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Transmission

I

Content

Transmission（6MT）

I、Overview .................................................... 1-1

（I）structure outline ......................................... 1-1

（II）system theory ............................................ 1-8

（III）technical parameters, maintenance parameters

............................................................................... 1-10

（IV）torque parameters .................................. 1-11

（V）maintenance precautions ........................ 1-11

（VI）special tools ........................................... 1-12

II、Fault diagnosis ........................................ 1-13

（I）diagnosis sheet ......................................... 1-13

（II）diagnosis flow sheet ................................ 1-14

III、Discharge and refueling of transmission oil

....................................................................... 1-16

（I）special tools .............................................. 1-16

（II）discharge and refueling ........................... 1-16

IV、Selecting and shifting gear flexible shaft assy

....................................................................... 1-17

（I）special tools .............................................. 1-17

（II）disassembly ............................................. 1-17

（III）assembly ................................................ 1-18

V、Operating mechanism with hand lever assy

....................................................................... 1-20

（I）special tools .............................................. 1-20

（II）disassembly ............................................. 1-20

（III）assembly ................................................ 1-20

VI、Selecting and shifting gear base assy .... 1-20

（I）special tools .............................................. 1-20

（II）disassembly ............................................. 1-20

（III）assembly ................................................ 1-21

VII、Transmission assy. ............................... 1-21

（I）special tools ............................................. 1-21

（II）disassembly ............................................ 1-21

（III）assembly ................................................ 1-24

VIII、Release bearing and fork assy. ............ 1-26

（I）special tools ............................................. 1-26

（II）disassembly ............................................ 1-26

（III）assembly ................................................ 1-26

IX、Rear housing .......................................... 1-27

（I）special tools ............................................. 1-27

（II）disassembly ............................................ 1-27

（III）assembly ................................................ 1-28

X、Reverse gear intermediate shaft assy ...... 1-29

（I）special tools ............................................. 1-29

（II）disassembly ............................................ 1-29

（III）assembly ................................................ 1-29

XI、Selecting and shifting gear fork and fork shaft

...................................................................... 1-30

（I）special tools ............................................. 1-30

（II）disassembly ............................................ 1-30

（III）assembly ................................................ 1-30

XII、Input and output shaft assy. .................. 1-31

（I）special tools ............................................. 1-31

（II）disassembly ............................................ 1-32

（III）dismounting ........................................... 1-33

（IV）inspection .............................................. 1-39

（V）assembly ................................................. 1-41

（VI）mounting ............................................... 1-50

XIII、Differential lock assy .......................... 1-50

（I）special tools ............................................. 1-50

（II）disassembly ............................................ 1-50

（III）dismounting ........................................... 1-51

（IV）assembly ............................................... 1-54

（V）mounting ................................................ 1-55

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Transmission

II

Transmission（CVT）

I、Overview .................................................... 2-1

（I）structure outline ......................................... 2-1

（II）system theory ............................................ 2-5

（III）technical parameters, maintenance parameters

............................................................................... 2-11

（IV）torque parameters .................................. 2-11

（V）maintenance precautions ........................ 2-12

（VI）special tools ........................................... 2-12

II、Fault diagnosis ........................................ 2-14

（I）diagnosis sheet ......................................... 2-14

（II）noise description ..................................... 2-15

（III）noise problem’s check and maintenance2-16

（IV）malfunction code and measurement .... 2-20

III、Driving strategy ..................................... 2-32

（I）parking gear and neutral gear’s functional

characteristic .......................................................... 2-32

（II）function of D gear and R gear................. 2-32

（III）malfunction default pattern ................... 2-33

IV、Self-adaptive update .............................. 2-33

（I）introduction .............................................. 2-33

（II）requirement ............................................. 2-34

（III）procedure ............................................... 2-34

（IV）common problems ................................. 2-37

V、Transmission oil ...................................... 2-38

（I）special tools .............................................. 2-38

（II）oil level check description ...................... 2-38

（III）oil level check ........................................ 2-39

VI、Shifting gear lever assy. ........................ 2-39

（I）special tools .............................................. 2-39

（II）disassembly ............................................. 2-40

（III）assembly ................................................ 2-40

（IV）adjustment ............................................. 2-40

（V）inspection ............................................... 2-41

VII、Shifting gear rocker arm and sleeve ... 2-41

（I）special tools ............................................. 2-41

（II）disassembly ............................................ 2-41

（III）assembly ................................................ 2-41

（IV）inspection .............................................. 2-41

VIII、Selecting gear wire drawing assy. ....... 2-42

（I）special tools ............................................. 2-42

（II）disassembly ............................................ 2-42

（III）assembly ................................................ 2-43

（IV）inspection .............................................. 2-43

IX、Transmission control mechanism assy. .. 2-43

（I）special tools ............................................. 2-43

（II）disassembly ............................................ 2-43

（III）assembly ................................................ 2-44

（IV）inspection .............................................. 2-44

X、Differential lock oil seal .......................... 2-44

（I）special tools ............................................. 2-44

（II）disassembly ............................................ 2-44

（III）assembly ................................................ 2-45

XI、Input shaft oil seal .................................. 2-45

（I）special tools ............................................. 2-45

（II）disassembly ............................................ 2-45

（III）assembly ................................................ 2-46

XII、Selecting gear shaft oil seal .................. 2-46

（I）special tools ............................................. 2-46

（II）disassembly ............................................ 2-47

（III）assembly ................................................ 2-48

XIII、Driving cone gear end cap ................... 2-48

（I）special tools ............................................. 2-48

（II）disassembly ............................................ 2-48

（III）assembly ................................................ 2-48

XIV、Oil pump ............................................. 2-48

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Transmission

III

（I）special tools .............................................. 2-48

（II）disassembly ............................................. 2-49

（III）assembly ................................................ 2-49

XV、Driving cone axle ball bearing ............. 2-50

（I）special tools .............................................. 2-50

（II）disassembly ............................................. 2-50

（III）assembly ................................................ 2-51

XVI、Driven cone axle end cap .................... 2-52

（I）special tools .............................................. 2-52

（II）disassembly ............................................. 2-52

（III）assembly ................................................ 2-52

XVII、Oil sump ............................................ 2-52

（I）special tools .............................................. 2-52

（II）disassembly ............................................. 2-52

（III）assembly ................................................ 2-53

XVIII、Oil filter ............................................ 2-53

（I）special tools .............................................. 2-53

（II）disassembly ............................................. 2-53

（III）assembly ................................................ 2-53

XIX、Driving pattern sensor ........................ 2-53

（I）special tools .............................................. 2-53

（II）disassembly ............................................. 2-53

（III）assembly ................................................ 2-54

XX、Hydraulic control block ....................... 2-54

（I）special tools .............................................. 2-54

（II）disassembly ............................................. 2-55

（III）assembly ................................................ 2-55

XXI、Driven cone pulley speed sensor and bracket

..................................................................... 2-56

（I）special tools .............................................. 2-56

（II）disassembly ............................................. 2-56

（III）assembly ................................................ 2-57

XXII、Driving cone pulley speed sensor .... 2-57

（I）special tools .............................................. 2-57

（II）disassembly ............................................ 2-57

（III）assembly ................................................ 2-58

XXIII、Main connector and internal harness 2-58

（I）special tools ............................................. 2-58

（II）disassembly ............................................ 2-58

（III）assembly ................................................ 2-59

XXIV、Breather pipe .................................... 2-60

（I）special tools ............................................. 2-60

（II）disassembly ............................................ 2-60

（III）assembly ................................................ 2-60

XXV、Electric appliance schematic ........... 2-61

（I）TCU connector diagram .......................... 2-61

（II）Electronic components inspection chart . 2-66

（III）transmission system circuit diagram ... 2-68

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6MT Transmission

1-1

Transmission (6MT)

Ⅰ Overview

（Ⅰ） Structural outline

The name and meaning of transmission

Structural form

Manual shifting gear mechanical transmission, with six forward gears and a reverse gear; the shifting gear mechanism uses cable.

Gears diagram.

Exploded view

Transmission operating system

1. Transmission operating mechanism with hand lever assy. 2. Shifting gear flexible shaft.

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6MT Transmission

1-2

Transmission assembly

1. transmission housing assy

2. reverse gear intermediate shaft assy

3.

input shaft assy

4. output shaft assy

5. differential lock assy

6.transmission housing assy

7. selecting and shifting gear shaft and fork assy

8. reverse gear base assy

9.

selecting and shifting gear base assy

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6MT Transmission

1-3

Selecting and shifting gear base assy

1.shift gear shaft subassembly

2.select and shift gear shaft oil seal

3.linear bearing

4.gas outlet valve

5.select and shift gear base

6.select and shift gear resistance pin

7.select and shift gear block

8.reverse gear paddle

9.reverse gear paddle torsion spring

10.interlock plate

11.shift gear ball

12.select gear arm subassembly

13.elastic cylindrical pin

14. cylindrical pin

15.bushing

16.flange bolt

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6MT Transmission

1-4

Housing assembly

1.housing

2.oil groove

3.oil seal(differential lock)

4.magnet

5.back-up light switch gasket(drain plug)

6.reverse gear shaft bolt gasket(fill plug)

7.oil fill plug

8.gasket

9.drain plug assy

10.spring gasket

11.harness bracket

12.self-lock pin subassembly

13.stud

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6MT Transmission

1-5

Transmission housing assembly

1.locating pin

2.bearing pressure plate bolt

3.bearing pressure plate

4.oil seal(differential lock)transmission housing

5.ball support

6.harness stator

7.harness stator

8.shock pad support

9.bracket shock pad

10.flange bolt

11.wire drawing bracket

12.transmission housing

13.oil deflector plate

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6MT Transmission

1-6

Input draft assembly

1.plug

2.ball bearing(behind the input shaft)

3.input sixth gear thrust gasket

4.input sixth gear tooth subassemblies

5.input sixth gear needle bearing

6.input sixth gear bushing

7.fifth and sixth gear synchronizing ring

8.5/6 synchronizer assy

9.fifth and sixth gear synchronizing ring

10. input fifth gear tooth subassemblies

11. input fifth gear needle bearing

12. input fifth gear bushing

13. input fourth gear tooth subassemblies

14. input fourth gear needle bearing

15. input fourth gear bushing

16. fourth gear synchronizing ring

17. 3/4 synchronizer assy

18. third gear synchronizing ring elements

19. input third gear tooth subassemblies

20. input third gear needle bearing

21.input shaft

22. ball bearing (in front of the input shaft)

23.snap ring (in front of the input shaft)

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6MT Transmission

1-7

Output shaft assembly

1.conical roller bearing (in front of the input shaft)

2.output shaft

3.output first gear tooth

4.output first gear needle bearing

5.first gear synchronizing ring elements

6. 1/2 synchronizer assy

7. 1/2 synchronizer snap ring

8. second gear synchronizing ring elements

9. output second gear tooth

10.output second gear needle bearing

11. output third gear tooth

12. output fourth gear tooth

13. output fifth gear tooth

14. output sixth gear tooth

15. adjustment gasket (output shaft rear bearing)

16. conical roller bearing (behind the input shaft)

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6MT Transmission

1-8

Differential lock assembly

1.conical roller bearing

2.hexagon bolt

3.final drive gear

4.diffrential lock housing

5.groove pin

6.half axle gear thrust gasket

7.half axle gear

8.planet gear shaft

9. planet gear thrust gasket

10. planet gear

（Ⅱ） System theory

System operating principle

Because the variation range of engine’s output torque and rotate speed is quite narrow which cannot meet the need for driving in

complicated condition demanded with large variation range of traction and speed. For engine’s output torque and rotate speed, transmission

enlarges driving wheel’s torque and rotate speed by changing the transmission ratio. This makes the vehicle can adapt the variable condition of

usage.

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6MT Transmission

1-9

Reverse gear’s working state:

Engine---clutch---input shaft spline 1---input reverse gear tooth 5---reverse gear idler 6---1/2 gear synchronizer 4---output shaft

15---output shaft final drive gear 21---differential lock 20

1st gear working state:

Engine---clutch---input shaft spline 1---input 1st gear tooth 3---input 1st gear tooth 2---1/2 gear synchronizer 4---output shaft 15---output

shaft final drive gear 21---differential lock 20

2nd gear working state:

Engine---clutch---input shaft spline 1---input 2nd gear tooth 6---input 2nd gear tooth 7---1/2 gear synchronizer 4---output shaft 15---output

shaft final drive gear 21---differential lock 20

3rd gear working state:

Engine---clutch---input shaft spline 1---3/4 gear synchronizer 10---input 3rd gear tooth 9--- output 3rd gear tooth 19--- output shaft

15---output shaft final drive gear 21---differential lock 20

4th gear working state:

Engine---clutch---input shaft spline 1---3/4 gear synchronizer 10---input 3rd gear tooth 9--- output 3rd gear tooth 19--- output shaft

15---output shaft final drive gear 21---differential lock 20

5th gear working state:

Engine---clutch---input shaft spline 1---5/6 gear synchronizer 13---input 5th gear tooth 12--- output 5th gear tooth 17--- output shaft

15---output shaft final drive gear 21---differential lock 20

6th gear working state:

Engine---clutch---input shaft spline 1---5/6 gear synchronizer 13---input 6th gear tooth 14--- output 6th gear tooth 16--- output shaft

15---output shaft final drive gear 21---differential lock 20

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6MT Transmission

1-10

Operating principle

By controlling the control lever in cab, we can eventually manipulate selecting and shifting gear rocker arm to select or shift gears.

Directions showed on the hand ball on control lever are in accord with the different select and shift gear location. Every time you put out the

gear, lever will return to neutral gear; only if you are in neutral gear, you can select gears, and you can only shift reverse gear by pull up the

reverse gear lock on the control lever.

1、While shifting gears, fully step on the release pedal, to let the transmission get off the engine’s torsion. Then manipulate the gear shift

lever quickly. Please use low speed gear when you start the vehicle.

2、Please use low speed gear in climbing uphill or downhill and turning a corner. Do not slide with cutting-off the transmission.

3、If you find any difficulty on manipulating gear shift lever, please stop to check for reasons, and do not push it so hard.

Recommended speed under corresponding transmission gears:

Gear 1

st

gear 2

nd

gear 3

rd

gear 4

th

gear 5

th

gear 6

th

gear

Speed （km/h）

0~20 10~30 20~40 40~60 60~80 80~max

△Notice:

1、Gear shift should be done within the corresponding speed.

2、Gears of the transmission mounted in different models of vehicles are in accord with different speed range.

Gear shifting principle

While driving forward, gear shifting principles are: shift gears one by one from 1 to 6 both in speeding up and slowing down; do not shift

into reverse gear while driving. In order to avoid mistakes, the transmission set a lock which makes driver cannot shift reverse gear from 6

th

gear.

You should shift reverse gear 3 seconds after stepping on clutch; do not shift reverse gear while driving; as well, do not shift forward gears while

backing up.

△

Notice: You can violate the gear shifting principle only in emergency while driving.

(Ⅲ) Technical parameters, maintenance parameters

Technical parameters

Driving mode 2 front wheel-driving

Number of gears 6

Clutch operation Hydraulic

Weight (kg)

40（without oil）

Transmission lubrication oil standard 75W/90(GL-4)

Transmission lubrication oil refilling method Refill with the standard quantity from the side filler

Transmission lubrication oil capacity

2.0（+0.2,0）L

Transmission ratio

Control mode Remote operation

Input rated torque 180 N·m

Model MF20B1

Ratio

1

st

gear 3.769

2

nd

gear 2.053

3

rd

gear 1.393

4

th

gear 1.031

5

th

gear 0.778

6

th

gear 0.681

Reverse gear 3.583

Final drive ratio 主减速比

4.056

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6MT Transmission

1-11

(Ⅳ) Torque parameters

No

.

Items

Torque

（N·m）

Remark

Transmission operation

1 Select and shift gear wire drawing and vehicle body fixed bolt 20~30

2 Fixed bolt of select and shift gear operating device 20~30

3 Transmission lower board 8~12

4 Fixed bolt between transmission and engine 35~45

Transmission assembly

1 Differential mechanism housing and final drive connecting bolt 75~85 Precoat thread-locking adhesives

2 Drain plug 40~60 Smear silicone sealant

3 Bolt and washer fitting (housing and clutch housing) 34.3~41.2 Precoat thread-locking adhesives

4 Hexagon flange bolt (housing and clutch housing) 34.3~41.2 Precoat thread-locking adhesives

5 Reverse gear shaft bolt 42.2~53.9

Smear high strength thread glue in central

of thread

6 Refuel plug 30~40 Smear silicone sealant

7 Backup light switch 29.4~34.3 Precoat thread-locking adhesives

8

Flange bolt (select and shift gear base mounting bolt, wire

drawing bracket)

25~30 Precoat thread-locking adhesives

9 Hexagon flange bolt (harness fixed bolt) 8~12 Precoat thread-locking adhesives

10 Self-lock pin fitting 30~40 Precoat thread-locking adhesives

11 Ball head support 32~40 Precoat thread-locking adhesives

12 Plug 75~85 Precoat thread-locking adhesives

13 Guide pin 15~22 Precoat thread-locking adhesives

14 Hexagon socket cap screw (shift gear supporting base bolt) 15~22 Precoat thread-locking adhesives

15 Hexagon flange bolt (wheel cylinder mounting bolt) 22~28 Precoat thread-locking adhesives

16 Bearing pressure plate bolt 8~12 Precoat thread-locking adhesives

17 Stud 35~45 Precoat thread-locking adhesives

（Ⅴ） Maintenance precautions

1. In the process of diagnosis and maintenance, you must obey the standard of safety and regulation to avoid injury for people and

damage for vehicle.

