
rushes
when in
rapid
acceleration of the
vehicle
Self-learning not fully completed Re-learning
Filling the wrong gearbox oil or water Replace the gearbox oil
Driving bevel wheel speed sensor damage Replace
Hydraulic control block (body) fault Replace the hydraulic control block
(body)
Driven bevel wheel speed sensor is damage Replace
7
Hanging D
gear
, release
the brake and
the vehicle is
completely
stationary.,
When the
engine speed
isf about 2000
rpm or so, the
vehicle
Check the cold car fault code Re-learning
Braking signal has a problem which
will lead
to problems
Check the brake signal and wiring
harness
If the above checks have no problem, there
may be a problem for the body
Replace the valve body, and self-
learning
S2 Transmission
Internal gearbox bearing noise flowchart
检查变速箱部位
否
是确定噪音是否
跟随发动机转
速上升而上升
检查发动机部位
是
否
否
是否存在噪音 更换
半轴轴承
更换变速箱
否
否
是
故障现象：轴承嗡嗡
噪音（只在D 档开起
来有噪音）
更换主动锥轮滚珠轴承
检查半轴轴承
是否存在噪音
是
检查变速箱内部其
他轴承
更换相关部件
是
是否存在噪音
检查发动机部位
系统正常
确定噪音是否
跟随车速上升
而上升
S2 Transmission
N or P gear noise flowchart
（IV）Fault code and measures
General Description
Once the gearbox control unit shows fault codes, fault light on the dashboard lights up。
Whenever you read DTC by detection tool and found fault code, first check the fault code is not the fault history, and does not
appear in the final of the driving cycle, if so, delete the fault code and check whether the fault code will reappears. If the fault is not
history but current fault, the following fault codes to gradually resolve. Check always the software is not up to date. If not, refresh to the
latest software, and then check the fault code is still present. General Description: Whenever a fault code generation or transmission
problems, first check the basic three:
A.Check whether the CVT special oil.
b. Check the oil level.
c.Re-selflearning
检查发动机部位
确定噪音是否
跟随发动机转
速上升而上升
是
否
否
是否存在噪音
更换
油泵
更换变速箱
否
否
是
故障现象：N 档或P 档
有噪音
检查车辆其他部件噪音
检查
油泵
是否存在噪音
是
检查行星轮或者输入
轴轴承噪音
更换发动机部件
是
是否存在噪音
检查发动机部位
系统正常
N or P gear noise
Check the
engine parts
Check whether
noise rises with the
engine speed
Yes
Yes
Yes
Yes
No
No
No
No
Check whether
noise is from other
parts
Check the
pump
Whether there
is noise
Change the
pump
Check the Check the
planetary gear input
shaft or bearing noise
Whether there
is noise
Whether there
is noise
Check the
engine parts
Change the
transmission
Change the
engine parts
All is normal
All is normal
S2 Transmission
You do not have to complete all following procedures until the problem is solved.
No.
DTC
code
TCU
measure
Repair guide
1
P0710 oil temperature
sensor fault
Fault indicator light, customize
system Transmission oil temperature
Check t
ransmission oil temperature by the detector, if
the signal data should be appropriate, put DTC Clear
and check out whether it will happen once again.
Check the wire (open circuit, short circuit, earth).
Check
gear main fitting resistance between the two pins
(20℃ the resistance should be between 980-
1000 ohms)
to determine whether the oil temperature sensor is
damaged, if
damaged, skip to the next step and direct
replacement of a main connector
Replace a new TCU
Replace the transmission
2
P2765 driving bevel off
wheel speed sensor fault
Three pressure regulators are off,
fault indicator light
Check t
ransmission oil temperature by the detector, if
the signal data should be appropriate, put DTC Clear
and check out whether it will happen once again.
Check the wire (open circuit, short circuit, earth)
Replace a new TCU
Replace the speed sensor
3
P0720 driven bevel off
wheel speed sensor fault
Fault indicator light, customize
system driven bevel off wheel speed
Check t
ransmission oil temperature by the detector, if
the signal data should be appropriate, put DTC Clear
and check out whether it will happen once again.
Check the wire (open circuit, short circuit, earth)
Replace a new TCU
Replace the engine speed sensor
4
P0840 driven bevel wheel
pressure sensor
Three pressure regulators are off,
fault indicator light
Check the driven bevel wheel actual oil pressure
by
detector and then compare the target value. If
signal
data is
appropriate, put the fault code clear and check
whether there will happen again
According to the first step in the value detection circuit
(ground: 0bar(Actual pressure), short circuit: 60bar;
disconnection: 60bar)
Replace a new TCU
Replace the valve body
5
P0641 pressure sensor
supply fault
Three pressure regulators are off,
fault indicator light
Check by detector whether the input voltage is 5V. I
f the
data is correct, clear fault codes and detect whether the
current again
Check the voltage between pressure sensor and
ground, based on the results in the first step
Check the wire (open circuit, short circuit, earth)
Replace a new TCU
Replace the hydraulic control block (body)
S2 Transmission
No.
DTC
code
TCU
measure
Repair guide
6
P0651 driving mode
sensor and the speed
sensor are power failure
Three pressure regulators are off,
fault indicator light
Check by detector whether the input voltage is 8.4V. I
f the
data is correct,
clear fault codes and detect whether the
current again
Check the voltage between pressure sensor and ground,
based on the results in the first step
Check the wire (open circuit, short circuit, earth)
Replace a new TCU
7
P0659 pressure regulator
is short circuit
Three pressure regulators are off,
fault indicator light
Check HS voltage and compare with battery voltage
If the voltages are same, please detect circuit (whether short
circuit between the battery positive electrode and VHS
gearbox Interface) and repair the harness
If they are different and higher than 3.4V, replace TCU
8
P0658 pressure regulator
short circuit or ground
Three pressure regulators are off,
fault indicator light
Check HS voltage and compare with battery voltage
If the battery voltage is normal, high voltage is less than
3.4V, it means that there is a ground wire
If the battery voltage is normal, high voltage is greater than
3.4V, it means a place to break
In both cases, according to the specific circumstances of
checking pin power cable, check if the end of the wire
was found intact for the replacement TCU
If the battery voltage is not normal, check the battery
9
P0702TCU internal
detection system is fault
Three pressure regulators are off,
fault indicator light
Replace the TCU
10
P0962EDS1 Driving
bevel wheel pressure
regulator ground
Three pressure regulators are off,
fault indicator light
Check driving bevel wheel pressure regulator resistance -
should be 5.05 ohms ± 6%
Check the wire (ground), according to test results replace the
wiring harness inside the gearbox or the engine wiring
harness
Replace the hydraulic control block
11
P0963EDS1 Driving
bevel wheel pressure
regulator short circuit
Three pressure regulators are off,
fault indicator light
Check driving wheel pressure regulator cone resistance
Check the wire (open circuit), on the basis of test results
replace the wiring harness inside the gearbox or the engine
wiring harness
Replace the hydraulic control block
12
P0966EDS2 Drivenbevel
wheel pressure regulator
ground
Three pressure regulators are off,
fault indicator light
Check driven wheel pressure regulator cone resistance
Check the wire
(ground), according to test results replace the
wiring harness inside the gearbox or the engine wiring
harness
Replace the hydraulic control block
13
P0967EDS2 Driven bevel
wheel pressure regulator
short circuit
Three pressure regulators are off,
fault indicator light
Check driven bevel wheel pressure regulator resistance
Check wiring (short circuit), on the basis of test results
replace the wiring harness inside the gearbox or the engine
wiring harness
Replace the hydraulic control block
S2 Transmission
No.
