Preface

To help JAC authorized professional maintenance technicians for effective and

proper maintenance and repair of JAC S4 transmission, we compile this transmission

maintenance manual. MF622D31 transmission applies to JAC S4 MT model which is equipped

with 1.5T engine. MF20B9 transmission applies to JAC S4 MT model which is equipped

with 1.6DVVT engine. CVT transmission applies to JAC S4 model which is equipped with

1.5T and 1.6DVVT engine.

All contents in this manual, including pictures, technical parameters are the

latest. Due to the product updates, JAC will provide technical briefs or supplemental

volumes, so please pay close attention to the latest developments in obtaining

relevant information. JAC reserves the right to make changes in product design,

additions or improvements.

This manual may not be reproduced or modified in any form, including but not

limited to electronic, paper, audio-visual and mechanical, without the written

authorization of JAC.

The final interpretation of this manual belongs to JAC.

During the process of maintaining JAC transmission, if use non-genuine parts of

JAC or disqualified oil, the transmission may be damaged.

Anhui Jianghuai Automobile Group Co., Ltd

November 2018

General Catalogue

CVT Automatic

Transmission................................................................- 1 -

MF622D31 Manual

Transmission..................................................- 107 -

MF20B9 Manual

Transmission..................................................- 141 -

- 1 -

CVT Automatic

Transmission

Chapter I

Overview………………………………………………………………………-

7 -

1. Structure

Outline...............................................- 7 -

1.1 Comparison of traditional automatic transmission and CVT

transmission...............................- 7 -

1.2

Transmission schematic

diagram...................................................- 8 -

2. System

Principle................................................- 12 -

2.1 Mechanical Torque

Transmit.................................................- 12 -

2.2 Control System......................................................-

18 -

2.3 External Device.....................................................-

20 -

3. General

Information.................................................- 22 -

3.1 Towing Vehicle......................................................-

22 -

3.2 Maintenance

Period......................................................- 22 -

- 2 -

3.3 Lubricating Oil

Specification....................................................- 22-

3.4 CNG (Compressed Natural Gas), LPG (Liquefied Petroleum Gas)

etc..........................- 22 -

4. Technical Parameter/Maintenance

Parameter......................................- 23 -

5. Torque

Parameters................................................- 23 -

6. Special Tool..............................................- 24

-Chapter II Driving

Strategy...........................................- 26 -

1. Function Characteristic of Parking and Neutral

Gear.................................- 26 -

1.1 Parking Locking

Mechanism..................................................- 26 -

1.2 Function of D/R

Gear..................................................- 26 -

1.3 Failure Default

Mode..................................................- 28 -

Chapter III Usage

Instruction...........................................- 29 -

1. Transmission

Oil................................................- 29 -

1.1 Special Tool (No)..................................................-

29 -

1.2 Oil Level

- 3 -

Inspection......................................................- 30 -

2. Disassembly and Assembly of Shift Control Mechanism System

Component and Pull Cable Adjusting Method................- 31 -

2.1 Special Tool......................................................-

31 -

2.2 Gear Shift Pull Rode

Assembly..................................................- 31 -

2.3 Gear Shift Rocker Arm and

Sleeve................................................- 33 -

2.4 Gear Select & Shift Pull Cable

Assembly................................................- 35 -

2.5 Shift Control Mechanism

Assembly..............................................- 37 -

3. Half Shaft...................................................-

39 -

3.1

Installation..........................................................- 39 -

4. Differential Oil

Seal.............................................- 41 -

4.1 Failure

Instruction......................................................- 41 -

4.2 Special Tool......................................................- 41

4.3 Removal..........................................................- 41

4.4

Installation..........................................................- 41 -

5. Input Shaft Oil

- 4 -

Seal.............................................- 42 -

5.1 Failure

Instruction......................................................- 42 -

5.2 Special Tool......................................................- 42

5.3 Removal..........................................................- 42

5.4

Installation..........................................................- 42 -

6. Gear Select Shaft Oil

Seal.............................................- 43 -

6.1 Failure

Instruction......................................................- 43 -

6.2 Special Tool......................................................- 43

6.3 Removal..........................................................- 44

6.4

Installation..........................................................- 45 -

7. Drive Bevel Gear End

Cover.........................................- 46 -

7.1 Failure

Instruction......................................................- 46 -

7.2 Removal..........................................................- 46

7.3

Installation..........................................................- 46 -

8. Oil Pump...................................................- 46

- 5 -

8.1 Failure

Instruction......................................................- 46 -

8.2 Special Tool......................................................- 47

8.3 Removal..........................................................- 47

8.4

Installation..........................................................- 48 -

9. Drive Bevel Wheel Shaft Ball

Bearing......................................- 48 -

9.1 Failure

Instruction......................................................- 48 -

9.2 Special Tool......................................................- 48

9.3 Removal..........................................................- 49

9.4

Installation..........................................................- 51 -

10. Driven Bevel Wheel Shaft End

Cover.........................................- 52 -

10.1 Failure

Instruction......................................................- 52 -

10.2 Removal..........................................................-

52 -

10.3

Installation..........................................................- 52 -

11. Oil Pan...............................................- 53 -

- 6 -

11.1 Failure

Instruction......................................................- 53 -

11.2 Removal..........................................................-

53 -

11.3

Installation..........................................................- 53 -

12. Oil Filter................................................- 54

12.1 Failure

Instruction......................................................- 54 -

12.2 Removal..........................................................-

54 -

12.3

Installation..........................................................- 54 -

13. Driving Mode Sensor........................................- 55

13.1 Failure

Instruction......................................................- 55 -

13.2 Removal..........................................................-

55 -

13.3

Installation..........................................................- 56 -

14. Hydraulic Control

Module...........................................- 57 -

14.1 Failure

Instruction......................................................- 57 -

- 7 -

14.2 Removal..........................................................-

57 -

14.3

Installation..........................................................- 58 -

15. Driven Bevel Wheel Speed Sensor and

Bracket.........................................- 60 -

15.1 Failure

Instruction......................................................- 60 -

15.2 Removal..........................................................-

60 -

15.3

Installation..........................................................- 61 -

16. Drive Bevel Wheel Speed

Sensor.........................................- 62 -

16.1 Failure

Instruction......................................................- 62 -

16.2 Removal..........................................................-

62 -

16.3

Installation..........................................................- 62 -

17. Main Connector and Inner Wire

Harness......................................- 62 -

17.1 Failure

Instruction......................................................- 62 -

17.2 Removal..........................................................-

62 -

17.3

Installation..........................................................- 64 -

18. Breather Pipe..............................................-

- 8 -

65 -

18.1 Special Tool......................................................-

65 -

18.2 Removal..........................................................-

65 -

18.3

Installation..........................................................- 66 -

Chapter IV Electrical Schematic

Diagram.........................................- 67 -

1. TCU Connector

Diagram..............................................- 67 -

1.1 TCU Connector..............................................- 67 -

1.2 TCU and Transmission

Connector..............................................- 68 -

1.3 Pins of Transmission Main

Connector.............................................. - 69 -

1.4 Circuit Diagram of TCU

Pins.................................................- 70 -

2. Electronic Component Inspection

List.........................................- 72 -

2.1 Driving Mode Sensor..................................................-

72 -

2.2 Corresponding Resistance Value of Each

Pin..............................................- 72 -

2.3 Oil Temperature

Sensor....................................................- 72 -

2.4 Revolution Speed

Sensor....................................................- 72 -

- 9 -

2.5 Oil Pressure

Sensor....................................................- 73 -

2.6 Clutch Pressure

Regulator..............................................- 73 -

2.7 Drive Bevel Wheel Pressure

Regulator............................................- 73 -

2.8 Driven Bevel Wheel Pressure

Regulator............................................- 73 -

3. Circuit Diagram of Transmission

System........................................- 74 -

4. Adaptive Update..............................................-

76 -

4.1 Instruction......................................................- 76

4.2 Demand

Condition......................................................- 76 -

4.3 Program..........................................................- 76

5. Common

Problems................................................- 79 -

Chapter V

Troubleshooting...........................................- 81 -

1. Diagnosis

List.................................................- 81 -

2. Noise Problem Check and

Maintenance.....................................- 83 -

- 10 -

3. DTC and Measures.......................................- 89 -

3.1 General

Instruction......................................................- 89 -

- 11 -

- 12 -

Chapter I Overview

1. Structure Outline

The continuous change of the transmission ratio can be achieved by a speed change

device which consists of two opposed cone wheels and a V-shaped transmission steel

belt surrounding the two wheels. The transmission ratio of the transmission is

transmitted to the differential in the transmission through the countershaft.

This manual briefly introduces the transmission, including the design and

function of each part of the transmission, and describes the dynamic transmission

and control device. In addition, this manual also outlines the transmission's oil

cooling system and external gear shifting mechanism.

The transmission's stepless shift mode allows you to drive more comfortably and

improves vehicle performance.

Using this automatic transmission has the following advantages:

- In the condition of constant speed, the engine speed is low;

- Improve emission control/reduced fuel consumption;

- NVH (noise, vibration, jangle) is small;

- Accelerate smoothly;

- Drive flexibly on mountain roads;

1.1Comparison of traditional automatic transmission and CVT transmission

The following figure shows the comparison of transmission ratio between CVT and

manual or conventional automatic transmission. The transmission ratio of a

conventional automatic transmission is a series of fixed values.

When the transmission is in high gear, the transmission ratio shown on the right

figure will vary along the thick solid or dashed line according to the opening degree

of the throttle valve. However, with CVT transmission, the transmission ratio

variation diagram is shown on the left. The shift points of both transmissions are

related to the opening degree of the throttle valve operated by the driver.

When the opening degree of the throttle valve becomes larger, the engine speed

increases and the transmission changes into high gear.If use the traditional

- 13 -

transmission, the engine speed will be significantly reduced, but use the CVT

transmission, the engine speed will not reduce. In the condition of constant engine

speed, CVT transmission can be rotated into high gear by moving cone (see below).

In addition, there are other gear shift strategies available, which will help the

new user of CVT transmission accept it more quickly.

- 14 -

Speed ratio change diagram of CVT transmission (left) and 4-gear automatic

transmission (right)

1.2Transmission Schematic Diagram

1.2.1 Transmission Three View Drawing

- 15 -

1.2.2 Transmission Cutaway View

1. Torsional shock

absorber/Flywheel

2. Oil Pump

3. Backward clutch

4. Planet mechanism

6. Steel belt

7. Drive bevel

wheel

8. Driven bevel

wheel

- 16 -

1.2.3 Transmission Exploded View

- 17 -

1. Input shaft rubber guard sleeve 482235 26. Differential speed sensor

bracket fixing screw 481289

2. Input shaft oil seal 481274 27. Differential speed sensor

bracket 482468

3. Differential oil seal cover 481296 28. Revolution speed

sensor fixing bolt 481283

4. Differential oil seal 483329 29. Oil pan washer 482504

5. Oil filling screw plug washer 481247 30. Valve body assembly

482589

6. Oil filling screw plug 481248 31. Valve body bolt 481311

7. Breather pipe cap 483420 32. Plastic buckle 482253

8. Breather pipe assembly 483114 33. Oil filter assembly 483165

9. Driven bevel wheel shaft end cover O-type ring (small) 481254 34. Oil pan

magnet 481870

10. Driven bevel wheel shaft end cover sealing ring 481877 35. Oil pan assembly

11. Driven bevel wheel shaft end cover O-type ring (big) 481255 36. Oil drain

screw plug 482442

12. Driven bevel wheel shaft end cover 482982 37. Driving mode

sensor fixing screw 481090

13. Driven bevel wheel shaft end cover countersunk screw 482208 38. Driving

mode sensor 482493

14. Drive bevel wheel shaft ball bearing 482294 39. Oil cooler screw

plug O-type ring 481258

15. Drive bevel wheel shaft nut 481293 40. Oil cooler screw plug

482121

16. Conical spring washer 481856 41. Oil level screw plug washer

481249

17. Oil pump sealing ring 481826 42. Oil level screw plug 481250

18. Oil pump O-type ring 481259 43.Main connector cover 482104

19. Oil pump (with O-type ring) 483323 44.Main connector buckle 482105

20. Oil pump bolt 481284 45.Main connector and inner wire

- 18 -

harness 482475

21. Drive bevel wheel shaft end cover O-type ring 481253 46. Gear select

pull rod nut 481329

22. Drive bevel wheel shaft end cover 481173 47. Gear select pull

rod 483185

23. Drive bevel wheel shaft end cover buckle 481189 48. Gear select pull

rod nut washer 482584

24. Drive bevel wheel shaft end cover bolt 481283 49. Oil seal (gear

select shaft) 482099

24. Oil pan bolt 481283 50. Locating pin 483138

25. Revolution speed sensor 482410 51. Metal buckle 481456

- 19 -

2. System Working Principle

These components can be divided into three groups according to the corresponding

functions of the VT2/VT3 transmission:

· Group 1 - mechanical transmission device. This part is designed to provide

mechanical transmission and torque transfer.

· Group 2 - control system and control system related components. According to

the load condition and driving requirement, the control system ensures that the

transmission transfers power and changes the transmission ratio at the appropriate

time.

· Group 3 - external connecting device and some components that are connected

to the external of transmission. Some of these components are located in or connected

to the transmission, while others are part of the overall system but are distributed

elsewhere in the vehicle.

2.12.1 Mechanical Torque Transmit

2.1.1 Planet Mechanism

The planetary mechanism enables the transmission to provide forward and backward

driving torque. The torque provided by the engine is usually transmitted to the

transmission through the input shaft on the planetary carrier. The multi-plate clutch

engaged in the forward direction can directly connect the planetary carrier to the

solar gear. At this point, the planetary carrier and the solar gear become a rotating

whole through engagement, and the engine torque is directly transferred to the drive

gear. The planetary gear does not transmit any torque, so there is no mechanical loss

to the planetary mechanism, and the drive gear will rotate in the same direction as

the engine. This is the forward mode.

In the reversing mode, engaging the reversing multi-plate clutch can keep the

gear ring in the planetary mechanism still, and the planetary carrier drives the three

pairs of planetary gear sets to make the solar gear rotate in the opposite direction.

At this time, the gear set's transmission ratio is 1:1.1, and slight deceleration

and torque increasing will occur to compensate for the friction loss of the planetary

- 20 -

mechanism.

Planet mechanism

1. Planet gear

2. Input shaft

3. Solar

gear

- 21 -

2.1.2 Multi-disk Clutch

There are two sets of multi-disc wet clutches: one for forward and one for backward.

Each group of clutches has three friction plates with a total of six friction surfaces.

The hydraulic system controls the clutch to enable the vehicle to move forward

smoothly when the throttle valve is in any open degree. When drive gear is engaged,

controls the clutch engagement quantity to enable the vehicle to stop. Cooling oil

directly cools the clutch plate to prevent the friction surface from overheating.

Clutch in planet mechanism

1. Forward clutch group 2.

Backward clutch group

2.1.3 Bevel Gear and Steel Belt

The main design feature of the CVT transmission is a pair of V-shaped bevel gear

connected by a steel belt. The center distance between the drive gear and the driven

gear is 155mm. Each bevel gear is divided into two half: one half is fixed, the other

half slides along the axial direction, the inclination angle of both are 11°. The

24mm wide "Van Doorne" push-drive belt is used to transfer torque between wheels (a

30mm belt is available for larger torque values). Lubricate and cool the belt with

a nozzle by means of an oil jet. To reduce the angle error of the transmission belt

when shifting gears, two moving half-wheels are placed on the diagonal of the two,

and each moving half-wheel is connected to the hydraulic cylinder/piston. Hydraulic

pressure is controlled by control system, see "control system". Spherical splines

- 22 -

prevent moving the half wheel relative to

their fixed half wheel rotation.

Since the sun wheel is splined to the

active cone wheel, the torque transmitted

by the planetary gear set can be directly

applied to the active cone wheel. The

steel belt transfers power from the

driving cone to the driven cone, and then

from the driven cone to the intermediate gear shaft.

The torque and speed of the driven wheel are determined by the position of the

belt. The size of the two wheels is designed to provide a transmission ratio of 2.416:1

~ 0.443:1, with the maximum transmission ratio 5.45 times of the minimum one. The

fuel consumption is lowest when overspeed transmission ratio.

The transmission steel belt consists of 450 steel plates and 24 steel belts fixed

together with 12 steel belts on each side.

Drive belt

2.1.4 Countershaft

The countershaft (pinion shaft) decelerates the two meshed helical gears between

the driven cone and the differential, thus ensuring that the drive shaft rotates in

the correct direction. The deceleration between driven cone wheel and driving shaft

1. Steel belt 2. Steel

- 23 -

greatly improves vehicle performance. The countershaft is fixed by two conical

bearings located in the clutch housing and the independent bearing housing.

Gear ring and intermediate gear

2.1.5 Differential

Like the manual transmission, the torque on the crown wheel is transmitted to

the wheels through the differential, the crown wheel is bolted to the differential

housing by eight bolts, and the drive shaft is bolted to the differential by the

traditional ball-cage universal joint and gasket. Taper bearing is used to fix the

differential.

1. Driving bevel shaft

transmission gear

2. Differential crown gear

3. Transmission pinion

4. Transmission

intermediate gear

5. Driven cone

- 24 -

Differential assembly

2.1.6 Machinery Operation

· Transmission ratio change

The transmission ratio number of traditional planetary automatic transmission

is limited, usually four, five or six; but the CVT is different, as the name suggests,

CVT transmission ratio is continuous change. Low speed gear (low transmission ratio)

makes it easier for a stationary vehicle to start. The diameter of the drive bevel

gear is relatively small, but that of the driven bevel gear is relatively large. The

belt is used to transmit power and torque. If the high-speed ratio is selected by

increasing the diameter of the drive bevel gear and reducing the diameter of the driven

bevel gear, the acceleration can be generated. Ensures optimum transmission ratio

by controlling the degree of variation.

CVT transmission has two rotating gears of drive bevel gear and driven bevel gear,

each bevel gear is composed of two halves, one half is fixed, the other half can be

moved by hydraulic control. The position of the belt on the runner determines the

transmission ratio. If the moving half wheel is close to the corresponding fixed half

wheel, then the belt will move towards its periphery. When the two cone wheels are

separated, the circumference of the wheel will become smaller, and the moving half

wheel of the active cone wheel and the driven cone wheel are in their respective

diagonal positions. At this time, the radius of the driving belt on the active cone

wheel reduces, while the radius of the driving belt on the driven cone wheel increases.

1.Differential

bearing

2.Differential

shell

4. Differential

planet gear

5. Differential

- 25 -

A low transmission ratio is required for a vehicle to start. For this reason,

the driving cone wheels are separated so that the belt is attached to it and the belt

moves around the closed driven cone wheel. When the vehicle speed increases, a high

transmission ratio is required. For this reason, the moving half wheel of the active

cone wheel gradually approaches the corresponding fixed half wheel, and the wheel

circumference of the cone wheel increases. At the same time, the driven cone wheel

is forced to separate, and the radius decreases, resulting in a higher transmission

ratio. When the driving cone wheel is completely closed and the driven cone wheel

is completely separated, the transmission ratio of overdrive gear is produced. The

drive and driven bevel gear rotate at a transmission ratio of about 1:2.5.

1. Engine input

2. Output to the wheels

3. Min diameter driving

wheel (low speed)

- 26 -

Belt pulley position when in low gear

Belt pulley position when in high gear

1. Engine input

2. Output to the wheels

3. Min diameter driving wheel

Max diameter driven wheel

- 27 -

· Gear selecting handle is in neutral or parking position

· In this state, reversing clutch (2) and forward clutch (4) separates, can’t

make the wheel move.

- Transmission input shaft (1) and engine speed

are the same.

- Backward clutch (4) separates.

- Forward clutch (4) separates.

- Planet gear (3) idle running around sun gear

- Sun gear not move, drive gear (5), driven gear

(7) and the vehicle also keep still.

For all automatic transmissions, the engine can

only be started in neutral or in park gear. In parking

gear, the mechanical lock prevents the vehicle from

moving back and forth. In order to avoid damage to the

transmission, the parking gear can only be used when the vehicle is not moving.

· Gear selecting handle is in forward gear

In this state, the forward clutch (4) engages to

make the wheels move.

- Transmission input shaft (1) is the same with the

engine speed.

- Reversing clutch (2) separates.

- Forward clutch (4) engages

- Planet gear (3) of planet mechanism, sun gear and

gear ring rotate together.

- Drive gear (5) is the same with the engine speed, the direction is forward gear

1. Input shaft 5. Drive gear

2. Backward clutch 6. Driven steel belt

3. Planet gear 7. Driven bevel

gear

- 28 -

direction.

- Driven gear (7) is the forward gear direction, its speed depends on the transmission ratio in this running

state.

Transmission

1. Input shaft 6. Drive steel

belt

2. Reversing clutch 7. Driven

cone

3. Planet gear 8. Driven bevel

gear

1. Input shfat 6. Drive steel belt

2. Reversing clutch 7. Driven cone

shaft

3. Planet gear 8. Driven bevel gear

4. Forward clutch 9. Input shaft

5. Drive bevel gear

- 29 -

· The gear selecting handle is in rerversing gear

In this state, backward clutch (2) engages, gear ring (9) is locked in

transmission housing. Planet gear (3) makes the rotating direction of sun gear (10),

drive gear (5) and driven gear (7) be opposite

to the transmission input shaft (1).