2. When disassemble the transmission for repairing, do not let the dust get into it; must use special tools for repairing transmission, so

that the repairing efficiency and quality can be improved and damages won’t be occurred on vehicles.

3. Do not reuse drained transmission gear oil.

4. When examine and replace transmission gear oil, remember that change oil has no relevance with cleaning parts; please keep the

vehicle level.

5. Keep the inside clean when dismount and mount transmission.

6. Before dismount and mount transmission, please check for the right mounting position. If you need to remark, make sure it won’t

influence the function of parts.

7. According to the regulation, you should follow multi steps and be in accord with the diagonal order; tighten the middle on first and

then the outside bolts and nuts. If the tightening order is demanded, please follow the requirement.

8. Do not damage the sliding surface and fitting surface.

9. Before assembling needle bearings, please smear lubricating grease on circular surface.

10. Before assembling oil seal, please smear lubricating grease on its lip.

11. When press-fitting synchronizer units, please match the synchronizer sliding block with the block groove on synchronizer ring first.

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6MT Transmission

1-12

（

VI

）

Special tools

No. Tools No. Tool name Outside view Function

1 27G0059 Differential mechanism oil seal mounting tool Mount differential oil seal

2 27G0060 Shift fork shaft fixed pin compacter Dismount shift fork shaft fixed pin

3 27G0061 Backup light switch sleeve Dismount backup light switch

4 27G0062 Mounting tool of input shaft oil seal Mount input shaft oil seal

5 27G0063

Dismount and mount heel block of

differential bearing

Dismount and mount differential

bearing

6 27G0064 Mounting tool of differential bearing Mount differential bearing

7 27G0065 Dismount and mount heel block of input shaft

Dismount and mount input shaft

and synchronizer

8 27G0066 Mounting tool of input shaft 6

th

gear sleeve

1.mount input shaft 6

th

gear sleeve

2.mount input shaft rear end

bearing

3.mount output shaft end bearing

9 27G0067 Mounting tool of 4

th

and 5

th

gear sleeve Mount 4

th

and 5

th

gear sleeve

10 27G0068 Mounting tool of input shaft front bearing Mount input shaft front bearing

11 27G0069

Mounting tool of output shaft front bearing

outer ring

Mount output shaft front bearing

outer ring

12 27G0070

Mounting tool of output shaft rear bearing

outer ring

Mount output shaft rear bearing

outer ring

13 27G0071

Mounting tool of differential bearing outer

ring

Mount differential bearing outer

ring

14 27G0072 Mounting tool of select-gear shaft oil seal Mount select-gear shaft oil seal

15 27G0073

Mounting tool of select-gear shaft linear

bearing

Mount select-gear shaft linear

bearing

16 27G0074

Dismount and mount heel block of output

shaft

Dismount and mount output shaft

gear and synchronizer

17 27G0075 Dismounting tool of 4

th

,5

th

and 6

th

gear tooth Dismount 4

th

,5

th

and 6

th

gear tooth

18 27G0076 Dismounting tool of 3

rd

gear tooth Dismount 3

rd

gear tooth

19 27G0077 Mounting tool of output shaft gear

Mount output shaft 3

rd

,4

th

,5

th

and

6

th

gear tooth

20 27G0078 Mounting tool of output 1

st

gear synchronizer Mount output 1

st

gear synchronizer

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6MT Transmission

1-13

Ⅱ Fault diagnosis

（Ⅰ） Diagnosis sheet

No.

Fault

phenomenon

Fault reason analysis Solutions Remark

1

Vibration, noise

Connecting place of engine and transmission

is loosen up

Tightening

Refer to the flow

diagram of

transmission

vibration and

noise

Axial clearance between gears is too big Adjust the clearance

Wearing of gears Replace

Deterioration of lubricating oil Change gear oil

Lack of lubricating oil Refuelling

Damage of bearing Replace

Unstability of engine idle speed Adjust the speed in idle

2

Oil leakage Damage of oil seal Replace an oil seal

3

Shift-gear difficulty

Damage of operating wire drawing Replace the operating wire drawing

Refer to the flow

diagram of

shift-gear

difficulty

Poor match or wearing between synchronizer

ring and gear conical face

Replace or repair

Failure of synchronizer sliding block

Replace a synchronizer sliding

block

Wrong model of gear oil Change the gear oil

4

Easy to jump gears

Wearing on upper engage tooth or side cone

of sleeve

Replace the gear or tooth sleeve

Shift-gear fork wearing or the ball lock spring

breaks off

Replace the fork or ball lock spring

Clearance between synchronizer hub and tooth

sleeve is too big

Replace the synchronizer tooth hub

and tooth sleeve

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6MT Transmission

1-14

( )Ⅱ Diagnosis flow diagram

Flow diagram of shift-gear difficulty

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6MT Transmission

1-15

Flow diagram of transmission vibration and noise

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6MT Transmission

1-16

Ⅲ Draining and refueling of transmission oil

（Ⅰ） Special tools

（Ⅱ） Draining and refueling

1. Prepare work

1). Put the vehicle horizontally, and then pull up the hand brake.

2). Wait for the transmission oil to cool down.

2. Drain the transmission gear oil

1). Dismount transmission drain plug.

2). Drain off all transmission gear oil.

3). Check if there is scrap iron on the surface of the drain oil plug. If there is some,

wipe them off timely.

3. Refuel the transmission gear oil

1). Dismount filling plug

2). Keep refueling new gear oil until the oil lever comes near to the maximum

location of filler.

4. Check the transmission oil lever

1). Confirm that if there is gear oil leakage in manual transmission or around it.

2). Dismount the filler plug.

3). Check that if the transmission gear oil lever is as high as lower margin of

filler.

4). If the transmission gear oil lever is lower than the lower margin of filler,

please refuel specified MT gear oil from the filler till the oil begins to outflow.

5). Tightening filler plug.

△

Notice: Check if the transmission gear oil deteriorated. If it’s true, please change the

gear oil.

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6MT Transmission

1-17

Ⅳ Select and shift gear flexible shaft assembly

（

Ⅰ

） Special tools（Null）

（

Ⅱ

） Dismount

1. Dismount batteries (Refer to chapter battery)

2. Dismount air filter assy (Refer to air filter assy)

3. Dismount auxiliary dash board (Refer to auxiliary dash board)

4. Dismount select and shift gear flexible shaft

1). Dismount the lock pin and spring lock of lateral select and shift

gear flexible shaft of transmission.

2). Take off the select and shift gear flexible shaft fixed sleeve from

the transmission bracket.

△

Notice: Just pull up the select and shift gear levers’ flexible shafts; the

black fixed sleeve was mounted on the stay wire as a unit.

3). Cut off the connection between select gear flexible shaft and shift

gear control mechanism.

4). Cut off the connection between shift gear flexible shaft and shift

gear control mechanism.

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6MT Transmission

1-18

5). Take off the lateral select and shift gear flexible shaft fixed

sleeve of control mechanism.

6). Dismount the select and shift gear wire drawing fixed bolt on

the side of engine front plate.

7). Remove the select and shift flexible shaft assembly.

（

Ⅲ

） Mounting

1. Mount the select and shift gear flexible shaft

1). Connect the select gear flexible shaft on the control mechanism.

2). Connect the shift gear flexible shaft on the control mechanism.

3). Fix the select and shift gear fixed sleeve.

4). Connect the select and shift gear flexible shaft on the transmission shift gear control mechanism.

△

Notice: Mount the select and shift gear wire drawing correctly.

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6MT Transmission

1-19

3). Fix the select and shift gear fixed sleeve.

4). Connect the select and shift gear flexible shaft on the

transmission shift gear control mechanism.

△

Notice: Mount the select and shift gear wire drawing correctly.

△

Notice: Mounting direction of spring lock.

5). Mount U-type snap-gauge; fix the select and shift gear flexible

shaft on the bracket of transmission.

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6MT Transmission

1-20

6). Mount the select and shift gear wire

drawing fixed bolt on the side of engine

front plate.

Tightening torque: 20~30N·m.

2. Check if the parts mounted correctly

1). Put the select gear lever on the side of 1

st

to 2

nd

gears and 5

th

to 6

th

gear, make sure the select gear lever can smoothly shift into the natural.

2). When the lever shift into every gear, please make sure it goes

smoothly.

3. Mount auxiliary dash board

4. Mount air filter assembly

Ⅴ Operation mechanism with lever assembly

（

Ⅰ

）

Special tools (null)

（

Ⅱ

） Dismount

1. Dismount auxiliary dash board (Refer to Chapter Dash board)

2. Cut off the select and shift gear flexible shaft (Refer to Chapter Select and

shift gear flexible shaft assembly)

3. Dismount operation mechanism with lever assembly

1). Dismount the fixed bolt of the select and shift gear operation

mechanism.

2). Remove the operation mechanism with lever assembly.

（

Ⅲ

） Mounting

1. Mount the operation mechanism with lever assembly

1). Mount the operation mechanism with lever assembly on the vehicle.

2). Tighten the 4 fixed bolts.

Tightening torque

:

20~30 N·m

2. Mount auxiliary dash board

3. Mount air filter assembly

Ⅵ Select and shift gear base assembly

（

Ⅰ

） Special tools (null)

（

Ⅱ

） Dismounting

1. Dismount air filter assembly (Refer to chapter air filter assy)

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6MT Transmission

1-21

2. Dismount the select and shift gear base assembly

1). Dismount the 5 fixed bolts of the select and shift gear base assembly

2). Put the transmission in neutral, then pull up the select and shift gear

arm fitting.

（

Ⅲ

） Mounting

1. Mount Select and shift gear base assembly.

1). Put the transmission in neutral, then mount the select and shift gear

arm fitting.

2). Mount the 5 fixed bolts of the select and shift gear base assembly, and

tighten them.

Tightening torque

:

25~30N·m

2. Mount air filter assembly

Ⅶ Transmission assembly

（

Ⅰ

） Special tools

No.

Tool number

Tool name

Diagram

1

27G0061

Backup light switch sleeve

（

Ⅱ

） Dismounting

1. Drain the transmission gear oil

2. Dismount batteries (Refer to Chapter Battery)

3. Dismount air filter assembly (Refer to Chapter Air filter assembly)

4. Dismount starter (Refer to Chapter Starter)

5. Dismount front driving shaft (Refer to Chapter Front driving shaft)

△

Notice: After dismounting the front driving shaft, please put a suitable plug in the side oil seal to avoid impurities

into the transmission.

6. Dismount engine guide plate (Refer to Chapter Engine guide plate)

7. Dismount the transmission assembly

1). Dismount batteries pallet

2). Cut off the harness connector of backup light switch.

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6MT Transmission

1-22

3). Cut off the transmission select and shift gear flexible shaft.

4). Mount hanging bracket on engine lifting hook.

5). Dismount the fixing bracket of clutch oil pipe.

6). Dismount clutch wheel cylinder fixed bolts; cut off the clutch wheel

cylinder from transmission.

7). Use jack lever to lift the transmission assembly.

8). Dismount transmission lower clapboard.

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1-23

9). Dismount three fixed bolts on transmission and upper side of engine.

10). Dismount fixed bolts in the middle of transmission and engine.

11). Dismount transmission rear suspension.

12). Dismount the transmission left suspension fixing bracket.

13). Pull down the jack lever; remove the transmission assy from

vehicle.

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6MT Transmission

1-24

（

Ⅲ

） Mounting

1. Mount transmission assembly

1). Mount the transmission on the vehicle.

2). Mount the transmission left suspension.

3). Mount and tighten the 3 connecting bolts between left suspension

and vehicle body.

Tightening torque

:

50~60N·m

4). Mount transmission rear suspension.

5). Tighten the connecting bolts between rear suspension and

sub-frame.

Tightening torque: 115~145N·m

6). Mount fixed bolts in the middle of transmission and engine.

Tightening torque: 34.3~41.2N·m

7). Mount and tighten the three fixed bolts on transmission and upper

side of engine.

Tightening torque: 34.3~41.2N·m

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6MT Transmission

1-25

8). Mount transmission lower clapboard and tighten the fixed bolts.

Tightening torque: 8~12N·m

9). Connect the clutch wheel cylinder and tighten the fixed bolts.

Tightening torque: 20N·m

10). Connect the shift gear flexible shaft.

11). Connect the reverse gear switch harness connection.

2. Mount engine guide plate

3. Mount front driving shaft

4. Mount the starter

5. Mount air filter assembly

6. Mount batteries

7. Refuel transmission gear oil

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6MT Transmission

1-26

Ⅷ Release bearing and shifting fork assembly

（

Ⅰ

）Special tools (null)

（

Ⅱ

）Dismounting

1. Dismount transmission assembly Refer to chapter transmission assembly)

2. Remove release bearing and shifting fork assembly

1). Remove the release bearing.

2). Exert strengths to break the release shifting fork snap spring away

from support point, then remove the release shifting fork.

（

Ⅲ

）Mounting

1. Mount release bearing and shifting fork assembly

1). Mount the release shifting fork snap spring on its right position.

2). Mount well the release bearing and shifting fork at the same time.

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6MT Transmission

1-27

Ⅸ Rear housing

（

Ⅰ

） Special tools (null)

（

Ⅱ

） Dismounting

1. Dismount transmission assembly ( Refer to chapter transmission assembly)

2. Dismount reverse switch assembly (Refer to chapter reverse switch assembly)

3. Dismount select and shift gear base assembly (Refer to chapter select and shift gear base assembly)

4. Dismount the release bearing and shifting fork assembly

(

Refer to chapter release bearing and shifting fork assembly)

5. Dismount rear housing

1). Dismount the reverse gear shaft bolts directly with wrench.

2). Dismount three self-lock pin fittings.

3). Dismount the 12 fixed bolts outside.

4). Dismount the 3 fixed bolts inside.

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6MT Transmission

1-28

5). Use copper bar to slightly smash the clutch housing to make the clutch

housing and junction surface of shell separated.

（

Ⅲ

）Mounting

1. Mount rear housing

1). Align the locating pin, and then mount the transmission rear

housing on the clutch shell.

2). Pre-smear thread locking adhesives on bolts; tighten the 3 fixed

bolts inside.

Tightening torque: 34.3~41.2N·m

3). Pre-smear thread locking adhesives on bolts; tighten the 12 fixed

bolts outside.

Tightening torque: 34.3~41.2N·m

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1-29

4). Mount three self-lock pin fittings.

Tightening torque: 30~40N·m

5). Mount the reverse gear shaft bolts directly with wrench.

2. Mount the release bearing and shifting fork assembly

3. Mount select and shift gear base assembly

4. Mount reverse switch assembly

5. Mount transmission assembly

Ⅹ Reverse gear intermediate shaft assembly

（Ⅰ） Special tools

（null）

（Ⅱ）

Dismounting

1. Dismount transmission assembly (Refer to Chapter Transmission assembly)

2. Dismount reverse switch assembly (Refer to Chapter Reverse switch assembly)

3. Dismount select and shift gear base assembly (Refer to Chapter Select and shift gear base assembly)

4. Dismount the release bearing and shifting fork assembly (Refer to Chapter Release bearing and shifting fork assembly)

5. Dismount rear housing (Refer to Chapter Rear housing)

6. Dismount reverse gear intermediate shaft assembly

1). Pull up reverse gear intermediate shaft in axial direction, then

the reverse gear shaft fitting can be removed.

（

Ⅲ

）Mounting

1. Mount reverse gear intermediate shaft

1). Mount the reverse gear shaft fitting in the mounting hole.

2). Rotate reverse gear tooth to see if it rotates smoothly.

2. Mount rear housing

3. Mount the release bearing and shifting fork assembly

4. Mount select and shift gear base assembly

5. Mount reverse switch assembly

6. Mount transmission assembly

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6MT Transmission

1-30

Ⅺ Select and shift gear fork and shifting fork shaft

（

Ⅰ

） Special tools（null）

（

Ⅱ

） Dismounting

1. Dismount transmission assembly (Refer to Chapter Transmission assembly)

2. Dismount reverse switch assembly (Refer to Chapter Reverse switch assembly)

3. Dismount select and shift gear base assembly (Refer to Chapter Select and shift gear base assembly)

4. Dismount the release bearing and shifting fork assembly (Refer to Chapter Release bearing and shifting fork assembly)

5. Dismount rear housing (Refer to Chapter Rear housing)

6. Dismount reverse gear intermediate shaft assembly (Refer to Chapter Reverse gear intermediate shaft assembly)

7. Dismount select and shift gear fork and shifting fork shaft

1). Remove the two bolts on support base, and then pull them up to

take off the shift gear shaft support base.