DTC
code
TCU
measure
Repair guide
14
P0964EDS2
Driven bevel
wheel pressure regulator
disconnection
Three pressure regulators are off, fault
indicator light
Check driven bevel wheel pressure regulator resistance
Check the wire (open circuit), on the basis of test results
replace the wiring harness inside the gearbox or the
engine wiring harness
Replace the hydraulic control block
15
P0902EDS2 Clutch
pressure regulator
ground
Three pressure regulators are off, fault
indicator light
Check the resistance of the clutch pressure regulator
Check the wire (ground), according to test results
replace the wiring harness inside the gearbox or the
engine wiring harness
Replace the hydraulic control block
16
P0903EDS2S2 Clutch
pressure regulator
short circuit
Three pressure regulators are off, fault
indicator light
Check the resistance of the clutch pressure regulator
Check wiring (short circuit), on the basis of test results
replace the wiring harness inside the gearbox or the
engine wiring harness
Replace the hydraulic control block
17
P1763 Starting lock short
circuit or ground
Three pressure regulators are off, fault
indicator light
Check wiring, if sensor gear has a problem
sometimes reported this DTC
Replace the ECU
18
P1764 Starting lock short
circuit
Three pressure regulators are off, fault
indicator light
Check wiring
Replace TCU
19
P1768 Reversing light
ground
Three pressure regulators are off, fault
indicator light
Check wiring
Replace TCU
20
P1769 Reversing light
short circuit or circuit-
breaker
Three pressure regulators are off, fault
indicator light
Check wiring
Replace TCU
21
P0868 Preload pressure
regulator failure
Three pressure regulators are off, fault
indicator light
Check the oil level and oil
Replace pump
Replace the hydraulic control block
Replace the transmission
22
P0811 Clutch (forward or
backward) slipping
Fault indicator light, the clutch opens
Re-do the self-learning, this DTC in the cold state
may have occurred, so in the cold state to do self-
learning
Check the oil level and oil type
Replace the hydraulic control block
Replace the transmission
S2 Transmission
No.
DTC
code
TCU
measure
Repair guide
23
P0730 Ratio control fault
Three pressure regulators are off,
fault indicator light
Check signal given by speed sensor by
detector, and
check the input current driving bevel wheel pressure
regulator and the feedback current
Based on failure to take appropriate measures, such
as speed sensors there are problems and check the
speed sensors, pressure sensors have a problem
checking pressure
Check the oil level and oil type
Replace the pump
Replace the hydraulic control block
Replace the transmission
24
P0730 Drive ratio fault
Three pressure regulators are off,
fault indicator light
Check signal given by speed sensor by
detector, and
check the input current driving bevel wheel pressure
regulator and the feedback current
Based on failure to take appropriate measures, such
as speed sensors there are problems and check the
speed sensors,
pressure sensors have a problem
checking pressure
Check the oil level and oil type
Replace the pump
Replace the hydraulic control block
Replace the transmission
25
Driven bevel wheel
pressure is too low
Three pressure regulators are off,
fault indicator light
Check the actual pressure in dynamic driving
situations (like the manual shift, etc.) and compare
with the target value
Check the oil level and oil type
Fully complete self-learning (DTCs may occur in the
case of self-learning has not completed)
Check the engine side can cause the engine torque
reduction reasons: spark plugs, throttle, catalytic, etc.
(the longer the engine of this issue may occur)
Replace the hydraulic control block
Replace the pump
Replace the transmission
26
P1766
Driven bevel wheel
pressure is too high
fault indicator light
Check the actual pressure in dynamic driving
situations (like the manual shift, etc.) and compare
with the target value
Check the oil level and oil type
Replace the hydraulic control block
Replace the pump
Replace the transmission
27
P0701 Two fault appears
simultaneously require
pressure regulator power
break
fault indicator light
Check other DTCs
S2 Transmission
No.
DTC
code
TCU
measure
Repair guide
28
P0218 Transmission oil
temperature is too high
fault indicator light
Check the oil cooler
Try under ordinary driving conditions to make this
failure once again, if it does not
appear, ask the customer
at what driving conditions fault occurs
Under step 2 driving conditions, the gearbox oil
temperature can be measured, can be used to detect
whether the detected transmission oil temperature
≥
120 ℃ (time of occurrence o
f fault codes minutes
shorter than filter30 not right) to take measures to
avoid
future transmission temperature is too high
29
P1767 Transmission oil
temperature is out of
range
Three pressure regulators are off, fault
indicator light
Try under ordinary driving conditions to make
this
failure once again, if it does not
appear, ask the customer
at what driving conditions fault occurs
Check the oil cooler
Checkthe oil level
Replace the valve body
Replace the gearbox
30
P0219 Power system
speed is out of range
Three pressure regulators are off, fault
indicator light
It should never appear in principle
Check that the engine speed is limited to less than
6000rpm
31
P2766 Driving bevel
wheel speed does not
match with the real speed
Three pressure regulators are off, fault
indicator light
Test other Speed information by detector (engine speed,
output shaft speed, vehicle speed) is not also lost; if it is
to solve these problems first and then check whether the
fault occurs again
Test driving bevel wheel speed signals w
ith detector
in the clutch engagement state and
the engine speed,
a difference should be less than 200rpm. It should
be in the low engine speed range to the high speed
All Compare (up to 6000 rpm)
Check wiring
Replace a well-TCU
Check the position of the sensor, angle, speed
sensing plate
also want to check. Check there are no
objects in front of the sensor (steel fragments, etc.)
NOTE: This is a mechanical failure, electrical
failure there are other fault codes
Replace the drive bevel wheel speed sensors
Replace the transmission harness inside
Replace the engine wiring harness
Replace the gearbox
S2 Transmission
No.
DTC
code
TCU
measure
Repair guide
32
P0721 Driven bevel
wheel speed does not
match with the real speed
Fault indicator light
Increase the clamping force to the
level 0, the system custom driven
bevel wheel speed
Speed detector test with other information (engine
speed, output shaft speed, vehicle speed) is not also
lost; if it is to solve these problems first and
then
check whether the fault occurs again
Test driving bevel wheel speed signals w
ith detector
in the clutch engagement state and the engine speed,
a difference should be less than 200rpm. It should be
in the low engine speed range to the high speed
All
Compare (up to 6000 rpm)
Check circuit
Replace the TCU
Check the position of the sensor, angle, speed sensing
plate also want to check. Check there are no objects
in front of the sensor (steel fragments, etc.) NOTE:
This is a mechanical failure, electrical failure there
are other fault codes
Replace the drive bevel wheel speed sensors
Replace the transmission harness inside
Replace the engine wiring harness
Replace the gearbox
33
P0944 Insufficient
clamping force (VSM)
Fault indicator light
Increase the clamping force to the
level 0, the system custom driven
bevel wheel speed
Check the ECU code
Replace the ECU
Check the oil level and oil
Fully complete self-learning (DTCs have in this case
not sufficient to complete the self-learning may occur)
Check the engine side which
cause the engine torque
reduction reasons: spark plugs, throttle, catalytic, etc.
(the longer the engine of this issue may occur)
Replace the valve body
Replace the oil pump
Replace the gearbox
34
P0782 Winter driving
mode failure
Fault indicator light, the system
Custom winter mode Close
Check circuit
Replace the ECU
35
P0783 Cruise control fault
Fault indicator light, cruise control
system custom feature off
Check circuit
Replace the ECU
Replace theTCU
36
P0810
Adaptive update
unfinished offline
Fault indicator flashes
Adaptive update once again
37
P1762 Current value is
fixed and can not be
changed
Three pressure regulators are off,
fault indicator light
Check P0962 、 P0963 、 P0960、 P0966、 P0967
、
P0964、P0902、P0903、P0900、 P1763、P1764
and
repair,which may remove fault code
Replace a well-TCU
S2 Transmission
No.
DTC
code
TCU
measure
Repair guide
38
P0882 Battery or high
voltage is too low
Three pressure regulators are
off, fault indicator light
When this occurs there is a failure at the time of recording
the battery voltage (so you can tell whether or not the
battery failure caused by high-
voltage); if not history, the
next step directly inspection
Detector test with high-voltage or battery voltage -
Temperature greater impact on the value: Refer to the software
content
Check the battery to between ECU circuit (fuse, main relay)
Replace / Check battery
If the problem is high voltage: Check the circuit from the
gearbox to the TCU
Replace TCU
39
P0883 Battery or high
voltage is too high
Three pressure regulators are
off, fault indicator light
When this occurs there is a failure at the time of recording
the battery voltage (so you can tell whether or not the
battery failure caused by high-
voltage); if not history, the
next step directly inspection
Detector test with high-voltage or battery voltage -
Temperature greater impact on the value: Refer to the software
content
Check the battery to between ECU circuit (fuse, main relay)
Check / replace battery or generator
If the problem is high voltage: Check the circuit from the
gearbox to the TCU
Replace the TCU
40
P2787
Clutch temperature
is too high
Fault indicator light, the clutch
opens
Check how many times This failure happens. I
f only once
or a few times to see if the data at
TCU and internal
customer was asked about a special driving environment
like climbing lane, then you can delete fault code
Check the oil level and oil
Fully complete self-learning (DTCs have in this case not
sufficient to complete the self-learning may occur)
Only in doing stall test when it might occur this DTC,
delete fault codes and see if there is a fault code
Replace the TCU
There may be a stuck throttle. Replace the throttle valve
41
P0727 The hard-
line
engine speed signal
transmitted from the ECU
to the TCU Does not
match the true speed
fault indicator light
Check the engine's test report to see if the engine fails, and if
so, engine repair
The inspecting ECU input signal - which is a frequency signal
(900 rev / min to 30Hz, 3000 rev / min to 100Hz)
Replace the TCU
Replace the engine speed sensor
S2 Transmission
No.