Now reversing gear is selected.

- Transmission input shaft (1) is the same with

the engine speed.

- Reversing gear (4) separates.

- Forward clutch (4) separates.

- Gear ring (9) connects to transmission case

through backward clutch (2).

- Direct transmitting planet gear (3) of

transmission input shaft (1) make it rotate

around the gear ring, thus drive the sun gear (10),

belt gear (5) and driven cone gear (7) rotate

backward.

2.2Control System

The functions of control system are as follows:

1. Make the clamping force of the steel transmission belt tension adapt to the

engine torque to prevent the belt from slipping.

2. Control the forward clutch and the backward clutch while driving.

3. Provide the best transmission ratio for driving.

4. Provide the necessary lubricating oil and cooling oil for the transmission.

1. Input shaft 6. Drive steel

belt

2. Backward clutch 7. Driven

cone shaft

3. Planet gear 8. Driven bevel

- 30 -

2.2.1 Oil Pump

The oil pump in the transmission is the external engaging gear pump. The engine

drives the oil pump shaft, which reaches the inside of the oil pump through the hollow

drive bevel gear shaft. The pump shaft is splined to the planetary gear rack. The

pump shaft has been running at the engine speed. The pump oil is about

10cm³/r. System pressure up to 40～50bar depending on input torque.

Oil pressure is not only used for hydraulic control of the transmission, but also

for lubrication.

Oil pump full figure

1. Oil pump drive shaft 2. Oil

pump assembly

Oil pump inlet

1. Oil pump inlet 2. Oil pump

- 31 -

seal

2.2.2 Transmission Control Device

The transmission control device minimizes the tension between the belt and the

runner without slipping, and also provides the transmission ratio based on the target

values given by the driving strategy (calculated based on the input (drive) and output

(driven) speeds of the transmission). During the service life, the performance

degradation of the control device will be kept within a certain range without obvious

impact on vehicle comfort and belt tension.

2.2.3 Tension Control Device

The tension control device can obtain the required minimum tension force when

the belt is not slipping, which has the least impact on the transmission transmission

efficiency and the lowest fuel consumption.

In addition to normal driving, the tension control device also takes into account

the special circumstances of transmission torque maximum input and output, so as to

maximize the protection of the transmission. The control device takes into account

anti-lock braking system (ABS), tire lock (no ABS) and other driving force control

system (such as ESP, anti-slipping control device, etc.). In addition, the device

also takes into account special roads and conditions, such as passing through

pot-holed road, road shoulder, high and low adhesion coefficient transition, and tire

slip (such as on low adhesion coefficient road).

The software can compare the transmission performance of the transmission torque

with the expected input torque of the transmission. When the tension control device

finds that the tension force is insufficient, the ECU receives the instruction to

reduce the torque, so as to adjust the engine torque within the appropriate range.

This function also protects the transmission.

If there is no electronic drive circuit system in the vehicle, the ECU transmits

the torque signal through the CAN bus. If there is no CAN bus, the transmission control

system (TCU) software itself generates the default torque signal.

2.2.4 Speed Ratio Control Device

- 32 -

The transmission controls the transmission ratio by controlling the input and

output pressure to balance the pressure on the drive and driven bevel gear. The

transmission ratio can be calculated according to the speed sensor signals of the

drive bevel gear and the driven bevel gear, and the required transmission ratio can

be obtained by changing the output pressure. The minimum pressure can be determined

by the tensioning method. The physical model of the transmission helps to quickly

adjust the pressure level to the variable operating point. The control software also

considers the interference from other components of the transmission, so it was

developed to minimize delay errors and target speed ratio errors as possible(to

improve fuel economy).

In order to meet the requirements of transmission machinery and durability limit

state, we developed some driving strategies in limit state. In addition to the speed

limit, the rate of change of the transmission ratio (the set point) is within the

allowable range through the software. In addition, the software also prevents the

engine speed from exceeding a certain limit due to the vehicle speed and the condition

of the gear lever (POS). To achieve this limitation, the software will require a

reduction in engine torque or a shift of the vehicle into higher gear.

2.2.5 Transmission Control Unit

The software controls transmission is integrated in TCU (Transmission Control

Unit). TCU is installed inside the cab.

2.3External Device

2.3.1 Oil Cooler Connector

There are two oil cooler pipes in front of the transmission housing. The inlet

of one oil cooler is installed next to the engine radiator, to keep the temperature

of the lubricating oil below 120 °C. The oil in the transmission flows out from the

right port, which should be connected to the lower port of the oil cooler.

The oil of the oil cooler enters into the transmission from the port on the left

side of the transmission, so the port on the left side of the transmission should

be connected to the upper port of the oil cooler.

- 33 -

oil cooler pipe connector

2.3.2 Shift lever

The gear position of VT2/VT3 transmission may include stop gear (P), reverse gear

(R), neutral gear (N), forward gear (D), and sport mode (S).

Customer can customize the configuration of the shift lever. For the sake of

safety, it is recommended to apply gear shift locking device as starting protection.

CVT transmission can also achieve manual mode, which requires the addition of

new pins on the TCU to receive signals, and the calibration of the maximum speed of

the engine within a certain range. All JAC

CVT transmissions have manual mode.

2.3.3 Main Connector

Main connector is on transmission

housing, includes 16 pins. Wire harness is

connected by circular connector.

- 34 -

2.3.4 Torsional shock absorber

Most conventional automatic transmissions use a torque converter to connect the

engine to the input shaft, but this one uses a torsional shock absorber.

- 35 -

3.General Information

3.1Towing Vehicle

Vehicle equipped with VT2 or VT3 transmission cannot be directly towed, because

only when the engine is running, oil pressure can be generated in the cone wheels

and the transmission belt can run. Therefore, the front wheel must be lifted from

the ground when towing.

3.2Maintenance Period

Every 60,000km or two years (whichever is the first), the transmission oil and

oil filter must be replaced. Therefore, the transmission is equipped with oil drain

plug and refueling screw plug. Vehicle manufacturer can reduce the transmission

maintenance period, so that it can match the vehicle’s standard maintenance period.

3.3Lubricant Oil Specification

Please use MOBIL(ESSO) EZL799(A) or IDEMITSU CVTF-EX1, the two types oil can be

mixed, but it’s not advised.

The use of other oil may result in damage to the interior of the gearbox. Once

other oil is used, this gearbox cannot be claimed.

3.4 CNG (compressed natural gas), LPG (liquefied petroleum gas), etc.

Risks of switching to CNG:

-- the vehicle will have a different or unstable torque diagram, which will result

in:

• different performance

• very poor driving response

• generate fault codes

• clutch movement problem

• self-learning problems

• steel belt slips

PUNCH does not allow vehicls to be changed to other fuel systems: CNG,

LPG,...PUNCH immediately discontinued this gearbox warranty as soon as the vehicle

was fitted with another fuel system.

- 36 -

4. Technical Parameter/Maintenance Parameter

No.

Items

Parameters

Transmission

VT2/VT3

Type of lubricant oil

MOBIL(ESSO) EZL799(A)/DEMISTU

CVTF-EX1

5. Torque parameters

No.

Items

Tightening torque (N · m)

Oil filler plug

21±3

Driven bevel wheel shaft end cover

countersunk screw

9.5±0.95

Drive cone gear shaft nut

197.5±17.5

Oil pump bolt

10±1

Driven bevel gear shaft end cover

bolt

9.5±2.5

Oil pan bolt

9±1

Speed sensor fixing bolt

8.5±2

Speed sensor bracket fixing screw

in differential

9.5±0.95

Valve bolt

11±1

Oil drain plug

11±1

Driving mode sensor fixing screw

9.5±0.95

Oil level screw plug

15±2.25

Gear shifting handle nut

14.5±1.5

- 37 -

6. Special Tool

Numbe

Tool No.

Tool name

Tool illustration

Usage

16G0049

Drive bevel

gear bearing

Plug

Remove the drive bevel

gear bearing

16G0043

Gear select

shaft oil

sealing

Installation

tool

Install gear select

shaft oil sealing

16G0050

Drive bevel

gear bearing

plunger chip

Install the drive bevel

gear shaft ball

bearing

16G0048

Drive bevel

gear bearing

Removal tool

Remove the drive bevel

gear shaft ball

bearing

16G0041

Input shaft oil

seal

Installation

tool

Install the input shaft

oil seal

- 38 -

16G0040

Input shaft oil

seal

Locating

bushing

Install the input shaft

oil seal

No.

Tool No.

Tool name

Tool illustration

Usage

16G0042

Gear select

shaft oil

sealing

Removal tool

Remove the gear select

shaft oil sealing

16G0046

Hydraulic

control block

Locating pin

Install the hydraulic

control block

16G0038

Differential

oil seal

Installation

tool

Install the

differential oil seal

16G0045

Oil pump

removal tool

Remove the oil pump

16G0044

Air pipe

assembly tool

Install the respirator

hose

- 39 -

CVT-HDFJ-1

N gear

installation

auxiliary tool

Transmission gear

shift rocker arm

position limiting

- 40 -

1. Stop stop pawl 2. Driven

Chapter II Driving strategy

1. Function Characteristic of Parking and Neutral Gear

No matter what kind of transmission, the engine can only be started in the parking

and neutral state. The mechanical lock in the parking gear prevents the vehicle from

moving back and forth. Had better be in vehicle static condition uses parking gear,

in case injury transmission.

If you accidentally use the parking gear when the speed is high, the parking device

can only work if the speed is reduced to about 5km/h.

1.1 Parking Locking Mechanism

When the vehicle starts up, TCU will control the starting relay, and the starting

relay can control to start the engine.

The vehicle's gear is controlled by an

internal driving mode sensor, which is

connected directly to the gearshift lever.

To shift parking (P) or neutral (N) to

drive (D) or reverse (R), the brake pedal

is pressed. If the brake pedal is not

pressed, the gear lever remains locked in

either P or N.

Parking lock mechanism

- 41 -

1.2 Function of D/R Gear

1.2.1 General operation

When driving, the operation of this transmission is completely different from

that of traditional automatic transmission, so you should pay attention to adapt.

For example, if you press the accelerator pedal too hard, the engine speed will

increase obviously, but the speed will not change much. This feature is normal for

CVT transmission, but if the driver does not know about the transmission, it may be

mistaken for a faulty gearbox.

Other analogies to traditional automatic transmissions may also exist.

1.2.2 Self-adaption updating

Whether forward or reverse, the corresponding clutch should be calibrated again

to achieve the best effect in its service life.

- 42 -

1.2.3 Creep

According to the performance of automatic transmission, when the shift lever is

in forward gear (D) or reverse gear (R), if the driver releases the brake pedal, the

vehicle will start crawling (flat road). If the road slope is less than 8 °, the

vehicle also can crawl; If the road slope is greater than 8 °, the vehicle will be

slightly backward, which is the same with the vehicle equipped with hydraulic torque

transmission, it will not backward if the slope degree is not large. Regardless of

the slope of the road, the maximum speed at which the vehicle climb will be less than

a limit (8km/h). Especially downhill, the control system will allow the clutch to

switch from separation to "engage" mode, allowing the engine to brake during the

glide.

1.2.4 Idling parking (only for D gear state)

The VT2/VT3 transmission can idle stop. The vehicle (battery status, A/C ON/OFF)

and the transmission (without affecting the transmission durability) can idle stop

under certain conditions. If all conditions are met, the internal combustion engine

can stop at rest. Only when the brake pedal is released and the engine starts up again

and the transmission works quickly can the vehicle move forward and backward.

The idle stop feature is particularly useful for hybrid drives, but is useless

for standard drives without a special starter or starter motor.

1.2.5 Acceleration and deceleration

The acceleration process mainly provides acceleration according to the driver's

requirements and driving conditions. At this time, the change trend of engine speed

corresponds to the initial speed, so as to achieve the best driving comfort.

The clutch controller also provides some means of compensating for the difference

in clutch wear (it differs between different vehicles) to ensure driving comfort.

1.2.6 Acceleration support

In order to achieve optimal driving comfort, it is necessary to determine the

most appropriate engine speed, which is between the minimum traction engine speed

and the engine speed when the vehicle maintains a constant speed (economic speed)

- 43 -

cruise state.

The transmission control system provides functionality to meet these

requirements by using a combined control mode between the transmission (ratio control)

and the starting clutch. Therefore, when the vehicle starts, the control target is

always focused on the driving performance of the higher engine speed related to the

acceleration of the vehicle, while when the vehicle cruises or glides, the control

target is transferred to the fuel economy of the transmission system.

1.2.7 Deceleration

If the driver presses the brake pedal at the same time as the accelerator pedal,

the engine speed will be limited to a certain range (similar to the torque converter).

Therefore, the gearbox needs to be combined with the engine control system to block

torque so that the gearbox can react quickly to the driver's sudden release of the

brake pedal and start to control the clutch.

Long-term use will cause high temperature loss of the clutch, the transmission

also has the risk of damage, so we use the monitoring function to detect these

dangerous conditions. Activate the transmission's internal diagnostic system to open

the clutch. If the driver keeps his foot on the gas pedal, the engine will rise up

to its maximum speed. In addition, the clutch controller can also follow the highest

control goal in other cases, to ensure the original safety and improve the driving

comfort.

1.2.8 Driving and brake

When the vehicle decerates to stop, the clutch is separated again to prevent the

engine from stopping. The clutch pressure is controlled to drop steadily to gradually

separate the clutch, so as not to cause torque fluctuations. Therefore, the controller

provides different modes according to the change of speed to separate the clutch.

The clutch pressure control also controls the power of the hydraulic control system

according to the oil temperature of the transmission. The clutch can be quickly ready

to start after separation.

In order to make the driving comfort optimal during the vehicle braking and

starting process, the transmission software and other transmission control device

- 44 -

work together, this role makes the torque transmission temporarily interrupted, idle

speed increase.

1.2.9 Clutch combines/separates when driving

If the clutch is not used while driving, the transmission controller has little

effect on the comfort of driving, as the absence of the clutch has nothing to do with

the characteristics of the hydraulic system. In such case (low load, stopping, low

engine speed), the driving comfort may be reduced when the clutch is applied again

compared with when the clutch is applied in the stationary state.

1.3Failure Default Mode

When the software detects a system error, the default rule is applied.This is

transmitted to the drive through the instrument group's fault display. The driver

will take a different default driver state depending on the severity of the error.

In some cases, the main relay will be turned on. All fault codes will appear on the

OBD.

- 45 -

Chapter III Usage Instruction

1. Transmission Oil

1.1 Special Tool (No)

1.1.1 Oil level check instruction

The following oil level check should be carried out whenever draining the

transmission oil or replacing new transmission.

The service transmission has no oil inside.4.3±0.05 L ESSO EZL799(A) or Idemistu

CVTF-EX1 should be added after installing the transmission. Please follow the

following methods to refuel and check the oil level.

1.Shift the operation lever to P gear position.

2.Remove the oil filling plug (3) on the top.

3.Ensure that the oil drain plug (1) is assembled.

4.Fill 4.2±0.05 L transmission oil Esso EZL 799A to the transmission oil from

the oil filling plug (3) on the top.

5.Reinstall the oil filling plug (3). Tightening torque (M14) : 21N·m.

6.Step the brake pedal.

7.Start the engine.

8.Run the engine for 10 seconds.

9.Shift the shift lever away from P gear position.

10.Note: the sound of air circulating through the system may be heard at the

initial start-up. This is normal operation.

11.Switch the operation lever to each gear (P-R-N-D) and remain in each gear for

5 seconds before switching to the next gear.

12.Shift the operation lever to D gear position.

13.Release the brake pedal.

14.Step lightly on the accelerator pedal to 60km/h (engine speed must not be

higher than 2500rpm).

15.Release the accelerator pedal and tap the brake brake until the vehicle stops.

16.The above two steps should be performed at least twice.

17.Driving around at least 5 minutes (hope temperature rises from 30 ℃ to 50 ℃).

- 46 -

18.Step the brake pedal.

19.Wait 2 seconds.

20.Shift the operation lever to R gear position.

21.Release the brake pedal.

22.Wait 10 seconds.

23.Step the brake pedal.

24.Wait 2 seconds.

25.Shift the operation lever to N gear position.

26.Keep the engine idling.

27.The engine must be running and the lever must be in N gear.

28.Check the oil temperature: must be between 30 ℃ to 50 ℃.

29.Wait 2 minutes until oil level stabilizes.

30.Remove the oil level plug (2) (the engine is still running).

31.Wait a few minutes until the oil drips off from the oil level plug.

32.Reinstall the oil level plug.

33.Tighten oil level plug (tightening torque (M14) : 21N·m).

34.Stop the engine and shift the lever to P gear position.

1.2 Oil level checkIf the initial oil filling is correct, the oil level should be in the correct position (oil level bolt

position).

Normal allowrance (such as new transmission residual oil and production line

fueling allowrance) should be oil level bolt position, oil level can be ±0.165L.

1. Check the oil level of the transmission

1) Remove the oil filling bolt on the upper end of the transmission.

2) Add accurate 0.5L±0.05L oil to the transmission.

3) Install the oil filling screw plug. Tightening torque 18～4N·m.

4) Starting the engine to make transmission temperature rising to about 60 ℃.

5) Place the vehicle on the flat ground.

6) Press the brake pedal, and wait 2 seconds, and then shift to P gear position.

7) Keep the engine idling running.

8) Remove the oil level inspection bolt when the engine is idling.

9) Correct oil draining (at least 0.335L and at most 0.665L).

- 47 -

Min of 0.235L (0.5 ADDED oil-0.165 tolerances - 0.1L = 0.235L) oil will flow from

the gearbox, and if less than that, the original oil level is too low.

Max of 0.565L (0.5 ADDED oil+ 0.165 tolerances - 0.1L = 0.565L) oil will flow

from the transmission, and if less than

that, the original oil level is too high.

▲Note: All data comes from when the

transmission oil temperature is 60 ℃.

10) add new gaskets and tighten oil

level bolts.

Tightening torque 18～24N·m

11) Stop the engine.

Oil draining bolt (1) Oil level bolt (2)

Oil filling screw plug (3)

2. Disassembly and Assembly of Shift Control Mechanism System

Component and Pull Cable Adjusting Method

- 48 -

2.1. Special tool

CVT-HDFJ-1

N gear

installation

auxiliary tool

2.2 Gear Shift Pull Rode Assembly

This procedure describes how to correctly connect the gearshift lever. Failure

to follow this instruction may result in

transmission gear disorder. The dashboard

will always show the transmission gear

status regardless of the gear lever position.

A precise shift wire drawing installation

allows the instrument panel and shift lever

to indicate the same shift status (PRND).

If replacing the gear shift control mechanism, select &shift gear wire drawing,

rear suspension bracket, shift rocker arm and bushing, pull rod assembly,

transmission or other components that affect the transmission gear shifting operation

control, they must be re-adjusted, otherwise there will be a shift disorder or even

cause the vehicle can not run and other faults.

2.2.1 Disassembly

1) First remove the worm at position a (using flat screwdriver or open wrench).

2) Then loosen the nut at position b (S13 open wrench) [note that the transmission shift rocker arm may

move back after loosening the nut, and shall be immediately restored to the initial position (the transmission shift

rocker arm is basically vertical downward)].

3) Replace the new pull rod assembly. First, go to the cab to manipulate the shift

lever for 5 times, and finally put the shift lever to N gear.

4) Press lever assembly a position into the shifting rocker arm ball head.

5) Finally, the transmission shifting rocker arm is clamped with auxiliary tool,

and then the nut at position b is tightened (tightening torque: 20～28N·m).

- 49 -

2.2.2 Installation

1) Install the new shift lever on the transmission.

2) Shift the shift lever back and forth for 5 times, and then place the shift

lever to N gear.

3) Press the shifting rocker arm ball head at position a into the worm.

4) Clamp the transmission shifting rocker arm with auxiliary tool, and then

tighten the nut at position b.

▲Note: The auxiliary equipment must be fully stuck into the position shown in

the "diagram of auxiliary equipment installation and adjustment" to ensure that its

limit groove is in full contact with the transmission gear shifting rocker arm plane.

During tightening the nut, hold the handle of the auxiliary equipment by hand and

try to keep the transmission gear shifting rocker arm from moving or shaking.

Tighten torque 20～28N·m

- 50 -

2.2.3 Adjustment

1) Shift the shift lever to P gear.

2) Ensure the transmission is in P gear.

3) If the shift lever is not in P gear position, push it to the correct position

by hand.

▲Note: P gear can be confirmed through the dashboard

gear display.

4) Rrotate the front wheels of the vehicle

until the wheels are locked. Now that the

transmission is in P gear, you can still shift

P gear on the gear shifting lever, but don't

do that. If the there is bracket fixing cable,

please first connect the cable to the bracket.

5) Connect the cable to the shift lever with bolt and nut.

6) Tighten the nut.

▲Note: Do not bend the cable or shift lever!