2). Remove three resilient pins connecting the shifting fork with

fork shaft; pull up the fork shaft and then take off the fork, fork shaft and

fork block.

（

Ⅲ

） Mounting

1. Mount select and shift gear fork and shifting fork shaft

1). Mount the fork, fork shaft and fork block on input and output shafts.

2). Mount resilient pins.

3). Mount the shift gear shaft support base, and then tighten the 2 fixed

bolts.

Tightening torque

:

15~22N·m

2. Mount reverse gear intermediate shaft

3. Mount rear housing

4. Mount the release bearing and shifting fork assembly

5. Mount select and shift gear base assembly

6. Mount reverse switch assembly

7. Mount transmission assembly

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6MT Transmission

1-31

Ⅻ Input and output shaft assembly

（

Ⅰ

） Special tools

No. Tool number Tool name Diagram Function

1

27G0060

Compacter of fork shaft fixed

Dismount fork shaft fixed pin

2

27G0062

Mounting tool of input shaft

oil seal

Mount input shaft oil seal

3

27G0065

Mount and dismount heel

block of input shaft

Mount and dismount input shaft

bearing and synchronizer

4

27G0066

Mounting tool of input shaft

6th gear sleeve

1.mount input shaft 6th gear sleeve

2.mount input shaft rear end

bearing

3. mount output shaft end bearing

5

27G0067

Mounting tool of 4th and 5th

gear sleeve

Mount 4th and 5th gear sleeve

6

27G0068

Mounting tool of input shaft

front bearing

Mount input shaft front bearing

7

27G0069

Mounting tool of output shaft

front bearing outer ring

Mount output shaft front bearing

outer ring

8

27G0070

Mounting tool of output shaft

rear bearing outer ring

Mount output shaft rear bearing

outer ring

9

27G0071

Mounting tool of differential

bearing outer ring

Mount differential bearing outer

ring

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6MT Transmission

1-32

10

27G0072

Mounting tool of select gear

shaft oil seal

Mount select gear shaft oil seal

11

27G0073

Mounting tool of select gear

shaft linear bearing

Mount select gear shaft linear

bearing

12

27G0074

Mount and dismount heel

block of output shaft

Mount and dismount output shaft

gear and synchronizer

13

27G0075

Dismounting tool of 4th,5th

and 6th gear

Dismount 4th,5th and 6th gear

14

27G0076 Dismounting tool of 3rd gear Dismount 3rd gear

15

27G0077

Mounting tool of output shaft

gear

Mount 3rd,4th,5th and 6th gear

16

27G0078

Mounting tool of output shaft

1st gear synchronizer

Mount output shaft 1st gear

synchronizer

（

Ⅱ

） Dismounting

1. Dismount transmission assembly (Refer to Chapter Transmission assembly)

2. Dismount reverse switch assembly (Refer to Chapter Reverse switch assembly)

3. Dismount select and shift gear base assembly (Refer to Chapter Select and shift gear base assembly)

4. Dismount the release bearing and shifting fork assembly (Refer to Chapter Release bearing and shifting fork assembly)

5. Dismount rear housing (Refer to Chapter Rear housing)

6. Dismount reverse gear intermediate shaft assembly (Refer to Chapter

Reverse gear intermediate shaft assembly)

7. Dismount select and shift gear fork and shifting fork shaft (Refer to Chapter

Select and shift gear fork and shifting fork shaft)

8. Dismount input and output shaft

1). Take off the pressure plate by removing the 4 screws.

2). Pull upward the input and output shaft at the same time.

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1-33

（

Ⅲ

） Disassembling

1. Disassemble input shaft assy.

1). Put the input shaft vertically on the working table.

4). Remove the input 6

th

gear sleeve with special tool.

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6MT Transmission

1-34

5). Remove the 5/6

th

gear synchronizer assy and 5/6

th

gear synchronizing

ring together.

6). Take down the input 5

th

gear fitting and 5

th

gear needle bearing.

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6MT Transmission

1-35

7). Take down the 5

th

gear sleeve with special tool, and then take down

the input 4

th

gear fitting and its needle bearing.

8). Hook the lower end of input 3

rd

gear tooth fitting, and then pull down

input 4

th

gear sleeve, 3/4

th

gear synchronizer assy and input 3

rd

gear tooth

fitting together to take off the 3

rd

gear needle bearing.

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6MT Transmission

1-36

9). Dismount input shaft front bearing.

2. Disassemble the output shaft

1). Put the output shaft vertically on the working table.

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6MT Transmission

1-37

2). Remove the adjusting shim.（Output shaft rear bearing）

3). Dismount the output 6

th

gear and output shaft rear bearing together.

△

Notice: Hook the lower end of output 6

th

gear with special tool, and

then pull down the 6

th

gear and bearing together.

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6MT Transmission

1-38

4). Hook the lower end of output 4

th

gear with special tool, and then pull

down the 5

th

gear and 4

th

gear together.

5). Hook the lower end of output 2

nd

gear fitting with special tool, and then

pull down the 3

rd

gear and 2

nd

gear together, finally take down the 2

nd

needle

bearing.

△

Notice: Check if there is any damage of the needle bearing.

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6MT Transmission

1-39

6). Dismount the 1/2 gear synchronizer assy and 1/2 synchronizing ring

together with special tool.

7). Dismount output 1

st

gear fitting and 1

st

gear bearing (please check

if there is any damage of the needle bearing).

（

Ⅳ

） Checking

1. Check the input shaft

1). Check the input shaft to see whether the gear is broken or the gear surface occurred pitting, wearing and agglutination. If these

phenomena occurred, you must replace the input shaft.

2). Use your hands to”feel” whether the bearing rotates flexibly or occurred nimbleness. If these situations happened, you must

replace the bearing.

2. Check the output shaft

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1-40

1). Check the output shaft to see whether the gear is broken or the gear surface occurred pitting, wearing and agglutination. If these

phenomena occurred, you must replace the output shaft.

2). Check whether the output shaft spline has severe wearing or damage. If there is any damage, you must replace the output shaft.

3). Use your hands to” feel” whether the bearing of output shaft front end rotates flexibly or occurred nimbleness. If these

situations happened, you must replace the bearing.

3. Check (toothed) gear of every gear

1). Check to see whether gears of every gear are broken or the gear surface occurred pitting, wearing and agglutination. If these

damages occurred, you must replace the corresponding gears.

4. Check the needle bearing of every gear

1). Check to see whether needle bearing of every gear occurred following phenomena including severe wearing; falling off of the

needle bearing or incompleteness of the holder. If these damages occurred, you must replace the needle bearing.

5. Check the synchronizing ring

1). Check whether the surface of synchronizing ring has any damage or failure.

2). Check whether the cone surface has any damage or wearing and whether the thread has been crushed.

3). Synchronizing ring of 4

th

, 5th and 6

th

is single-cone ring. Check the

clearance “A” while pushing the synchronizing ring towards the gear. If “A”

is less than the minimum, then please replace the synchronizing ring.

Minimum: A=0.5mm

4). Synchronizing ring of 1

st

, 2

nd

and 3

rd

is tri-cone ring. Check the

clearance “B, C” while pushing the synchronizing ring towards the gear. If

“B, C” is less than the minimum, then please replace the synchronizing ring.

Minimum: "B"=0.5mm "C"=0.5mm

6. Check the synchronizer

1). Assemble the gear sleeve and hub of synchronizer together, and

check to see if they can slide smoothly or has any nimbleness.

2). Check if there is any damage on two ends of gear sleeve’s internal

surface.

△

Notice: If you need to replace the synchronizer for nimbleness or damage,

please replace with a whole set.

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1-41

（Ⅴ） Assembly

1. Assemble input shaft assy.

1). Smear lubrication on input shaft bearing end before mounting the bearing.

Mount the ball bearing (in the front of input shaft) on the input shaft.

2). Mount the 3

rd

needle bearing and input 3

rd

gear fitting on the input shaft.

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6MT Transmission

1-42

3). Mount 3/4 synchronizer assy and 3/4 synchronizing ring on the

input shaft.

△

Notice:

1. Please pay attention to the direction of synchronizer during assembly.

2. The gear hub trisection groove should match the outer ring trisection

boss.

4). Smear lubrication on input shaft 4

th

gear, and then mount the input

4

th

gear sleeve on input shaft.

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6MT Transmission

1-43

5). Mount the 4

th

needle bearing and input 4

th

gear fitting on the input shaft.

△

Notice: Smear lubrication when mount input 4

th

gear needle bearing, and

smear again on the whole mounting place after assembly. The input 4

th

gear

fitting should rotate flexibly and without nimbleness after the assembly.

6). Smear lubrication on input shaft 5

th

gear, and then mount the input 5

th

gear sleeve on input shaft.

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1-44

7). Mount the 5

th

needle bearing and input 5

th

gear fitting on the input shaft.

△

Notice: Smear lubrication when mount input 5

th

gear needle bearing,

and smear again on the whole mounting place after assembly. The input 5

th

gear fitting should rotate flexibly and without nimbleness after the assembly.

8). Mount 5/6 synchronizer assy and 5/6 synchronizing ring on the input

shaft.

△

Notice:

1. Please pay attention to the direction of synchronizer during assembly,

the conical surface of synchronizing ring shall be downward.

2. The gear hub trisection groove should match the outer ring trisection

boss.

9). Smear lubrication on input shaft 6

th

gear, and then mount the input 6

th

gear sleeve on input shaft.

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6MT Transmission

1-45

10). Smear lubrication on input shaft 6

th

gear needle bearing, and then mount

the input 6

th

gear needle bearing, fitting and thrust washer on input shaft.

△

Notice: Smear lubrication on the whole mounting place after assembly.

The input 6

th

gear fitting should rotate flexibly and without nimbleness after the

assembly.

11). Smear lubrication on input shaft bearing end , and then mount the ball

bearing (behind the input shaft) on the input shaft.

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1-46

12). Mount the plug screw on the input shaft.

13). After press-mounting the bearing, assemble the snap ring on input

shaft front bearing to finish the assembly of input shaft assy.

2. Assemble output shaft assy

1). Smear lubrication on output shaft bearing end before mounting the

bearing; press-mount the tapered roller bearing (in the front of output shaft).

△

Notice: Please pay attention to the direction of bearing during

press-mount the tapered roller bearing.

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6MT Transmission

1-47

2). Smear lubrication on output 1

st

gear needle bearing; mount the output 1

st

needle bearing and output 1

st

gear fitting.

△

Notice: Smear lubrication on the whole mounting place after assembly.

The output 1

st

gear fitting should rotate flexibly and without nimbleness after the

assembly.

3). Mount 1/2 synchronizer assy and 1/2 synchronizing ring on the output

shaft.

△

Notice:

1. Please pay attention to the direction of synchronizer during assembly.

2. The gear hub trisection groove should match the outer ring trisection

boss.

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6MT Transmission

1-48

6). Heat the output 4

th

gear to 130°±5°, then press-mount it on the right

position.

7). Heat the output 5

th

gear to 130°±5°, then press-mount it on the right

position.

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8). Heat the output 6

th

gear to 130°±5°, then press-mount it on the right

position.

9). Smear lubrication on input shaft bearing end first; press-mount the

output shaft rear tapered roller bearing and adjusting shim (rear bearing of

output shaft).

△

Notice:

1. Please pay attention to the direction of bearing during press-mount the

tapered roller bearing.

2. Selecting the shim during mould assembling.

10). Finish the assembly of output shaft.

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（

Ⅵ

） Mounting

1. Mount input and output shaft assembly

1). Put the input shaft and output shaft assembly into the shell.

2). Mount the pressure plate and tighten the 4 screws.

Tightening torque: 8~12N·m

2. Mount select and shift gear fork and shifting fork shaft

3. Mount reverse gear intermediate shaft assembly

4. Mount rear housing

5. Mount the release bearing and release shifting fork fitting

6. Mount select and shift gear base assembly

7. Mount reverse switch assembly

8. Mount transmission assembly

XIII Differential case assembly

（

Ⅰ

） Special tools

No.

Tool number

Tool name

Diagram

Function

1

27G0059

Mounting tool of differential case

oil seal

Mount differential case oil seal

2

27G0063

Mount and dismount heel block of

differential case bearing

Mount and dismount

differential case bearing

3

27G0064

Mounting tool of differential case

bearing

mount differential case

bearing

（Ⅱ）Dismounting

1. Dismount transmission assembly (Refer to Chapter Transmission assembly)

2. Dismount reverse switch assembly (Refer to Chapter Reverse switch assembly)

3. Dismount select and shift gear base assembly (Refer to Chapter Select and shift gear base assembly)

4. Dismount the release bearing and shifting fork assembly (Refer to Chapter Release bearing and shifting fork assembly)

5. Dismount rear housing (Refer to Chapter Rear housing)

6. Dismount reverse gear intermediate shaft assembly (Refer to Chapter Reverse gear intermediate shaft assembly)

7. Dismount select and shift gear fork and shifting fork shaft (Refer to Chapter Select and shift gear fork and shifting fork shaft)

8. Dismount input and output shaft (Refer to Chapter Input and output shaft)

9. Dismount differential case

1). Take out the differential case assy. from the transmission

rear housing.

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（

Ⅲ

） Disassembly

1. Disassembling differential case assy.

1). Use bearing puller to remove off the driven gear side bearing of

final drive.

2). Dismount the driven gear fixed bolts of final drive.

3). Take down the driven gear of final drive.

4). Use bearing puller to dismount side bearing at the opposite of

final drive gear.

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5). Use proper tool to dismount the planet axle lock-pin.

6). Take out the planet axle.

7). Rotate the planet gear.

△

Notice: Rotate the planet gear by 90 degree as showed in the

picture.

8). Take out the planet gear.

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9). Take out the side output pinion at the opposite side of final

drive gear.

10). Take out the side output pinion at one side of final drive gear.

11). Take out the planet gear gasket of differential case.

12). Take out the planet gear gasket of differential case.

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13). Dismounted planet gear and output gear.

△

Notice: if the engage clearance between planet gear and

output gear has to be adjusted, you can adjust the thickness of

adjusting shim.

（Ⅳ） Mounting

1. Mount the differential case assy.

1). Use proper tool to assemble bearing at the gear side of final drive.

2). Use proper tool to assemble bearing at the opposite side of final

drive gear.

3). Mount planet gear and output gear.

△

Notice: Pay attention to the state of shim between planet gear and

output gear during assembly.

4). Mount planet axle.

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5). Use proper tool to mount the planet axle lock-pin on the right

position.

△

Notice: Put the surface of planet axle lock-pin with spline groove

upward.

6). Mount the driven gear of final drive.

7). Tighten the fixed bolts of final drive driven gear diagonally.

Tightening torque 75~85N·m

△

Notice: Fixing bolts in diagonal sequence.

（Ⅴ） Mounting

1. Mount the differential case assy.

1). Mount the differential case assy on the transmission rear housing.

2. Mount input and output shaft assembly.

3. Mount reverse gear intermediate shaft assembly.

4. Mount rear housing.

5. Mount the release bearing and release shifting fork fitting.

6. Mount select and shift gear base assembly.

7. Mount reverse switch assembly.

8. Mount transmission assembly.

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CVT Transmission

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Transmission （CVT）

Ⅰ Summary

（Ⅰ） Structure summary

The continuously varying transmission drive ratio can be achieved by means of a device, the device includes two opposed cone wheel

and V-shaped driving strip wrapped around the two wheels.The transmission ratio of the device is transmitted to the differential in the

transmission through the intermediate shaft.

This manual briefly describes the transmission, including the design and function of the various components of the transmission, and

elaborates the power-train and control devices. In addition, the manual also elaborates the transmission oil cooling system and external shift

mechanism.

The continuously variable shift model can make you have more comfortable driving, and can improve vehicle performance.

Use this type of automatic transmission has the following advantages:

- In a constant vehicle speed situation, the engine has lower speed;

- Improve emission / reduce fuel consumption;

- Better NVH (noise, vibration, harshness);

- Steady acceleration;

- Have a maneuverability on the mountain road.

Comparison of Traditional automatic transmission and a continuously variable transmission

The figure below shows the CVT and manual or regular automatic transmission ratio change chart. regular automatic transmission

(transmission device) gear ratio is a series of fixed values.

When the transmission is shifted to higher gear, the gear ratio will vary according to throttle opening size along the thick solid or

broken lines shown on the right. However through the use of continuously variable transmission, can obtain the gear ratio change chart as

shown in the left, two transmission shift points all related with the throttle opening degree applied by the driver.