DTC
code
TCU
measure
Repair guide
42
P1761 Pressure regulator
current fault
Three pressure regulators are off,
fault indicator light
Test with detector pressure regulator and pressure
inside each and provisions of the current compared to
h l
C
ompared with the current regulations and the detector
test pressure regulator current, and if you
find one with
a predetermined current does not, check the pressure
regulator wire (also check the gearbox section)
Replace theTCU
Replace the hydraulic control block
Replace the transmission harness inside
Replace the engine wiring harness
43
U0301 Vehicle
configuration error
(As with other vehicle
ECU)
Three pressure regulators are off,
fault indicator light
Check TCU combination of hardware and software is
correct and effective
If EMS or TCU new brush software: new software on
the
controller must be wrong (incompatibility transmission
between the controller and the engine controller)
44
P0706 Driving mode
sensor singlet error
Fault indicator light, custom sensor
location system
Check the cord with the detector in problem and
the reason
of the problem, like
a short circuit, etc. B line (which
indicates that the fault line has a fault)
Check related wire between the gearbox and TCU-
Replace a well-TCU
Replacing the drive mode sensor
Replace the transmission harness inside
Replace the engine wiring harness
45
P0705 Driving mode
multi-line sensor error
Three pressure regulators are off,
fault indicator light
Check the cord with the detector in problem and
the reason
of the problem, like
a short circuit, etc. B line (which
indicates that the fault line has a fault)
Check related wire between the gearbox and TCU-
Replace a well-TCU
Replacing the drive mode sensor
Replace the transmission harness inside
Replace the engine wiring harness
46
P0571 Brake signal fault
Fault indicator light, brake signal
combination
Check the brake with the detector signal status
Check the brake signal line
Check the brake switch
Replace the TCU
47
P0955
Manual subtraction
gear signal failure
Fault indicator light, no manual
mode
Check the wire between TCU and shifting
Replace the shifting mechanism
Replace a well-TCU
S2 Transmission
No.
DTC
code
TCU
measure
Repair guide
48
U0001 CAN Bus fault
Fault indicator light, activated in emergency
mode, there is no manual mode
Increase the clamping force level 1 (highest),
custom-lock system and rotation
status,
activate the internal driving strategy, system
Custom engine speed, engine torque system
custom, custom system engine coolant
temperature, brake signal engagement, digital
fixed the accelerator pedal, the system
custom left front wheel speed, front
right
wheel speed system custom, custom system
left
Rear wheel speed, rear right wheel
speed custom system.
If the fault occurs on all other controllers,
it means the problem is the wiring harness
(CAN and CAN low-speed short-
circuit):
Check the car harness
If the fault is only stored in the TCU: replace a
perfectly good TCU
49
U0121ABSCANCommun
ication breakdown
Fault indicator light, activated in emergency
mode, there is no manual mode
Increase the clamping force level 0, system
and custom
locking condition rotation system
custom left front wheel speed, front right
wheel speed system custom, custom system
left rear wheel speed, rear right wheel speed
custom system
Check the ABS controller and on the CAN
communication interface (or promise on the
other controllers will report the fault)
50
U0100ECUCANCommun
ication breakdown
Fault indicator light activates emergency
mode, there is no manual mode
Increase the clamping force levels 0,
activates the internal driving policy, the
system
custom engine torque, engine coolant
temperature system custom accelerator pedal
fixed value, stop the data transfer on the
CAN
Check the ABS controller and on the CAN
communication interface (or promise on the
other controllers will report the fault)
51
U1012CAN
Engine speed
signal error on bus
System custom engine speed
Check the MCU controller (engine speed
sensor and sensor wiring)
52
U1013CAN Bus
accelerator pedal signal
error
Fault indicator light, the accelerator pedal fixed
value
Check the EMS controller (accelerator pedal
sensor and sensor wire)
S2 Transmission
No.
DTC
code
TCU
measure
Repair guide
53
U1014CAN Bus engine
torque signal error
Fault indicator light
activates
emergency
mode, there is no manual
mode activates the
internal driving strategy,
system custom engine
torque
Check the EMS Controller Notes: three pressure regulator power
down: When a fault code and the pressure regulator off, the clutch
is opened, and then the car in gear can not walk, only when the
engine stalled, the key position to zero, and then reignite and then
the car can continue to forward
Increase the clamping force level 0: pressure driven bevel wheel is
fixed, this pressure is higher than normal, lower than the highest
level
Increase the clamping force Level 1: driven bevel wheel pressure is
fixed at the highest level
EDS1: driving bevel wheel pressure regulator EDS2: driven bevel
wheel pressure regulator
Emergency Mode: also called limp-home mode, such as the
case when there will be activated:
CAN line off
CAN ECU communication failure
CAN engine torque signal error
All associated with the engine and ABS signals will be replaced
(Security measures): the throttle opening is fixed
MAP of engine replacement engine torque engine coolant
temperature is fixed to the wheel speed is replaced with the gearbox
output shaft speed
Movies from the engine speed with the speed signal lines pass over
the clutch open or in combination with relatively rigid
, as if there is
no calibration data in it
The maximum engine speed is limited to 3200 rpm
The maximum speed is limited to 98km / h
Transmission will only accelerate in a policy shift
CVT will only work in the most basic conditions, provide sufficient
driving performance allow the car to travel to a nearby service
station
After two seconds, or sports gear manual transmission can not be in
use, and the lights and the fault
III、Driving Strategies
（I）Parking gear and neutral gear function
No matter what type is the transmission, only in parking gear neutral condition the engine can be started. Mechanical lock at the
parking gear so that the car can not move back and forth. The best use of the vehicle parking gear is in a stationary state, to prevent
damage to the transmission.
If you are not careful to use the parking gear at a high speed, the vehicle speed is only about 5km / h for
the docked device to work.
The parking lock mechanism
When the vehicle is started, TCU will start control relay, starter relay
and starter motor can be controlled.
Cars driving by the internal gear mode sensor control while driving
mode sensor directly connected to the shift lever.
If you want to change (P) or (N) shift into forward gear (D) or
reverse gear (R), you need to depress the brake pedal. If you do not step on
the brake pedal, gear lever to continue to be locked in P or N block.
1
2
1. Parking detent pawl 2. Driven bevel
wheel
S2 Transmission
（II）D and R gear function
General operation
The driving operation of the CVT transmission and conventional automatic transmission is completely different, so you should
pay attention to adapt. For example: If you step on the gas pedal too hard, the engine speed will be significantly increased, and the
speed changed little. This function is normal for a continuously variable transmission, the transmission if the driver did not
understand this; it might be mistaken for the gearbox failure. Other operations may also be approximated to conventional automatic
transmission.
Adaptive update
Either forward or reverse, the corresponding clutch are to be re-calibrated in the period of its use to achieve the best results.
Climb
The automatic transmission performance shows that, when the shift lever is in a forward gear (D) or reverse gear (R), if the driver
releases the brake pedal, the car began to climb the line (flat road). If the road surface gradient is not more than 8 °, cars can crawl; if the
road surface slope greater than 8 °, the car will be slightly back, which is equipped with a torque converter transmission as a vehicle, as
it will not retreat when the slope is not. No matter the size of the road surface gradient, the maximum speed of cars crawling will be less
than a limit value (eg 8kph). Especially in the downhill, the control system such that the clutch by the separation swapped "engagement"
mode, so you can use engine braking taxiing.
Idling stop (only forward gear state)
VT2 idling stop transmission can be realized. Vehicle (battery status, air conditioning on / off) and the transmission side (does not
affect the durability of the transmission case) have reached an idling stop can occur under certain conditions. If all conditions are met,
the stationary state of the engine is turned off. Only release the brake pedal, the engine restarts, the transmission quickly work vehicle in
order before and after exercise.