2.2.4Check

1) Quickly shift 3 cycles back and forth from P/R/N/D/S/M+/-M-, check whether

the position of gear shift lever is consistent with the display gear of the instrument,

and whether the instrument shows the correct gear.

2) In slow speed, shift 3 cycles back and forth from P/R/N/D/S/M+/-M-, check

whether the shift shift lever position is consistent with the instrument display gear,

and whether the instrument shows the correct gear.

3) If there is any inconsistency between the position of the instrument and the

gear shift lever or the instrument does not show the gear, the gear must be readjusted.

- 51 -

2.3 Gear Shift Rocker Arm and Sleeve

2.3.1Removal

1. Remove the select&shift gear lever

assembly. Refer to the select&shift gear

lever assembly.

2. Remove the gear shift rocker arm and

sleeve.

1) Remove the worm at position c (by flat

screwdriver or open wrench).

2) Remove the bolt at position e.

3) Take down the gear shift rocker arm and sleeve.

2.3.2Installation

1. Install the gear shift rocker arm and sleeve.

1) Replace the new gear shift rocker arm and sleeve.

▲Note: The upper arrow on the rocker arm is aligned with the transmission, while

the flange face of the bushing is close to the transmission mounting surface.

2) Install the bolt at position e, and tighten.

Tighten torque 20～28N·m

2. Install the gear shift pull rod assembly.

2.3.3Inspect

1. Check the installation condition.

1) Quickly shift 3 cycles back and forth from P/R/N/D/S/M+/-M-, check whether

the position of gear shift lever is

consistent with the display gear of the

instrument, and whether the instrument shows

the correct gear.

2) In slow speed, shift 3 cycles back and

forth from P/R/N/D/S/M+/-M-, check whether

the shift shift lever position is consistent

- 52 -

with the instrument display gear, and whether the instrument shows the correct gear.

3) If there is any inconsistency between the position of the instrument and the

gear shift lever or the instrument does not show the gear, the gear must be readjusted.

2.3.4N gear installation auxiliary tool using method

Move the transmission gearshift rocker arm to the N gear position, then limit the gearshift rocker arm with

the auxiliary tool (Part No. CVT-HDFJ-1), and finally tighten the tie rod assembly and the connection nut of

gearshift rocker arm (Q32008).

▲Note: The auxiliary tool must be fully stuck into the position shown in the

"auxiliary equipment installation and adjustment diagram", to ensure that the limit

slot is in full contact with the transmission gear shifting rocker arm plane. During

the tightening of the nut, hold the handle of the auxiliary tools by hand (the

auxiliary tools cannot be shaken or moved in this process), and try to make the

transmission gear shifting rocker arm do not move or shake.

- 53 -

2.4 Gear Select & Shift Pull Cable Assembly

2.4.2Removal

1. Remove the select&shift gear lever assembly. Refer to the select&shift gear lever

assembly.

2. Remove the gear shift rocker arm and sleeve. Refer to the gear shift rocker arm

and sleeve.

3. Remove the gear select&shift pull cable

assembly.

▲

Note: It must be ensured that the brackets

are all located in the connector clip slots.

1) disconnect the quick connector of gear

select&shift cable at position d from the

cable bracket, and disconnect the connection between the gear select&shift cable

assembly and the transmission.

2) Shift the gear shifting lever to N

gear position, and remove the connection of

the cable and the transmission control mechanism.

3) Remove the spring card.

4) Loosen the 2 M8 nuts on the front of

- 54 -

the vehicle body.

5) Remove the gear select&shift cable assembly.

- 55 -

2.4.2Installation

1. Install the gear select&shift pull cable

assembly.

2. Pass the new gear select&shift pull

cable assembly into the cabin through the

vehicle body front wall hole from engine

compartment.

2). Tighten the 2 M8 nuts on vehicle body

front wall.

Tighten torque 20～28N·m

3) Connect the cable joint (at

transmission control mechanism end) to the pin

shaft of the transmission control mechanism.

4) Assemble the spring card in place.

2. Install the gear select&shift rocker arm and bushing.

3. Install the gear select&shift lever assembly.

2.4.3Inspect

1. Check the installation condition.

1) Quickly shift 3 cycles back and forth from P/R/N/D/S/M+/-M-, check whether

the position of gear shift lever is consistent with the display gear of the instrument,

and whether the instrument shows the correct gear.

2) In slow speed, shift 3 cycles back and forth from P/R/N/D/S/M+/-M-, check

whether the shift shift lever position is consistent with the instrument display gear,

and whether the instrument shows the correct gear.

- 56 -

3) If there is any inconsistency between the position of the instrument and the

gear shift lever or the instrument does not show the gear, the gear must be readjusted.

- 57 -

2.5 Transmission control mechanism assembly

2.5.1Removal

1. Remove the transmission control mechanism assembly.

1) Shift the gear select&shift lever to

N gear, and remove the connection of the cable

and the transmission control mechanism.

2) Remove the spring card.

3) Remove the 4 fixing bolts, and remove

the transmission control mechanism assembly.

2.5.2Installation

1. Install the transmission control

mechanism assembly.

1). Install the new transmission control

mechanism assembly to the vehicle body.

2). Tighten the 4 fixing nuts.

Tighten torque 20～28N·m

- 58 -

3) Connect the cable joint (at

transmission control mechanism end) to the

pin shaft of the transmission control

mechanism.

4) Assemble the spring card in place.

2. Install the gear select&shift rocker arm and bushing.

3. Install the gear select&shift lever assembly.

2.5.3Inspect

1. Check the installation condition.

1) Quickly shift 3 cycles back and forth from P/R/N/D/S/M+/-M-, check whether

the position of gear shift lever is consistent with the display gear of the instrument,

and whether the instrument shows the correct gear.

2) In slow speed, shift 3 cycles back and forth from P/R/N/D/S/M+/-M-, check

whether the shift shift lever position is consistent with the instrument display gear,

and whether the instrument shows the correct gear.

3) If there is any inconsistency between the position of the instrument and the

gear shift lever or the instrument does not show the gear, the gear must be readjusted.

- 59 -

3. Half shaft

3.1Installation

When installing the half-shaft to the full transmission, we strongly recommend

using PUNCH 480145 tool to protect the differential oil seal.

If the differential shaft is damaged, the transmission will inevitably leak oil.

Using special tool will significantly

reduce the chance of oil seal damage.

1) Remove the oil seal protective cover.

2) Install the tool on the half-shaft oil seal and install

it well.

3) Put the half-shaft into the transmission at a

maximum depth of 4cm.

- 60 -

4) Put the half-shaft into the transmission at a

maximum depth of 4cm, with a distance of 2cm between

the half-transmission and the tool.

5). Take down the tool

Fully push the half shaft into the transmission, and

the half shaft

is installed.

- 61 -

4. Differential oil seal

4.1Fault code instruction

There is oil seal damage or oil leakage, half shaft damage or oil leakage.

4.2Special tool

480143

Differential oil

seal installation

tool

4.3Removal

1. Discharge transmission oil.

2. Remove the half shaft. Refer to the drive

shaft.

3. Remove the differential oil seal.

1) Use large flat screwdriver to pry out

the oil seal.

▲Note: Be careful not to put the flat

screwdriver too deep to protect the shell.

4.4Installation

1. Install the differential oil seal

1) Put the new oil seal to the sheel.

2) Put the special tool 16G0038 on the

oil seal and hammer it into the shell with

rubber hammer to ensure the installation in

place.

▲Note: The depth of the oil seal should

- 62 -

be 3mm±0.3mm from the shell edge.

2. Install the half shaft.

3. Fill the transmission oil.

五、Input shaft oil seal

5.1 Fault instruction

Input shaft oil seal damage or oil leak.

5.2Special tool

No.

Tool No.

Tool name

Tool illustration

16G0041

Assembly tool of

input shaft oil seal

16G0040

Input shaft oil seal

locating bushing

5.3Removal

1. Discharge the transmission oil.

2. Remove the transmission assembly. Refer

to the transmission assembly.

3. Remove the input shaft oil seal.

1) Remove the oil seal from the shell

with large flat screwdriver.

▲Note: Pry along the middle of the oil

seal to the outside, must be very careful,

or it will damage the transmission input

shaft.

5.4Installation

- 63 -

1. Install the input shaft oil seal.

1) Place the oil seal locating bushing

16G0040 on the input shaft.

2) Place the new oil seal on the

locating bushing.

3) Put the special tool 16G0041 on the

input shaft, hit the special tool with a

rubber hammer and install it in place.

2. Install the transmission.

3. Fill the transmission oil.

六、Gear select shaft oil sealing

6.1Fault code instruction

Gear select shaft oil sealing leaks oil.

6.2Special tool

No.

Tool No.

Tool name

Tool illustration

- 64 -

16G0043

Assembly tool of gear

shift shaft oil seal

16G0042

Disassembly tool of

gear shift shaft oil

seal

6.3Removal

1. Discharge the transmission oil.

2. Remove the transmission.

3. Remove the gear select shaft lever.

4. Remove the gear select shaft oil seal.

1) Put the special tool 16G0042 on the

shift shaft, and screw the special tool into the oil seal with wrench.

▲Note: Press the top of the wrench so that special tool screw into the oil seal.

2) Turn the bolt on the special tool

with the tool to pull the gear select

shaft oil seal out of the shell.

3) Rotate the small bolt to pull out

- 65 -

the oil seal.

- 66 -

4) Take out the oil seal.

6.4Installation

1. Install the gear select shaft oil seal.

1) Apply vaseline or lubricating grease to the tip of the oil seal punch 16G0043.

2) Install the new oil seal lightly on the punch 16G0043.

3) Put the special punch 16G0043 with oil seal on the gear shift shaft and tap

with a hammer until it is installed in

place.

4) Take out the punch 16G0043.

▲Note: Pull the punch out, or it may

lead to the oil seal and the punch be

pulled out together.

2. Install the gear select lever, and

tighten the nut with new washer and nut,

torque 14.5N·m±5N·m.

- 67 -

3. Install the transmission.

4. Fill the transmission oil.

- 68 -

7. Drive Bevel Gear End Cover

7.1 Fault code instruction

Drive bevel gear end cover leaks oil

7.2 Removal

1. Dischrage about 1L oil from the transmission (see replacing the oil filter).

2. The transmission does not need to be removed from the vehicle. It is easier to

replace the engine and transmission if they are placed together.

3. Remove the bolt and remove the clasp. Remove the cover with a larger flat

screwdriver, and place a cloth pad under it to prevent damage to the transmission

housing.

4. Remove the end cover with a larger

flat screwdriver and put a piece of

cloth under it to prevent damage to the

ring transmission housing.

5. Remove the larger type O-ring and

throw it away with the end cover.

7.3Installation

1. Install a new O-ring.

2. Replace a new end cover and tighten the bolt and buckle.

Torque: 9.5N·m±2.5N·m.

3. Fill 1L oil into the transmission.

8. Oil Pump

- 69 -

8.1 Fault instruction

If the transmission pressure is found to be too low or the driving process

vibration or abnormal phenomenon, there are two important components can cause this

problem: oil pump and hydraulic control block. Use the fault code to determine which

one needs to be replaced. In most cases it is not completely clear which one is the

problem, just replace one by one to see whether the problem is solved.

- 70 -

8.2Special tool

No.

Tool No.

Tool name

Tool illustration

480141

Oil pump removal tool

8.3Removal

1. Remove the end cover according to the sequence of replacing the drive bevel gear

end cover.

2. Remove the 6 bolts from the oil pump and

put the special tool on the oil pump shaft.

3. Pull out the oil pump with special T-tool

(480141).

4. When replacing new oil pump, it must be

confirmed that two new 0-rings are put on the

new oil pump. Be careful not to pull out the

conical return spring, and make sure the

larger end is facing to the oil pump.

- 71 -

8.4Installation

1. Install oil pump

1) When installing the new oil pump, make sure to put two new O-rings on the new

oil pump.

▲Note: Do not take out the conical return spring, and make sure the larger end

is facing to the oil pump.

2) Reinstall the 6 bolts, and

tighten them with the torque of

I0N

m+/-IN

3) Put the end cover back

according to the steps, do not

replace the O-ring and end cover.

▲Note: Do not replace the O-ring

and end cover.

3. Install the transmission

4. Fill the transmission oil.

9. Drive Bevel Gear Shaft Ball Bearing

9.1Fault instruction

Replace the drive bevel gear shaft ball bearing if it wear out. A worn drive bevel

gear shaft ball bearing will have large noise, and the noise varies with engine speed.

So if you change from D gear to manual mode at constant speed and the noise suddenly

increases, it is very likely that the bearing is damaged. Because after changing to

manual gear, the speed remains the same but the engine speed increases.

9.2Special tool

- 72 -

No.

Tool No.

Tool name

Tool illustration

16G0049

Drive bevel gear

shaft bearing plug

16G0050

Drive bevel gear

shaft bearing punch

16G0048

Drive bevel gear

shaft bearing

removal

tool

16G0047

Drive bevel gear

shaft big nut removal

and installation

sleeve

9.3Removal

1. Discharge the transmission oil.

2. Remove the transmission.

3. Remove the drive bevel gear shaft end cover. Refer to the drive bevel gear shaft

end cover.

4. Remove the oil pump. Refer to the oil pump.

- 73 -

5. Remove the drive bevel gear shaft ball bearing.

1) Take out the conical return spring.

2) Mark the shaft and nut.

3) Remove the nut with the special sleeve.

- 74 -

4) Remove the dust cover from the bearing with flat screwdriver.

5) Put the protection plug on the shaft.

6) Assemble bearing remover (16G0048),

and hook the outer ring of the

bearing with its foot.

- 75 -

- 76 -

7) Tighten the middle bolt to pull out the bearing.

9.4Installation

1. Install the drive bevel gear shaft ball bearing

1) Cean the sealant of the drive

bevel gear shaft and oil pump drive

shaft lock belt, and oil pump chamber.

2) Put the new bearing in place

and install it with a special punch

(16G0050).

3) Knock the punch into place with

a rubber hammer.

4) Tighten the nut so that the

mark on the shaft coincides with the

mark on the nut. Standard coincidence

degree ±5°

5) Install the conical return spring.

- 77 -

2. Install the drive bevel gear shaft end cover.

▲Note: Do not replace the O-ring and end cover.

3. Install the transmission.

4. Fill the transmission oil.

▲Note: The larger end of the diameter is toward the oil pump.

- 78 -

10. Driven Bevel Gear Shaft End Cover

10.1 Fault code instruction

Driven bevel gear shaft end cover damaged or leaks oil

10.2 Removal

1. Remove the driven bevel gear shaft end cover.

1). Remove the 4 countersunk screws.

2) Take down the two O-rings and

the one sealing ring on the end cover.

10.3Installation

1. Install the driven bevel gear shaft end cover.

1) Install the two O-rings and the one sealing ring on the end cover.

2) Clear the thread glue in the 4 screw holes on the shell.

3). Tighten the 4 screws.

Tightening torque 9.5±0.95N·m.

- 79 -

十一、Oil pan

11.1Fault instruction

Oil pan damaged or leaks oil

11.2Removal

1. Discharge the transmission oil.

2）Remove the oil pan.

1) Install the 13 bolts on the oil

pan.

11.3Installation

1. Install the oil pan.

1) Install the new oil pan and gasket.

2) Install the oil pan bolts according to the sequence as shown in the picture.

▲Note: Use new bolt gasket.

Tightening torque 9.5±1N·m.

2. Fill the transmission oil.

- 80 -

12. Oil Filter

12.1 Fault instruction

Oil filters should be replaced at least every 60,000km or 2 years (whichever comes

first), and the period can be reduced according to the standard of each manufacturer.

12.2Removal

1. Discharge the transmission oil.

2. Remove the oil pan. Refer to the oil pan.

3. Remove the oil filter.

1) Take out the oil filter

slightly and abandon it.

12.3Installation

1. Install the oil pan.

1) Install oil filter with a new O-ring, and lubricate it with ESSO EZL799 (A).

2) Gently press the oil filter in

place.

▲Note: The hole in the middle of

the oil filter is matched with the

middle bolt on the hydraulic control

block.

3) Clean the magnet and the oil

pan.

2）Install oil pan.

3. Fill the transmission oil.

- 81 -

- 82 -

13. Driving Mode Sensor

13.1 Fault code instruction

The fault code should display the fault of the driving mode sensor, replace the

driving mode sensor.

13.2Removal

1. Discharge the transmission oil.

2. Remove the oil pan. Refer to the oil pan.

3. Remove the oil filter. Refer to the oil filter.

4. Remove the driving mode sensor.

1) Remove the 2 screws on the

driving mode sensor.

2) Carefully take down the driving mode sensor from the hydraulic control block.

▲Note: Behind the sensor is a

small pin with hydraulic pressure.

The metal slider on the control

block is fixed together, pressing

the sensor down to release the pin

from the slider.

- 83 -

3) Use flat screwdriver to open the lock on the sensor joint, and press the white

lock to separate the joint.

13.3Installation

1. Install the driving mode sensor.

1) Take a new sensor, connect the connector, and press the white lock button inside

to lock it.

2) Put the pin behind the sensor on the metal slider and install it in place.

3) Move the sensor to expose the bolt hole.

4) Tighten the 2 fixing screws.

Tightening torque 9.5±0.95N·m.

2. Install the oil filer.

3. Install the oil pan.

4. Fill the transmission oil.

- 84 -

14. Hydraulic Control Module

14.1 Fault instruction

If the transmission pressure is found to be too low or the driving process

vibration or abnormal phenomenon, there are two important components can cause this

problem: oil pump and hydraulic control block. Use the fault code to determine which

one needs to be replaced. In most cases it is not completely clear which one is the

problem, just replace one by one to see whether the problem is solved.

No.

Tool No.

Tool name

Tool illustration

16G0046

Locating pin of

hydraulic control

module

14.2Removal

1. Discharge the transmission oil.

2. Remove the oil pan. Refer to the oil pan.

3. Remove the oil filter. Refer to the oil filter.

4. Remove the driving mode sensor. Refer to the driving mode sensor.

5. Remove the hydraulic control

module

1) Remove the bolts according to

the sequence from 20 to 1 as shown in

the picture.

- 85 -

2) Take out the hydraulic control module, and separate the

4 connectors.

▲Note: Use flat screwdriver can

easily take down the connector.

14.3Installation

1. Install the hydraulic control

module

1) Install the hydraulic control

module in place and put a small pin

behind the hydraulic control mpdule

in the correct position.

- 86 -

2) Ensure that the metal slide and the pin on the shift cam

are in place.

3) Install the middle bolt and

tighten it by hand.

4) Install the special tool

16G0046 in the bolt hole in the upper

left

corner.

5) Press the wire of the drive

bevel gear speed sensor on the upper

left corner of the hydraulic control

module.

6)Install all the bolts of the

hydraulic control module and tighten

them in the order from 1 to 20.

- 87 -

Tightening torque 11N·m.

2. Install the driving mode sensor.

3. Install the oil filter.

4. Install the oil pan.

5. Fill the transmission oil.

- 88 -

15. Driven Bevel Gear Speed Sensor and Bracket

15.1Fault instruction

Judge the fault of this component by the fault code.

15.2 Removal

1. Discharge the transmission oil.

2. Remove the oil pan. Refer to the oil pan.

3. Remove the oil filter. Refer to the oil filter.

4. Remove the driving mode sensor. Refer to the driving mode sensor

5. Remove the hydraulic control module. Refer to the hydraulic control module.

6. Remove the driven bevel gear speed sensor and bracket.

1). Loosen the sensor bracket bolts.

▲Note: This bolt is disposable.

2) Take out the bracket from the gear shifting shaft.

- 89 -

3) Remove the sensor and connector with needle-nosed pliers.

4) Loosen the bolts on the bracket and remove the speed sensor.

15.3Installation

1. Install the driven bevel gear speed sensor and bracket.

1) Install the new sensor and

bracket, and tighten the fixing bolts.

2) Connect the wire, and clamp the

bracket to the gear shifting shaft, and

install it in place.

3) Use new bolt to fix the bracket.

Tightening torque 9.5±0.95N·m.

2. Install the hydraulic control

module

3. Install the driving mode sensor.

4. Install the oil filter.

5. Install the oil pan.

6. Fill the transmission oil.

- 90 -

16. Drive Bevel Gear Speed Sensor

16.1Fault instruction

Judge the fault of this component by the fault code.

16.2 Removal

1. Discharge the transmission oil.

2. Remove the drive bevel gear end cover. Refer to the drive bevel gear end cover.

3. Remove the drive bevel gear speed sensor.

1) Remove the fixing bolt, and take out the sensor.

2) Separate the wire and take down the sensor.

16.3Installation

1. Intall the drive bevel gear speed sensor.

1) Install the new sensor, and tighten the bolt.

Tightening torque 8.5±2N·m.

2) Connect the wire to the sensor.

2. Install the drive bevel gear end cover

3. Fill the transmission oil.

17. Main Connector and Inner Wire Harness

17.1Fault instruction

Judge the fault of this component by the fault code.

17.2Removal

1. Discharge the transmission oil.

2. Remove the oil pan. Refer to the oil pan.

3. Remove the oil filter. Refer to the oil filter.

4. Remove the driving mode sensor. Refer to the driving mode sensor

5. Remove the hydraulic control module. Refer to the hydraulic control module.

6. Remove the main connector and inner wire harness.

1). Separate the two speed sensor connector.