When the throttle opening degree becomes larger, the engine speed increases, the transmission shifted into high gear; if use traditional

transmission, the engine speed will be significantly decreased, while use continuously variable transmission will not. CVT can be into high

gear at the engine speed remains unchanged situation by moving rotating cone (as description below). In addition, you can also choose other

shift strategy, which will help new users faster accept CVT.

CVT (left) and 4-speed AT (right) ratio change chart

CVT ratio change chart

4-

speed AT ratio change chart

Driving gear speed

Dr

ive

n

ge

ar

sp

Dr

ive

n

ge

ar

sp

ee

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Sectional view of the transmission

1. Torsion damper / flywheel 6. Steel strip

2. Pump 7. Driving bevel wheel

3. Reverse clutch 8. Driven bevel wheel

4. Planetary body 9. Intermediate shaft

5. Forward clutch 10. Differential

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Transmission exploded view

1. Input shaft rubber protective sleeve 482235

2. Input shaft oil seal 481274

3. Differential oil seal cover 481296

4. Differential oil seal 483329

5. screw plug gasket 481247

6. oil filler bolt 481248

7. ventilator tube cap 483420

8. ventilator tube assy 483114

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9. Driven bevel wheel cover O type gasket (small)

10. Driven bevel wheel cover gasket 481877

11. Driven bevel wheel cover O type gasket (big) 481255

12. Driven bevel wheel cover 482982

13. screws driven bevel wheel cover countersunk 482208

14. Driving bevel wheel ball bearing 482294

15. Driving bevel wheel shaft nut 481293

16. Cone type spring washer 481856

17. Pump seals 481826

18. Pump O-ring 481259

19. oil pump (including o-ring) 483323

20. pump bolt 481284

21. Driving bevel wheel shaft cover O-ring 481253

22. Driving bevel wheel shaft cover 481173

23. Driving bevel wheel shaft cover snaps 481189

24. Driving bevel wheel shaft cover bolt 481283

24. sump bolt 481283

25. speed sensor 482410

26. speed sensor bracket mounting bolts at differential 481289

27. speed sensor bracket at differential 482468

28. Speed sensor mounting bolts 481283

29. Oil pan gasket 482504

30. valve assy 482589

31. valve bolt 481311

32. plastic clip 482253

33. Oil filter assy 483165

34. Sump magnet 481870

35. oil sump assy

36. oil drain screw 482442

37. Driving mode sensor mounting screw 481090

38. Driving mode sensor 482493

39. Oil cooler plug O type gasket 481258

40. Oil cooler plug 482121

41. Oil level plug gasket 481249

42. oil level plug 481250

43. Main connector cover 482104

44. main connector snap 482105

45. main connector and inner harness 482475

46. Gear selection lever nut 481329

47. Gear selection lever 483185

48. Gear selection lever nut gasket 482584

49. Seal (gear selection shaft) 482099

50. Locating Pin 483138

51. material snap 481456

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（Ⅱ） System Principles

CVT Transmission components can be divided into three groups according to the corresponding function.

· Group 1 - mechanical transmission device function of this component is to provide mechanical transmission and torque transfer.

· Group 2 - the control system associated with the control system components. According to the load conditions and drive requirements,

the control system ensures that the transmission power is transmitted and to change the transmission ratio at the appropriate time.

· Group 3 - some components of the external connection apparatus connected to the outside of the transmission. Among these

components, some located within the transmission or gearbox connected, and some components are part of the whole system, but they are

distributed in other parts of the vehicle.

Group 1 mechanic torque transmission

Planetary body

Planetary body can provide the transmission have forward and backward driving torque. Engine torque usually passed to the

transmission through the planetary carrier input shaft. Engaging the forward direction of the multiple disc clutch can be directly connected to

the planet carrier sun gear, at this time by the engagement, the planet carrier and sun wheel become a whole rotation, the engine torque is

transferred directly to the driving wheel. Planetary gears do not transmit any torque, so there is no mechanical loss, and the rotation direction

of the drive wheel will be consistent with the rotation direction of the engine. This is the forward mode.

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 the sun gear can counter-rotate, the gear ratio at this time is 1: 1.1, there will be a slight

deceleration to compensate planetary mechanism frictional losses.

Planetary body

1. planet gear 3. sun gear

2. input shaft 4. ring gear

Multiple disc clutch

Have two sets of multi-plate wet clutch: one for forward and one for reverse. Each set has three friction disc, six total friction surface.

hydraulic system control the clutch can make the vehicle go forward smoothly at any throttle opening level, when the driving gear is engaged,

through the control amount of the clutch engagement can also stop the vehicle. Cooling oil directly cools the clutch disc to prevent

overheating of the friction surface.

The clutch at the planetary mechanism

1. forward clutch set

2. reverse clutch set

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CVT Transmission

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Bevel wheel and steel strip

The main design features of the CVT is a pair of "V" type bevel wheel connected by a steel belts. driving wheel and driven wheel

center distance is 155mm. Each bevel wheel is divided into two halves: half fixed, half axial sliding, tilt are both 11 °. Width of 24mm "Van

Doorne" push belt is used for transmitting torque between wheels (if you want to use a larger torque values, you can use 30mm belt). By the

way of injecting lubricate oil to cools the drive belt . In order to reduce the belt angle error when shift gear, the two movable gear halves are

placed between the two diagonal positions, and then move the gear halves connected to each hydraulic cylinder / piston. Hydraulic pressure

is controlled by the control system. details refer to "group 2 control system ". Spherical spline can prevent the movable gear halve from

rotating with the fixed gear halve.

Because the sun gear is connected to driving bevel wheel by the spline, so the torque can be directly transmitted to driving bevel wheel

from the planetary gear set. Steel strip transmits power to the driven wheels from the driving bevel wheel, then the power is transferred to the

intermediate gear shaft.

Driven wheel torque and speed is determined by the position of the driving strip. Design the two gear dimensions, so they can provide a

2.416: 1 - 0.443: 1 gear ratio, the maximum ratio is 5.45 times the minimum transmission ratio. Overdrive ratio is the minimum fuel

consumption.

Driving strip is made by 450 steel disc and 24 strips, each side has 12 strips.

Strip

1. steel strip 2. steel disc

Intermediate shaft

Intermediate shaft (pinion shaft) can make the driven bevel and differential meshed helical gear set reduce speed, so you can ensure the

correct direction of the drive shaft rotation. The speed decelerate between driven bevel gear and intermediate shaft largely improves vehicle

performance. Intermediate shaft is fixed by two bevel bearings which inside the clutch shell and inner the independent bearing seat.

Differential

Like the manual transmission, the crown wheel torque transmitted to the wheels through a differential, crown wheel is fixed by 8 bolted

to the differential housing, drive shaft is fixed by traditional rzeppa universal joints and seals to the differential inside. bevel bearing is used

to fix differential.

Mechanical manipulation

Transmission ratio change

Traditional planetary gear automatic transmission ratio progression is limited, usually four, five or six, but the continuously variable

transmission is different, as its name implies, the continuously variable transmission gear ratio varies continuously. Low gear (lower gear

ratio) make it easier to start the vehicle stationary, the driving bevel wheel has a relatively small diameter but driven bevel wheel has a

relatively large diameter. driving strip is used to transmit power and torque, if through increasing driving bevel gear diameter and narrow

driven bevel gear diameter to select high ratio, this can produce acceleration. By controlling the degree of change to ensure the most

appropriate gear ratio.

CVT has driving bevel wheel and driven bevel wheel, each bevel wheel consists of two half-bevel，one is fixed, the other can be moved

by hydraulic control. Position of the belt on the wheel can determine transmission ratio. If move the movable half wheel close to fixed half,

the driving strip will move to outer periphery. When the two halves of the bevel wheel separation, the wheel circumference will be smaller,

driving bevel wheel and driven bevel wheel located at their respective semi-diagonal position, at this time driving bevel wheel with radius

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shrinks, while the driven bevel wheel increase the belt radius.

Vehicle starting require low gear ratio, therefore, the driving bevel wheel separate to make the strip closed on the wheel , and the driven

bevel wheel close to make strip moves on the outer peripheral. high speed need big transmission ratio, so the driving bevel wheel movable

half would move to fixed half, the bevel wheel circumference increase, at the same time, driven bevel wheel was separated , driven bevel

wheel circumstance decrease, then create high ratio. When the driving bevel wheel completely closed , driven bevel wheel completely

separate, then produce the overdrive ratio. Driving bevel gear and driven bevel wheel transfers at about 1: 2.5 ratio.

Pulley position at low-speed

1. engine input 2. output to wheel

3. the minimum diameter of the transmission wheel (low speed)

4. The maximum diameter of the driven wheel (low speed)

Pulley position at high-speed

1. engine input 2. output to wheel

3. the minimum diameter of the transmission wheel

4. The maximum diameter of the driven wheel

· Selector lever is in neutral or the parking gear

In this state, the reverse clutch (2) and the forward clutch (4) separate, can not drive the wheel.

- Transmission input shaft (1) have the speed with the engine.

- Reverse clutch (2) separate.

- Forward clutch (4) separate.

- Planetary wheel (（3）rotate around the sun gear idle

- The sun wheel does not move, driving wheel (5), driven wheel(7)and the vehicle also remain intact.

For all automatic transmission, only when gear in neutral or parking position can start the engine, when at the state of parking station,

mechanical lock can prevent vehicle move. To avoid damaging the transmission, can use parking gear only when the vehicle is not moving.

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Transmission torque mechanism shown at right

1. input shaft 5. driving gear

2. reverse clutch 6. Drive steel strip

3. planetary gear 7. driving gear

4. forward clutch

· Selector lever at forward gear

In this state, the forward clutch (4) engages the wheel make the vehicle move.

- Transmission input shaft (1) have the same rotation speed with the engine.

- Reverse clutch (2) separates.

- Forward clutch (4) engages.

-Planetary mechanism Planetary Gear (3), the sun gear and the ring gear

rotate together.

- driving gear (5) have the same rotation speed with engine, forward direction.

-driven gear (7) is also forward direction, the speed is up to the transmission

ratio at the moment.

Transmission torque mechanism shown at right

1. input shaft 6. driving steel strip

2. forward clutch 7. driven bevel gear

3. planetary gear 8. driven bevel gear

4. forward clutch 9. input shaft

5. driving bevel gear

· Selection lever at reverse gear

In this state, the reverse clutch (2) engages, the ring gear (9)locked in the

transmission housing. Planetary gear (3) makes the sun gear (10), the

driving gear (5) and the driven gear (7) have the anti-direction of the

transmission input shaft (1).

Now reverse gear is selected.

- Transmission input shaft (1) have the same rotation speed with the engine.

- reverse clutch (2) engages.

- forward clutch (4) separates.

- ring gear (9) connects the transmission case through reverse clutch (2).

- Transmission input shaft (1) direct drive the planetary gear (3) which

rotates around the ring gear, thereby drive gear (10), pulley gear (5) and

the driven bevel gear (7) rotated in reverse.

Transmission torque mechanism shown at right

1. input shaft 6.driving steel strip

2. reverse clutch 7. driven bevel gear

3. planetary gear 8. driven bevel gear

4. forward clutch 9. ring gear

5. driving bevel gear 10.sun gear

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Group 2 control system

Control system function as follows:

1. Make the steel strip tension of the clamping force adapted to the engine torque, to prevent strip slipping.

2.Control the forward and reverse clutch when driving.

3. Provide the best gear ratio for driving.

4. Provide the transmission with necessary lubricanting and cooling oil.

Oil pump

the oil pump inside the transmission is external gear pump, engine drives oil pump shaft , pump shaft connects the pump through

hollow driving bevel gear axle. pump shaft is connected to planetary gear carrier through spline, the pump run as the engine rotation speed all

the time, oil pump about 10 cm3/ r. system pressure is up to input torque , maximum 40~50bar.

Oil pump figure

oil pressure not only can used to control transmission hydraulic, but also can lubricate.

1. pump driving shaft 2. pump assy

Pump inlet

1. pump inlet 2. pump oil seal

Transmission control device

Transmission control device makes the tension between the strip gear have the minimum value but no slipping, and also according to the

driving strategy target value provides the gear ratio (based on the transmission input (active) and output (driven) speed calculate). During the

life, the control device performance degradation can be kept within a certain range, and will not significantly affect the vehicle comfort and

strip tension.

Tension control device

Tension control device can obtain the minimum tension force required for the strip without slippage, so this would give the minimal

impact to transmission efficiency, and this will get the lowest fuel consumption.

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Except normal driving situation, the tension control device also takes into account the maximum torque input and output at special

situation, thus can extremely protect the transmission. control device also considers the anti-lock braking system (ABS) brakes, tire locking

(no ABS) as well as other driving force control systems (such as ESP, anti-skid control devices, etc.). In addition, the device also considers

the road and special circumstances, such as through road potholes, curbs, low friction coefficient changes, tire slip (such as at low friction

coefficient road).

Software can compare the transmission's transmission performance and the transmission expected input torque. When the tension

control device finds tension is insufficient, ECU receives torque reduced command, thereby adjust the engine torque to a suitable range. This

function can also protect transmission.

If there is no electronic drive line systems in motor vehicles, ECU via CAN bus transfer torque signal, if there is no CAN bus,

transmission control system (TCU) software itself generate default torque signal.

Ratio control device

Transmission through the control of input and output pressure to balance the pressure of driving bevel gear and driven bevel gear , to

control the transmission ratio. Through the driving bevel gear and driven bevel gear speed sensor signal can calculates the transmission ratio,

and can change the output pressure to get the required ratio. The minimum pressure can be determined by the tension method. Transmission

physical model will contribute to rapidly adjust the pressure level to variable operating point. Control software also takes into account the

interference from other components of the transmission, so the software can minimize the delay error and target ratio errors, etc. (in order to

improve fuel economy).

In order to ensure it meets the transmission mechanical and durability limit state requirements, we have developed a strategy to some

drive limit situation. Except the speed limit, software also limit the transmission ratio change rate (set point) within the allowable range. In

addition the software also avoided the engine speed due to vehicle speed and gear lever condition (POS) changes beyond a certain limit. To

achieve this limitation, the software will reduce engine torque or change the drive car to high gear.

Transmission control unit

Transmission control software integrated inside the TCU (Transmission Control Unit). TCU is installed in the cab.

Group 3 external device

Oil cooler interfaces

In front of the transmission case has two oil cooler interfaces. An oil cooler interface mounted beside the engine radiator, make the

lubricating oil temperature maintained below 120°C. Gearbox oil outflow from the right mouth, the mouth should be connected to the oil

cooler of lower interface.

Oil flows into the transmission from the left side of the transmission, so the left mouth of the transmission should connects with the oil

cooler upper interface.

Oil cooler interface

outlet

inlet

Oil cooler

Direction

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Gear selector

VT2 transmission includes parking gear (P), reverse gear (R), neutral (N), forward gear (D) and sport mode (S).

Customers can configure their own custom selector lever. For security reasons, we recommend to apply shift locking device as a

starter protection.

CVT can also achieves manual mode, which requires the TCU add new pins to receive the signal, at the same time the maximum

speed of the engine should be calibrated within a certain range, all of the JAC CVT has a manual mode.

Main connector

Main connector is located on the transmission housing, including 16 pins. Harness connected by circular connectors.

Main connector on transmission

1. harness connector on the transmission

Torsion damper

Most of the traditional automatic transmission use torque converter to connect the engine and the transmission input shaft, but this

transmission uses torsion damper.

(Ⅲ) Technical parameters, maintenance parameters

No. Project Parameter

1 transmission VT2

2 Lubrication oil MOBIL(ESSO) EZL799(A)

(Ⅳ) Torque parameters

No. Project

Tighten torque

1 refuel plug 21±3

2 driven bevel gear shaft cover countersunk screws 9.5±0.95

3 driving bevel gear shaft bolt 197.5±17.5

4 oil pump bolts 10±1

5 driving bevel gear shaft cover bolts 9.5±2.5

6 oil sump bolts 9±1

7 speed sensor mounting bolts 8,5±2

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8 speed sensor bracket screws at differential 9.5±0.95

9 valve bolts 11±1

10 oil drain plug 11±1

11 driving model sensor mounting screws 9.5±0.95

12 oil level plug 15±2.25

3 gear selection lever nut 14.5±1.5

( ) Maintenance NoticeⅤ

Vehicle equiped with VT2 transmission can not be directly haul, because only when the engine is running the bevel gear can produce

hydraulic, the strip can operate. Therefore, when haul the vehicle you have to lift the front wheel from the ground (vacant haul).