Idling stop function is especially suitable for hybrid drives, but no special starters or start a standard
power transmission unit of the motor, the transmission of the idling stop function has no effect.
Acceleration and deceleration
Acceleration process mainly depends on the driver’s requirements and driving conditions so that the engine speed changes and
trends in initial velocity corresponding to the range to reach the optimum driving comfort.Clutch controller also provides some ways to
compensate for the difference (the difference between different vehicles) produced clutch wear, thus ensuring driving comfort.
Acceleration support
To achieve optimum driving comfort, the most appropriate engine speed should be determined; this speed is between the
minimum and traction to keep the vehicle engine speed constant between (economic speed) cruise engine speeds. Transmission control
system by between transmission (ratio control) and start joint use of the clutch control mode provides functionality to meet these
requirements. Therefore, the vehicle started, the control target has focused on control and acceleration of the vehicle-related driving
performance of a high engine speed, and when the vehicle is cruising or coasting, the control is transferred to the target transmission
fuel economy up.
Deceleration
If the driver stepped on the accelerator pedal at the same time stepping on the brake pedal, the engine speed will be limited within a
certain range (with torque converter transmission is similar). To this end, the transmission and the engine control system requires
blocking torque so that the transmission can be in the driver suddenly releases the brake pedal when starting to fast response to control
clutch.
Long-term use brake can cause clutch high temperature, which is the risk of damaging the transmission, so we use the monitoring
function to detect these dangerous conditions. Activate transmission's internal diagnostic system that can open the clutch. Then if the
driver has been stepping on the accelerator pedal, the engine will rev to the maximum. And in other cases to follow up clutch control also
control objectives to ensure intrinsic safety and improve driving comfort.
Driving and braking
When the car decelerates to a standstill, the clutch is again separated to prevent engine stalls, the clutch control pressure steady decline
gradually separating clutch, it will not cause torque fluctuations. Therefore, the controller provides different modes disengage the clutch
according to the speed change. Clutch pressure control device is also based on the transmission oil temperature control system to control
the hydraulic power. Prepare quickly after starting clutch. In order to make the best vehicle driving comfort, transmission software means
interaction with other transmission control braking and start the process, this action causes the torque transmission is temporarily
interrupted, idling increases
Clutch engaging and separation in driving
S2 Transmission
If the driver does not use the clutch, the transmission controller has little effect on driving comfort, because they do not use the clutch to
nothing to do with the characteristics of the hydraulic system. (Low load, parking, low engine speed) In this case the application of the clutch
again compared with the application of a stationary state of the clutch, driving comfort may decline.
（III）Failure default mode
When the software detects a system error, the default rule will be applied; and it will be transmitted to the drive through the fault of the
instrument cluster display. The drive will follow the seriousness of the error to take a different default drive state. In some cases, the main relay
opens. All fault code will appear on the OBD.
IV、Adaptive update
（I）Directions
The following conditions need to be adaptive learning:
• ECU software refreshment
• Replacement of gearbox
• Replacement of the TCU
The clutch needs to be done to update the adaptive (self-learning) to compensate for production process tolerances. It can shift in the
idle condition to achieve this functionality. Before self-learning is not completed, TCU fault indicator blinks once every two seconds.
Once the first self-learning is completed, after the entire life cycle of self-learning is done automatically.
（II）Conditions required
This condition requires prior completion of self-learning:
• require idling under steady state engine torque and speed, the engine also needs to be done ahead of self-learning, self-learning engine
for more information, please read the documents ECU suppliers.
• Engine speed demand: ECU target value ± 200rpm
• engine torque demand: ECU target value ± 12N • m
• gearbox temperature should be between 30 ℃ to 80 ℃.
• Air conditioning is off
• a non-adaptive XTCU will always issue a request to the idle raised to 1150rpm engine. If you have made self-learning before XTCU,
including
1. Refresh software
2. Replace gearbox
First you should remove the value of self-learning from TCU. MLT can be implemented in software, or the manufacturer detector
implementation.
（III）Program
When we all fulfill all the conditions, we should perform the following actions:
• Speed = 0kph
• without refueling
• the whole process to slam the brake pedal
• gear switch to "D" gear
S2 Transmission
故障码FC 55激发
保持全程踩下制动踏板
进行滚筒高速测试
开始
结束
确认发动机温度是否
大于60°C ，变速箱
温度是否在 30°C
到 80°C 之间
启动核心E O L程序计时器 T1=0 ；
计时器开始启动
删除TC U 自学习值
执行以下的操作：
- 车速 = 0 kph
- 不加油门
- 踩住制动踏板
- 空调处于关闭状态
- 档位切换到“D ”档
自学习周期 T1>120秒
离合器自适应成功
读取FC 55故障码
等待或驱动直到
温度处于规定范围
否
否
否
否
是
是
是:完成自适应时间约为40s
是
Start
Wait or drive until the
tempreture stability in a
predetermined range
Conduct high-speed drum test
Remove ECU self-learning
Confirm whether engine
tempreture is around 60
and whether transmission
tempreture is in 30-80
No
Yes
Perfrom the following:
• Speed = 0kph
• without refueling
• the whole process to slam the brake pedal
• gear switch to "D" gear
•air conditioner off
Read DTC FC55
Start core EOL timer T1=0; timer stars
Yes
Yes
No
DTC FC55 activation
Holding full brake pedal
No
No
Self-learning period T1>120s
Clutch adaptive success
Yes: Self-learning period is around 40s
End
S2 Transmission
故障码FC 55激发
保持全程踩下制动踏板
结束
确认发动机温度是否
大于60°C ，变速箱
温度是否在 30°C
到 80°C 之间
启动核心E O L程序计时器 T1=0 ；
计时器开始启动
执行以下的操作：
- 车速 = 0 kph
- 不加油门
- 踩住制动踏板
- 空调处于关闭状态
- 档位切换到“D ”档
自学习周期 T1>120秒
离合器自适应成功
读取FC 55故障码
等待或驱动直到
温度处于规定范围
否
否
否
否
是
是
是:完成自适应时间约为40s
是
Clutch adaptive program will start automatically. In the learning process, if there is interference adaptive case, the fault code FC55
(P1774) will be excited, then the time fault light will stay on for as a warning. As long as the clutch self-learning is not completed, the
fault code FC51 (P080A) will inspire them. At the same time, the fault lamp flashes.
When everything is to be very smooth, complete adaptation of the block time is about 40s. If in the 120s, adaptation has not been
completed, then the self-adaptation will fail.
When in this gear, after the completion of an adaptive clutch, the engine speed will be raised to 1500rpm again in a short time, then
we can make the next step.
Note: For aftersales vehicle, we do no need for high-speed drum
test. Be sure to check again whether the study has been
completed all prerequisite of self-pieces.
Wait or drive until the
tempreture stability in
a predetermined range
No
Confirm whether engine
tempreture is around 60
and whether transmission
tempreture is in 30-80
Yes
Perfrom the following:
• Speed = 0kph
• without refueling
• the whole process to slam the brake pedal
• gear switch to "D" gear
•air conditioner off
Start core EOL timer T1=0; timer stars
Read DTC FC55
DTC FC55 activation
Yes
No
No
No
Yes
Holding full brake pedal
Self-learning period T1>120s
Clutch adaptive success
Yes: Self-learning period is around 40s
End
DTC FC55 activation
Yes
Yes
No
No
No
Holding full brake pedal
Self-learning period T1>120s
Clutch adaptive success
S2 Transmission
Please follow the steps below:
• Speed = 0kph
• release the accelerator pedal
• Keep full brake pedal
• switch gear to "R" block
Offline adaptive clutch starts automatically. In the learning process, if there is interference adaptive case, the fault code FC55 (P1774)
will be excited, then the time fault light will stay on for as a warning. As long as the clutch self-learning is not completed, the fault
code FC51 (P080A) will inspire them. At the same time, the fault lamp flashes. If adaptive process is smooth, the adaptive time to
complete is approximately 40s. If in the 120s, adaptation has not been completed, then it lost this adaptive effect. If the clutch after
successful adaptation, the engine speed will be raised to 1500rpm in a short time and then suddenly fell to the idling speed (850rpm),
this time gearbox fault light will automatically turn off.
Remarks:
First in the self-learning starts from D gear to R gear and this order is not mandatory. Similarly，there is no problem to start self-
learning from R to D gear.