- 91 -

2). Take the wire connecting vehicle and main connector.

3) Take down the buckles on the main connector, and press

the connector into the transmission.

▲Note: The driving mode sensor connector

is clamped on the housing, take down

the connector first.

4) Take the whole main connector

from the transmission.

- 92 -

17.3Installation

1. Install the main connector and inner wire harness

1) Take a new main connector, and put it into the transmission.

▲Note: The main connector is attached to the housing

by a spline, and it is easier to

press upward with a 45 degree nose

clamp.

2) Install the buckle.

- 93 -

3) Press the driving mode sensor

connector onto the housing.

4) Connect the speed sensor and

connector.

2. Install the hydraulic control module

3. Install the driving mode sensor.

4. Install the oil filter.

5. Install the oil pan.

6. Fill the transmission oil.

18. Breather Pipe

18.1 Special tool

No.

Tool No.

Tool name

Tool illustration

16G0044

Installation

tool-breather pipe

18.2Removal

1. Remove the engine intake pipe.

2. Remove the battery and bracket.

3. Remove the breather pipe.

1) Remove the clips from the top of

the breather pipe and the transmission.

2) Clamp is placed at the connection

between the shell and the breather pipe,

and take down the breather pipe.

- 94 -

18.3Installation

1. Install the breather pipe.

1) Place the new breather pipe in the special tool (16G0044) and apply a little

vaseline to the aluminum tube at the bottom of the breather pipe.

2) Place the breather pipe in the tool box on the shell and keep it parallel.

Hit the tool vertically with the rubber hammer to make the breather pipe enter into

the shell.

3) Put plastic clips 482253 on the

breather pipe.

4) Insert the pin of the plastic

clasp into the hole of the metal clasp

481456.

5) Install the metal clasp firmly on

the reinforcing rib of the transmission

housing.

- 95 -

6) Install the breather pipe cap 483117 on the pipe, and pay attention to the

installation in place.

2. Install the battery and bracket.

3. Install engine intake pipe.

- 96 -

Chapter IV Electrical Schematic Diagram

一、TCU Connector Diagram

1.1TCU Connector

- 97 -

1.2TCU and Transmission Connector

- 98 -

1.3Pins of Transmission Main Connector

Signal

Description

DMS

Driving mode sensor or gear/restrain

sensor

EDS_1

Drive bevel gear pressure regulator

(solenoid valve)

EDS_2

Driven bevel gear pressure regulator

(solenoid valve)

EDS_3

Clutch pressure regulator (solenoid

valve)

P_S2

Driven bevel gear pressure sensor

- 99 -

N_ab

Driven bevel gear speed sensor

N_S1orN_Prim

Drive bevel gear speed sensor

- 100 -

1.4Circuit Diagram of TCU Pins

- 101 -

TCU pin distribution

VT2-signal

Always close power supplyy Kl.30

1; 2

Ignition power supply Kl.15

Grounding Kl.31

3; 4

VHSD1 (Actuator power supply)

Speed and position sensor power supply

30; 77; 78

Pressure sensor power supply (5V)

32; 74

GND Driving mode sensor

GND sensor grounding

41; 64; 86

Transmission oil temperature

N_Prim (drive bevel gear speed)

N_ab (driven bevel gear speed)

N_MOT (Engine speed signal)

DMS_A (Driving mode sensor signal)

DMS_B (Driving mode sensor signal)

DMS_C (Driving mode sensor signal)

DMS_D (Driving mode sensor signal)

Brake signal

Manual mode signal

Gear inceasing signal

Gear deceresing signal

P_S2 (Driven bevel gear pressure)

Snow mode

Gear shift lock

K-line

CAN-H

CAN-L

Start lock

EDS1 (Driven bevel gear pressure

EDS2 (Driven bevel gear pressure

EDS3 (Driven bevel gear pressure

Reversing lamp relay

- 102 -

2. Electronic Component Inspection List

2.1Driving mode sensor

Check the resistance between different pins, and judge if the driving mode

sensor is good.

DMS_GND = pin-6

DMS_A = pin-13

DMS_B = pin-14

DMS_C = pin-15

DMS_D = pin-16

DMS_Supply = pin-9

2.2 Corresponding Resistance Value of Each Pin

DMS_Supply

DMS_A

DMS_B

DMS_C

DMS_D

DMS_Supply

17.2MΩ

DMS_A

17.2MΩ

9KΩ

DMS_B

17.2MΩ

9KΩ

DMS_C

17.2MΩ

9KΩ

DMS_D

17.2MΩ

9KΩ

DMS_GND

4.5KΩ

2.3Oil Temperature Sensor

Measure the inner resistance of oil temperature sensor.

Measure the resistance between Pin-5 and Pin-7.

When the temperature is 20℃ to 40℃, the resistance should be 942Ω to 1121Ω.

2.4Speed sensor

This is a complex two-wire component, and there is no very simple way to measure

whether it works in the following range:

- 103 -

· The resistance measured between Pin-9 and Pin-11 is around 24.3MΩ.

· The resistance measured between Pin-9 and Pin-12 is around 24.3MΩ.

▲Note: This method can not be measured to ensure that the speed sensor is well.

2.5Oil Pressure Sensor

The resistance measured between Pin-7 and Pin-10 is about 44.3KΩ.

2.6Clutch Pressure Regulator

The resistance measured between Pin-7 and Pin-10 is about 5.2Ω.

2.7Drive Bevel Gear Pressure Regulator

The resistance measured between Pin-1 and Pin-3 is about 5.2Ω.

2.8Driven Bevel Gear Pressure Regulator

The resistance measured between Pin- and Pin-2 is about 5.2Ω.

TCU can’t be detected.

▲Note: Varying the precision of the measuring instrument will result in different

measured resistance ranges.

- 104 -

3. Circuit Diagram of Transmission System

TCU controller and gear shifting controller power supply, grounding, data wire.

- 105 -

Transmission, gear shifting control module

- 106 -

4. Adaptive Update

4.1 System description

Adaptive learning is required in the following situations:

· Refresh the TCU software

· Replace the transmission

· Replace the TCU

The clutch needs to be adaptively renewed (self-learning) to compensate for

tolerances in the production process in order to achieve this function by shifting

gears at idle. Before the self-learning is completed, the TCU fault indicator flashes

every 2 seconds. Once the first self-learning is complete, it is automatic throughout

the life cycle.

4.2Demand Condition

This condition needs to be completed before self-learning:

· Engine torque and speed are required to be stable at idle. Self-learning of

the engine is also required to be completed in advance. For more information about

self-learning of the engine, please read the document provided by the ECU supplier.

· Engine speed requirement: ECU target value ±200rpm.

· Engine torque demand: ECU target value ±12N·m

· Transmission temperature should be between 30 ℃ to 80 ℃.

· The A/C is turned off.

· An unadaptive TCU will keep making request to the engine for idling up to

1150rpm.

If TCU has done self-learning before, this includes: 1. Refresh the software;

2. Replace transmission TCU, first need to delete the self-learning value. This can

be done with MLT software, or with a factory tester.

4.3 Program

When we have fulfilled all the conditions, we will perform the following

operations:

- 107 -

· Vehicle speed =0kph.

· Not step accelerator pedal.

· Step on the brake pedal during the whole process.

· Shift gear to "D" gear.

- 108 -

The clutch adaptive program will start automatically. In the learning process,

if there is interference adaptive condition, the fault code FC55(P1774) will be

activated, and then the fault lamp will be on all the time as a warning. As long as

- 109 -

the clutch self-learning is not completed, the fault code FC51(P080A) will be

activated. At the same time, the fault lamp will keep flashing.

- 110 -

When everything is running smoothly, the adaptive time at the end of the gear

is about 40s. If the adaption is not completed within 120s, the adaption will fail.

When the clutch adapts in this gear, the engine speed will rise to 1500rpm in

a short time, at which time we can proceed to the next step.

- 111 -

Note: for the whole vehicle in the aftermarket, no high-speed test of the roller is

required.

Be sure to check again if all the self-learning prerequisites have been completed.

Please follow the steps below:

· Vehicle speed = 0 kph

· Release the accelerator pedal

· Keep the brake pedal during the whole process

· Shift gear to "R" gear

The off-line clutch adapts to start automatically. In the learning process, if

there is interference adaptive condition, the fault code FC55(P1774) will be

activated, and then the fault light will be on all the time as a warning. As long

as the clutch self-learning is not completed, the fault code FC51(P080A) will be

activated. At the same time, the fault lamp will keep flashing. When the adaption

is running smoothly, the time to complete the adaption is about 40s. If the adaption

is not completed within 120s, the adaption will fail. If the clutch adapts

successfully, the engine speed will rise to 1500rpm in a short time and then suddenly

drop to idle speed (850rpm), at which time the gearbox fault indicator will

automatically go out.

Note: first in D gear and then in R gear self-learning, the order is not mandatory.

Also, first in R gear and then into D gear, such an adaptive order, is no problem.

5. Common Problems

Clutch

self-learning

Fault code

Type

Engine torque not steady

A/C already in open state

Pressure too high

- 112 -

Engine speed too low

Engine speed too high

Invalid times too frequent

problem

Possible reasons

solution

Over 120s

self-learning

Failure

In the process of learning, the

transmission oil temperature is

below 30 ℃

Start the engine, wait for

after the oil temperature

rise above 30 ℃, self

In the process of learning, the

transmission oil temperature is

higher than 80 ℃

Close the engine, wait for

after the oil temperature

down to under 80 ℃, self

In the learning process, engine

temperature is below 60 ℃

Start the engine, wait for

after the oil temperature

rises above 60 ℃, self

The brake pedal was loose during the

learning process

Re-self-learning to make

sure the brake pedal be

pressed during the whole

FC55: the offline

adaptive fault

code is 1

Engine torque not steady

Steadily increase engine

torque to ensure

successful self-learning

FC55: clutch

self-learning

fault code is 2

The A/C is on

Turn off the A/C and start

self-learning again

FC55; The offline

adaptive fault

code is 4

Clutch pressure increased, but

engine torque did not

Put the gear in D or R,

check whether the

transmission torque is

normal, check to make sure

the engine torque signal is

FC55; The offline

adaptive fault

code is 8

Engine speed too low

Steady increase engine

speed, re-self-learning

- 113 -

FC55; The offline

adaptive fault

code is 16

Engine speed too high

Steady increase engine

speed, re-self-learning

FC55; The offline

adaptive fault

code is 32

Abnormal torque, whether the switch

is started, etc

Confirm that all auxiliary

functions are not used, and

re-self-learning after

Chapter V Troubleshooting

1. Diagnostic table

No.

Fault symptoms

Fault analysis

Solutions

Remark

Transmission oil

pan gasket leakage

Oil pan bolt damage

Replace

Oil pan gasket

Replace

Oil drainage port

Replace

Oil pan assembly

Replace

Transmission oil

drain screw plug

leakge

Screw plug fixing is not well

Fasten

Oil drain screw plug damage

Replace

Oil pan assembly damage

Replace

Drive bevel gear

end cover leakage

Sealing cover fixing is not

well

Fasten

O-ring damaged

Replace

Drive bevel gear end cover

damaged

Replace

Driven bevel gear

end cover leakage

Sealing cover fixing is not

well

Fasten

Sealing cover O-ring damaged

Replace

- 114 -

No.

Fault symptoms

Fault analysis

Solutions

Remark

Driven bevel gear end cover

assembly damaged

Replace

Gear selecting

lever leakage

Gear selecting lever sealing

gasket damaged

Replace

Input shaft leakge

Input shaft sealing gasket

damaged

Replace

Differential oil

seal leakage

Oil seal damage

Replace

oil cooler pipe

connector leakage

Pipe fixing is not good

Tighten

oil cooler pipe connector

sealing ring damaged

Replace

Piping damaged

Replace

In the process of

driving in D gear,

the vehicle will

be charged, or the

vehicle will be

charged when

accelerating

rapidly

Self-learning is not fully

completed

relearning

Fill wrong oil or

transmision

water inflow

Replace the

transmission

oil again

Drive bevel gear speed

sensor damaged

Replace

Hydraulic control module

malfunction

Self-learning

again

Driven bevel gear speed

sensor damaged

Replace

Shift to D gear,

release the brake

pedal, the vehicle

is completely

Check the fault code when in

cold engine state

Diagnosis by

fault code

Check self-learning

Re-self-learning

again

- 115 -

No.

Fault symptoms

Fault analysis

Solutions

Remark

There is a problem with the

brake signal. When the brake

pedal is not stepped on, the

brake signal is actually in

Check the brake

signal and

Wiring harness

If the inspections above

have no problems, there may

be the valve body problem

Replace the valve

body, and

self-learning

- 116 -

2. Noise Problem Check and Maintenance

• Driven bevel gear noise

When the speed is 60kph to 90kph, there is obvious noise when accelerating slowly.

Release the accelerator pedal, the sound becomes smaller.

The sound is similar to a whistle. It increases with the speed of the vehicle

and is a normal sound. It is the sound produced by the meshing of the driven bevel

gear and countershaft gear.

• R Reverse gear noise

Shift to the R gear, keep the vehicle still, a small whistle can be heard.

This is the normal sound produced when the planetary gear inside the transmission

works.

• Low speed noise

When the vehicle speed is 40km/h, release the accelerator pedal, and when the

vehicle speed drops slowly, a whistle can be heard. This whistle is less audible and

less audible than the sound described by the driven bevel gear, which is the normal

sound between the pinion and the differential.

- 117 -

No.

Fault symptoms

Fault analysis

Solutions

Remar

the drive bevel

gear ball bearing

noise, when the

vehicle driving in

D gear, it sends

noise, the noise

is a buzzing

sound, sound size

and frequency

increases with the

engine speed, but

not with the

vehicle speed.

When driving at a constant speed

(constant throttle valve opening,

the vehicle speed is about 60km/h)

in D gear, and then in S mode, the

engine speed will increase by

about 500rpm in 1 to 2 seconds. In

this process, the vehicle speed is

basically unchanged. If the sound

rises with the engine speed, it is

the sound caused by the damage of

the drive bevel gear ball bearing

Replace the

drive bevel gear

ball bearing

In manual mode 4th gear, constant

a certain throttle valve opening,

keep the stable vehicle speed of

about 60km/h, then shift to manual

3rd gear, the engine speed will

rise about 800rpm at this moment,

and then change to 4th gear from

3rd gear, the engine speed will

drop about 800rpm, the entire

process speed basic remains the

same, if the sound rises with the

engine speed up, the sound is from

drive bevel gear ball bearing

damage

Replace the

drive bevel gear

ball bearing

- 118 -

The bearing noise

inside the

transmission

makes noise during

the moving process

of the vehicle in D

gear. The noise is

a buzzing sound.

According to the drive bevel gear

ball bearing noise detection

method, if the noise does not rise

with the engine speed, but only

rises with the vehicle speed, it

may be the wheel half-shaft

bearing noise, if the half-shaft

bearing fault is eliminated, it is

the transmission internal bearing

noise

It is very

difficult to

judge the noise

problem

correctly, so

before you

decide to

replace the

transmission

parts or the

entire

transmission,

you need to make

sure that the

noise is coming

from the

transmission.

Easily

replaceable

parts of the

vehicle can be

replaced to

determine the

noise source

See

flow

chart

inter

nal

beari

noise

trans

missi

Gearbox water

noise, shift to D

Drain oil, remove oil pan and

drive bevel gear end cover. If

Replace with a

new oil filter

- 119 -

gear or R gear,

slowly release the

brake pedal, as

long as the wheels

move there will be

gurgling sound, if

step the

accelerator

pedal, the vehicle

speed from 10km/h

to 40km/h will

have a squeak

----, continuous

sound; more than

40km/h, the sound

disappear.

In the beginning

of the water inlet

phase, may only

hear the

"gurgling" sound,

when

accelerating, you

can not hear the

"squeak ----"

continuous sound.

Some vehicle may

start with a jump,

depending on the

there is a white substance inside

the drive bevel gear end cover and

the same white substance in the

oil pan, it is sufficient to prove

that there is water in the

transmission or that the

transmission is mixed with other

oil or liquid

and refill the

transmission

oil

Drive at various speeds and

accelerating/decerating speed

for about 5 minutes. "Gurgling"

sound should disappear, "squeak

----" sound should be reduced

Release the

transmission

oil and refill

it with new

transmission

oil

"Squeak ----" sound can be done by

stall experiment to increase the

clutch temperature to solve.

Shift to D gear, step the brake

pedal and accelerator pedal

If during the process, it occurs

fault code P2787 clutch

temperature is too high to

disconnect the clutch, this is

only the transmission's

self-protection function, rather

than a fault. When the failure

lamp is automatically off, the

stall test can continue until the

Replace the

transmission

- 120 -

water level.

noise disappears

Too much water or mixed with too

much other oil, the noise and

channeling phenomenon can not be

solved

Noise in N or P

gear (noise

increases with the

engine speed (the

noise increases

when accelerating

in N gear))

Determine whether the engine part

sound or the transmission part

sound. If it is the transmission

part sound, check whether the oil

pump has abnormal noise

Check the oil

pump

If it is the transmission noise,

but not the sound of the oil pump,

it may be the sound of the input

shaft bearing or planetary gear

set

Replace the

transmission

Noise in N gear

(noise doesn’t

increase with the

engine speed)

This noise is from other parts of

the vehicle and check the vehicle

parts

It is very

difficult to

judge the noise

problem

correctly, so

before you

decide to

replace the

transmission

parts or the

entire

transmission,

Refer

“Noi

se in

N or P

gear

”

check

flow

chart

- 121 -

you need to make

sure that the

noise is coming

from the

transmission.

Easily

replaceable

parts of the

vehicle can be

replaced to

determine the

noise source

During driving,

the vehicle

rushes; when in D

gear driving, the

vehicle rushes; or

when accelerating

rapidly, the

vehicle rushes

Self-learning is not fully

Complete the

Fill wrong oil or there is water

in the transmission, leading the

Replace the new

transmission

Drive bevel gear speed sensor

failure

Replace the

drive bevel gear

Hydraulic control module (valve)

failure

Replace the

hydraulic

Driven bevel gear speed sensor

failure

Check

self-learning

The vehicle can

not start (without

accelerating),

shift to D gear,

after releasing

Check there is failure when the

vehicle is cold

Check

self-learning

There is failure in the brake

signal. When there is no brake,

the brake signal is actually in

the braking state, which will lead

Check the brake

signal and

wiring harness

- 122 -

If none of the above is found to

be a problem, it may be the valve

body problem

Replace valve

body. And

self-learning

- 123 -

Flow chart of internal bearing noise in transmission

- 124 -

Flow chart of noise detection in N or P gear

- 125 -

3. Fault code and measures

3.1 General instruction

Once there is fault code in the transmission control unit, the failure lamp on

the instrument panel will light up.

Whenever you read the DTC and find the fault code with the diagnosis deveice,

first check that if the fault code is historical fault and did not appear in the last

driving cycle. If so, delete the fault code and check that if the fault code will

appear again. If it is not the historical fault but the current fault, follow the

fault code below to solve it step by step.

Check for the latest software every time. If not, refresh to the latest software,

and then check if the fault code still exists.

General instructions: whenever there is a fault code or transmission problems,

first check the most basic three:

a. Check whether it is special oil for CVT.

b. Check oil level.

c. Do self-study again.

There is no need to complete all of the following procedures, and once the problem

is solved, there is no need to proceed any further.

No.

DTC code

TCU solution

Maintenance instruction

P0710 Oil

temperature

sensor failure

Fault indicator

lamp is on, system

self-set

transmission oil

temperature

Use the tester to measure the

transmission oil temperature. If the

signal data is suitable, clear the

fault code and check whether it will

appear again.

Check the circuit (open circuit, short

circuit, grounding).

Measuring the resistance between the

- 126 -

No.

DTC code

TCU solution

Maintenance instruction

two pins of transmission main

connector (when at 20 ℃, the

resistance should be 980-1000Ω) to

determine whether the oil temperature

sensor is damaged, if there is damage,

jump to the next step and change main

connector directly

Replace it with a good TCU

Replace the transmission

P2765 Drive

bevel gear

speed sensor

failure

All three pressure

regulators are

power off, fault

indicator lamp is on

Use the tester to measure the

transmission oil temperature. If the

signal data is suitable, clear the

fault code and check whether it will

appear again

Check the circuit (open circuit, short

circuit, grounding).

Replace it with a good TCU

Replace the speed sensor

P0720 Driven

bevel gear

speed sensor

failure

Fault indicator

lamp is on, system

self-set driven

bevel gear speed

Use the tester to measure the

transmission oil temperature. If the

signal data is suitable, clear the

fault code and check whether it will

appear again.

- 127 -

No.

DTC code

TCU solution

Maintenance instruction

Check the circuit (open circuit, short

circuit, grounding).