( )Ⅵ Special tools

No. Tool No. Tool name Tool figure use

1 16G0049

Driving bevel gear

bearing stopper

remove driving bevel gear bearing

2 16G0043

Selection gear shaft

seal installation tool

Install the selection gear shaft seal

3 16G0050

Driving bevel gear

bearing punch

Install driving bevel gear shaft ball

bearing

4 16G0048

driving bevel gear

bearing remove tool

remove the driving bevel gear

bearing

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5 16G0041

input shaft oil seal

install tool

install input shaft oil seal

6 16G0040

Input shaft seal

bushing

install input shaft oil seal

7 16G0042

selection gear shaft

seal remove tool

remove selection gear shaft seal

8

16G0046

Hydraulic control

block locating pin

install hydraulic control block

9 16G0038

Differential oil seal

installation tool

install differential oil seal

10 16G0045 Pump removal tools

remove pump

11 16G0044

Snorkel installation

tool

install snorkel

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12 CVT-HDFJ-1

N gear assembly aid

tool

Limit on the transmission shift

rocker

Ⅱ Troubleshooting

( )Ⅰ Troubleshooting sheet

No.

Fault

phenomenon

Fault Analysis Solution Remark

1

Transmission oil

pan gasket leak

oil

oil sump bolts damaged replace

oil sump washer replace

oil drain hole replace

oil sump assy replace

2

Transmission

drain plug leak

oil

bolts are not mounted tightly retighten

Drain plug is damaged replace

oil sump assy is damaged replace

3

driving bevel

gear cover leak

oil

sealed cover is not tighten retighten

O-ring damage replace

driving bevel gear cover damage replace

4

driven bevel gear

cover leak oil

sealed cover is not tighten Re-tighten

O-ring damage replace

driven bevel gear cover damage replace

5

selector gear

lever leak oil

selector gear lever washer damage replace

input lever oil

leakage

input shaft washer damages replace

Differential oil

seal leakage

seal damages replace

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6

Oil cooler

interface oil

leakage

lines are not tightened tighten

oil cooler interface washer damages replace

lines damage replace

7

Vehicle hashes

when at D

position, or

hashes when

quick

acceleration

Self-learn is not fully completed re-self learn

Fill the wrong gearbox oil or get in water Replace the gearbox oil

Driving bevel gear speed sensor damages replace

hydraulic control model fault re-self learn

Driven bevel gear speed sensor damages replace

8

on D position,

release the brake,

the vehicle keeps

stationary, then

press the

accelerator pedal,

until the engine

speed reaches

about 2000 rpm,

the vehicle

suddenly rush

out, accompanied

by a great impact

Check the cold vehicle fault codes According to fault codes diagnosis

Check the self-learning re-self learn

Brake signal fault, when do not hit the

braking pedal, the brake signal actually is

in braking condition, cause this fault.

Check the brake signal and wiring

harness

if there is no problem after check, it is maybe

the valve problem

replace valve, and self-learning

( )Ⅱ Noise description

Driven bevel gear voice

There is significantly howling when accelerating at 60km/h-90km/h, release the accelerator pedal, the sound becomes smaller, depress

the accelerator pedal, the sound immediately recovered.

Sounds like whistles, voice rises with increasing speed, the sound is normal voice. the sound is issued by the engagement of

intermediate shaft gear and driven bevel gear.

Reverse sound

Linked to reverse gear, keep the vehicle stationary, you can hear the small whistle sound.

This is a normal sound generated by transmission internal planetary gear.

Low speed voice

When the speed at 40km / h, release the accelerator pedal, along with the speed is slowing down, you can hear a whistle. The whistles

sound is smaller than the driven bevel gear and not easy to heard, this is a normal sound between the pinion and differential.

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( )Ⅲ Noise inspection and maintenance

No. Fault phenomenon Fault Analysis Solution Remark

1

Driving bevel gear ball bearing

noise:

Noise generated in the process

of moving on D gear position, is

buzzing sound, the sound

volume and frequency rises

along with the engine speed

rises, do not rise with vehicle

speed.

Drive at a constant speed on D gear position (at a constant

throttle opening, the vehicle speed at about 60km / h) ,

then linked to S mode, the engine speed will increases

about 500 rpm in 1-2 seconds, at the process, vehicle speed

substantially unchanged, if the sound rises along with

engine speed rises, that means the noise is generated by

driving bevel gear ball bearing damaged.

Replace driving bevel

gear ball bearing.

On 4 gear position at manual model, keep the throttle

opening level, the vehicle speed maintains at a steady

speed about 60km / h, then links to 3gear position, the

engine speed will increase about 800 rpm, and then links

from 3 to 4 gear position, the engine speed will reduces

about 800 rpm, the speed remained unchanged throughout

the process, if the sound rises along with engine speed

rises, that means the noise is generated by driving bevel

gear ball bearing damaged.

Replace driving bevel

gear ball bearing.

2

Transmission inner bearing

noise:

Noise generated in the process

of driving on D gear position, is

buzzing sound, the sound

volume and frequency rises

along with the vehicle speed

rises.

According to the noise inspection method of driving bevel

gear ball bearing, if noise doesn't rise along with engine

speed rises, just rises along with vehicle speed, it maybe

the wheel axle bearing noise, if the axle bearings

troubleshooting, it is the internal gearbox bearing noise.

Correctly judge the

noise problem is very

difficult, so before

deciding to replace the

gearbox parts or

replace the entire

transmission, need to

identify the noise is

generated from the

gearbox. Can replace

some easily replaced

parts on the car firstly,

to determine the noise

source.

Refer to

transmissio

n internal

bearing

noise chart.

3

Transmission water inlet noise:

Linked on D or R gear position,

slowly release the brake pedal,

as long as the wheels move, it

will generate giggle sound,

depress the accelerator pedal,

there would have squeak ------

consecutive sound at the speed

between 10km / h to 40km / h,

the noise disappear after vehicle

exceed 40km / h.

At the beginning of the water

inlet, you may only hear "Kaka

Lo" sound, can't hear "squeak

------" continuous sound when

accelerating. Some cars may

rush when started, this is based

on the degree of water inlet.

Drain oil, remove oil sump and driving bevel gear cover.

If the driving bevel gear inner cover have some white

matters, and oil sump also has the same matters, this can

sufficiently prove the transmission have water inlet, mixed

with other oil or liquid.

Replace the new oil

filter, re-fuel new

transmission oil.

Driving at various speeds, acceleration and deceleration

for about 5 minutes.

“Kaka Lo "sound should disappear," squeak ------ "sound

should be reduced.

Drain the transmission

oil and refuel new oil.

"Squeak ------" sound can be solved by doing stall

experiment to rise clutch temperature. links to D gear

position, accelerates and depress the braking pedal tightly.

If appears faulty code P2787 (clutch temperature is too

high and off the clutch) at this process , this is just the

transmission self-protection, not fault. after the faulty light

Replace transmission

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automatically turns off, can continue to do the stall

experiment, until the noise disappears.

Too much water or mixed with other oils, it does not solve

the noise and rocky rush phenomenon.

4

Neutral or P gear position noise

(noise rises with the engine

speed rises (accelerate at neutral

position, sound bigger))

Judge the noise from engine or transmission, if come from

the transmission parts, then check the oil pump abnormal

noise.

Check the oil pump

If it is the transmission noise, and it's not the oil pump

noise, it is maybe the input shaft bearing or planetary gear

set noise.

Replace transmission

5

Neutral or P gear position noise

(noise doesn't rise with the

engine speed rises.)

The noise comes from other parts of the vehicle, check the

vehicle parts.

Correctly judge the

noise problem is very

difficult, so before

deciding to replace the

gearbox parts or

replace the entire

transmission, need to

identify the noise is

generated from the

gearbox. Can replace

some easily replaced

parts on the car firstly,

to determine the noise

source.

Refer to

neutral or P

gear noise

inspection

flow chart.

6

Vehicle hashes when at D

position, or hashes when quick

acceleration.

Self-learn is not fully completed. Complete self-learning

Fill the wrong gearbox oil or get in water, make the

transmission oil go bad.

Replace transmission

oil

Driving bevel gear speed sensor trouble. Replace driving bevel

gear speed sensor

Hydraulic control model (valve) trouble. Replace hydraulic

control model (valve)

Driven bevel gear speed sensor trouble. Check the self-learning

7

The vehicle can't move on D

position, release the brake, the

vehicle keeps stationary, then

press the accelerator pedal, until

the engine speed reaches about

2000 rpm, the vehicle suddenly

rush out, accompanied by a

great impact.

Check the vehicle there is a fault at the cold situation. Check the self-learning

Brake signal fault, when do not hit the braking pedal, the

brake signal actually is in braking condition, cause this

fault.

Check braking signal

and harness

If there is no problem after check, it is maybe the valve

problem.

Replace valve and

self-learning

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Transmission inner bearing noise flow chart

Symptom:bearing has

buzzing noise (on D

position )

Check transmission

Check the noise

whether rises with

transmission speed

Yes

No

Yes

No

Check other bearing in

the transmission

Check half shaft bearing

Check engine

Replace driving bevel

gear ball bearing

Replace shaft bearing

Check the engine

Check the noise

whether rises with

vehicle speed

Whether has noise

System is normal

Replace related parts

Replace transmission

Symptom: bearing has

noise (only at D

position )

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Neutral or P gear noise inspection flow chart

Symptom: N or P gear

has noise

Check the engine

Check the noise

whether rises with

engine speed

Check vehicle other

parts noise

Replace engine parts

Replace transmission

Replace oil pump

Check the engine

Check the planetary

gear or input shaft

bearing noise

Check the oil pump

Whether has noise

Yes

No

System is normal

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( ) Ⅳ The fault code and measures

General Description

Once the gearbox control unit has fault code, fault light on the instrument panel will light up.

Whenever you check DTC fault code by inspection tool, first check the fault code is not a historic fault, and does not appear in the final

drive period, if so, delete the fault code and check whether the fault code will reappear again. If the fault is not a historic fault, but a current

fault, solve by the following fault code method.

Always check whether the latest software. If not, update to the latest software, and then check whether there is fault code.

General Description: Whenever there is fault code generated or transmission problems, first check the basic three:

a. check whether is CVT special used oil

b. check the oil lever

c. re-self learning

Do not need to complete all of the following programs, if problem solved, there is not necessary to go deeper.

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No. DCT code TCU take measures Maintenance guidance

1

P0710 oil

temperature

sensor trouble.

Fault indicator lighted, the system

defines gearbox oil temperature.

Measure transmission oil temperature with a detector, if

signal data is appropriate, clear fault code and check

whether appear again.

Check the harness (open circuit, short circuit, ground).

Measure the resistance between the two gearbox main

connector pins (when temperature at 20℃, the resistance

should be between 980-1000 ohms) to determine whether

the oil temperature sensor is damaged, if there is damaged,

skip the next step and directly replace a main connector.

Replace a new TCU.

Replace transmission.

2

P2765 driving

bevel gear speed

sensor trouble.

Three pressure regulators are power

off, fault indicator lighted.

Measure transmission oil temperature with a detector, if

signal data is appropriate, clear fault code and check

whether appear again.

Check harness (short circuit, open circuit, ground).

Replace a new TCU.

Replace speed sensor.

3

P0720 driven

bevel gear speed

sensor trouble.

Fault indicator lighted, the system

defines driven bevel gear speed.

Measure transmission oil temperature with a detector, if

signal data is appropriate, clear fault code and check

whether appear again.

Check harness (open circuit, short circuit, ground).

Replace a new TCU.

Replace speed sensor.

4

P0840 driven

bevel gear

pressure sensor.

Three pressure regulators are power

off, fault indicator lighted.

Measure the driven bevel gear actual oil pressure by the

detector, and then compare with the target. if signal data is

appropriate, clear fault code and check whether appear

again.

According to the first step of value test the circuit (ground:

0bar (actual pressure), short circuit: 60bar; breake circuit:

60bar).

Replace a new TCU.

Replace valve.

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5

P0641 pressure

sensor power

trouble.

Three pressure regulators are power

off, fault indicator lighted.

Measure the input voltage whether is 5V, if data is

appropriate, clear fault code and check whether appear

again.

Measure the voltage between sensor power wire and

ground wire, based on the results in the first step.

Check harness (short circuit, open circuit, ground ).

Replace a new TCU.

Replace hydraulic control model (valve).

6

P0651 driving

model sensor and

speed sensor

power trouble.

Three pressure regulators are power

off, fault indicator lighted.

Measure the input voltage whether is 5V, if data is

appropriate, clear fault code and check whether appear

again.

Measure the voltage between sensor power wire and

ground wire, Based on the results in the first step.

Check harness (short circuit, open circuit, ground).

Replace a new TCU.

7

P0659 pressure

regulator short

circuit.

Three pressure regulators are power

off, fault indicator lighted.

Compare the measured voltage of HS and battery.

If the same, inspect the circuit (check short circuit

between the battery positive and VHS and transmission)

and fix the wiring harness.

If different and more than 3.4V, then replace TCU.

8

P0658 pressure

regulator is open

circuit or

grounded.

Three pressure regulators are power

off, fault indicator lighted.

Compare the measured voltage of HS and battery.

If battery voltage is normal, high end voltage is less than

3.4V, it means some wires are grounded.

If battery voltage is normal, high end voltage is more

than 3.4V, it means some wires are open circuit.

For these two situation, check the PIN wire according to

the fact, if the wire is good , then replace the TCU.

If the battery voltage is abnormal, check the battery.

9

P0702 TCU inner

inspection system

fault.

Three pressure regulators are power

off, fault indicator lighted.

Replace TCU.

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10

P0962 EDS1

driving bevel gear

pressure regulator

is grounded.

Three pressure regulators are power

off, fault indicator lighted.

Measure the of driving bevel gear regulator, it should be 5.05Ω

±6%.

Check the wire(ground), replace the transmission inner wire or

engine wire according to inspection result.

Replace hydraulic control model.

11

P0963 EDS1

driving bevel gear

pressure regulator

is short circuit.

Three pressure regulators are power

off, fault indicator lighted.

Measure the resistance of driving bevel gear pressure regulator.

Check wire (open circuit), replace the transmission inner wire

or engine wire according to inspection result.

Replace hydraulic control model.

12

P0966 EDS2

driven bevel gear

pressure regulator

is grounded.

Three pressure regulators are power

off, fault indicator lighted.

Measure the resistance of driven bevel gear pressure regulator.

Check the wire(ground), replace the transmission inner wire or

engine wire according to inspection result.

Replace hydraulic control model.

13

P0967 EDS2

driven bevel gear

pressure regulator

is short circuit.

Three pressure regulators are power

off, fault indicator lighted.

Measure the resistance of driven bevel gear pressure regulator.

Check wire (short circuit), replace the transmission inner wire

or engine wire according to inspection result.

Replace hydraulic control model.

14

P0964 EDS2

driven bevel gear

pressure regulator

is open circuit.

Three pressure regulators are power

off, fault indicator lighted.

Measure the resistance of driven bevel gear pressure regulator

Check wire (open circuit), replace the transmission inner wire

or engine wire according to inspection result.

Replace hydraulic control model.

15

P0902 EDS3

clutch pressure

regulator is

grounded.

Three pressure regulators are power

off, fault indicator lighted.

Measure the resistance of clutch pressure regulator.

Check the wire(ground), replace the transmission inner wire or

engine wire according to inspection result.

Replace hydraulic control model.

16

P0903 EDS3

clutch pressure

regulator is short

circuit.

Three pressure regulators are power

off, fault indicator lighted.

Measure the resistance of clutch pressure regulator.

Check wire (short circuit), replace the transmission inner wire

or engine wire according to inspection result.

Replace hydraulic control model.

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17

P1763 starter lock

is grounded or

short circuit.

Three pressure regulators are power

off, fault indicator lighted.

Check wire, if gear position sensor has problem, it also has this

fault code.

Replace TCU.

18

P1764 starter lock

is short circuit.

Three pressure regulators are power

off, fault indicator lighted.

Check wire.

Replace TCU.

19

P1768 reverse

indicator lighter is

grounded.

Three pressure regulators are power

off, fault indicator lighted.

Check wire.

Replace TCU.

20

P1769 reverse

indicator lightor is

short circuit or

open circuit.

Three pressure regulators are power

off, fault indicator lighted.

Check wire.

Replace TCU.

21

P0868 pressure

pre-tighten adjust

fault.

Three pressure regulators are power

off, fault indicator lighted.

Check the oil lever and oil quality.

Replace oil pump.

Replace hydraulic control model.

Replace transmission.

22

P0811 clutch slips

(forward or

reverse).

Fault indicator lighted, clutch open.

Re-self learning, this fault code is likely to occur at the cold

vehicle situation, so do self-study in the cold vehicle situation.

Check the oil lever and oil type.

Replace hydraulic control model.

Replace transmission.

23

P0730

transmission ratio

control fault.

Three pressure regulators are power

off, fault indicator lighted.

Inspect the output signal of speed sensor, and inspect the input

and feedback current of driving bevel gear pressure regulator.

Take appropriate measures on the basis of failure, such asif

there is a problem with the speed sensor checks the speed

sensor, if there is problem with pressure check pressure sensor.

Check the oil lever and oil type.