（IV）Common problem
Clutch self-learning
error code
Type
1 Engine torque is unstable
2 Air conditioner is off
4 Pressure is too high
8 Engine speed is too low
16 Engine speed is too high
32 Too frequent failure
FC55: Offline adaptive
Fault code is 1
Engine torque is unstable
Smoothly enhance the engine torque to ensure the successful
completion of the self-learning
FC55: Clutch self-learning
error code is 2
Air conditioner is on
Turn off air conditioning to restart self-learning again
FC55: Offline adaptive
Fault code is 4
Clutch pressure is increased, but the
engine torque does not enhance
Placing in D or R gear, check whether the transmission torque is
normal and check to make sure the engine torque signal is normal
to
re-learning
FC55: Offline adaptive
Fault code is 8
Engine speed is too low
Steady increase the engine speed to re-learning
FC55: Offline adaptive
Fault code is 16
Engine speed is too high
Steady increase in engine speed to re-learning
FC55: Offline adaptive
Fault code is 32
Abnormal torque, whether the start
switch, etc.
Confirm that all auxiliary functions are not used.Restart self-
learning after confirmation
Fault
Possible causes
Solution
Self-learning over 120s
failure
Transmission oil temperature is below
30 ℃ in learning process
Start the engine until the oil temperature is above 30 ℃, then start
self-learning
Transmission oil temperature is over 80 ℃
in learning process
Close the engine until the oil temperature is below 80 ℃
, then start
self-learning
Engine temperature is below 60 ℃ in
learning process
Start the engine until the oil temperature is above 60 ℃, then start
self-learning
S2 Transmission
Foot brake loose in learning process Re-learning to ensure that in the whole process the foot brake has
been slam
S2 Transmission
V、 Transmission Oil
（I）Special tool （None）
（II）Description for checking the oil level
Whenever discharge gearbox oil or replace the gearbox，following oil level inspection should be carried out. As a service accessory
gearbox no refueling is required after loading increases by approximately 4.2 ± 0.05 liters ESSO EZL799 (A) or IDEMITSU CVT-
EX1. Check the oil level in accordance with the following method after refueling:
1) Start the engine and run at idle for at least 10 seconds (Note: When the engine starts to hear voices airflow circulating in the system
is normal)
2) Switching to a different gear shift lever (parking block - reverse gear - neutral - Drive) and before switching to the next gear for 5
seconds on each gear.
3) Shift into "D" (Drive).
4) Release the foot brake pedal.
5). Overtook 60 km / h (engine speed is not higher than 2500 rpm).
6) Release the throttle, slow to a stop (all just starting noise caused by air circulation will disappear).
7). The oil heating, careless driving at least 5 minutes or until the transmission reaches a temperature of about 60 ° C.
8) Parking on level ground.
9) Step on the foot brake pedal.
10) Wait 2 seconds.
11). Shift into "R" (Reverse).
12) Release the brake pedal.
13) Wait 10 seconds.
14). Step on the foot brake pedal.
15). Shifting to "N" (neutral).
16) Keep the engine idling.
17) The engine idling.
18) Loosen the oil level plug.
19). There are at least able to determine the oil level plug release after 0.2 liters of oil outflow from the tube. (Otherwise prove
insufficient initial oil) if less than 0.2 liters, 0.5 liters plus oil, then put the above procedure done again.
20) Wait until the oil begins to drip from the oil level plug ports.
21) Re-tighten the new gasket with oil level plug (torque: 18 ~ 24N • m).
22). Turn off the engine.
23). Shift to "P" (parking gear).
（III）Check the oil level
If the initial refueling correct, the oil level should be (on the oil level plug) in the correct position.
Normal tolerances (like new gearbox production line and residual fuel tolerance) position should the oil level plug, the oil level can
be ± 0.165L.
1. Check the gearbox oil level
1) Remove the upper transmission refueling bolts.
2). Fill the transmission precise 0.5L oil.
3) Mounted on the fuel plug.
Tightening torque 18 ~ 24N • m
4) Start the engine temperature is raised to enable the transmission of about 60 ℃.
5). Place The vehicle on the ground.
6). Slam the brakes, wait two seconds to change to P block.
7) Keep the engine idling.
8) Remove the oil level plug in the engine idling conditions.
9). Proper discharge of oil (up to a minimum of 0.335L 0.665L).
S2 Transmission
Minimum 0.235L (0.5 ADDED oil -0.165 tolerances -0.1L = 0.235L) gearbox oil will flow out. If amount of oil is smaller: the
original oil level is too low.
Maximum 0.565L (0.5 ADDED oil +0.165 tolerances - 0.1L = 0.565L) gearbox oil outflows.If amount of oil is smaller: the original
oil level is too high.
△Attention All data is derived gearbox oil temperature 60 ℃.
10). The installation of a new gasket and tighten bolts greasy.
Tightening torque 18 ~ 24N • m
11) Turn off the engine.
VI、The shift lever assembly
（I）Special tool (None)
（II）Disassembly
1. Remove the shift lever assembly
1). Put the shift lever to P
2). Remove worm at a (using a flat head screwdriver or pull opening).
3).
Then loosen the nut at b.
Note: here loosen the nut transmission shift after shift rocker may vary,
after the release immediately restore to its original position
(The transmission gear change rocker is substantially vertically downward).
4). Remove the shift lever assembly
a
b
（III）Assembly
1. Install the shift lever assembly
1). The new shift lever is mounted on the gearbox.
2). The manipulation of the shift lever shift back and forth five times, then the shift lever to the N block.
3) Put the of head the arm ball under into worm.
S2 Transmission
4). Press transmission shift rocker tighten, then tighten the nut at b.
a
b
（IV）Check
1.Check the installation
1) Fast change from P / R / N / D / S / M +/- M- hang back and forth all three cycles, always check the transmission shift lever position is
consistent with gear display, and the meter displays the correct gear and instruments.
2). Slow change from P / R / N / D / S / M +/- M- hang back and forth all three cycles, always check whether the shift selector lever
position is consistent gear and instruments, as well as whether the instrument displays the correct gear .
3). Inconsistent or meter does not show the gear position if circumstances arise instruments and gear shift lever gear, the gear must be
readjusted.
VII、Shift rocker and bushing
（I）Special tool (None)
（II）Disassembly
1. Remove the shift lever assembly ,checking the shift lever assembly
2. Remove shift arm and sleeve
1) Remove the worm at c (using a flat head screwdriver or pull opening).
2) Remove the bolt at e.
3) Remove the shift arm and bushing.
e c
S2 Transmission
（III）Assembly
1. Install the rocker arm and the shift bush
1) Replace the upper arm and the shift bushing.
Attention The direction of the arrow aligned with the
transmission rocker, while the bushing flange tight
stick transmission mounting surface.
2).
Installat the bolts at e and tighten.
Tighten torque 20~28N·m
2.Install the shift lever assembly
e c
（IV）Check
1. Check the
installation
1) Fast change from P / R / N / D / S / M +/- M- hang back and forth all three cycles, always check the transmission shift lever position is
consistent with gear display, and the meter displays the correct gear and instruments.
2). Slow change from P / R / N / D / S / M +/- M- hang back and forth all three cycles, always check whether the shift selector lever
position is consistent gear and instruments, as well as whether the instrument displays the correct gear .
3). Inconsistent or meter does not show the gear position if circumstances arise instruments and gear shift lever gear, the gear must be
readjusted.
VIII、The shift drawing assembly
（I）Special tool (None)
（II）Dsiassembly
1. Remove the shift lever assembly, checking the shift lever assembly
2. Remove shift arm and bushing, checking shift arm and bushing
3.
Remove the shifting drawing assembly
1).
Disengage the shift drawing quick coupling from the drawing frame
at d side, brushed off the shifting assembly connected with the
gearbox.
Attention Ensure joint holder all in the slot.
d
S2 Transmission
2). shift lever linking to the N gear, remove the conncection of drawing
and transmission operating mechanism connected with the side.
3). Remove spring cards.
4). Remove two M8 nuts from the body.
5). Remove the shifting assembly drawing.
（III）Assembly
1. Install the shifting drawing assembly
1).
Put new drawing from engine cabin through the "front body around
vias" extending into the the cockpit.
2). Tighten two M8 nuts to the body
Tighten toruqe 20~28N·m
3). The "drawing fitting (variable speed control mechanism end)" is
connected to the transmission control mechanism pin shaft.