Replace it with a good TCU

Replace the speed sensor

P0840 Driven

bevel gear

pressure sensor

All three pressure

regulators are

power off, fault

indicator lamp is on

Use the tester to measure the actual

oil pressure of the driven bevel gear

and then compare it with the target

value. If the signal data is

appropriate, clear the fault code and

check whether it will appear again

Check the circuit according to the

value in the first step (grounding:

0bar (actual pressure), short

circuit: 60bar; open circuit: 60bar)

Replace it with a good TCU

Replace the valve body.

P0641 Pressure

sensor power

supply failure

All three pressure

regulators are

power off, fault

indicator lamp is on

Use the detector to measure whether

the input voltage is 5V, and if the

data is correct, clear the fault code

and detect whether it appears again

Measure the voltage between the power

supply wire and the grounding wire of

the pressure sensor, based on the

- 128 -

No.

DTC code

TCU solution

Maintenance instruction

results in the first step

Check the circuit (open circuit, short

circuit, grounding).

Replace it with a good TCU

Replace the hydraulic control module

(valve) failure

P0651 Driving

mode sensor and

speed sensor

power supply

failure

All three pressure

regulators are

power off, fault

indicator lamp is on

Use the detector to measure whether

the input voltage is 8.4V, and if the

data is correct, clear the fault code

and detect whether it appears again

Measure the voltage between the power

supply wire and the grounding wire of

the pressure sensor, based on the

results in the first step

Check the circuit (open circuit, short

circuit, grounding).

Replace it with a good TCU

P0659 Pressure

regulator short

circuit

All three pressure

regulators are

power off, fault

indicator lamp is on

Measure HS voltage and compare with

battery voltage

If the same, test the circuit (whether

there is a short circuit between the

battery anode and the VHS and gearbox

- 129 -

No.

DTC code

TCU solution

Maintenance instruction

interfaces) and repair the wiring

harness

If it is different and higher than

3.4V, replace the TCU

P0658 Pressure

regulator open

circuit or

grounding

All three pressure

regulators are

power off, fault

indicator lamp is on

Measure HS voltage and compare with

battery voltage

If the battery voltage is normal and

the high end voltage is less than 3.4V,

it indicates that there is circuit

wire grounding

If the battery voltage is normal and

the high end voltage is greater than

3.4V, it indicates that there is open

circuit

In both cases, check the pin wire

according to the specific situation,

and replace the TCU if the wire is

found intact after the inspection

If the battery voltage is abnormal,

check the battery

P0702 TCU inner

inspection

system failure

All three pressure

regulators are

power off, fault

Replace TCU

- 130 -

No.

DTC code

TCU solution

Maintenance instruction

indicator lamp is on

P0962 Drive

bevel gear

pressure

regulator

grounding

All three pressure

regulators are

power off, fault

indicator lamp is on

Measure the resistance of the drive

bevel gear pressure regulator - should

be at 5.05Ω±6%

Check the wiring (grounding) and

replace the transmission internal

wiring harness or engine wiring

harness according to the inspection

result

Replace the hydraulic control module

P0963 EDS1

Drive bevel

gear pressure

regulator short

circuit

All three pressure

regulators are

power off, fault

indicator lamp is on

Measure the resistance of the drive

bevel gear pressure regulator

Check the wiring (grounding) and

replace the transmission internal

wiring harness or engine wiring

harness according to the inspection

result

Replace the hydraulic control module

P0966 EDS2

Driven bevel

gear pressure

All three pressure

regulators are

power off, fault

Measure the resistance of the driven

bevel gear pressure regulator

Check the wiring (grounding) and

- 131 -

No.

DTC code

TCU solution

Maintenance instruction

regulator

grounding

indicator lamp is on

replace the transmission internal

wiring harness or engine wiring

harness according to the inspection

result

Replace the hydraulic control module

P0967 EDS2

Driven bevel

gear pressure

regulator short

circuit

All three pressure

regulators are

power off, fault

indicator lamp is on

Measure the resistance of the driven

bevel gear pressure regulator

Check the wiring (grounding) and

replace the transmission internal

wiring harness or engine wiring

harness according to the inspection

result

Replace the hydraulic control module

P0964 EDS2

Driven bevel

gear pressure

regulator open

circuit

All three pressure

regulators are

power off, fault

indicator lamp is on

Measure the resistance of the driven

bevel gear pressure regulator

Check the wiring (grounding) and

replace the transmission internal

wiring harness or engine wiring

harness according to the inspection

result

Replace the hydraulic control module

P0902 EDS3

Clutch pressure

All three pressure

regulators are

Measure the resistance of the clutch

pressure regulator

- 132 -

No.

DTC code

TCU solution

Maintenance instruction

regulator

grounding

power off, fault

indicator lamp is on

Check the wiring (grounding) and

replace the transmission internal

wiring harness or engine wiring

harness according to the inspection

result

Replace the hydraulic control module

P0903 EDS3

Clutch pressure

regulator

short circuit

All three pressure

regulators are

power off, fault

indicator lamp is on

Measure the resistance of the clutch

pressure regulator

Check the wiring (grounding) and

replace the transmission internal

wiring harness or engine wiring

harness according to the inspection

result

Replace the hydraulic control module

P1763 Start

lock

grounding or

open circuit

All three pressure

regulators are

power off, fault

indicator lamp is on

Check the wire, if the gear sensor has

failure, sometimes

it will have the fault code

Replace TCU

P1764 Start

lock

short circuit

All three pressure

regulators are

power off, fault

indicator lamp is on

Check the wire

Replace TCU

P1768 Reversing

All three pressure

Check the wire

- 133 -

No.

DTC code

TCU solution

Maintenance instruction

lamp

grounding

regulators are

power off, fault

indicator lamp is on

Replace TCU

P1769 Reversing

lamp

short circuit

or open circuit

All three pressure

regulators are

power off, fault

indicator lamp is on

Check the wire

Replace TCU

P0868 Pressure

pre-tension

regulating

failure

All three pressure

regulators are

power off, fault

indicator lamp is on

Check the oil level and the oil quality

Replace the oil pump

Replace the hydraulic control module

Replace the transmission

P0811 Clutch

(forward or

backward) slip

The failure

indicating lamp is

on, the clutch is

open

Do self-learning again, this fault

code may occur in the cold vehicle

state, so do self-learning in the cold

Check oil level and oil type

Replace the hydraulic control module

Replace the transmission

P0730

Transmission

ratio control

failure

All three pressure

regulators are

power off, fault

indicator lamp is on

Use the detector to check the signal

given by the speed sensor, and check

the input current and feedback current

of the drive bevel gear pressure

regulator

- 134 -

No.

DTC code

TCU solution

Maintenance instruction

According to the fault to take the

corresponding measures, such as the

speed sensor has a problem to check the

speed sensor, pressure has a problem

to check the pressure sensor

Check oil level and oil type

Replace the oil pump

Replace the hydraulic control module

Replace the transmission

Driven bevel

gear pressure

too low

All three pressure

regulators are

power off, fault

indicator lamp is on

Measure actual pressure to compare

with the target during dynamic driving

conditions (like manual shift, etc.)

Check oil level and oil type

Fully complete self-learning (fault

codes may occur in the condition of

self-learning uncompletion)

Check the causes of engine torque

reduction at the engine end: spark

plug, throttle valve, ternary

catalysis, etc. (the longer the engine

is used, the more likely this problem

will occur)

Replace the hydraulic control module

- 135 -

No.

DTC code

TCU solution

Maintenance instruction

Replace the oil pump

Replace the transmission

P1766 Driven

bevel gear

pressure too

high

Failure indicating

lamp is on

Measure actual pressure to compare

with the target during dynamic driving

conditions (like manual shift, etc.)

Check oil level and oil type

Replace the hydraulic control module

Replace the oil pump

Replace the transmission

P0701 Two

failure occur

at the same

time,require

pressure

regulator power

off

Failure indicating

lamp is on

Check other fault code

P0218

Transmission

oil temperature

is too high

Failure indicating

lamp is on

Check the oil cooler

Try to have this failure occur again

under normal driving condition. If

not, ask the customer under what

driving condition this failure

occurred

- 136 -

No.

DTC code

TCU solution

Maintenance instruction

In the driving condition of step 2, the

transmission oil temperature can be

measured, can use the detector to

detect whether the transmission oil

temperature ≥120 ℃ (if the time of

occuring the fault code is shorter

than 30 minutes, it is wrong) take

measures to prevent

transmission occurring transmission

temperature too high

P1767

Transmission

oil temperature

exceeds

standard range

All three pressure

regulators are

power off, fault

indicator lamp is on

Try to have this failure occur again

under normal driving condition. If

not, ask the customer under what

Check the oil cooler

Adjust or add the oil

Replace the valve body.

Replace the transmission

P0219 Power

system speed

exceeds the

range

All three pressure

regulators are

power off, fault

indicator lamp is on

Never occur in principle

Check if the engine speed is limited

within 6000rpm

P2766 Drive

bevel gear

speed is not

accord with the

All three pressure

regulators are

power off, fault

indicator lamp is on

Use the detector to detect if other

speed information (engine speed,

output shaft speed, vehicle speed) is

also lost; If so, fix these problems

- 137 -

No.

DTC code

TCU solution

Maintenance instruction

Use the detector to detect the drive

bevel gear speed signal. The

difference between the engine speed

and the clutch speed should be within

200rpm. All comparisons should be made

within the low to high speed range of

the engine (up to 6000rpm).

Check the circuit

Replace it with a good TCU

Check the position of the sensor, the

angle, and the speed sensor panel as

well. Check if there is object in front

of the sensor (steel strip debris,

Replace the drive bevel gear speed

sensor

Replace the transmission inner wiring

harness

Replace the engine wiring harness

Replace the transmission

P0721 Driven

bevel gear

speed is not

accord with the

real speed

Failure indicating

lamp is on

Increase the

clamping force to

the level of 0,

system self-set

Use the detector to detect if other

speed information (engine speed,

output shaft speed, vehicle speed) is

also lost; If so, fix these problems

first and then check if the failure

occurs again

- 138 -

No.

DTC code

TCU solution

Maintenance instruction

driven bevel gear

speed

Use the detector to detect the drive

bevel gear speed signal. The

difference between the engine speed

and the clutch speed should be within

200rpm. All comparisons should be made

within the low to high speed range of

the engine (up to 6000rpm).

Check the circuit

Replace it with a good TCU

Check the position of the sensor, the

angle, and the speed sensor panel as

well. Check if there is object in front

of the sensor (steel strip debris,

etc.) Note: this is a mechanical

fault, electrical fault has other

fault code

Replace the drive bevel gear speed

sensor

Replace the transmission inner wiring

harness

Replace the engine wiring harness

Replace the transmission

P0944 Clamping

The fault indicator

Check ECU fault code

- 139 -

No.

DTC code

TCU solution

Maintenance instruction

force

not enough

(VSM)

lamp is on. Increase

the clamping force

to the level of 0,

system self-set

driven bevel gear

Replace ECU

Check the oil level and oil quality

Fully complete self-learning (this

fault code may occur if the

self-learning is not fully completed)

Check the causes of engine torque

reduction at the engine end: spark

plug, throttle, ternary catalysis,

etc. (the longer the engine is used,

Replace the valve body.

Replace the oil pump

Replace the transmission

P0782 Winter

driving

The fault indicator

lamp is on, system

Check the circuit

Replace ECU

P0783 Cruise

control failure

The fault indicator

lamp is on, system

self-set cruise

Check the circuit

Replace ECU

Replace TCU

P0810 Offline

adaptive

updating not

The fault indicator

lamp twinkles

Do adaptive updating again

P1762 Current

value is fixed,

can’t change

All three pressure

regulators are

power off, fault

indicator lamp is on

Check and remove the fault code P0962,

P0963, P0960, P0966, P0967, P0964,

P0902, P0903, P0900, P1763, P1764, and

there may be no fault code

Replace it with a good TCU

- 140 -

No.

DTC code

TCU solution

Maintenance instruction

P0882 Battery

high end

voltage too low

All three pressure

regulators are

power off, fault

indicator lamp is on

When this happens, there is a record

of the battery's current voltage (so

you can tell if it is caused by battery

or high voltage); if not history

record, check next step directly

Use the detector to detect the high

voltage or battery voltage -

temperature has a great influence on

the value: please refer to the

software for details

Check the circuit from the battery to

the TCU (fuse, main relay)

Replace/check the battery

If it is high voltage problem: check

the circuit from the transmission to

the TCU

Replace TCU

P0883 Battery

high end

voltage is too

high

All three pressure

regulators are

power off, fault

indicator lamp is on

When this happens, there is a record

of the battery's current voltage (so

you can tell if it is caused by battery

or high voltage); if not history

record, check next step directly

Use the detector to detect the high

voltage or battery voltage -

- 141 -

No.

DTC code

TCU solution

Maintenance instruction

Check the circuit from the battery to

the TCU (fuse, main relay)

Check/Replace the battery or

If it is high voltage problem: check

the circuit from the transmission to

the TCU

Replace TCU

P2787 Clutch

temperature is

too high

The failure

indicating lamp is

on, the clutch is

open

Check how many times this failure

occurred, if only once or a few times,

look at the internal TCU data at that

time and ask the customer about the

special driving environment at that

time, such as the climbing driving,

then you can delete the fault code

Check the oil level and oil quality

Fully complete self-learning (if the

self-learning is not fully completed,

The fault code can only appear when the

stall test is done. Delete the fault

Replace TCU

It could be that the throttle valve is

P0727 From the

ECU to TCU

hardwire engine

speed signal

transmission is

Failure indicating

lamp is on

Check the engine test report to see if

there is engine failure, and if so,

Check TCU input signal - this is a

frequency signal (900rpm is 30Hz,

- 142 -

No.

DTC code

TCU solution

Maintenance instruction

Replace TCU

Replace the engine speed sensor

P1761 Pressure

regulator

circuit failure

All three pressure

regulators are

power off, fault

indicator lamp is on

Use the detector to detect the

pressure decreasing inside the

pressure regulator and compare it to

the specified current of each pressure

regulator

Use the detector to detect the current

of the pressure regulator and compare

it with the specified current. If one

of the current is found to be different

from the specified current, check the

wire of the pressure regulator (also

check the inside of the transmission).

Replace TCU

Replace the hydraulic control module

Replace the transmission inner wiring

harness

Replace the engine wiring harness

U0301 Vehicle

configuration

failure (such

as use other

vehicle ECU)

All three pressure

regulators are

power off, fault

indicator lamp is on

Check whether the combination of TCU

hardware and software is correct and

effective

If it is EMS or TCU new brush software:

the software on the new controller

- 143 -

No.

DTC code

TCU solution

Maintenance instruction

must be wrong (the incompatibility

between the transmission controller

and the engine controller)

P0706 Driving

mode sensor

single wire

failure

The fault

indicating lamp is

on, the system

self-set sensor

position

Use the detector to check that if there

is something wrong with the wire, what

is the problem, such as short circuit

in line B, etc. (this fault indicates

that one of the wires is faulty)

Check the wiring between the

transmission and TCU

Replace it with a good TCU

Replace the driving mode sensor

Replace the transmission inner wiring

harness

Replace the engine wiring harness

P0706 Driving

mode sensor

multi wire

failure

All three pressure

regulators are

power off, fault

indicator lamp is on

Use the detector to check that if there

is something wrong with the wire, what

is the problem, such as short circuit

in line B, etc. (this fault indicates

that one of the wires is faulty)

Check the wiring between the

transmission and TCU

Replace it with a good TCU

Replace the driving mode sensor

Replace the transmission inner wiring

harness

Replace the engine wiring harness

- 144 -

No.

DTC code

TCU solution

Maintenance instruction

P0571 Brake

signal failure

The fault

indicating lamp is

on, brake signal

combined

Use the dectector to check the state

of brake signal

Check the brake signal circuit

Check the brake switch

Replace TCU

P0955 Manual

increasing/dec

reasing gear

signal fault

The fault

indicating lamp is

on, no manual mode

Check the circuit between TCU and gear

shifting

Replace the gear shift mechanism

Replace it with a good TCU

U0001 CAN bus

failure

The fault

indicating lamp is

on, activate the

emergency mode, no

manual mode;

increase the

clamping force

level 1 (highest),

the system self-set

the lock and the

rotating condition,

activate the

internal driving

strategy, system

self-set the engine

speed, the system

self-set the engine

torque, the system

self-set engine

If this fault occurs in all other

controllers, it is wiring harness

problem (CAN-H and CAN-L speed short

circuit) : check the vehicle wiring

harness

If the fault is stored only in the TCU:

replace a good TCU

- 145 -

No.

DTC code

TCU solution

Maintenance instruction

coolant

temperature, brake

signal combines,

accelerator pedal

digital is fixed,

the system self-set

the left front wheel

speed, the system

self-set the right

front wheel speed,

the system self-set

the left rear wheel

speed, the system

self-set the right

rear wheel speed.

U0121 ABS CAN

communication

failure

The fault

indicating lamp is

on, activate the

emergency mode, no

manual mode;

increase the

clamping force

level 0, the system

self-set the lock

and the rotating

condition, the

system self-set the

Check the CAN communication connector

on the ABS controller (perhaps this

fault will be reported on other

controllers)

- 146 -

No.

DTC code

TCU solution

Maintenance instruction

left front wheel

speed, the system

self-set the right

front wheel speed,

the system self-set

the left rear wheel

speed, the system

self-set the right

rear wheel speed.

U0100 ECU CAN

communication

failure

The fault

indicating lamp is

on, activate the

emergency mode, no

manual mode;

increase the

clamping force

level 0, activate

the internal

driving strategy,

the system self-set

the engine torque,

the system self-set

engine coolant

temperature,

accelerator pedal

digital is fixed,

stop the data

Check the CAN communication connector

on the ABS controller (perhaps this

fault will be reported on other

controllers)

- 147 -

No.

DTC code

TCU solution

Maintenance instruction

transmitting on CAN

U1012 CAN bus

engine speed

signal failure

The system self-set

the engine speed

Check MCU controller (Engine speed

sensor and sensor grounding wire)

U1013 CAN bus

accelerator

pedal signal

failure

The failure

indicating lamp is

on, the accelerator

pedal value is fixed

Check EMS controller (Accelerator

pedal sensor and sensor power supply

wire)

U1014 CAN bus

engine torque

signal failure

The fault

indicating lamp is

on, activate the

emergency mode, no

manual mode;

activate the

internal driving

strategy, the

system self-set the

engine torque

Check EMS controller

Note: the three pressure regulators

are power off: when there is fault code

and the pressure regulator power off,

the clutch is opened, the vehicle can

no longer drive forward when shifting

gear, only when the engine is turned

off, the key position to zero, and then

re-ignition, then the vehicle can

continue to drive

Increase clamping force level 0:

driven bevel gear pressure is fixed,

this pressure is higher than normal,

- 148 -

No.

DTC code

TCU solution

Maintenance instruction

lower than the highest level

Increase clamping force level 1:

driven bevel gear pressure is fixed at

the highest level

EDS1: Drive bevel gear pressure

regulator

EDS2: Driven bevel gear pressure

regulator

EDS3: Clutch pressure regulator

Emergency mode: also called

claudication home mode, is activated

when:

CAN bus wire is loosened

CAN ECU communication failure

CAN engine torque signal fault

All signals related to engine and ABS

will be replaced (apply safe measure):

Throttle valve opening is fixed

Engine MAP instead of engine torque

The engine coolant temperature is

fixed

The wheel speed is replaced by the

speed of the transmission output shaft

Engine speed signal is transmitted by

a filer

Clutch opens or combines relatively

rigid, as if no calibration data is

inside

The maximum engine speed is limited to

3200rpm

The maximum speed is limited to 98km/h

The transmission will shift gear in

only one acceleration strategy

The CVT will only work under the most

basic conditions, providing enough

- 149 -

No.