Replace oil pump.

Replace hydraulic control model.

Replace transmission.

24

Driven bevel gear

pressure is too

low.

Three pressure regulators are power

off, fault indicator lighted.

Measure in dynamic driving situations (like the manual shift

mode, etc.) to compare the actual and the target pressure.

Check the oil lever and oil type.

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Completely self-study (fault code may occur in the case of

self-study is not completed).

Check the engine side reason which can cause the engine

torque reduction: spark plugs, throttle, catalytic, etc. (the longer

the engine use, the more this problem may occur).

Replace hydraulic control model.

Replace oil pump.

Replace transmission.

25

P1766 driven

bevel gear

pressure is too

high.

Fault indicator lighted.

Measure in dynamic driving situations (like the manual shift

mode, etc.) to compare the actual and the target pressure.

Check the oil lever and oil type.

Replace hydraulic control model.

Replace oil pump.

Replace transmission.

26

P0701 Two faults

occur at the same

time require

pressure regulator

power off.

Fault indicator lighted. Check others fault code.

27

P0218

transmission oil is

too high.

Fault indicator lighted.

Check oil cooler.

Try to reappear the fault under normal driving conditions again,

if you don't appear, ask customers for this failure occurred

under what driving conditions.

At step 2 driving conditions, the gearbox oil temperature can be

measured, check the gearbox oil temperature whether≥120 ℃

by detector (if the DTC appear time shorter than filter 30

minutes is not right) take measures to avoid transmission occurs

over-temperature.

28

P1767

Transmission oil

temperature is out

of range.

Three pressure regulators are power

off, fault indicator lighted.

Try to reappear the fault under normal driving conditions again,

if you don't appear, ask customers for this failure occurred

under what driving conditions.

Check oil cooler.

Check the oil lever.

Replace valve.

Replace transmission.

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29

P0219 Power

system speed is

out of range.

Three pressure regulators are power

off, fault indicator lighted.

Generally speaking, it would never appear.

Check the engine speed whether is limited to less than

6000rpm.

30

P2766 Driving

bevel gear rotate

speed doesn't

match the real

rotate speed.

Three pressure regulators are power

off, fault indicator lighted.

Check other parts speed information by detector (engine rpm

output shaft rpm, vehicle speed)whether is also lost; if it is,

solve these problems first and then check whether the fault

occurs again.

Measure the driving bevel gear RPM signal with

detector,compare with the engine RPM in the clutch engaged

situation, the difference should be less than 200 rpm.

Check the circuit.

Replace a new TCU.

Check sensor's position and angle, RPM sensing plate should

also be checked.

Check whether there are no materials in front of the sensor (the

strip chip, etc.) Note: This is a mechanical failure, electrical

failure has other DTCs.

Replace driving bevel gear speed sensor.

Replace the transmission inside harness.

Replace engine harness.

Replace transmission.

31

P0721 Driven

bevel gear RPM

doesn't match the

real RPM.

Fault indicator lighted.

Increase the clamping force to 0

level, the system would define

driven bevel gear RPM.

Check other parts speed information by detector (engine rpm

output shaft rpm, vehicle speed)whether is also lost; if it is,

solve these problems first and then check whether the fault

occurs again.

Measure the driving bevel gear RPM signal with

detector,compare with the engine RPM in the clutch engaged

situation, the difference should be less than 200 rpm. Should

compare at all speed range, from low to high (up to 6000 rpm).

Check the circuit.

Replace a new TCU.

Check sensor's position and angle, RPM sensing plate should

also be checked.

Check whether there are no materials in front of the sensor (the

strip chip, etc.) Note: This is a mechanical failure, electrical

failure has other DTCs.

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Replace driving bevel gear speed sensor.

Replace the transmission inside harness.

Replace engine harness.

Replace transmission.

32

P0944 Clamping

force is

insufficient

(VSM)

Fault indicator lighted.

Increase the clamping force to 0

level, the system would define

driven bevel gear RPM.

Check the ECU DTC.

Replace ECU

Check the oil lever and quality.

Completely self-study (fault code may occur in the case of

self-study is not completed).

Check the engine side reason which can cause the engine

torque reduction: spark plugs, throttle, catalytic, etc. (the longer

the engine use, the more this problem may occur).

Replace valve.

Replace oil pump.

Replace transmission.

33

P0782 Winter

driving mode

fault.

Fault indicator lighted, the system

defines winter mode closed.

Check the circuit.

Replace ECU.

34

P0783 Cruise

control fault.

Fault indicator lighted, the system

defines cruise control function mode

closed.

Check the circuit.

Replace ECU.

Replace TCU.

35

P0810 Offline

adaptive update

unfinished.

Fault indicator light flashes. Do adaptive update once again.

36

P1762 Current

value is fixed and

can not be

changed.

Three pressure regulators are power

off, fault indicator lighted.

Check the P0962, P0963, P0960, P0966, P0967, P0964, P0902,

P0903, P0900, P1763, P1764 DTC and fix them, there may be

no DTC.

Replace a new TCU.

37

P0882 Battery or

high end voltage is

too low.

Three pressure regulators are power

off, fault indicator lighted.

When this failure occurred there would have a record of the

battery voltage at that time (so it is not possible to identify

whether high end or battery voltage fault caused); if no history,

direct exam next.

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M

easure the voltage of high end and battery by detector,

Temperature would have greater impact on the value: detailed

information refer to Software Content.

Check the circuit from the battery to TCU (fuse, main relay).

Replace / Check battery.

If it is the high - end voltage problem: check the circuit from

the gearbox to the TCU.

Replace TCU.

38

P0883 Battery or

high end voltage is

too high.

three pressure regulators are power

off, fault indicator lighted.

When this failure occurred there would have a record of the

battery voltage at that time (so it is not possible to identify

whether high end or battery voltage fault caused); if no history,

direct exam next.

M

easure the voltage of high end and battery by detector,

Temperature would have greater impact on the value: detailed

information refer to Software Content.

Check the circuit from the battery to TCU (fuse, main relay).

Check/replace battery or generator.

If it is the high - end voltage problem: check the circuit from

the gearbox to the TCU.

Replace TCU.

39

P2787 Clutch

temperature is too

high.

Fault indicator lighted, clutch open.

Check this failure occurred how many times, if only once or a

few times, then take a look inside TCU data and ask the

customer whether had a special driving environment, such as

climbing lane, if so, you can delete DTC.

Check the oil lever and quality.

Completely self-study (fault code may occur in the case of

self-study is not completed).

Only in doing the stall test it would appear this DTC , delete

DTC, check whether re-occur.

Replace TCU.

May be the throttle is stuck, replace the throttle.

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40

P0727 The

hard-wire from the

ECU to the TCU

engine RPM

doesn't match with

actual RPM.

Fault indicator lighted.

Check engine test report to see whether if the engine failure, if

it is, repair the engine.

Inspect ECU input signal - this is a frequency signal (900 rev /

min is 30Hz, 3000 rev / min is 100Hz).

Replace TCU.

Replace engine speed sensor.

41

P1761 Pressure

regulator current

fault.

Three pressure regulators are power

off, fault indicator lighted.

Measure the pressure drop of pressure regulator by detector,

and compare with every pressure regulator specified current.

Measure the current of pressure regulator and compare with

specified current, If you find that one is different from specified

current, check the pressure regulator wire (also check the inside

gearbox wire).

Replace TCU.

Replace hydraulic control model.

Replace the transmission inside harness.

Replace engine harness.

42

U0301 Vehicle

configuration error

(such as use other

car's ECU).

Three pressure regulators are power

off, fault indicator lighted.

Check the TCU's hardware and software combination is correct

and effective.

If EMS or TCU newly upgrade software: new software on the

controller must be wrong (transmission controller and engine

controller is incompatible).

43

P0706 Driving

mode sensor

single line error.

Fault indicator lighted, the system

defines sensor position.

Check with detector which lines have problem, what is the

problem, such as B-line short-circuit and so on (this Fault

showed one line has a faulty).

Check the related wire between the gearbox and the TCU.

Replace a new TCU.

Replace driving mode sensor.

Replace the transmission inside harness.

Replace engine harness.

44

P0705 Driving

mode sensor

multi-line error.

Three pressure regulators are power

off, fault indicator lighted.

Check with detector which lines have problem, what is the

problem, such as B-line short-circuit and so on (this Fault

showed one line has a faulty).

Check the related wire between the gearbox and the TCU.

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Replace a new TCU.

Replace driving mode sensor.

Replace the transmission inside harness.

Replace engine harness.

45

P0571 Brake

signal fault.

Fault indicator lighted, brake signal

engaged.

Check the brake signal status with the detector.

Check the brake signal harness.

Check the brake switch.

Replace TCU.

46

P0955 Manual

gear acceleration

signal fault.

Fault indicator lighted, no manual

mode.

Check the circuit between TCU and gear shift.

Replace gear shift mechanism.

Replace a new TCU.

47

U0001 CAN bus

fault.

Fault indicator lighted, emergency

mode is activated, no manual mode.

Increase clamping force level 1

(highest), system defines locking

and rotation status, activate internal

drive strategy, system defines engine

speed and engine torque, system

defines engine cooling water

system, the brake signal engages,

the accelerator pedal digital fixed,

system defines all the four wheels'

RPM.

If the fault occurs in all other controllers, it means the problem

is the wiring harness (CAN high speed and low speed

short-circuit): check the car harness.

If the fault is only stored in TCU: replace a new TCU.

48

U0121 ABS CAN

communication

fault.

Fault indicator lighted, emergency

mode is activated, no manual mode.

Increase clamping force level 0，

system defines locking and rotation

status, system defines all the four

wheels' RPM.

Check the CAN communication connectors on the ABS

controller box (perhaps it would also report this Fault on the

other controllers).

49

U0100 ECU CAN

communication

fault.

Fault indicator lighted, emergency

mode is activated, no manual mode.

Increase clamping force level 0,

activate internal drive strategy,

system defines engine torque,

system defines engine cooling water

system, the accelerator pedal digital

fixed, stop data transfer on the

CAN.

Check the CAN communication connectors on the ABS

controller box (perhaps it would also report this Fault on the

other controllers).

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50

U1012 CAN bus

engine speed

signal fault.

System defines engine RPM.

Check the MCU controller (engine speed sensor and sensor

wiring).

51

U1013 CAN bus

accelerator signal

fault.

Fault indicator lighted, fixed value

of the accelerator pedal.

Check the EMS controller (accelerator pedal sensor and sensor

wires)

52

U1014 CAN bus

engine torque

signal fault.

Fault indicator lighted, emergency

mode is activated, no manual mode,

activate internal drive strategy,

system defines engine torque.

Check the EMS controller.

Note: three pressure regulators power off: When have DTC and

pressure regulator power off, the clutch open, the car can not go

forward even in gear. Only power off the engine and

re-ignition, the car can continue to work.

Increase clamping force level 0: driven bevel gear pressure is

fixed, the pressure is higher than normal condition, lower than

the highest level.

Increase clamping force level 0: driven bevel gear pressure is

fixed at highest level.

EDS1 driving bevel gear pressure regulator.

EDS2 driven bevel gear pressure regulator.

EDS3 clutch pressure regulator.

Emergency Mode: also called lameness home mode, when one

of the following cases is activated:

CAN bus falls off.

CAN ECU communication fault.

CAN bus engine torque signal fault.

All engine and ABS related signals will be replaced (safety

measures):

Throttle opening degree is fixed.

Engine MAP figure replace the engine torque.

Engine cooling temperature is fixed.

Wheel speed is replaced by the gearbox output shaft speed.

Engine speed uses the speed signal passed by video wire.

The engagement and separation of the clutch is very 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 be shifted in a acceleration strategy.

CVT will only work in the most basic conditions, provide

adequate driving performance to make the car drive to a nearby

service station.

After two seconds, manual or sports gear can't use, and fault

indicator turns on.

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Ⅲ Driving strategy

( )Ⅰ Parking and neutral gear functional properties

No matter what transmission, the engine can be started only in the parking or neutral gear. Mechanical lock at the parking gear can

make the car never move around. It's better to use parking gear when vehicle in the stationary state, to prevent damaging the transmission

.

If you carelessly use the parking gear at high speed, mechanic lock will work only after the speed is slow down to 5km / h.

Parking lock mechanism

When start the vehicle, TCU will control the starter relay, starter relay

will control starter motor.

Car gear is controlled by the internal driving mode sensor, and driving

mode sensor directly connects to the gear shift lever.

If you want to shift from parking gear (P) or neutral gear (N) to forward gear (D)

or reverse gear (R), you need to depress the brake pedal. If you do not depress the brake

pedal, gear lever is still locked at the P or N gear.

( ) D or R gear functionⅡ

Regular operation

When driving the vehicle, the operation of this transmission is completely different from the traditional transmission, so you need to

pay attention to adapt. For example: when depresses the accelerator pedal fastly, the engine speed will significantly rise, but the vehicle

speed will change little. This phenomenon is normal for a continuously variable transmission, if the driver did not understand this, he may

mistakes for a gearbox failure.

Other approximate situation with the traditional automatic transmission may also exist.

Adaptive update

Either forward or reverse, the clutch has to be re-calibrated accordingly, to achieve the best performances in its lifetime.

Crawl

According to the automatic transmission performance, when the gear shift lever is in forward gear (D) or reverse gear (R), if the driver

release the brake pedal, the car begin to crawl (flat road). If the road surface gradient is less than 8 °, car will crawl; if the road surface

gradient is greater than 8 °, Car will be slightly back, like car equipped torque converter transmission, it wouldn't back if the gradient is not

great. No matter the road surface gradient, the maximum vehicle crawling speed will be less than a limit value (e.g. 8kph). Especially when

going downhill, the control system will change the clutch from separation to engagement mode, so that we can use the engine brake in the

downhill.

Idling stop (only forward gears status)

VT2 transmission can achieve idling stop. Vehicles (battery status, air conditioning on / off) and the transmission terminal (does not

affect the durability of the transmission) can achieve the idling stop under some certain conditions. If all conditions are satisfied, the engine

power off in stationary state. Only release the brake pedal, the engine restarts, transmission work quickly, the vehicle can move again.

The idling stop function is particularly suitable for a hybrid power transmission device, but for standard power transmission device

without special starters or start motors, the idling stop function is useless.

Acceleration and deceleration

Acceleration process is mainly based on the driver's request and driving conditions to provide acceleration, at the time the engine speed

change trend corresponds with initial speed, which can achieve optimum driving comfort.

1. parking detent pawl

2. driven bevel gear

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Clutch controller also provides some methods to compensate the difference caused by clutch wear (it's difference between different

vehicles), thus ensuring driving comfort.

Acceleration support

To achieve the optimum driving comfort, we should determine the most appropriate engine speed, the rotation speed between the

minimum tractive force engine speed and the vehicle maintain the constant velocity (economic speed) cruising engine speed.

Transmission control system through the federated control mode between transmission (ratio control) and starting clutch provides

functionality to meet these requirements. Thus, when starting the vehicle, the control target focuses on the control associated with the

acceleration of the high engine speed driving performance, and when the vehicle is cruising or coasting, the control target changes to the the

fuel economy.

Deceleration

If the driver depresses on the accelerator pedal and brake pedal at the same Time, the engine speed will be limited within a certain

range (similar with torque converter transmission ). To this end, the transmission and engine control systems need to block torque together,

so if the driver suddenly releases the brake pedal, the transmission can react quickly to control the clutch.

Long-term use can cause clutch high temperature consumption, the transmission also has damage risk, so we use the monitoring

capability to detect these dangerous conditions. activate transmission internal diagnostic system, can open the clutch. Then if the driver has

been depressing on the accelerator pedal, the engine will accelerate to maximum rotation speed. And in other cases, clutch controller can

follow the highest control objectives to ensure intrinsic safety, improve driving comfort.

Driving and braking

When the car decelerates to a standstill, the clutch separated again to prevent engine stalling, control the clutch pressure steady

decline,the clutch gradually separated, and therefore does not cause torque fluctuations. Therefore, the controller provides different modes to

make the clutch separate according to the speed change. Clutch pressure control device can also according to the lubricating oil

temperature of the transmission control hydraulic control system power. the clutch quickly prepare starting after release.

In order to make the best vehicle driving comfort at the starting and braking process, transmission software works together with other

transmission control devices, this action causes temporary interruption of torque transmission, idling increases.

Clutch engagement / separation while driving

If the driver does not use the clutch, the transmission controller has little effect on driving comfort, because if don't use clutch there

would have no relationship with the hydraulic system characteristics.In this case (Low load, parking, low engine speed) compared with the

application again and the stationary state application, driving comfort may decline.

( ) the fault default modeⅢ

When the software detects a system error, the default mode will be applied; and this will be transferred to the drive through the

instrument fault display. The drive will take different default driving state in accordance with the severity of the error. In some cases, the

main relay opens. All fault codes will appear on the OBD.