4).Install spring cards.
2. Install shift arm and bushing
3. Install the shift lever assembly
（IV）Check
1.Check the installation
S2 Transmission
1) Fast change from P / R / N / D / S / M +/- M- hang back and forth all three cycles, always check the transmission shift lever position is
consistent with gear display, and the meter displays the correct gear and instruments.
2). Slow change from P / R / N / D / S / M +/- M- hang back and forth all three cycles, always check whether the shift selector lever
position is consistent gear and instruments, as well as whether the instrument displays the correct gear .
3). Inconsistent or meter does not show the gear position if circumstances arise instruments and gear shift lever gear, the gear must be
readjusted.
IX、Variable speed control mechanism assembly
（I）Special tool (None)
（II）Disassembly
1. Remove the variable speed
control mechanism assembly
1). shift lever linking to the N gear, remove the connection of drawing
and transmission operating mechanism connected with the side.
2).
Remove spring cards.
3). Remove the 4 fixing screws and remove the shift actuator assembly.
（III）Assembly
1.Install the variable speed
control mechanism assembly
1). Install the variable speed control mechanism assembly to body
2).Tighten 4 nuts
Tighten torque 20~28N·m
S2 Transmission
3). The "drawing fitting (variable speed control mechanism end)" is
connected to the transmission control mechanism pin shaft.
4).Install spring cards.
2. Install shift arm and bushing
3. Install the shift lever assembly
（IV）Check
1.Check the installation
S2 Transmission
1) Fast change from P / R / N / D / S / M +/- M- hang back and forth all three cycles, always check the transmission shift lever position is
consistent with gear display, and the meter displays the correct gear and instruments.
2). Slow change from P / R / N / D / S / M +/- M- hang back and forth all three cycles, always check whether the shift selector lever
position is consistent gear and instruments, as well as whether the instrument displays the correct gear .
3). Inconsistent or meter does not show the gear position if circumstances arise instruments and gear shift lever gear, the gear must be
readjusted.
X、Differential Seal
（I）Special tool
1 16G003 Differential oil seal installation tool
（II）Disassembly
1. Drain the gearbox oil
2. Remove the axle shaft
3.
Remove differential oil seal
1).
pry out the oil seal with a large flat head screwdriver.
△Attention Be careful not to put too flat head screwdriver to protect the casing.
S2 Transmission
（III）Installation
1. Install differential oil seal
1).
Place the new seal into the housing.
2).
Put the special tool 16G0038 on the seal, then knock into the housing
with a rubber mallet to to make sure it fits.
△Attention The depth of the seal must be from the edge of the housing 3mm ± 0.3mm.
2.
Install axle
3.
Fill the gearbox oil
XI、The input shaft seal
（I）Special tool
No.
Tool code
Tool
Outline drawing
1
16G0041
Input shaft seal installation tool
2
16G0040
The input shaft seal bushing
（II）Disassembly
1. Drain the gearbox oil
2.
Remove the axle shaft
3. Remove differential oil seal
1).
pry out the oil seal with a large flat head screwdriver.
△Attention Pull out along the outside seal, you must be very
careful, otherwise it will damage the gearbox input
shaft.
S2 Transmission
（III）Installation
1. Install the input shaft oil seal
1).
Put the seal bushing 16G0040 on the input shaft
2). Put the new seal on the bushing.
3).Put the special tool 16G0041on the input shaft with rubber mallet
percussion and install in place.
2. Install the transmission
3. Refill the transmission oil
XII、
Gear selection shaft oil seal
（I）Special tool
No
Tool code
Tool
Outline drawing
1
16G0043
Gear shaft oil seal
installation tool
S2 Transmission
No
Tool code
Tool
Outline drawing
2
16G0042
Gear shaft oil seal removal
tool
（II）Disassembly
1. Discharge gearbox oil
2. Remove the gearbox
3.
Remove the gear shift lever
4. Remove the gear shift shaft oil seal
1).Put
the special tool 16G0042 on the election gear shaft with a
wrench special tool procession seal.
△Attention Squeeze the top wrench special tool which makes the procession seal.
2). Turning the bolt on the special tool and pull out the shift shaft
oil seal from the housing.
3). Rotate small bolt and pull seal out.
S2 Transmission
4). Remove the oil seal.
（III）Installation
1. Install gear selection shaft seals
1).
Smear Vaseline or grease at the tip of the oil seal punch 16G0043
2).
Mount lightly the new seal on the punch 16G0043.
3). The seal will be installed on a dedicated punch 16G0043 selected
gear shaft and tap with a hammer to place.
4). Remove the punch 16G0043.
△Attention Pull out the punch with rotation, otherwise it may lead
to seal and pulled out a punch.
2.
Install gear shift
lever
3. Install the transmission
4. Refill the
transmission oil
XIII
、
Driving bevel shaft
cover
（I）Special tool (None)
（II）Disassembly
1. Drain the transmission oil
2. Remove the driving bevel gear cover
1).
Remove the three bolts and remove the snap.
S2 Transmission
2). Remove the O-ring and cap.
△Attention prevent damage to the gearbox housing with a cloth pad below.
（III）Installation
1. Install driving bevel gear cover
1).
Install a new O-ring, and install a new cap and tighten the fixing bolts and snaps.
Tighten torque 9.5±2.5N·m
2. Refill the transmission oil
XIV、Pump
（I）Special tool
No
Tool code
Tool
Outline drawing
1
16G0045
Pump removal tool
（II）Disassembly
1. Drain the transmission oil
2. Remove the transmission
3.
Remove the driving wheel shaft cover
4. Remove the pump
1).
Remove the six bolts on the oil pump and put special tool to the pump shaft.
S2 Transmission
2). Pull pump out with a special tool 16G0045.
（III）Installation
1. Install the pump
1).
Install a new pump. Please ensure put two new O-ring on the new pump.
△Attention Do not remove conical return spring and make sure the
diameter of the larger end toward the pump.
2).
Replace the six screws and tighten.
Tighten torque 10±1N·m
2.
Install driving wheel shaft cover
△Attention O-ring and cap do not have to be replaced.
3. Install the transmission
4. Refuel the transmission oil
XV、Driving bevel shaft ball bearing.
（I）Special tool
No
Tool code
Tool
Outline drawing
1
16G0049
Driving bevel wheel
bearing stopper
S2 Transmission
No
Tool code
Tool
Outline drawing
2
16G0050
Driving wheel bevel
bearing punch
3
16G0048
Driving bevel wheel bearing
removal tool
4 16G0047 Driving bevel big axle sleeve
nut disassembly
（II）Disassembly
1. Drain the transmission oil
2. Remove the transmission
3.
Remove the driving wheel shaft cover
4. Remove the pump
5. Remove driving bevel shaft ball bearing
1). Remove the conical return spring.
2).
Cook mark on the shaft and the nut.
3).
Remove the nut with a special sleeve.
4).Remove the bearing dust cover
S2 Transmission
5). Put the protective cover on the shaft.
6). Assemble bearing puller (16G0048), with its foot hook in the bearing outer ring.
7). Tighten the middle bolts to pull out of of the bearing.
（III）Installation
1. Install driving wheel ball bearing shaft
1).
Clean driving bevel shaft and oil pump drive shaft lock sealant tape
and clean the pump chamber.
2). Place the new bearing and install it with a special punch (16G0050).
S2 Transmission
3). Punch correctly with a rubber hammer
4). Tighten the nut so that the mark coincides with the axis of the marks and the nut.
Standard Coincidence degree ±5°
5).
Install conical return spring back together.
△Attention larger diameter is toward the end of the pump.
2. Install the pump
3. Install driving wheel shaft cover
△Attention O-ring and cap do not have to be replaced.
4. Install the transmission
5. Refuel the transmission oil
XVI
、
Driven wheel bevel
cover
（I）Special tool (None)
（II）Disassembly
1. Remove the driven wheel bevel cover
1).
Remove the four countersunk screws.
2). Remove two O-rings and a seal.
（III）Assembly
1. Install the driven wheel bevel cover
1). Install two O-rings and a seal.
2).
Remove the plastic thread from four screws bore on the housing.
3).Tighten four bolts
Tighten torque 9.5±0.95N·m
XVII、Sump
（I）Special tool
(None)
S2 Transmission
（II）Disassembly
1. Discharge the transmission oil
△Attention Throw away the old oil
drain plug
2. Remove the sump
1).