DTC code

TCU solution

Maintenance instruction

drivability to get the vehicle to the

nearby maintenance station

After 2 seconds, manual gear or sport

gear are not in use, and the failure

lamp is on

- 150 -

- 151 -

MF622D31 Manual

Transmission

Chapter I Outline and

Instruction.........................,............- 109 -

1. Outline...............................................- 109 -

1.1 Transportation and

Storage.................................................- 110 -

1.2 Usage........................................................- 111 -

1.3 Maintenance....................................................- 111 -

Chapter II

Specification.............................................- 113

1. Fastener specifications......................................-

113 -

1.1 Manual transmission

specification..............................................- 113 -

2. Component locating

diagram..........................................- 114 -

2.1 Input shaft

assembly..................................................- 114 -

2.2 Countershaft

assembly.................................................- 114 -

2.3 Differential

assembly.................................................- 115 -

2.4 Reverse shaft

- 152 -

assembly.................................................- 116 -

2.5 Transmission case

assembly...................................................- 117 -

Chapter III Diagnosis Information and

Operation...................................- 119 -

1. Symptom-Manual

transmission.....................................- 119 -

Chapter IV Maintenance

Guide.........................................- 120 -

1. Removal under the

vehicle............................................- 120 -

1.1 Loosen the oil draining screw plug to drain th

oil............................................- 120 -

1.2 Remove hydraulic separating

bearing...........................................- 120 -

1.3 Remove gear shifting shaft

assembly.......................................- 121 -

1.4 Remove transmission assembly bolt and

disassembly.......................................- 121 -

1.5 Remove left transmission body

assembly.......................................- 122 -

1.6 Remove the shaft assembly, differential assembly and inner gear shifting

mechanism.......................................- 123 -

1.7 Remove right transmission body

assembly.......................................- 124 -

1.8 Remove input shaft assembly.......................................- 124

- 153 -

1.9 Remove countershaft assembly.......................................-

125 -

Remove reversing shaft assembly.......................................-

128 -

Remove differential assembly.......................................- 129 -

Chapter V Installation under the

vehicle.......................................- 130 -

1. Caution............................................- 130 -

2. Assemble............................................- 131 -

2.1 Assemble right transmission body

assembly.......................................- 131 -

2.2 Assemble input shaft assembly.......................................-

131 -

2.3 Assemble countershaft assembly.......................................-

132 -

2.4 Assemble reversing shaft

assembly.......................................- 135 -

2.5 Assemble differential assembly.......................................-

136 -

2.6 Assemble shaft assembly, differential assembly and inner gear shifting

mechanism.......................................- 137 -

2.7 Assemble left transmission body

assembly.......................................- 138 -

2.8 Assemble left transmission body assembly and assembly

bolt.......................................- 138 -

2.9 Assemble gear shifting shaft

assembly.......................................- 139 -

2.10 Assemble the assembly bolt on the right transmission body and clutch

hydraulic separating bearing......................................- 139 -

- 154 -

2.11 Assemble transmission oil draining screw

plug......................................- 140 -

- 155 -

Chapter I Outline and instruction

1. Outline

●Main usage and application range

The MF622D31 sedan transmission is designed to match the 1.5T engine horizontal

front drive transmission. This transmission is suitable for the model of S4 with 1.5T

engine.

●Applicable working condition and environment

The transmission can adapt to various working conditions and working environment

of the vehicle equipped with 1.5T engine.

●Structure type and main technical parameter

1. Structure form

All synchromesh manually shifted mechanical transmission has flexible gear

shifting, good manipulation, low noise, compact structure, large payload and good

airtightness. All gears are normally engaged transmission of helical gears, shift

gears of single cone and triple cone synchronizer, shift gears are controlled by

soft cable, structure drawing of assembly is as follows:

- 156 -

1. Differential

assembly

2. Reversing shaft

assembly

3. Countershaft

assembly

4. Input shaft

assembly

5. Hydraulic

- 157 -

2. Main technical parameter

1.1 Transportation and storage

1. Transmission should be rust proof, to ensure that the transmission in the normal

transport and storage will not rust.

2. Transmission before transport should be packaged and sealed on the shelf after

fastening, shelves should ensure that in normal transport, the transmission will not

damage.

3. The transmission shall be stored in a ventilated and dry warehouse and shall be

kept in good packing condition.

4. Under the condition of keeping the transmission in good condition, the storage

Torque capacity

210 N·m

Type

Manual operation

Driving mode

Transverse front wheel drive

Gear of shifting

6 forward gears, 1 reversing gear

Transmission ratio

1st gear/3.455, 2nd gear/1.864

3rd gear/1.241, 4th gear/0.943

5th gear/0.744, 6th gear/0.630

Reversing gear/3.364, final drive/4.462

Clutch control

Hydraulic type

Weight (kg)

42 (without oil)

Lubricating oil

specification

Kunlun MTF10 75W/85 GL

Filling method

Fill from oil filling plug hole (the highest oil plug)

Lubraicating oil level

Lower surface of oil level plug hole (the middle oil

plug)

Lubricant oil filling

volume

1.9～2L

- 158 -

period shall not exceed half a year.

5. After the transmission is assembled in the engine, it should be loaded into the

whole vehicle as soon as possible to avoid the aging of oil seal lip caused by the

long transmission exposure in the air.

6. When the transmission is loaded on the vehicle, the special lubricating oil for

the transmission shall be added according to the regulations, and the internal parts

of the transmission shall be fully lubricated before being sold out of the factory.

1.2 Usage

1. The proper suggested figures of the speed per hour for each forward gear are as

follows:

Gear position

Vehicle speed (km/h)

1st gear

0～15

2nd gear

15～30

3rd gear

30～40

4th gear

40～60

5th gear

60～75

6th gear

75～100

▲Notes: a. Transmission shift operation should be carried out within the speed

range.

b. When the transmission is matched with different vehicles, the speed suitable

for each gear is different.

2. Gear shifting principle

A. The gear shifting principles while forwarding are as follows: speedup from

1st-6th gear grade by grade; speed-down from 6th to 1st grade by grade. Reverse gear

mustn’t be selected while forwarding.

Note: To prevent the maloperation of gear shifting, the transmission has locking

device that does not allow 6th gear to reverse gear.

b. When shifting to R gear, it requires the vehicle to be in static state. In

order to avoid abnormal sound when reversing, it is required to wait for about 3

- 159 -

seconds after fully pressing the clutch pedal, and then shift to R gear. It’s

forbidden to shift to R gear when in driving forward state; meanwhile, don’t shift

to forward gears while reversing.

▲Note: When the vehicle is running, the transmission shifting principle may not

be obeyed in an emergency.

3. Operation

By controlling the lever in the cab, the selector lever and the shift lever can be finally

manipulated for shifting operation. Indicate the corresponding locations of different gear shifting

and selecting according to the different directions the control rod knob indicates. The control lever

will automatically return to neutral position after each gear shifting; you can select gear only if it

returns to neutral; when gear shifting, fully press the release pedal to enable the transmission to

come off the engine’s torsion and control the shift lever. Low speed gear shall be selected while

starting.

a. Low speed gear shall be selected while climbing up and down and turning. Taxiing with

clutch disengaged is not allowed.

b. When it becomes difficult to control the shift rod, parking shall be done to check the

reasons without too much thrust.

1.3. Maintenance

1. For the initial maintenance, after the transmission is running-in, the first warranty of 3000km

does not need to replace the new transmission oil; then do regular maintenance. Its maintenance

should be in the vehicle special maintenance station.

2. Regular maintenance: replace mileage: check every 30000km (supplement or replace if

necessary), replace every 100000km;

Replace period: check every 3 years (if necessary add or replace), replace every 5 years.

▲Note: B: replace transmission oil when necessary for maintenance inspection;

H: replace the transmission oil;

a. Maintenance period should according to the mileage or the number of month,

whichever first.

- 160 -

b. Suitable for various driving conditions (repeated short distance driving;

driving on uneven or muddy roads; driving on dusty roads; driving on extremely cold

or saline roads; a short, repetitive drive in extremely cold weather).

c. Replace transmission oil when necessary for maintenance inspection.

d. For other maintenance operations but not oil replacement, when lifting the

vehicle, should also check whether the transmission leaks oil.

3. Maintenance and troubleshooting under the condition of the vehicle;

4. During maintenance, check the transmission oil as follows:

a. Confirm whether the vehicle is in horizontal state to check the oil level.

b. Check the transmission for oil leakage. If so, repair the leaking part. See

the maintenance manual for the repair method.

c. Remove the oil filling screw plug.

d. Check the oil level. The oil level can be roughly checked through the oil filling hole, that is,

remove the oil filling screw plug, if the transmission oil flows out from the oil inlet hole, or the oil

level can be seen to reach the oil inlet hole, the oil level is normal. Otherwise, should add the

transmission oil until to the oil inlet hole.

5. During maintenance, the transmission oil can be replaced as follows:

a. Before replacing the oil, the engine must stop and lift the vehicle

horizontally.

b. Under the condition of lifting the vehicle, check the oil level and whether

there is oil leakage. If there is oil leakage, deal with it.

c. Remove the oil screw plug, discharge the waste oil, and add the specified new

oil according to the specified oil quantity (add it to the oil level hole).

d. Oil drain screw plug is coated with sealant and tighten it according to the specified torque.

- 161 -

Chapter II Specification

1. Fastener specification

application

specification

Separating bearing installation bolt

10.2～13.8 N·m

Transmission assembly bolt

18～28 N·m

Reversing lamp switch assembly

installation bolt

7～10 N·m

Neutral signal sensor installation bolt

5～8 N·m

Oil inlet screw plug

12～18 N·m

Oil drain screw plug

12～18 N·m

Gear shifting transmission bolt

18～28 N·m

Cable bracket bolt

19～25 N·m

Differential bolt

80～100 N·m

Tighten screw sleeve

121～129 N·m

1.1 Manual transmission specification

1.1.1 Function-Manual transmission

application

Specification

Final drive ratio

4.462

1st gear transmission ratio

3.455

2nd gear transmission ratio

1.864

3rd gear transmission ratio

1.241

4th gear transmission ratio

0.943

5th gear transmission ratio

0.744

6th gear transmission ratio

0.630

Reversing gear transmission

ratio

3.364

Transmission oil volume

1.9～2.0 L

Transmission type

Manual MF622D31

- 162 -

1 2 3

2. Component locating diagram

2.1 Input shaft assembly

No.

Spare parts name

Code

Quanti

Remark

Input shaft left

bearing

1709401-MF622C01

Input shaft

assembly

1701110-MF622C01

Main shaft front

bearing

1709406-MR513B01

2.2.

Countershaft assembly

No.

Spare parts name

Code

Quant

ity

Remark

Countershaft right

bearing inner ring

1709412-MF622C01

Countershaft

1701131-MF622D01

Tighten screw sleeve

1709301-MF515B01

Countershaft left

bearing inner ring

1709422-MF622C01

Countershaft 6th gear

assembly

1701360-MF622C01

- 163 -

5th/6th gear

synchronizer stop ring

1709505-MF620C11

Single cone

synchronizer ring

1701432-MF618A01

5th/6th gear

synchronizer assembly

1700406-MF618A01

Countershaft 5th gear

assembly

1701350-MF622C01

2nd/3rd gear clamp ring

1709503-MF622D01

4th/5th gear clamp ring

1709504-MF620C11

Countershaft 4th gear

assembly

1701340-MF622C01

3rd/4th gear

synchronizer stop ring

1709502-MF620C11

Double cone

synchronizer gear ring

assembly

1700603-MF622C01

1st/2nd gear

synchronizer assembly

1700405-MF622C01

Countershaft 3rd gear

assembly

1701330-MF622C01

Countershaft 2rd gear

assembly

1701320-MF622C01

1st/2nd gear

synchronizer gear ring

assembly

1700601-MF622C01

1st gear needle bearing

1709451-MF622C01

Countershaft 1st gear

assembly

1701310-MF622C01

Countershaft 1st gear

gasket

1709229-MF618A01

- 164 -

2.3 Differential assembly

No.

Spare parts name

Code

Quanti

Remark

Differential bearing

inner ring

1709432-MF622D01

Differential shell

2303411-MF622D01

Planetary gear gasket

2309228-DF727A01

Planet gear

2303331-DF727A01

Planetary gear shaft

2303351-DF727A01

Shaft retaining ring

0983190

hexagon flange bolt

0905100020D

Main reduction gear

2303511-MF622D01

Half shaft gear gasket

2309218-DF727A01

Half shaft gear

2303341-DF727A01

- 165 -

2.4. Reversing shaft assembly

No.

Spare parts name

Code

Quant

ity

Remark

Reversing gear shaft

1701511-MF622D01

Deep groove ball

bearing

09306204A

Reversing

gear left

High speed

synchronizer clamp

1709522-MR510A01

R gear synchronizer

assembly

1700407-MF618A01

Double cone

synchronizer gear

1700603-MF618A01

Reversing gear idling

gear

1701561-MF622C01

1st gear needle

bearing

1709451-MF515A01

Reversing shaft

reversing gear gasket

1709229-MF622D01

Input shaft front

bearing

1709401-MR623B01

Reversing

gear right

- 166 -

2.5 Transmission body assembly

Part No.

Part Name

Quant

ity

Remark

1709161-MF514M01

Differential oil seal

1709803-MF626A01

Transmission assembly pin

0904060025

hexagon flange bolt

Separating

bearing mounting

bolt

0904080040

hexagon flange bolt

Left and right

transmission

assembly bolt

1706265-MF622A01

Clutch hydraulic separating

bearing

1706192-MF515A01

Bracket shorck absorber pad

1706191-MF622D11

Cable bracket

1706193-MF515A01

Shock absorber seat pad

0971080

Big washer A class

0904080030

hexagon flange bolt

Cable bracket

mounting bolt

1701721-MF622D11

Right transmission body

- 167 -

1706211-MF622A01

Air discharging valve

connection

1701726-MF622D01

Countershaft oil collecting

tray

1709812-MF513A01

Transmission connecting pin

1709819-MF618A01

1st/2nd gear selecting

locating pin

1701726-MF622C01

Reversing shaft oil

collecting tray

1709421-MF622C01

Countershaft right bearing

outer ring

1709110-MF620A11

Input shaft oil seal

1709411-MF622C01

Countershaft left bearing

outer ring

1709711-MF626A01

Shift fork shaft sleeve

1709208-MF622C01

Countershaft adjusting

gasket

0904080040

hexagon flange bolt

Gear shifting case

transmission

assembly bolt

0904060016-3

Hex flange bolt

Neutral gear

signal sensor

bolt

1707110-MF618A11

Neutral gear signal sensor

1700531-MF622D11

Gear shift shifting assembly

0928060012

Cylindrical pin non -

hardening steel and

austenitic

stainless steel

1709905-MR406A11

Plug screw

1709904-MR508A21

Oil drain plug

1702255-MR513B11

Clip

1701711-MF622D11

Left transmission body

1709219-MF622C01

Differential adjusting

washer

1709431-MF622D01

Differential bearing outer

ring

1709551-MF513A01

磁铁

- 168 -

Chapter III Diagnosis information and

operation

1. Symptom-Manual transmission

Sym

pto

Operation

Reasons

Solutions

Take

off

the

gear

The shift lever is badly worn and

deformed

Manual straightening shift lever; if serious bending

or wear,

replace in time.

Gear shifting rocket arm is badly

worn and deformed

Replace gear shifting rocker arm in time

Gear shifting lock ball elasticity

reduced

Replace gear shifting lock ball in time

Wear and strain of shifting fork

Shifting fork bending deformation can be

straightened manually, but serious wear should be

replaced

Synchronizer gear shell, gear

sleeve or gear ring

abrasion

If gear taking off occurs, wear parts should be

replaced

After the adjustment, the

transmission did not return to the

N gear position, or the

adjustment mechanism is loose

Reposition to N gear, and adjust the clearance.

Insufficient gear shifting stroke

of gear shifting tower

Replace the gear shifting tower

The connection between engine

and transmission is too loose or

the clearance is not adjusted

properly

Can be solved by adjusting its clearance

Tran

smis

sion

noise

abno

rmal

soun

Insufficient transmission oil or

dirty oil

Fill enough oil or replace the oil

Too big gear axial clearance

Replace the gear.

Gear worn or gear broken

Replace the gear.

Synchronizer gear ring worn or

broken

Replace the gear

Bearing damage or worn

Replace the bearing

Diffi

culty

Shift lever or shift fork produce

deformation or uneven wear

Replace the component.

- 169 -

gear

shifti

Shift fork sleeve deformed

Replace the component.

The synchronizer ring is clamped

on the gear cone

The solution is to replace the gear ring

Synchronizer slider damaged

Replace the synchronizer slider

Gear sleeve wear or ring keyway

wear widen

Replace relevant parts.

Oil

leaka

Oil drain screw plug leak oil

First, it is possible that the tightening torque of the

screw plug is less than the specified value.The

second is possible with the deviation or thread

tooth damage, replace the corresponding parts

Leakage of sealing part

Replace the sealing part, and pay attention to the

normative operation

Oil leakage on transmission case

joint surface

Check and make the tightening torque of each

connection bolt conform to the regulations.

- 170 -

Chapter IV Maintenance guide

1. Removal under the vehicle

1.1 Loosen the oil drain screw plug to drain the oil

As shown in the figure below, loosen and remove the oil filling screw plug, the oil level screw

plug and the oil drain bolt to release the transmission oil;

1. Oil level screw plug 2. Oil drain screw plug 3. Oil filling screw plug

1.2 Remove hydraulic separating bearing

As shown in the figure below, first remove the clip on the separating bearing,

then pull out the air discharging valve connector, then remove the hydraulic

separating bearing bolt (2 in total), then remove the clutch hydraulic separating

bearing, and finally remove the transmission assembly bolts in right transmission

body (5 in total);

- 171 -

1. Air discharging valve connector 2. Hexagonal flange bolt (2) 3. Transmission

assembly hexagon flange bolt (5) 4. Hydraulic separating bearing.

1.3 Remove gear shifting shaft assembly

As shown in the figure below, first remove the gear shifting case bolts (3), then shift to N gear,

and remove the gear shifting shaft assembly (Note: the gear shifting shaft can be moved up and

down to select the gear, namely N gear).

1. Gear shifting shaft assembly 2. Hexagon flange bolt

1.4 Remove transmission assembly bolt and disassembly

As shown in the figure below, first remove the transmission assembly bolts (12 in total) on the left

transmission body, and then remove the left transmission body with the transmission body separator.

- 172 -

1. Hexagon flange bolt (12)

- 173 -

1.5 Remove left transmission body assembly

As shown in the figure below, after removing the transmission assembly bolts (12)

on the left transmission body, take down the clip on the bolt; then remove the neutral

signal sensor bolt, take down the neutral signal sensor; remove the left transmission

body differential oil seal with the oil seal puller (Note: scrap the oil seal, and

it cannot be used again); then remove the gear shifting case locating pin (Note: scrap

and cannot be used again); turned around and transmission body, remove the

countershaft left bearing outer ring and differential bearing outer ring with inertia

hammer; finally remove the shift fork sleeve of forward gears and reverse gear fork

fork rod hole (Note: scrap and cannot be used again).

1. Neutral signal sensor 2. Neutral sensor bolt 3. Gear shifting case locating

pin 4. Shift fork sleeve (2) 5. Counershaft left bearing outer ring 6.

- 174 -

Countershaft adjusting washer 7. Differential bearing outer ring 8.

Transmission assembly pin 9. Differential adjusting gasket 10. Left transmission

body 11. Clamp 12. Differential oil seal 13. Transmission assembly bolt (12)

- 175 -

1.6 Remove shaft assembly, differential assembly and inner gear

shifting mechanism

As shown in the figure below, first remove the input shaft assembly, then the countershaft

assembly and the forward gear shifting fork assembly, then the reverse shaft assembly and the

reverse gear shifting fork assembly, and finally the differential assembly.

1. Input shaft assembly 2. Forward gear shifting fork assembly 3. Reverse gear

shifting fork assembly 4. Reverse gear shaft assembly 5. Differential assembly 6.

Intermediate shaft assembly

- 176 -

1.7 Remove right transmission body assembly

1. Transmission assembly pin (2) 2. Cable bracket assembly 3. Cable bracket bolt

(3) 4. Cable bracket big washer (3) 5. Engine connecting pin (2) 6. Input oil seal

7. Differential oil seal 8. Differential right bearing outer ring 9. Magnet 10.

Countershaft right bearing outer ring 11. Countershaft oil collecting tray 12.

Reversing gear shaft oil collecting tray 13. Shift fork sleeve (2)

1.8 Remove input shaft assembly

Use bearing extractor to disassemble the input shaft. It can only be split into the input shaft

right bearing and the rest of the components.

1. Input shaft right bearing

- 177 -

1.9 Remove countershaft assembly

1. Tighten screw sleeve

1. 5th/6th gear synchronizer gear sleeve 2. Single cone synchronizer gear ring 3.

Countershaft left bearing inner ring 4. Countershaft 6th gear assembly

- 178 -

1. Countershaft 5th gear assembly 2. Single cone synchronizer gear ring 3. 5th/6th

synchronizer stop ring 4. 5th/6th synchronizer hub assembly

1. Double cone synchronizer gear ring assembly 2. Countershaft 4th gear assembly

3. 2nd/3rd gear clamp ring 1 4. 4th/5th gear clamp ring 2

1. 1st/2nd gear synchronizer assembly 2. 3rd/4th gear synchronizer stop ring 3.

Double cone synchronizer gear ring assembly

- 179 -

1. 3rd/4th gear synchronizer stop ring 2. Countershaft 3rd gear assembly

1. Countershaft 2nd gear assembly 2. 1st/2nd gear synchronizer gear ring assembly

3. 4th/5th gear clamp ring 2 4. 2nd/3rd gear clamp ring 1

1. 3rd/4th gear synchronizer stop ring 2. 1st/2nd gear synchronizer assembly 3.