AdaptiveⅣ update

( )Ⅰ Explanation

The following conditions need to be adaptive learning:

· ECU updates software TCU

· replace transmission

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· replace TCU

Clutch need to do to adaptive update (self-learning) to compensate tolerances from the production process.

By shift at the idle condition to achieve this functionality.

Before self-learning doesn't completed, TCU malfunction indicator light flashes once every two seconds.

Once the first time study is completed, all the self-learning are done automatically in the following entire life cycle.

( ) Ⅱ The required condition

This condition needs to be completed before the self-learning: need stable engine torque and speed under idle status, the engine also

needs to complete the self-learning ahead, for more engine self-learning information, please refer to ECU (the suppliers' documents. Engine

speed requirement: ECU target value ± 200rpm · engine torque requirement: ECU target value ±12N · m · Transmission temperature should

between 30 to 80 .℃ ℃ Air conditioning is off * A non-adaptive X CTU will always issue a request to the idling engine rose to 1150rpm.

If the X CTU done self-learning before, which include: 1. Update the software 2. Replace the gearbox. TCU first need to delete the

self-learning value. MLT software can solve or manufacturer's detector can solve.

( ) ProgramⅢ

After we all fulfill all the conditions, we execute the following operations:

· Speed = 0 kph · don't depress the accelerator pedal

· depress the brake pedal at the whole process

· Switching gears to the "D"

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Start

Idle or drive until

the temperature

reaches specified

Do high-speed roller test

Delete TCU self-learning value

Whether engine temperature

＞60

℃ and transmission

temperature is between

30℃ and 8

0

℃

Execute the following operation:

- speed = 0kph

- no acceleration

- depress braking pedal

- A/C is closed

-

shift to D gear

Read FC55 DTC

Yes

Self-learning period

T1≥120Sec

FC55 DTC is

excited

Start core timer T1-0

Timer start

Depress the brake pedal all the

time

Transmission

self-adaptive success

Yes

Yes: adaptive time is about 40Sec

End

No

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Clutch adaptive program will start automatically. In the learning process, if there some cases interfere adaptive learning, fault codes

FC55 (P1774) will be excited, then the fault light will stay on for warning. As long as the clutch self-learning is not completed, the fault code

FC51 (P080A) will be excited out. At the same time, the fault lamp flashes.

When everything goes well, complete the gear adaptation time is about 40s. If it has not been completed within 120s, then the adaptive

program will fail.

When at this gear, after the clutch adaptive program is completed, engine speed will increase to 1500rpm again in a short time, then we

can continue the next step.

Note: For after sale vehicle, does not require high-speed roller test.

Be sure to double-check all prerequisites for self-learning has been completed.

Please follow the steps below:

· Speed = 0 kph

· Release accelerator pedal

No

Yes

No

Yes

No

Yes

No

Yes: adaptive time is about 40Sec

Idle or drive until

the temperature

reaches specified

Whether engine temperature

＞60

℃ and transmission

temperature is between

30℃ and 8

0

℃

Yes

Execute the following operation:

- speed = 0kph

- no acceleration

- depress braking pedal

- A/C is closed

-

shift to D gear

FC55 DTC is

excited

Depress the brake pedal all the

time

Self-learning period

T1≥120Sec

Clutch self-adaptive

success

End

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· Keep depress the brake pedal all the process

· Switching gears to the "R"

Offline clutch adaptive program will start automatically. In the learning process, if theresome cases interfere adaptive learning, fault

codes FC55 (P1774) will be excited, then the fault light will stay on for warning. As long as the clutch self-learning is not completed, the

fault code FC51 (P080A) will be excited out. When everything goes well, complete the adaptation time is about 40s. At the same time, the

fault lamp flashes. If it has not been completed within 120s, then the adaptive program will fail. after the clutch adaptation successful done,

the engine speed will increase to 1500rpm in a short time and then suddenly drop to idle speed (850rpm), this time a transmission fault light

will automatically turn off.

Remark:

First in the D gear and then into the R gear, this order is not mandatory. Similarly hang R gear and then into the D gear, such adaptive

order is no problem.

( ) Frequently Asked QuestionsⅣ

Clutch self-learning

error code

Type

1 Engine torque is unstable

2 Air conditioning is in the open state

4 Pressure is too high

8 engine speed is too low

16 engine speed is too high

32 Too frequent failure

Problems Possible reasons Solutions

Self-learning fails over 120s

The transmission oil temperature is below

30 ℃ at the learning process

Start the engine, let the oil temperature rise above

30 ℃, self-learning again.

The transmission oil temperature isabove

80 ℃ at the learning process

Turned off the engine until the oil temperature

reduced below 80 ℃, self-learning again.

The engine temperature is below 60 ℃

at the learning process

Start the engine, let the oil temperature rise above

60℃, self-learning again.

There was release brake pedal loose case

at the learning progress

Self-learning again to ensure that depress the brake

pedal tightly all the time.

FC55:offline adaptive fault

code is 1

Engine torque is unstable

Increase the engine torque smoothly, ensure

successfully complete the self-learning.

FC55:Clutch self-learning error

code is 2

Air conditioning is turned on Turn off air conditioning, self-learning again.

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FC55:offline adaptive fault

code is 4

Clutch pressure rises, but engine torque

does not improve

Links into D or R gear, check the transmission torque

transmission is normal, check the engine torque signal

is normal, self-learning again.

FC55:offline adaptive fault

code is 8

Engine speed is too low

Increase the engine speed smoothly, self-learning

again.

FC55:offline adaptive fault

code is 16

Engine speed is too high

Increase the engine speed smoothly, self-learning

again.

FC55:offline adaptive fault

code is 32

Torque abnormal,. whether the switch is

activated etc

Confirm all auxiliary functions are not used, after

confirming, re-learning.

Ⅴ Transmission oil

(Ⅰ) Special tools (none)

(Ⅱ) Oil level examination description

Whenever replace the gearbox oil, or replace the new gearbox, oil level must be checked as follows.

As spare part, the gearbox has no oil, should add about 4.15 liters of ESSO EZL799 (A) after assembly.

Check the oil level in accordance with the following method after refueling:

1) Start the engine and idle at least 10 seconds (Note: When starts the engine hear air flow voice circulates in the system is normal).

2) Switch shift lever to different gear (parking-reverse-neutral-Drive) and stay at lest 5 seconds on each gear before switching to the

next gear.

3) Shift to the "D" (Drive).

4) Release brake pedal.

5) Accelerate over 60 km / h (engine speed is not higher than 2500 rpm).

6) Release the accelerator pedal, slowly to the stopping (all the noise caused by air circulation when start will disappear).

7) Heat up the oil, drive carefully at least 5 minutes or until the transmission oil temperature reaches about 60 ° C.

8) Park the car on flat ground.

9) Depress brake pedal.

10) Wait 2 seconds.

11) Shift to R (reverse gear).

12) Release brake pedal.

13) Wait 10 seconds.

14) Depress brake pedal.

15) Shift to N (parking gear).

16) Keep the engine idling.

17) The engine idle operation.

18) Loosen oil lever plug.

19) After loosen the oil lever plug, there will at lest 0.2 liters flow out from the tube. (Otherwise prove initial oil is inadequate) if less

than 0.2 liters, plus 0.5 liters oil, and then re-do the above process again.

20) Until the oil starts to drip from the oil level plug mouth.

21) Retighten the oil level plug with new gasket (torque: 18 ~ 24N · m).

22) Turn off the engine.

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23) Shift to P (parking gear).

（Ⅲ） Oil level examination

If the initial filling is correct, the oil level should be at the correct position (at the position of the oil level plug).

Normal tolerances position (like new gearbox residual oil and production line filling tolerance) should the oil level plug, the oil level can be

± 0.165L.

1. Check the transmission oil level

1). Remove the gearbox upper filling bolts.

2). Fill accurate 0.5L oil to the transmission.

3). Install the filling plug. Tightening torque 18 ~ 24N · m.

4). Start the engine, heat up the gearbox temperature to about 60 ℃.

5). Park the car on flat ground.

6). Depress brake pedal, wait for 2 seconds before shift to P gear.

7). Keep the engine idling operation.

8). Remove the oil level plug in the engine idling conditions.

9). Correctly drain oil (at least 0.335L, up to 0.665L).

Minimum 0.235L (0.5 ADDED oil - 0.165 tolerances - 0.1L = 0.235L) oil will outflow from the gearbox, if less than this amount, the

original oil level is too low.

Maximum 0.565L (0.5 ADDED oil + 0.165 tolerances - 0.1L = 0.565L) oil will outflow from the gearbox, if more than this amount, the

original oil level is too high.

△ ℃

Note: All data are derived from the gearbox oil temperature is 60 .

10). Install a new gasket, tighten the oil level plug.

Tightening torque 18~24N·m

11). Turn off the engine.

Ⅵ Shift lever assembly

（Ⅰ） Special tools

1 CVT-HDFJ-1 N gear assembly aid tool

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（Ⅱ） Remove

1. Remove shift lever assembly

1). Shift the gear lever on P.

2). Remove the worm at a place (use screwdriver or opening wrench).

3). Then loosen the nut at the b place.

Note: when loosen the nut, the transmission shift rocker may move at the

same time, then need to recover to the initial position immediately after release

(basic transmission shift rocker normally straight down).

4). Remove shift lever assembly.

（Ⅲ） Assembly

1. Assemble shift lever assembly

1). Mount the new shift lever on the gearbox.

2). Switch the shift lever shift back and forth for five times, and then shift to the N.

3). Press the gear shift rocker ball at a position into the worm.

4). Chucking the the transmission gear shift rocker by aids tool, then tighten the

nut at b position.

△

notice:

Aid must be fully snap to the position as "aid assembly and

adjustment chart "shown, to ensure its limit slot is fully contacted with transmission

shift rocker plane, against aids handle by hand at the nut tighten process, try to make

the transmission shift rocker don't move or shake.

Tighten torque 20 ~ 28N · m

( ) AdjustⅣ

1. Adjust gear shift lever

1). Shift the gear lever on P.

2). Ensure the gearbox is on P.

3). If gear shift lever is not on P position, push to the correct position by hand.

△

Note: P gear can be confirmed by dashboard gear display.

4). At the same time rotate the front wheels of the car until the wheels are

locked. Now gearbox is fixed on P position, and you can also switch out the shift

lever from P gear, but don't do so. If there is wire bracket,you should firstly connect

the wire to bracket.

5). connect the wire to the shift lever by bolts and nuts.

6). Tighten the nuts.

△Note: Do not bend the wire or shift lever!

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（Ⅴ） Check

1. Check the installation

1). Switch the gear shift lever rapidly from P / R / N / D / S / M +/ M- for three cycles, check whether the transmission shift lever

position is consistent gear display on dash board.

2). Switch the gear shift lever slowly from P / R / N / D / S / M +/ M- for three cycles, check whether the transmission shift lever

position is consistent gear display on dash board.

3). If instrument and gear shift lever position is inconsistent or instrument does not show the gear, you must re-adjust the gear.

Ⅶ Gear shift rocker and bushing

（Ⅰ） Special tools

1 CVT-HDFJ-1 N gear assembly aid tool

（Ⅱ） Remove

1. Remove shift lever assembly, refer to gear shift lever assembly.

2. Remove gear shift rocker and bushing.

1). Removed the worm at the C position (by use screwdriver or

opening wrench).

2). Remove bolts at e position.

3). Remove gear shift rocker and bushing.

（Ⅲ） Assemble

1. Assemble gear shift rocker and bushing

1). Replace the new gear shift rocker and bushing.

△

Note: The rocker arrow direction should align to the transmission, at the

same time the bush flange closely to the transmission mounting surface.

2). Install bolts at e-position, and tighten.

Tighten torque 20~28N·m

2. Assemble shift lever assembly

（Ⅳ） Check

1. Check the installation

1). Switch the gear shift lever rapidly from P / R / N / D / S / M +/ M- for three cycles, check whether the transmission shift lever

position is consistent gear display on dash board.

2). Switch the gear shift lever slowly from P / R / N / D / S / M +/ M- for three cycles, check whether the transmission shift lever

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position is consistent gear display on dash board.

3). If instrument and gear shift lever position is inconsistent or instrument does not show the gear, you must re-adjust the gear.

Ⅷ The gear shift wiredrawing assembly

（Ⅰ） Special tools

1 CVT-HDFJ-1 N gear assembly aid tool

（Ⅱ） Remove

1. Remove shift lever assembly, refer to gear shift lever assembly.

2. Remove gear shift rocker and bushing, refer to gear shift rocker and bushing.

3. Remove gear shift wiredrawing assembly.

1). Disconnect the gear shift wiredrawing quick coupling from the bracket at D position. disconnect the gear shift wiredrawing from

gearbox assembly.

△

Note: must ensure the brackets are all located in connector slot.

2). Shift to N position, remove the connector of wiredrawing and the

transmission operating mechanism.

3). Remove the spring snap.

4). Remove the 2 M8 bolts on body front wall.

5). Remove gear shift wiredrawing assembly.

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（Ⅲ） Assemble

1. Install gear shift wiredrawing assembly

1). Pass the new gear shift wiredrawing through the engine

compartment " body front wall through-hole " to cockpit.

2). Tighten the 2 M8 bolts on body front wall.

Tighten torque 20~28N·m

3). Connected the "wiredrawing connectors (gear shift mechanism end)"

to the gear shift mechanism pin.

4). Install the "spring snap" to right place.

2. Assemble gear shift rocker and bushing.

3. Assemble shift lever assembly.

（Ⅳ） Check

1. Check the installation

1). Switch the gear shift lever rapidly from P / R / N / D / S / M +/ M- for three cycles, check whether the transmission shift lever

position is consistent gear display on dash board.

2). Switch the gear shift lever slowly from P / R / N / D / S / M +/ M- for three cycles, check whether the transmission shift lever

position is consistent gear display on dash board.

3). If instrument and gear shift lever position is inconsistent or instrument does not show the gear, you must re-adjust the gear.

Ⅸ Gear shift operating mechanism assembly

（Ⅰ）

Special tools (none)

（Ⅱ） Remove

1. Remove gear shift operating mechanism assembly

1). Shift to N position, remove the connector of wiredrawing and the

transmission operating mechanism.

2). Remove the spring snap.

3). Remove the 4 bolts, remove gear shift operating mechanism assembly.

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（Ⅲ） Assemble

1. Install gear shift operating mechanism assembly.

1). Install gear shift operating mechanism assembly on body.

2). Tighten 4 bolts. Tighten torque 20~28N·m

3). Connected the "wiredrawing connectors (gear shift mechanism end)"

to the gear shift mechanism pin.

4). Install the "spring snap" to right place.

2. Assemble gear shift rocker and bushing.

3. Assemble shift lever assembly.

(Ⅳ) Check

1. Check the installation

1). Switch the gear shift lever rapidly from P / R / N / D / S / M +/ M- for three cycles, check whether the transmission shift lever

position is consistent gear display on dash board.

2). Switch the gear shift lever slowly from P / R / N / D / S / M +/ M- for three cycles, check whether the transmission shift lever

position is consistent gear display on dash board.

3). If instrument and gear shift lever position is inconsistent or instrument does not show the gear, you must re-adjust the gear.

Ⅹ Differential oil seal

（Ⅰ） Special tools

1 16G0038

Differential oil seal

installation tool

（Ⅱ） Remove

1. Discharge gearbox oil.

2. Remove Axle refer to the drive shaft.

3. Remove differential oil seal.

1). Pry out the seal with a large flat head screwdriver.

△

Note: Be careful don't put the screwdriver too deep to protect the casing.

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（Ⅲ） Assemble

1. Install differential oil seal

1). Put the new oil seal on the casing.

2). Put the special tool 16G0038 on seal, knock into the casing with a rubber

mallet, make sure it fits.

△

Note: The seal depth with casing edge distance is 3mm ± 0.3mm.

2. Install axle

3. Fill transmission oil

Ⅺ Input shaft seal

（Ⅰ） Special tools

No. Tool No. Tool name Tool figure

1 16G0041 Input shaft oil seal install tool

2 16G0040 Input shaft seal bushing

（Ⅱ） Remove

1. Discharge gearbox oil.

2. Remove transmission assembly, refer to transmission assembly.

3. Remove input shaft seal.

1). Pry out the seal with a large flat head screwdriver.

△

Note: pry out from void side, must be careful. Or may damage

transmission input shaft.

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（Ⅲ） Assemble

1. Install input shaft oil seal

1). Put the seal bushing 16G0040 on the input shaft.

2). Put the new oil seal on the bushing.

3). Put the special tool 16G0041 on input shaft, knock into the

special tool with a rubber mallet, make sure it fits.