Remove all 13 sump bolts
（III）Assembly
1. Install the sump
1).
Install the new sump and gasket.
2).
Install the sump bolts in the right shown order.
△Attention use the new gasket
Tighten torque 9.5±1N·m
3). Take a new oil drain plug.
Tighten torque 11±1N·m
2. Refill the transmission oil
XVIII、Oil
filters
（I）Special tool (None)
（II）Disassembly
1. Drain the transmission oil
△Attention Throw away the old oil drain plug
2. Remove the sump
3. Remove the oil filter
1).
Gently remove the filter
（III）Installation
1. Install the oil filter
1). Install the oil filter with a new O-ring, and lubricant with ESSO EZL799 (A).
S2 Transmission
2). Gently press the filter in place.
△Attention Oil filter hole in the middle and right hydraulic control
block matches with the bolts on the middle right.
3).
Clean the magnet and the sump.
2. Install the sump
3. Refill the
transmission oil
XIX
、
Driving Mood
Sensor
（I）Special tool (None)
（II）Disassembly
1. Drain the transmission oil
△Attention Throw away the old oil drain plug
2. Remove the sump
3. Remove the oil filter
4. Remove the driving mood sensor
1). Removed the two screws on the drive mode sensor.
2). Carefully remove the drive mode sensor from the hydraulic control block.
△Attention Sensors in the back by a small metal pin on the
hydraulic control block is fixed on a slide, the sensor
will push down the pin out of the sub-slide.
S2 Transmission
3). Open the sensor connector lock, and hold the white lock for the
joint separation.
（III）Installation
1. Install the driving mood sensor
1).
Take a new sensor connector and connect the pressure inside the white lock to lock.
2).
The sensor is placed on the back of the metal pin slide
3).
Movesensor so that the bolt holes are exposed.
4).Tighten two bolts
Tighten toruqe 9.5±0.95N·m
2. Install filter
3. Install sump
4. Refill the transmission oil
XX、Hydraulic control block
（I）
Speci
al
tool
（II
）
Disas
semb
ly
1. Drain the transmission oil
△Attention Throw away the old oil drain plug
2. Remove the sump
3. Remove the oil filter
4. Remove the driving mood sensor
No
Tool code
Tool
Outline drawing
1
16G0046
Hydraulic control block
locating pin
S2 Transmission
5. Remove the hydraulic control block
1). Remove the bolt as illustrated in the order of 20-1.
2). Remove the hydraulic control block and four separate connectors.
△Attention The connector can be easily removed with a small screwdriver.
（III）Installation
1. Install hydraulic control block
1).
The hydraulic control block in place, behind the hydraulic control
block has a small pin, to the right place.
S2 Transmission
2). Make sure the clips metal slide and shift on the cam with the place.
3). The intermediate bolts fitted and tightened by hand.
4). Install special tool 16G0046 in the upper left corner bolt holes.
5).
Press the driving bevel wheel speed sensor wire in the upper left corner of the hydraulic control block.
6). Remove the bolt as illustrated in the order of 1-20
Tighten torque 11N·m
2. Install the driving ood sensor
3. Install filter
4. Install sump
5. Refill the transmission oil
XXI
、
Driven bevel wheel speed sensor
and bracket
（I）Special tool (None)
（II）Disassembly
1. Drain the transmission oil
△Attention Throw away the old oil drain plug
2. Remove the sump
3. Remove the oil filter
4. Remove the driving mood sensor
5. Remove the hydraulic control block
6.
Remove the driven bevel wheel speed sensor and bracket
S2 Transmission
1). Loosen the sensor bracket bolts.
△Attention This bolt is disposable.
2). Withdraw the stent from the shift shaft.
3). Remove sensor and joint with needle-nosed pliers.
4). Loosen the screws on the bracket to remove the speed sensor.
（III）Installation
1. Install driven bevel wheel speed sensor and bracket
1). Install the new sensor and bracket and tighten the mounting bolts.
2).
Connect wires and card holder in the shift shaft
3). With new bolts to secure the bracket.
Tighten torque 9.5±0.95N·m
2. Install hydraulic control block
3.
Install drive mode sensor
4. Install filter
5. Install sump
6. Refill the transmission oil
XXII、Driving bevel wheel speed sensor
（I）Special tool (None)
S2 Transmission
（II）Disassembly
1. Drain the transmission oil
△Attention Throw away the old oil drain plug
2.
Remove the driving bevel gear cover 3. Remove the drive bevel wheel speed sensor
1). Remove the retaining bolt and remove the sensor.
2). Separat the wires and remove the sensor.
（III）Installation
1. Install driving bevel wheel speed sensor
1).
Install the new sensor, and tighten the bolts.
Tighten torque 8.5±2N·m
2).
Connect the wire to the sensor.
2.
Install driving bevel gear cover
3. Refill the transmission oil
XXIII、Main interface and internal wiring harness
（I）
Special tool (None)
（II）Disassembly
1. Drain the transmission oil
△Attention Throw away the old oil drain plug
2. Remove the sump
3. Remove the oil filter
4. Remove the driving mood sensor
5. Remove the hydraulic control block
6.
Remove the main interface and internal wiring harness
1). Separate two speed sensor connectorly.
2). Remove the main junction connecting cables d.
3). Remove the main fitting snap and the main fitting, and then press
into the gearbox.
S2 Transmission
△Attention Cab mode sensor connector is caught in the housing,
first remove the connector.
4).
Remove the entire primary interface from the gearbox.
（III）Installation
1. Install the primary interface and
internal wiring harness
1).
Take the new master interface and put into the gearbox.
△Attention Main connector is connected to the housing via a spline.
Forty-five degrees needle-nose pliers will position
righting pressure up relatively easily.
2). Replace the snap.
S2 Transmission
3). Press-fit the driving mode sensor connector to the housing.
4).
Connect the speed sensor to the connector.
2.
Install hydraulic control block
3.
Install drive mode sensor
4. Install filter
5. Install sump
6. Refill the transmission oil
XXIV、Respirator tube.
（I）Special tool
No
Tool code
Tool
Outline drawing
1
16G0044
Installation Tools
- breathing tube
（II）Disassembly
1. Remove the engine intake manifold
2.
Remove the battery and bracket
3. Remove the respirator tube
1).
Remove the snaps at the top of breathing tube connecting gearbox
2).Breathing tube will be removed
by pliers on housing and the junction of the respiratory airway.
S2 Transmission
（III）Installation
1. Installation respirator tube
1).
Put the new respirator into the special tool (16G0044), and wipe a
little Vaseline on the bottom of the tubes of the breathing tube.
2).
Put the tool box breathing tube on the case, to keep them parallel,
perpendicular down with a rubber hammer percussion instruments,
making breathing tube into the housing.
3).
Put the plastic buckle 482253 in the breathing tube.
4).
Insert the plastic buckle metal pin into the buckle holes 481 456.
5).
The metal snap securely mounted on the ribs of the transmission housing.
6). Mount the breathing tube cap 483 117 is on the pipe,
2.