1st/2nd gear synchronizer gear ring assembly 4. Countershaft 1st gear gasket

5. 1st gear needle bearing 6. Countershaft 1st gear assembly

- 180 -

1. Countershaft right bearing inner ring 2. Countershaft

- 181 -

1.10 Remove reverse shaft assembly

1. Reverse gear left bearing 2.R gear synchronizer gear sleeve 3. High speed

synchronizer clip ring

1. Reverse gear idling gear 2. R gear synchronizer hub assembly 3. Double cone

synchronizer gear ring assembly 4. Reverse gear shaft reverse gear gasket

5. 1st gear needle bearing

- 182 -

1. Reverse gear right bearing

1.11 Remove differential assembly

1. Shaft retaining

ring (2)

2. Planetary gear

shaft

1. Half shaft gear

gasket (2)

2. Half shaft gear (2)

3. Planey gear gasket

(2)

4. Planey gear (2)

1. Differential

bearing inner ring

- 183 -

1.Hex flange bolt (10)

2.Main reduction gear

第五章 Assembly under the vehicle

I. Cautions

Matters needing attention before assembly:

① Clean all parts, when assembly, please use the corresponding special auxiliary

tool, ensure the smooth assembly of each component;

② In the relative movement of parts surface, spray gear oil;

③ Needle bearing assembly should be in the peripheral surface of the gear oil;

④ Before the oil seal assembly, spread oil to the oil seal hole evenly;

⑤ When assembling the synchronizer, first align the synchronizer sliding block to

the sliding bolt slot on the synchronizer gear ring;

⑥

Pay attention to the position and direction of each part;

⑦

Note: When assembling the transmission (left and right transmission body; gear shifting case), the magnet can

not be mis-installed, and has been coated with transmission assembly glue;

⑧Note: when installing the input shaft assembly, the spline of the input shaft shall not scratch the oil seal of the

input shaft; otherwise, replace the oil seal of the input shaft;

⑨Pay attention to the assembly of the main reduction gear and the countershaft locking screw sleeve, the screw

teeth should be evenly coated with an appropriate amount of LETAI 271 thread fastening adhesive;

⑩

Pay attention to the tightening torque of each bolt;

- 184 -

2. Assembly

2.1 Assemble right transmission body assembly

1. Shift fork sleeve (2) 2. Transmission assembly pin (2) 3. Cable bracket

assembly 4. Cable bracket bolt (3) 5. Cable bracket big washer (3) 6. Engine

connecting pin (2) 7. Input oil seal 8. Differential oil seal 9. Differential

right bearing outer ring 10. Magnet 11. Countershaft right bearing outer ring 12.

Countershaft oil collecting tray

2.2 Assemble input shaft assembly

- 185 -

1. Input shaft right bearing 2. Output shaft left bearing

2.3 Assemble countershaft assembly

1. Countershaft right bearing inner ring 2. Countershaft

1. 3rd/4th gear synchronizer stop ring 2. 1st/2nd gear synchronizer assembly 3.

1st/2nd gear synchronizer gear ring assembly 4. Countershaft 1st gear gasket

5. 1st gear needle bearing 6. Countershaft 1st gear assembly

1. Countershaft 2nd gear assembly 2. 1st/2nd gear synchronizer gear ring assembly

3. 2nd/3rd gear clamp ring 1 4. 4th/5th gear clamp ring 2

- 186 -

1. 3rd/4th gear synchronizer stop ring 2. Countershaft 3rd gear assembly

1. 1st/2nd gear synchronizer assembly 2. 3rd/4th gear synchronizer stop ring 3.

Double cone synchronizer gear ring assembly

1. Double cone synchronizer gear ring assembly 2. Countershaft 4th gear assembly

3. 4th/5th gear clamp ring 2 4. 2nd/3rd gear clamp ring 1

- 187 -

1. 3rd/4th gear synchronizer stop ring 2. 1st/2nd gear synchronizer assembly 3.

Double cone synchronizer gear ring assembly 4. Countershaft 5th gear assembly

1. Single cone synchronizer gear ring 2. Countershaft 6th gear assembly 3.

Countershaft left bearing inner ring

1. Tighten screw sleeve

Caution:

1、In addition to pressing and installing the bearing, spread lubricating oil

to the countershaft and countershaft matched parts before each assembly step;

2、In the last step, the locking screw sleeve needs to be coated on the thread

with LPT 7649 catalyst and LPT 272 thread fastening adhesive.

- 188 -

3、At each assembly point, check whether the gear is flexible and whether the

clamp ring is in place;

2.4. Assemble reverse shaft assembly

1. Reversing gear left bearing

1. Reversing gear idling gear 2. High speed synchronizer clamp ring 3. R gear

synchronizer assembly 4. Double cone synchronizer gear ring assembly 5. 1st gear

needle bearing 6. Reversing gear reversing gasket

- 189 -

1. Reversing left bearing

Note: 1. Except for pressing and installing the bearing, when installing, spread the lubricating

oil to the reversing shaft surface and synchronizer and gear ring matched surface;

2. At each assembly point, check whether the gear is flexible and whether the clamp ring is in

place;

2.5 Assemble differential assembly

1. Hex flange bolt (10)

2. Main reduction gear

Caution:

1.This step is warm

installation;

2.Before tightening

the bolt, it is

necessary to spread

the thread with lenten

7649 catalyst and

lenten 272 thread

fastening adhesive;

1. Differential

bearing inner ring (2)

1. Half shaft gear

gasket (2)

2. Half shaft gear (2)

3. Planetray gear

gasket (2)

4. Planetary gear (2)

- 190 -

1. Shaft retaining

ring (2)

2. Planetary gear

shaft

2.6 Assemble shaft assembly, differential assembly and inner gear

shifting mechanism

1. Input shaft assembly 2. Forward gear shift fork assembly 3. Reversing gear shift

fork assembly 4. Reversing gear shaft assembly 5. Differential assembly

6. Countershaft assembly

After completing this step, need to measure distance between the countershaft

- 191 -

bearing outer ring end surface to the transmission assembly surface of the right

transmission body, the distance between the differential bearing outer ring end

surface to the transmission assembly surface of the right transmission body, the

distance between the left transmission body countershaft bearing hole end surface

(the end surface contact to the countershaft gasket) to the transmission assembly

surface of left transmission body, the distance between the left transmission body

countershaft bearing hole end surface (the end surface contact to the differential

gasket) to the transmission assembly surface of left transmission body. Calculate

the corresponding difference, according to the following principles to select the

appropriate countershaft gasket and differential gasket.

Selection principle of gasket:

1）Assemble and ensure that the countershaft assembly has an interference of

0.04mm～0.11mm in the transmission body;

2）Assemble and ensure that the differential assembly has an interference of

0.09mm～0.16mm in the transmission body;

- 192 -

2.7 Assemble left transmission body assembly

1. Neutral signal sensor 2. Neutral sensor bolt 3. Gear shifting case locating pin

4. Shift fork sleeve (2) 5. Countershaft left bearing outer ring 6. Countershaft

adjusting gasket 7. Differential bearing outer ring 8. Transmission assembly pin

9. Differential adjusting gasket 10. Left transmission body 11. Clamp 12.

Differential oil seal 13. Transmission assembly bolt (12)

- 193 -

2.8 Assemble left transmission body and transmission assembly bolt

2.9. Assemble gear shifting shaft assembly

1. Gear shifting shaft assembly 2. Hex flange bolt (3)

- 194 -

2.10 Assembly the transmission assembly bolt on the right

transmission body and clutch hydraulic separating bearing

1. Air discharging valve connector 2. Hex flange bolt (2) 3. Transmission assembly

hex flange bolt (5) 4. Hydraulic separating bearing

- 195 -

2.11 Assemble transmission oil drain screw plug

1. Oil level screw plug 2. Oil drain screw plug 3. Oil filling screw plug

- 196 -

MF20B9 Manual transmission

Chapter I Caution- 143 -

Chapter II Outline- 144 -

1. Transmission name and meaning- 144 -

2. Outline and related technical parameter- 144 -

2.1 Main usage and application range- 144 -

2.2 Structure type- 144 -

2.3 Relevant technical parameter- 144 -

2.4 Main technical parameter- 145 -

2.5 Tighten torque and installation requirement- 145 -

3. Circuit Diagram of Transmission System- 147 -

3.1. Transmission structure- 147 -

3.2 Transmission schematic diagram- 148 -

3.3 Working principle- 148 -

4. Transmission Disassembly Schematic Diagram- 150 -

4.1 Disassembly Schematic Diagram of Transmission Assembly- 150 -

4.2 Disassembly Schematic Diagram of Housing Assembly- 151 -

4.3 Disassembly Schematic Diagram of Input Shaft Assembly- 152 -

4.4. Disassembly Schematic Diagram of Clutch Housing Assembly- 153 -

4.5 Disassembly Schematic Diagram of Gear Select&Shift seat Assembly- 155

4.6 Disassembly Schematic Diagram of Output Shaft Assembly- 156 -

4.7 Disassembly Schematic Diagram of Output Shaft Assembly- 157 -

Chapter III Common Fault Diagnosis- 158 -

Chapter IV Disassemble transmission

............................................

- 160 -

- 197 -

1. Disassemble transmission assembly- 160 -

2. Disassemble output shaft assembly- 166 -

3. Disassemble input shaft assembly- 168 -

Chapter V Key parts check- 172 -

1. Input shaft check- 172 -

2. Output shaft check- 172 -

3. Differential assembly check

.........................................................

- 172 -

4. Each gear check- 172 -

5. Inspect the needle bearings of all the gears- 172 -

6. Synchronizing ring check- 173 -

7. Synchronizer check- 174 -

Chapter VI Assemble transmission

..................................................

- 175 -

1. Assemble input shaft assembly- 175 -

2. Assemble output shaft assembly - 179 -

3. Assemble Transmission Assembly- 182 -

Chapter VII Transmission Maintenance- 184 -

1.Maintenance- 184 -

1.1 Transmission Regular Inspection and Maintenance List- 184 -

2. Lubricating and Sealing- 185 -

Chapter VIII Quick-wear Part List

- 198 -

Chapter I Caution

● Don’t reuse the drained transmission gear oil

● Oil change has nothing to do with the components cleaning while checking or changing

the transmission gear oil with the vehicle staying in the horizontal condition.

● The interior cleanness shall be maintained while disassemble and assemble the

transmission.

● Check and determine the right location for assembly before the disassembly and

decomposition. ● If you need to make the installation mark, make sure that the marked

component is not affected by the mark.

● Screw the middle bolts and nuts in diagonal sequence step by step and then screw

the bolts and nuts at the sides as prescribed. The screwing shall be done as required

if there is the requirement of screwing sequence.

● Don’t damage the sliding surface or the mating surface.

● The needle bearing shall be painted with lubricating grease on circumferential

surface before assembly.

● The oil seal shall be painted with lubricating grease on the lip area before

assembly

● The synchronizer sliding block shall be aligned to the sliding bolt slot on the

synchronizer gear ring while press fitting the synchronizer components.

- 199 -

Chapter II Outline

1. Transmission name & meaning

M F 20 B

Two wheel drive

Torque(160Nm）

Front arranged

Manual

2. Outline and related technical parameter

2.1 Main usage and application range

The MF20B9 transmission is designed to match the 1.6DVVT engine horizontal drive

transmission. The transmission is suitable for the S4 with 1.6DVVT engine.

2.2 Structure type

Manually shifted mechanical transmission with six forward gears and one reverse. There is

no synchronizer in reverse gear. The 1st and 2nd gear are three-cone surface synchronizer, and the

others are single-cone surface synchronizer. The shift mechanism is the cable type.

2.3 Related technical parameter

Driving mode

Transverse front wheel drive

Gear of shifting

- 200 -

Clutch controlling

Hydraulic mechanical type

Weight (kg)

40 (without oil)

The specifications of

transmission lubricating

oil

Kunlun MTF10 75W/85 GL

The filling method of

transmission lubricating

oil

Refuel the specified oil quantity from the side

refueling hole

Refilling quantity of the

transmission lubricating

oil

2.2±0.1L

- 201 -

2.4 Main techinical parameter

Operation manner

Remote operation

Rating torque

200N·m

160N·m

Model

MF20B

MF20B9

Gear

ratio

1st gear

3.769

2nd gear

2.053

3rd gear

1.37

1.393

4th gear

0.97

1.031

5th gear

0.778

6th gear

0.681

Reversing

gear

3.583

Final gear ratio

3.842

4.529

2.5 Tighten torque and installation requirement

Items

N·m

Bolt

specification

Remark (spread

sealant)

The connecting bolt of the

differential case and the

main reduction gear

75-85

M12×1.25

Pre-spread thread

locking solid

adhesive

Oil drain plug

50-60

M18×1.5

Paint the silicon

sealant

- 202 -

Bolt & flat washer

assembly (housing and

clutch housing)

35-41

M10×1.25

Pre-spread thread

locking solid

adhesive

hexagon flange bolt

(Housing and

clutch housing)

35-41

M10×1.25

Pre-spread thread

locking solid

adhesive

Reverse gear shaft bolt

42-54

M10×1.25

Thread middle spread

high strength

thread adhesive

Oil filler plug

30-40

M16×1.5

Paint the silicon

sealant

back-up lamp switch

29-35

M14×1.5

Pre-spread thread

sealing adhesive

Flange bolt (gear

select&shift seat

installation bolt, cable

bracket)

25-30

M8×1.5

Spread high strength

thread adhesive

Hexagon flange bolt

(wiring harness fixing

bolt)

9-11

M6×1.25

Spread high strength

thread adhesive

Self-lock pin assembly

30-40

M14×1.5

Spread high strength

thread adhesive

Ball head support

32-40

M12×1.75

Spread high strength

thread adhesive

Plug screw

76-84

M16×1.5

Spread high strength

thread adhesive

Guide pin

15-22

M8×1.25

Spread high strength

- 203 -

thread adhesive

Hexagon socket head cap

screw (gear shifting

shaft supporting seat

bolt)

15-22

M8×1.5

Spread high strength

thread adhesive

Hexagon flange bolt

(sub-pump installation

bolt)

22-28

M8×1.5

Spread high strength

thread adhesive

Bearing pressure plate

bolt

9-11

M6×1.25

Spread high strength

thread adhesive

Stud bolt

35-45

M12×1.25

Spread middle-high

strength thread

adhesive

- 204 -

3. Transmission Cutaway View and Working Principle

3.1. Transmission inner structure

1. View the internal structure from the bottom of the transmission.

2. View the internal structure from the top of the transmission.

- 205 -

3.2 Transmission Cutaway View

3.3 Working Principle

1. 1st gear

Engine → Clutch → Input shaft spline 1 → Input 1st gear → Output 1st gear 2 →

1st/2nd gear synchronizer 4 → Output shaft 15 → Output shaft main reduction gear

21 → Differential 20

2. 2nd gear

Engine → Clutch → Input shaft spline 1 → Input 2nd gear 8 → Output 2nd gear 7

→ 1st/2nd gear synchronizer 4 → Output shaft 15 → Output shaft main reduction gear

21 → Differential 20

3. 3rd gear

Engine → Clutch → Input shaft spline 1 → 3rd/4th gear synchronizer 10 → Input

- 206 -

3rd gear 9 → Output 3rd gear 19 → Output shaft 15 → Output shaft Main reduction

gear 21 → Differential 20

- 207 -

4. 4th gear

Engine → Clutch → Input shaft spline 1 → 3rd/4th gear synchronizer 10 → Input

4th gear 11 → Output 4th gear 18 → Output shaft 15 → Output shaft main reduction

gear 21 → Differential 20

5. 5th gear

Engine → clutch → input shaft spline 1 → 5th/6th gear synchronizer 13 → input

5th gear 12 → output 5th gear 17 → output shaft 15 → output shaft main reduction

gear 21 → differential 20

6. 6th gear

Engine → clutch → input shaft spline 1 → 5th/6th gear synchronizer 13 → input

6th gear 14 → output 6th gear 16 → output shaft 15 → output shaft main reduction

gear 21 → differential 20

7. Reverse gear

Engine → clutch → input shaft spline 1 → input reverse gear 5 → reverse idler

6 → 1st/2nd gear synchronizer 4 → output shaft 15 → output shaft main reduction

gear 21 → differential 20

3.3.1 Machinery Operation

By controlling the control rod in the cabin, operate the select rocker arm and

the shift rocker arm to select and shift gears in the end. Indicate the corresponding

locations of different gear shifting and selecting according to the different

directions the control rod knob indicates. The control rod automatically returns to

neutral gear after idling. Gear selecting can only be conducted in neutral gear.

1. Fully depress the release pedal while gear shifting to enable the transmission

to come off the engine’s torsion and control the shift rod. Low speed gear shall

be selected while starting.

2. Low speed gear shall be selected while climbing up and down and turning. Taxiing

with clutch disengaged is not allowed.

3. When it becomes difficult to control the shift rod, parking shall be done to check

the reasons without too much thrust.

- 208 -

3.3.2 The recommended mileage for each gear position is as follows

gear：

1st gear

2nd gear

3rd gear

4th gear

5th gear

Sixth

gear

Mileage

0～20

10～30

20～40

40～60

60～80

80～max

Note: 1. The gear shifting shall be done within the mileage range.

2. The proper speed per hour for each gear varies in different vehicles.

3.3.3 Gear shifting principle

The gear shifting principles while forwarding are as follows: speedup from

1st-6th gear grade by grade; speed-down from 6th to 1st grade by grade. Reverse gear

mustn’t be selected while forwarding. The transmission is equipped with the lock

device for maloperation while gear shifting in case of maloperation. In principle,

the reverse gear shall be shifted after stepping the clutch with 31-second stop when

the CBU is still. Reverse gear mustn’t be selected while forwarding. Meanwhile,

forwarding gears mustn’t be selected while reversing.

Note: When the vehicle is running, the transmission shifting principle may not

be obeyed in an emergency.

- 209 -

4. Transmission Disassembly Schematic Diagram

4.1 Disassembly Schematic Diagram of Transmission Assembly

No.

(No.)

Code

(Code)

Name

(Name)

Number

D-1701800-50-00

11. Housing assembly

D-1701100-50-01

Input shaft assembly

D-1605100-50-02

1. Clutch housing

D-1702100-50-00

Select-shift gear base assembly

D-2303100-00-04

Differential assembly

D-1701300-50-09

Output shaft assembly

1 2 3 4 5 6

- 210 -

4.2. Disassembly Schematic Diagram of Housing Assembly

No.

(No.)

Code

(Code)

Item

(Name)

Number

H-1701515-79-00

Oil drain screw plug assembly

H-1701516-79-00

Washer(oil drain screw plug)

H-1701519-79-00

Washer (oil drain screw plug)

H-1701518-79-00

Oil filler plug

D-1701611-00-00

Reverse gear shaft bolt

D-1701601-00-00

Reverse gear shaft bolt gasket

D-1701651-00-00

Bolt & flat washer assembly

GB/T16674.2

M10×1.25×30

Hex flange bolt

D-1701631-50-02

Oil groove

D-2303011-00-00

Oil seal (differential)

D-2303021-00-00

Adjusting washer (differential)

D-1701671-50-00

Oil guide plate

D-1701731-50-00

Lifting lug

D-1701661-00-00

back-up lamp switch

D-1702291-50-00

Self-lock pin assembly

D-1701741-00-00

Stud bolt

D-1701641-50-00

Case

- 211 -

4.3 Disassembly Schematic Diagram of Output Shaft Assembly

No.

(No.)

Code

(Code)

Item

(Name)

Number

D-1701191-50-00

Plug screw

D-1701181-00-00

Ball bearing (behind input shaft)

D-1701203-50-00

Input 6the gear thrust cushion

D-1701202-50-00

Input 6th gear bushing

D-1701212-50-00

Input 6th gear needle bearing

D-1701230-50-00

Input 6the gear assembly

D-1708251-50-00

5th/6th gear synchronizer ring

D-1708260-50-00

5th/6th gear synchronizer assembly

D-1701220-50-00

Input 5th gear assembly

D-1701211-50-00

Input 5th gear needle bearing

D-1701201-50-00

Input 5th gear bushing

D-1701160-50-01

Input 4th gear assembly

D-1701132-50-00

Input 4th gear needle bearing

D-1701141-50-00

Input 4th gear bushing

D-1708241-50-00

4th gear synchromesh ring

D-1708230-50-00

3rd/4th gear synchronizer assembly

D-1708210-50-01

Third gear synchronizer ring

D-1701140-50-03

Input shaft 3rd gear assembly

D-1701131-50-00

Input 3rd gear needle bearing

D-1701121-50-01

Input shaft

D-1701111-00-00

Ball bearing (in front of the input shaft)

D-1701101-00-00

Clamp ring (in front of the input shaft)

- 212 -

4.4 Disassembly Schematic Diagram of Clutch housing

No.

(No.)

Code

(Code)

Item

(Name)

Number

D-1602021-50-03

Separating bearing

D-1602015-10-00

Ball head support

D-2303011-00-00

Oil seal (differential)

D-1601101-50-02

Clutch housing

L-1702222-50-00

Shock absorber supporting

L-1702221-50-00

Bracket shock absorber pad

Q1840825

Hex flange bolt

D-1702261-50-00

Cable bracket

D-1702281-50-00

Wiring harness fixing piece

Q1840612

Hex flange bolt

D-1701541-00-00

Locating pin

D-1702082-50-00

Bearing pressing plate

Q2580616

Bearing pressing plate bolt

D-1702010-50-00

1st/2nd shift fork assembly

D-1702050-50-00

3rd/4th gear shift fork shaft assembly

Q5270520

Screw spring pin

- 213 -

D-1702031-50-00

1st/2nd gear shift fork shaft

D-1702061-50-00

5th/6th gear shift fork

D-1702070-50-00

5th/6th gear shift fork shaft assembly

D-1702041-50-00

3rd/4th gear shift fork

D-1702090-50-00

Reverse shift fork assembly

D-1701671-50-00

Oil guide plate

H-1701513-79-00

Magnet

D-1701551-00-00

Oil sealing(input shaft）

D-1702310-50-02

Reverse shift fork assembly

D-1701270-50-05

Reverse gear engagement

D-1702361-50-00

Reversing gear shaft shock absorber pad

D-1701261-50-00

Reversing gear shaft

D-1702321-50-00

Reverse gear shift fork torsional spring

D-1702341-50-00

Washer

D-1702351-50-00

Guide pin

Q218B0825

Hexagon socket head cap screw

Y-1702421-00-00

Locating pin sleeve

Q43680

Open split washer

D-1702331-50-00

Gear shifting shaft supporting seat

D-1702371-50-00

Linear bearing

D-1701325-00-00

Cover

Q1420820

Bolt & flat washer assembly

D-1602010-10-00

Release fork assembly

D-1602014-50-00

Guard cover

Q1840820

Hex flange bolt

A-1702187-00-00

Reversing lamp bracket

D-1602031-50-00

Clutch cylinder assembly

- 214 -

4.5 Disassembly Schematic Diagram of gear select$shift base

assembly

No.