2. Assemble transmission.

3. Fill transmission oil.

Ⅻ Selection gear shaft seal

（Ⅰ） Special tools

No. Tool No. Tool name Tool figure

1 16G0043

Selection gear shaft seal

installation tool

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2-47

2 16G0042

Selection gear shaft seal remove

tool

（Ⅱ） Remove

1. Discharge gearbox oil

2. Remove transmission

3. Remove gear selection lever

4. Remove selection gear shaft seal

1). Put the special tool 16G0042 on selection gear shaft, rotate the

special tool into seal with a wrench.

△

Note: press the wrench top end which makes special tools screwed into seal.

2). Rotate the bolt on special tool with other tool, pull the selection gear shaft

seal out from the casing.

3). Rotate the small bolt, pull out seal.

4). Remove seal.

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（Ⅲ） Assemble

1. Install the selection gear shaft seal.

1). Apply vaseline or grease at the tip of the seal punch 16G0043.

2). Put the new seal on the punch 16G0043 slightly.

3). Put the installed special punch 16G0043 on selection gear shaft,

and tapping with a hammer to fit.

4). Remove punch 16G0043.

△

Note: rotate out the punch, or it would pull out seal and punch together.

2. Install gear shift lever

3. Assemble transmission

4. Fill transmission oil

XIII Driving bevel gear cover

（Ⅰ） Special tools (none)

（Ⅱ） Remove

1. Discharge gearbox oil

2. Remove driving bevel gear cover

1). Remove 3 bolts, take down snaps.

2). Pry the cover down with screwdriver, take out O ring and cover.

△

Note: place some clothes below the transmission to prevent damage the

casing.

（Ⅲ） Installation

1. Install driving bevel gear cover

1). Install new O ring, and assemble new cover and tighten the bolts and snaps. Tighten torque 9.5±2.5N·m

.

2). Fill transmission oil.

XIV Pump

（Ⅰ）

Special tools

No. Tool No. Tool name Tool figure

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CVT Transmission

2-49

1 16G0045 Pump removal tools

（Ⅱ） Remove

1. Discharge gearbox oil

2. Remove transmission

3. Remove driving bevel gear shaft cover, refer to driving bevel gear cover.

4. Remove pump

1). Remove the 6 bolts on the pump, put the special tool on pump shaft.

2). Pull out pump with 16G0045 special tool.

（Ⅲ） Assemble

1. Install pump

1). Install new pump, must make sure put 2 new O ring on the new pump.

△

Note: don't take out bevel return spring, and confirm the larger diameter end

towards the pump.

2). Re-install 6 bolts and tighten. Tighten torque 10±1N·m.

2. Install driving bevel gear shaft cover.

△

Note: don't need to replace O ring and cover.

3. Assemble transmission.

4. Fill transmission oil.

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2-50

XV Driving bevel gear shaft ball bearing

（Ⅰ） Special tools

No. Tool No. Tool name Tool figure

1 16G0049

Driving bevel gear bearing

stopper

2 16G0050

Driving bevel gear bearing

punch

3 16G0048

Driving bevel gear bearing

remove tool

（Ⅱ） Remove

1. Discharge gearbox oil.

2. Remove transmission.

3. Remove driving bevel gear shaft cover, refer to driving bevel gear cover.

4. Remove pump, refer to pump.

5. Remove the driving bevel gear bearing.

1). Take out bevel return spring.

2). Take marks on shaft and nuts.

3). Remove nuts with special tool.

4).Take down dust cover from shaft with screwdriver.

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5). Put the protect plug on the shaft.

6). Assemble bearing ejector（16G0048）, hook the out ring of

the bearing with it's foots.

7). Tighten the Middle bolt, in order to pull out bearing.

（Ⅲ） Assemble

1. Install driving bevel gear shaft ball bearing.

1). Clean the sealant on the the driving bevel gear shaft and pump

driving shaft lock belt, clean the oil pump chamber.

2). Put the new bearing on the right place, and install with special

punch（16G0050）.

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3). Tap the punch to right place with rubber hammer.

4). Tighten the nut to make the mark on the axis coincides with the mark on the nut.

Standard coincidence degree ± 5°.

5). install the bevel return spring.

△

Note: the larger diameter end towards the pump.

2. Install pump

3. Install driving bevel gear shaft cover

△

Note: don't need to replace O ring and cover.

4. Assemble transmission

5. Fill transmission oil

XVI Driven bevel gear shaft cover

（Ⅰ） Special tools (none)

（Ⅱ） Remove

1. Remove driven bevel gear shaft cover

1). Remove four countersunk screws.

2). Take down the two O rings and a seal ring on the cover.

（Ⅲ） Assemble

1. Install driven bevel gear shaft cover

1). Re-install the two O rings and a seal ring on the cover.

2). Clean the sealant in the casing's four screw holes.

3). Tighten four screws. Tighten torque 9.5±0.95N·m.

XVII Oil sump

（Ⅰ） Special tools (none)

（Ⅱ） Remove

1. Discharge gearbox oil

2. Remove oil sump

1). Remove the 13 bolts on the oil sump.

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（Ⅲ） Assemble

1. Install the oil sump

1). Install new oil sump and gasket.

2). Install the oil sump bolts as the figure shown.

△

Note: use the new bolt gasket. Tighten torque 9.5±1N·m.

2. Fill transmission oil

XVIII Oil filter

（Ⅰ） Special tools (none)

（Ⅱ） Remove

1. Discharge gearbox oil

2. Remove oil sump, refer to oil sump.

3. Remove oil filter.

1). Gently remove the oil filter and abolished.

（Ⅲ） Assemble

1. Install oil filter

1). Install a new oil filter with O ring, lubricate with ESSOEZL799(A）.

2). Gently push the filter in place.

△

Note: the oil filters middle hole is justly coincide with the hydraulic

control block middle bolt.

3). clean the magnet and oil sump.

2. Install the oil sump

3. Fill transmission oil

XIX Driving mode sensor

（Ⅰ） Special tools (none)

（Ⅱ） Remove

1. Discharge gearbox oil.

2. Remove oil sump, refer to oil sump.

3. Remove oil filter, refer to oil sump.

4. Remove driving mode sensor.

1). Remove the two screws on the driving mode sensor.

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2). Carefully remove the driving mode sensor from the hydraulic control block.

△

Note: the sensors is fixed on the hydraulic control block metal slide by a

small pin behind the sensor, and push down the sensor , the pins woud depart

from the metal slide.

3). Pry out the sensor connectors locker by screwdriver, and press the

white buckle to separate the connectors.

（Ⅲ） Assemble

1. Install driving mode sensor

1). Take a new sensor, connect the connector and press the white

buckle to lock.

2). Put the pin behind the sensor on the metal slide, and install to

right place.

3). Move the sensor to expose the bolt hole.

4). Tighten two screws.

Tighten torque 9.5±0.95N·m

2. Install oil filter

3. Install the oil sump

4. Fill transmission oil

XX Hydraulic control mode

（Ⅰ）

Special tools

No. Tool No. Tool name Tool figure

1 16G0046

Hydraulic control block locating

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（Ⅱ） Remove

1. Discharge gearbox oil.

2. Remove oil sump, refer to oil sump.

3. Remove oil filter, refer to oil sump.

4. Remove driving mode sensor, refer to driving mode sensor.

5. Remove hydraulic control mode

1). Remove the bolts as the figure shown, from 20 to 1.

2). Take out the hydraulic control mode, and separate the 4 connectors.

△

Note: it's easy to take down the connector with small screwdriver.

（Ⅲ） Assemble

1. Install hydraulic control block

1). Install the hydraulic control block to right place, there is a small

pin behind the hydraulic control block, place to right place.

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2). Make sure the metal slide fits with pin on the gear shift cam.

3). Install the Middle bolt, and tighten by hand.

4). Place the special tool 16G0046 into bolt hole on the upper left corner.

5). Press the driving bevel gear speed sensor wire under the hydraulic

control block upper left corner.

6). Assemble all the bolts of the hydraulic control block, tighten

sequence is from 1 to 20.

Tighten torque 11N·m

2. Install driving mode sensor

3. Install oil filter

4. Install the oil sump

5. Fill transmission oil

XXI Driven bevel gear speed sensor and bracket

（Ⅰ） Special tools (none)

（Ⅱ） Remove

1. Discharge gearbox oil.

2. Remove oil sump, refer to oil sump.

3. Remove oil filter, refer to oil sump.

4. Remove driving mode sensor, refer to driving mode sensor.

5. Remove hydraulic control mode, refer to hydraulic control mode.

6. Remove driven bevel gear speed sensor and bracket.

1). Loosen sensor bracket bolts.

△

Note: the bolts are disposable.

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2). Take out the bracket from gear shift shaft.

3). Remove the sensor and connector with needle-nose pliers.

4). Loosen the bracket bolts to take down the sensor.

（Ⅲ） Assemble

1. Assemble driven bevel gear speed sensor and bracket.

1). Assemble new sensor and bracket, tighten the fixed bolts.

2). Connect the wire and snap the bracket on the gear shift shaft,

make sure install to right place.

3). Fixed the bracket with new bolts.

Tighten torque 9.5±0.95N·m

2. Install hydraulic control block

3. Install driving mode sensor

4. Install oil filter

5. Install the oil sump

6. Fill transmission oil

XXII Driving bevel gear speed sensor

（Ⅰ） Special tools (none)

（Ⅱ） Remove

1. Discharge gearbox oil

2. Remove driving bevel gear shaft cover, refer to driving bevel gear cover.

3. Remove driving bevel gear speed sensor.

1). Remove the fixed bolts, take out the sensor.

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2). Separate the wire and take down the sensor.

（Ⅲ） Assemble

1. Assemble driving bevel gear speed sensor.

1). Assemble new sensor, and tighten the bolts.

Tighten torque 8.5±2N·m

2). Connect the wire to sensor.

2. Install driving bevel gear cover.

3. Fill transmission oil.

XXIII Main connector and inner harness

（Ⅰ） Special tools (none)

（Ⅱ） Remove

1. Discharge gearbox oil

2. Remove oil sump, refer to oil sump.

3. Remove oil filter, refer to oil sump.

4. Remove driving mode sensor, refer to driving mode sensor.

5. Remove hydraulic control mode, refer to hydraulic control mode.

6. Remove main connector and inner harness.

1). Separate the two speed sensors' connectors.

2). Remove the wire connected with the main connector.

3). Remove the snap on the main connector, and clamp the main

connector into the transmission.

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△

Note: Driving mode sensor connector is clamped on casing, remove this joint first.

4). Take the main connector out from the transmission.

（Ⅲ） Assemble

1. Install main connector and inner harness.

1). Take a new connector, place into transmission.

△

Note: main connector is connected to casing by a spline, it would be

easy to connect by pressing with a needle-nose ier at 45 degree position.

2). Re-install the snap.

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3). Assemble the driving mode sensor connector on the casing.

4). Connect the speed sensor with connector.

2. Install hydraulic control block

3. Install driving mode sensor

4. Install oil filter

5. Install the oil sump

6. Fill transmission oil

XXIV Ventilator tube

（Ⅰ）

Special tools

No. Tool No. Tool name Tool figure

1 16G0044 Install ventilator tube

（Ⅱ） Remove

1. Disassemble the engine intake manifold.

2. Disassemble the battery and bracket.

3. Disassemble the ventilator tube.

1). Remove the snaps which connects ventilator tube top and gearbox.

2). Place the plier on the junction of casing and ventilator tube, remove

the ventilator tube.

（Ⅲ） Assemble

1. Install ventilator tube

1). Place the new ventilator into special tool（16G0044）, apply a little

vaseline on aluminum tube at the bottom of the ventilator tube.

2). Place the tool box ventilator tube on the casing, keep them parallel,

tap tools perpendicular down with a rubber hammer to make ventilator tube

into the housing.

3). Place the 482253 plastic snap on the breathing tube.

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4). Insert the pin on the plastic snap into 481456 metal snap hole.

5). Securely mount the metal snap on the rib of the transmission casing.

6). Mount the 483117 breathing tube cap on the tube, pay attention to fit.

2. Assemble the battery and bracket.

3. Assemble the engine intake manifold.

XXV Electrical schematic diagram

（Ⅰ）

TCU Interface Figure

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The interface of TCU and transmission

Transmission

Pressure

sensor disc2

Optional

Pressure

sensor

Clutch

Oil temperature sensor

Driving mode sensor

Pressure sensor power

P-S2 signal

Ground sensor

Power

Pressure sensor power

P-clutch signal (optional)

Ground sensor

Speed sensor&DMS-power

N-ab-signal(output speed)

Speed sensor&DMS-power

n prim speed signal

Temperature sensor

Ground sensor

Speed sensor&DMS-power

In

put

Out

put

Communicatio

n

Tran

smiss

ion

end

Ve

hic

le

en

d

Gear shift relay

Backlit relay

Start lock relay

Key lock

Error indicator

Engine speed

(Pull)

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Transmission main connector pin

Signal Illustrate

DMS Driving mode sensor or gear / suppression sensor

EDS_1 Driving bevel gear pressure regulator (Solenoid valve)

EDS_2 Driven bevel gear pressure regulator (Solenoid valve)

EDS_3 Cutch pressure regulator (Solenoid valve)

P_S2 Driven bevel gear pressure sensor

N_ab Driven bevel gear speed sensor

N_S1orN_Prim Driving bevel gear speed sensor

Connector layout

(transmission side )

Pin allocation

Signal

Supply valve

Oil temperature

Sensor GND

Power-5v

Power- 8.4v

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TCU pin schematic

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TCU pin assignment

VT2- signal Pin

Normally closed power K1.30 1；2

Ignition power K1.15 6

Ground K1.31 3；4

VHSD1 (actuator 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 grounded 41；64；86

Transmission oil temperature 38

N_Prim (driving bevel gear speed) 61

N_ab(driven bevel gear speed) 63

N_MOT（Engine speed signal） 87

DMS_A（Driving mode sensor signal） 57

DMS_B（Driving mode sensor signal） 58

DMS_C（Driving mode sensor signal） 79

DMS_D（Driving mode sensor signal） 35

Brake signal 34

Manual mode signal 59

Plus gear signal 81

Lower gear signal 80

P_S2（driven bevel gear pressure） 75

Snow mode 76

Shift lock 48

K-Line 85

CAN- High speed 9

CAN- Low speed 8

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VT2- signal Pin

Starting lock 92

EDS1 driven bevel gear pressure regulator 91

EDS2 driven bevel gear pressure regulator 90

EDS3 driven bevel gear pressure regulator 89

Reversing Light Relay 71

TCU and gearbox pin corresponding figure

（II） Electronic Components Checklist

Driving mode sensor

Check the internal resistance of different pins, check whether the driving mode sensor is good.

TCU pins

Transmission pins

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DMS_GND = 6 pin

DMS_A = 13 pin

DMS_B = 14 pin

DMS_C = 15 pin

DMS_D = 16 pin

DMS_Supply = 9 pin

Corresponding to the resistance value of each pin

DMS_Supply DMS_A DMS_B DMS_C DMS_D

DMS_Supply

x 17.2 M Ω 17.2 M Ω 17.2 M Ω 17.2 M Ω

DMS_A

17.2 M Ω x 9 KΩ 9 KΩ 9 KΩ

DMS_B

17.2 MΩ 9 KΩ x 9 KΩ 9 KΩ

DMS_C

17.2 MΩ 9 KΩ 9 KΩ x 9 KΩ

DMS_D

17.2 MΩ 9 KΩ 9 KΩ 9 KΩ x

DMS_GND

4.5 KΩ 4.5 KΩ 4.5 KΩ 4.5 KΩ

Temperature sensor

Measure the temperature sensor internal resistance.

Measure the resistance between 5th pin and 7th pin.

When the temperature is between 20 ℃ to 40 ℃, the resistance should be 942 to 1121 Ω.

Rotation speed sensor

This is a complex two-wire components, there is no simple way to measure whether it works within the following ranges or not.

·Measured the resistance between 9 pin and 11 pin is about 24.3 M Ω.

·Measured the resistance between 9 feet and 12feet is about 24.3 M Ω.

△

Note: through this measure method can't guarantee the rotation speed is good.

Oil pressure sensor

Measured the resistance between 7 pin and 10 pin is about 24.3 KΩ.

Clutch pressure regulator

Measured the resistance between 1 pin and 4 pin is about 5.2 Ω.

Driving bevel gear pressure regulator

Measured the resistance between 1 pin and 4 pin is about 5.2 Ω.

Driven bevel gear pressure regulator

Measured the resistance between 1 pin and 4 pin is about 5.2 Ω.

TCU can't be measured

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△Note: different precision measuring instruments will lead to a different measure resistance range.

（III） Transmission system schematic

TCU controller and gear shift controller power, ground, data cable.

Cable electric box

Gear shift mode

TCU controller

To CAN

-H

To CAN

-L

To break

indicator

switch M17-2

To ECU

A24-10

To Engine

compartment

electrical box

EPD-8

To Engine

compartment

electrical box

EPD-28

Break signal

Engine speed

signal

Reverse

indicator

signal

Starter relay

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Transmission gear shift control module

Transmission module

TCU controller

Transmission module