Install batteries and bracket
3. Install the engine intake manifold
XXV、Electrical Schematic
S2 Transmission
（I）TCU Interface Figure
Transmission main connector pin
6(x6-34)
1(x6-5)2(x6-26) 5(x7-2) 执行器电源
P_离合器
34(x7-39)
48(x6-22)
换挡锁
输入1
输入2
输入3
输入4
DMS_A
DMS_B
DMS_C
DMS_D
背光继电器
压力电磁阀
起动锁
钥匙锁
错误指示灯
KI30
71(x6-42)
91(x7-35)
EDS1
TCU
EDS2
EDS3
90(x7-36)
89(x7-37)
76(x7-31)
59(x7-40)
81(x7-41)
80(x7-42)
33(x7-19)
57(x7-7)
58(x7-8)
79(x7-9)
35(x7-10)
30(x7-18)
77(x7-18)
78(x7-18)
61(x7-27)
63(x7-28)
41(x7-3)
64(x7-3)
86(x7-3)
38(x7-13)
32(x7-20)
74(x7-20)
75(x7-30)
9(x6-28)
8(x6-29)
85(x6-33)
87
92(x6-14)
70(x6-41)
49(x6-40)
3(x6-1) 4(x6-2)
KI.15Wake up
+4V
+2V
P
R
N
D
换挡杆
行车模式传感器
主速度传感器
副速度传感器
油温传感器
油压传感器
CAN-High
CAN-Low
K-Line
N_MOT 发动机转速
刹车灯开关
雪地模式按钮
S2 Transmission
Code
Description
DMS Driving mode sensor or gear / suppression sensor
S2 Transmission
1 2 3 4 5 6 8 9 30 32 33 34 35 38 41 48 49 57 58 59 61 63 64 71 74 75 76 77 78 79 80 81 85 86 87 89 90 91 92
8
9
4
7
6
10
1516
12
11
13
5
2
1
3
14
CAN-High1
TCU
错误指示灯
P_离合器
冬季模式/
SAT模式
CAN-Low1
K-Line
Tip Up
Tip Down
N_MOT
起动锁
点火KI.15
蓄电池KI.30
制动
换挡锁
运动/手动
倒车灯
接地
变速器连接器（后侧）
EDS_1 Driving bevel wheel pressure regulator (solenoid)
EDS_2 Driven bevel wheel pressure regulator (solenoid)
EDS_3 Clutch pressure regulator (electromagnetic valve)
P_S2 Driven bevel wheel pressure sensors
N_ab Driven bevel wheel speed sensor
N_S1or N_Prim Driving bevel wheel speed sensors
TCU Pin
Start lock
P-clutch
Reverse light
Sport/ Manuel
TCU fault light
Shift lock
Brake
Battery
Ground
Trnasmission connector
S2 Transmission
TCU
Pin assignment
VT2-signal
pin
Normally closed Power K1.30
1；2
Ignition power K1.15
6
GroundK1.31
3 ； 4
VHSD1(Executive Power)
5
Speed and position sensor power（8.4V） 30；77；78
Pressure sensor power（5V） 32；74
GND Driving mode sensor
33
GND Sensor ground
41；64；86
Transmission oil temperature
38
N_Prim(Driving bevel wheel speed)
61
N_ab(Driven bevel wheel speed)
63
N_MOT（Engine speed signal） 87
DMS_A（Driving mode sensing signal） 57
DMS_B（Driving mode sensing signal） 58
DMS_C（Driving mode sensing signal） 79
DMS_D（Driving mode sensing signal） 35
Braking signal
34
Manual mode signal
59
Gear increase signal
81
Gear decrease signal
80
P_S2（Driven bevel wheel pressure） 75
Snow mode
76
Shift lock
48
K-Line
85
CAN-high speed
9
CAN-low speed
8
Start lock
92
EDS1
（
Driven bevel wheel pressure regulator
）
91
EDS2
（
Driven bevel wheel pressure regulator
）
90
EDS2
（
Driven bevel wheel pressure regulator
）
89
Reversing light relay
71
S2 Transmission
ECU and transmission pins corresponding Figuer.
TCU pin Transmission pin
Supply valves (1.25mm
2
)
Pin5
Pin91
Pin90
Pin89
Pin38
Pin33
Pin41;64;86
Pin32;74
Pin30;77;78
Pin75
Pin63
Pin61
Pin57
Pin58
Pin79
Pin35
EDS_1 (0.75mm
2
)
EDS_2 (0.75mm
2
)
EDS_3 (0.75mm
2
)
Oil temperature (0.5mm
2
)
DMS_GND (0.5mm
2
)
Sensor_GND (0.5mm
2
)
Supply_5V (0.5mm
2
)
Supply_8.4V (0.5mm
2
)
p_S2 (0.5mm
2
)
n_ab (0.5mm
2
)
n_S1 (0.5mm
2
)
DMS_A(0.5mm
2
)
DMS_B (0.5mm
2
)
DMS_C (0.5mm
2
)
DMS_B (0.5mm
2
)
Pin1
Pin2
Pin3
Pin4
Pin5
Pin6
Pin7
Pin8
Pin9
Pin10
Pin11
Pin12
Pin13
Pin14
Pin15
Pin16
（II）Electronic Components Checklist
Driving mode sensor
Check the internal resistance between different PIN foot determines the
driving mode sensor is good
DMS_GND = 6
DMS_A =13
DMS_B =14
DMS_C = 15
DMS_D = 16
DMS_Supply =9
S2 Transmission
Resistance values corresponding to the respective pins
DMS_Supply DMS_A DMS_B DMS_C DMS_D
DMS_Supply
x
17.2
Meg
17.2
Meg
17.2
Meg
17.2
Meg
DMS_A
17.2
Meg
x
9
Kilohms
9
Kilohms
9
Kilohms
DMS_B
17.2
Meg
9
Kilohms
x
9
Kilohms
9
Kilohms
DMS_C
17.2
Meg
9
Kilohms
9
Kilohms
x
9
Kilohms
DMS_D
17.2
Meg
9
Kilohms
9
Kilohms
9
Kilohms
x
DMS_GND
4.5
Kilohms
4.5
Kilohms
4.5
Kilohms
4.5
Kilohms
Oil temperature sensor
Check resistance between temperature sensor and internal resistance also resistance between 5 feet and 7
feet.
When the temperature is between 20 ℃ to 40 ℃, the resistance should be 942 ohms to 1121 ohms
Speed Sensor
This is a complex of two-wire components; there is no simple way to measure whether or not it works in the following range:
·Resistance between 9 feet and 11 feet is about 24.3 megohm
·Resistance between 9 feet and 11 feet is about 24.3 megohm
△Attention The measurement by this method can not guarantee a good speed sensor
Oil pressure sensor
Resistance between 7 feet and 10 feet is about 44.3 kilohms
Clutch pressure regulator
Resistance between 1 foot and 4 feet is about 5.2 ohms
Driving bevel wheel pressure regulator
Resistance between 1 foot and 3 feet is about 5.2 ohms
Driven bevel wheel pressure regulator
Resistance between 1 foot and 2 feet is about 5.2 ohms
TCU
It can not be measures
△Attention Different precision measuring instruments do not lead to measured resistance range
S2 Transmission
（III）Transmission system circuit diagram
TCU controller and shift control power, ground, data lines
Transmission, shift control module
13
E16
37
E16E16
12
E16
48
E16
21
E16
E16
E16
29
E16
44
E16
1147
EI6
25
TCU
L4 M2E3L1J2
A2 M1 M4
H4
A4A3
24
10A
10A
E F 01
IF 28
19
I1-ME
I1-EM
0.5 O/V
0.5 O/V
20
I3-ME
I3-EM
0.5 O/Gr
0.5 O/Gr
16
I3-ME
I3-EM
0.5 0/Br
0.5 O/Br
G05
A
1.25 G/V
1.25 G/V
0.5 Br/G
0.5 Br/G
17
I3-ME
I3-EM
B+
0.5 G/Bl
0.5 G/Bl
0.5 G/Bl
0.5 G/Bl
前
舱
电
器
盒
座
舱
电
器
盒
IG1
0.5 R/W
0.5 R/W
0.5 Br/Bl 0.5 Br/Bl
A23
I1-EEL
0.5 Bl/Y
0.5 L/B
1.25 B
2.0 B
1.25 B
起动继电器
E R 01-86
ABS模块
E 17-30
倒车灯继电器
E R 04-86
EM S单元
A 22-80
30
CAN-H CAN-L
诊断接口
M 10-5
Start relay
ABS
Brake
relay
EMS
Front
cabin
electrical
box
Cockpit
electrical
box
Cockpit electrical box
Diagnostic Interface
M10-5
S2 Transmission
To reversing
radar relay
To starter
relay
S2 Transmission
0.5 Br/Y
8
E02
6
E02
16
E02
变速箱执行机构
9
E02
1
E02
5
E02
7
E02
13
E02
6
E16
7
E16
8
E16
43
E16
E16
10
E16
22
E16
34
E16
32
E16
17
E16
38
E16
26
E16
E16
31
E16
33
E16
EO2
12
EO2
11
EO2
4
EO2
10
EO2
EO2
3
EO2
2
EO2
2036
EI6
45
14 15
TCU
M3 B4G3H2B3E2H3
H1 K1 K2 K3
J3
G4 F1 G1J4
变速箱执行机构
1.25 Bl/P
0.5 Bl/O
0.5 G/O
0.5 Gr/R
0.5 W
0.5 Bl
0.5 Gr/B
0.5 Br/Bl
0.5 Bl/Br
0.5 Bl/Y
0.5 Bl/W
0.5 Gr/Y
0.5 R
0.5 Bl/R
0.5 G
Ճ
Gearbox actuator
Gearbox actuator