(No.)

Code

(Code)

Item

(Name)

Number

D-1702140-50-01

Gear shifting shaft assembly

D-1702241-50-00

Gear select&shift shaft oil sealing

D-1702371-50-00

Linear bearing

V-1701285-01

Air outlet valve

D-1702373-50-00

Select-shift gear base

D-1702181-50-00

Gear select&shift resistance pin

D-1702161-50-01

Gear select&shift block

D-1702211-50-00

Reverse gear shift knob

D-1702221-50-00

Reverse gear shift knob torsional

spring

D-1702191-50-00

Interlock plate

D-1702171-50-00

Gear shift knob

D-1702150-50-00

Gear selecting arm assembly

Q5280624

Elastic cylindrical pin

Q5280424

Elastic cylindrical pin

Q43680

Open split washer

D-1702372-50-00

bush

- 215 -

Q1840825

Hex flange bolt

Q5210512

Cylindrical pin

D-1702374-50-00

Oil baffle

4.6 Disassembly Schematic Diagram of Differential Assembly

No.

(No.)

Code

（Code）

Item

(Name)

Number

D-2303031-00-00

Tapered roller bearing

L-2303104-01

hexagonal head bolt

D-2303121-00-04

Main reduction gear

D-2303131-00-00

Differential case

D-2303141-00-00

Slot pin

D-2303181-00-00

Half shaft gear thrust washer

D-2303191-00-00

Half shaft gear

D-2303151-00-00

Planetary gear shaft

D-2303161-00-00

Planetary gear thrust washer

D-2303171-00-00

Planet gear

- 216 -

4.7 Disassembly Schematic Diagram of Output Shaft Assembly

No.

(No.)

Code

(Code)

Name

(Name)

Number

D-1701301-00-00

Tapered roller bearing (output shaft

front)

D-1701311-50-08

Output shaft

D-1701331-50-00

Output shaft 1st gear

D-1701321-50-00

Output 6th gear needle bearing

D-1708010-50-01

1st gear synchronizer ring assembly

D-1708040-50-03

1st/2nd gear synchronizer assembly

D-1708051-50-00

1st/2nd gear synchronizer snap ring

D-1708020-50-00

2nd gear synchronizer ring assembly

D-1701351-50-00

Output shaft 2nd gear

D-1701421-50-00

Output 2nd gear needle bearing

D-1701361-50-01

Output shaft 3rd gear

D-1701381-50-01

Output shaft 4th gear

D-1701401-50-00

Output shaft 5th gear

D-1701501-50-00

Output shaft 6th gear

D-1701391-60-00

Output shaft rear tapered roller bearing

- 217 -

D-1701591-00-00

Adjusting washer (output shaft rear

bearing)

- 218 -

Chapter III Common Fault Diagnosis

Please contact the special appointed maintenance station or professional

personnel at once when the transmission has abnormal situation, the detailed

disassembly picture and parts numbers please refer to the maintenance manual.

Faults situations

Possible reasons

Analysis and exclude

When vehicle driving,

jump

to neutral gear

(1) Excessive wear

of the shift knob

(2) Failure in shift

locating pin

(3) Over wear of the

poking fork working

surface. Over wear

of the ring gear or

gear sleeve

matching surface;

(4) Loosen wheel

gear shaft.

(1) Too large space between the poke

rod and the gearshift control (check

if the shift knob is excessive wear)

(2) Check the shift locating pin

failure of the shifting force is too

small.

(3) Check if the control system push

the gear shift push rod completely, or

disassemble the transmission, use

hand to push the poking fork to gear,

check the meshing situation.

① If not completely meshing,

should check whether the shift fork

deformation or working surface wear

too much.

② If the gear sleeve mesh

completely, please check the wear

situation of the back taper part

between gear sleeve and connecting

gear.

(4) Check if the gear axial movement

is too large.

- 219 -

In the condition of

clutch no failure,

shifting difficulty

with severe impact

sound or difficulty

in shifting to a

certain gear

(1) Synchronizer

ring wear

seriously.

(2) Ggear conical

surface severe

abrasion

(1) Replace the synchronizer ring.

(2) Replace the gear

Transmission noise

① Regular crush

noise.

② Even noise.

(1) The crushing of

some gear tooth.

(2) Increased gear

clearance or gear

damage.

(3) Bearing wear.

(4) Insufficient

lubricant oil.

(1) Check the part of failure and

exclude it.

(2) Disassemble, clean or replace the

broken gear or bearing.

(3) Replace or add the new oil.

Oil leakage

(1) High oil level.

(2) Oil sealing over

wear or

damage.

(3) Uneven painting

of the sealing

adhesive or damage

of the sealing paper

washer

(4) Breather plug

invalid.

(5) The bumped joint

surface isn’t

fixed in time.

(1) Disassemble the oil filling screw

plug and check the oil level.

(2) Replace oil sealing.

(3) Disassemble the components of all

the joint surfaces, check the bumping

spots and fix them.

(4) Evenly spread the sealant.

(5) Replace the breather plug.

- 220 -

Bearing abnormal

broken

(1) Lubricant oil

too dirty.

(2) Inadequate

lubrication or low

quality lubricating

oil,

which doesn’t meet

the requirements.

(3) Use unqualified

bearing.

(1) Replace lubricant oil.

(2) Check lubricant oil level, add or

replace

lubricating oil.

(3) Replace the bearing.

- 221 -

Chapter IV Disassemble transmission

1. Disassemble Transmission Assembly

1. Drain the oil. Remove the oil drain bolt.

Note: Use wrench to remove the oil drain screw plug, drain the oil from the oil

drain hole,

and it’s forbidden to drain the oil from other part.

2. Remove the wiring harness fixing piece.

Remove the hexagon flange bolt, and take down the wiring harness fixing piece.

3. Remove the cable bracket.

After removing the 3 bolts, take down the cable bracket.

- 222 -

4. Remove the gear selecting arm assembly.

Remove the split check ring, and take out the gear select&shift rocket arm

assembly.

5. Remove the gear select&shift base assembly

After loosen the 5 bolts, pull out the gear shift&select seat assembly.

6. Remove the reversing lamp switch.

Use wrench to remove directly.

- 223 -

7. Remove the reversing gear shaft bolt.

Use wrench to remove directly.

8. Remove the self-lock pin assembly.

Remove the self-lock pin assembly, totally 3.

9. Remove the clutch pump assembly and reversing lamp bracket.

First remove the 2 bolts, and take down clutch assembly

And reversing lamp bracket.

- 224 -

10. Remove the release bearing and release fork assembly.

First remove the release bearing, and then remove the release fork assembly.

11. Remove the tightening bolt (total 15).

This direction is total 12 bolts.

This direction is total 3 bolts.

- 225 -

12. Take down the transmission housing.

Slightly punch the clutch housing with the copper rod to separate the clutch

housing and the housing joint surface.

13. After the housing is removed, it is shown in the figure.

Output shaft

assembly

Input shaft

assembly

Gear

shifting

22. Reverse

shaft

Main

14. Remove the reverse gear shaft assembly.

Pull up the shaft, then can take down the reverse gear shaft assembly.

- 226 -

15. Remove the gear select&shift shaft supporting seat.

Remove the 2 bolts on the supporting seat, pull up and

take down the gear shift shaft support seat.

16. Remove the shift fork, shift fork shaft and the block.

Remove the three connected spring pins between the shift fork and the shift fork

shaft,

pull up the shift fork shaft, and take down

the shift fork, shift fork shaft and the block relatively.

17. Remove the input shaft bearing pressing plate.

Remove the 4 pressing plate screw, and take down the pressing plate.

- 227 -

- 228 -

18. Take down input shaft and output shaft together,

transmission assembly disassembly finished.

① Output shaft assembly.

② Input shaft assembly.

2. Disassemble output shaft assembly

1. The appearance of the output shaft assembly is shown in the figure.

2. Take down the adjusting washer (output shaft rear bearing).

①

②

- 229 -

Remove the output 6th gear and output shaft rear end bearing together.

Note: hook the lower end surface of the output 6th gear with the special

tool-puller

, and pull down the 6th gear and the bearing together.

Remove the output 5th gear and output shaft 4th gear together.

Note: hook the lower end surface of the output 4th gear with the special

tool-puller

, and pull down the 5th gear and the 4th gear together.

Remove the output 3rd gear, output 2nd gear assembly and 2nd gear

needle bearing together.

Note: hook the lower end surface of the output 2nd gear assembly with the special

tool-puller

, pull down the 3rd gear and 2nd gear assembly together

, and take down the 2nd gear needle bearing (pay attention to check

if the needle bearing is damaged).

- 230 -

Use the special tool to remove the 1st/2nd gear synchronizer assembly, 1st/2nd

gear synchronizer ring together.

7. Remove the output 1st gear assembly and 1st gear needle bearing (pay attention to

check if the needle bearing is damaged).

Note: Output shaft assemble disassembly is finished.

3. Disassemble input shaft assembly

1. Input shaft assembly is shown in the figure.

- 231 -

2. Remove the shaft rear screw plug.

3. Use special tool to remove the ball bearing, thrust washer, input 6th

gear assembly and input 6th gear needle bearing.

4. Remove the output 6th gear bushing.

Note: Use special tool to pull down the bushing.

- 232 -

Use special tool to remove 5th/6th gear synchronizer assembly, 5th/6th

gear synchronizer ring together.

Remove the input 5th gear assembly and 5th gear needle bearing.

7. Remove the input shaft 5th gear bushing, input 4th gear assembly and input 4th

gear needle bearing.

Note: Use special tool to pull down the bushing.

- 233 -

Remove the input 4th gear bushing, 3rd/4th gear synchronizer assembly, input 3rd gear

assembly and input 3rd gear needle bearing together.

Note: hook the lower end surface of the input 3rd gear assembly with the special

tool-puller

, pull down the input 4th gear bushing, 3rd/4th gear synchronizer assembly,

and input 3rd gear assembly together, and take down input

3rd gear needle bearing.

Note: Input shaft assemble disassembly is finished.

- 234 -

5. Key parts check

1. Input shaft check

Inspect the input shaft gear teeth to see if there are tooth wreckage, pitting

corrosion of tooth surface, severe abrasion of tooth surface or tooth surface scuffing.

If any of the above-mentioned phenomena arises, the input shaft must be replaced.

Use hand to feel if the bearing rotates neatly and has clamping stagnation, 2)the

first shaft must be replaced if it has.

2. Output shaft check

1. Check if there is any gear fracture, pitting corrosion or severe abrasion on

the gear surface, or the gear surface scuffing in the output shaft. If any of the

above-mentioned phenomena arises, the input shaft must be replaced.

2. Check the output shaft splines to see if there are severe wreckage and damage.

If there is any damage, the output shaft must be replaced.

3. Use hand to feel if the bearing rotates neatly and has clamping stagnation,

2)the first shaft must be replaced if it has.

3. Differential assembly check

1. Check if there is any gear fracture in the output shaft, pitting corrosion

or severe abrasion on the gear surface, or the gear surface scuffing of the main

reduction gear. If any of the above-mentioned phenomena arises, the main reduction

gear must be replaced.

2. Check the planet gear, half shaft gear and splines to see if there are severe

wreckage and damage. If there is any damage, replacement must be done.

3. Check the abrasion of the tapered roller bearing outer race and the roller.

If severe abrasion is found, the bearing must be replaced.

■ Taper needle bearing inner ring can not be disassembled.

■ Main reduction gear and differential housing can not be disassembled.

■ If the inner ring of tapered needle bearing is damaged, it is necessary to

replace the main reduction gear and the inner ring of tapered needle bearing at the

same time; It is required to re-select the adjusting gasket on the differential after

- 235 -

replacement, and the interference amount is 0.15-0.20mm.

4. Inspect all the gears

1) Inspect all the gears to see if there are tooth wreckage, pitting corrosion

of tooth surface, severe abrasion of tooth surface or tooth surface scuffing. If any

of the above-mentioned phenomena arise, the gear must be replaced.

5. Inspect the needle bearings of all the gears

1) Inspect the needles of all the gears to see if there is severe abrasion, if

the needle falls off and if the cage is intact. If any of the above-mentioned

phenomena arises, the needle bearing must be replaced.

6. Synchronizer ring check

1. Check if the synchronizer ring gear surface has damage or breakage.

2. Check if the conical surface has damage or wear and if the screw has compression

failure.

3. The 4th, 5th, and 6th gear synchronizer rings are single-cone rings. Press the

synchronizer ring toward the gear and inspect the clearance “A”. If “A” is less

than the limit value, the synchronizer ring shall be replaced.

Limit value "A"=0.5mm

4. The 1st, 2nd, and 3rd gear synchronizer rings are tri-cone rings. Press the

synchronizer ring assembly toward the gear and inspect the clearance “B” and “C”.

If “B” and “C” are less than the limit value, the synchronizer ring assembly shall

- 236 -

be replaced.

Limit value "B"=0.5mm; Limit value "C"=0.5mm

4. Synchronizer check

1. Assemble the synchronizer gear sleeve and the gear hub together. Inspect if they

can slide smoothly without any clamping stagnation.

2. Inspect if the interior surface rear and front ends of the gear sleeve are damaged.

■Notes: if the replacement is required due to the clamping stagnation or the

damage, the synchronizer must be replaced in a whole set.

- 237 -

- 238 -

Chapter VI. Assemble transmission

1. Assemble input shaft assembly

1. Press and install the ball bearing (in front of input shaft) on the input shaft.

Note: When pressing and installing the bearing, need to spread lubricating oil

to the input shaft bearing

2. Install the input 3rd gear needle bearing and input 3rd gear assembly to

the input shaft.

Note: Wjem installing the input 3rd needle bearing, the lubrciant is needed,

after installing bearing, spread the lubricating oil here, after installing input

3rd gear assembly,

it should rotate flexibly, and without any clamping stagnation.

- 239 -

3. Install the 3rd/4th gear synchronizer assembly and the 3rd/4th gear synchronizer ring to the input shaft.

Note: 1. When installing, pay attention to the direction of synchronizer;

2. The three-part groove of the gear hub and the sub-protrusion of the synchronous

ring three are matched.

4. Press and install the input shaft 4th gear bushing to the input shaft.

Note: When pressing and installing the bushing, need to spread lubricating oil

to the input shaft 4th gear

5. Install the input 4th gear needle bearing and input 4th gear assembly to

the input shaft.

- 240 -

6. Press and install the input 5th gear bushing to the input shaft.

Note: When pressing and installing the bushing, need to spread lubricating oil

to the input shaft 5th gear

7. Install the input 5th gear needle bearing and input 5th gear assembly to

the input shaft.

Note: When install the input 5th needle bearing, spread lubricating oil,

after installing bearing, spread the lubricating oil here, after installing input

5th gear assembly,

it should rotate flexibly, and without any clamping stagnation.

8. Install the 5th/6th gear synchronizer assembly and 5th/6th gear synchronizer ring to

the input shaft.

Note: 1. Pay attention to the direction of the synchronizer while assembling;

2. The three-part groove of the gear hub and the sub-protrusion of the synchronous

ring three

are matched.

- 241 -

9. Press and install the input 6th gear bushing to the input shaft.

Note: When pressing and installing the bushing, need to spread lubricating oil

to the input shaft 6th gear

10. Install the input 6th gear needle bearing, input 6th gear assembly and input

6Th gear thrust washer to the input shaft.

Note: When installing the input 6th gear needle bearing, the lubrciant is needed,

after installing bearing, spread the lubricating oil here, after installing input

6th gear assembly,

it should rotate flexibly, and without any clamping stagnation.

11.

Press and install the ball bearing (behind the input shaft) to the input shaft.

Note: When pressing and installing the bearing, need to spread lubricating oil

to the input shaft bearing

- 242 -

12. Install the screw plug to the input shaft.

Note: After pressing and installing the bearing, install the clamp ring in front

of the input shaft front bearing

, input shaft assembly installation is finished.

2. Assemble output shaft assembly

1. Press and install the tapered needle bearing (in front of the output shaft).

Note: When pressing and installing the tapered needle bearing, pay attention to

the press-fitting direction of the bearing

, and spread lubricating oil to the input shaft bearing position.

2. Install the output 1st gear needle bearing and output 1st gear assembly.

Note: When installing the output 1st needle bearing, the lubrciant is needed,

after installing bearing, spread the lubricating oil here, after installing input

1st gear assembly,

it should rotate flexibly, and without any clamping stagnation.

- 243 -

Install the 1st/2nd gear synchronizer assembly, the 1st/2nd gear synchronizer ring assembly and 1st/2nd

gear synchronizer snap ring.

Note: 1. Pay attention to the direction of the synchronizer while assembling;

2. The three-part groove of the gear hub and the sub-protrusion of the synchronous

ring three are matched.

Install the output 2nd gear needle bearing and output 2nd gear assembly.

Note: First heat the output 3rd gear to 130°±5°,

and then press and install it.

Install the output 4th gear.

Note: First heat the output 4th gear to 130°±5°,

and then press and install it.

- 244 -

Install the output 5th gear.

Note: First heat the output 5th gear to 130°±5°,

and then press and install it.

Install the output 6th gear.

Note: First heat the output 6th gear to 130°±5°,

and then press and install it.

Press and install the output rear tapered needle bearing and adjusting gasket (output

shaft rear bearing).

Note: When pressing and installing the tapered needle bearing, pay attention to

the press-fitting direction of the bearing

, and spread lubricating oil to the input shaft bearing position;

2. Gasket should be selected when assembling the transmission.

Output shaft assembly is finished.

- 245 -

3. Assemble Transmission Assembly

1. Put the all small assemblies together to the clutch housing.

2. Install the input shaft front bearing pressing plate, reversing gear shaft

assembly,

gear shifting shaft supporting seat, shift fork, shift block, shift fork shaft,

interlock plate.

3. Install the housing assembly.

Note: 1. Install the adjusting washer

(differential)

output shaft rear bearing adjusting

washer when assembling the transmission;

2. Spread sealant to the joint

surface of housing and clutch housing

;

- 246 -

3. After assembling transmission, first install reversing gear shaft bolt,

self-lock

pin assembly.

4. Install the gear select&shift assembly

Note: When installing the gear select&shift

assembly, shift each gear

to neutral position to install.

5. Accessory installation

Note: Install cable bracket, release fork, release

bearing,

release oil pump, reversing lamp

switch and other accessory

Assembly of transmission assembly is

finished.

- 247 -

Chapter VII Transmission Maintenance

1.Maintenance

1. The usage and maintenance of transmission should follow the usage and

maintenance of commercial vehicles, generally divided into three level technical

maintenance.

2. Check, replace or add the transmission lubricating oil regularly.

1.1 Transmission Regular Inspection and Maintenance List

Both the mileage and the time (by month) are marked on the item. The inspection

is subject to the figure (either the mileage or the time) that reaches the specified

data.

○ check, adjust or fasten; ★replace lubricant

Inspection interval(subject to the odometer value and month which comes first)

Months

Odometer

value×1000km

100

Transmission internal check

Check the gear oil level

in the transmission

○

Replace the

gear oil

level in the

transmission

Common

use

conditio

The first maintenance: no necessity to replace the

lubricant oil; check every 30,000km or 3 years later (if

necessary add or replace), replace every 100,000km or 5

years.

Other inspections

■ Note: the “severe operation conditions” include the following items:

- 248 -

(1) Driving in the area of much dust or the vehicle often explodes in the air or water

with salinity.

(2) Driving on the rugged, water-logged road or mountain road.

(3) Driving in cold area.

(4) Engine idles for long time or often drives in short distance in cold season.

(5) Use brake or emergency brake frequently.

(6) Tow the vehicle.

(7) Use as the taxi or self-rent vehicles.

(8) In the environment higher than 32℃, the driving time exceeds 50% of the total

driving time when driving slowly in the crowded city surpasses.

(9) In the environment higher than 30℃, the driving time exceeds 50% of the total

driving time when driving vehicle in more than 120km/h.

(10) Over-load driving.

2. Lubricating and Sealing

Items

Lubricating oil and

sealing adhesive

Quantity

Transmission wheel gear

oil

MTF10 75W/85 GL

2.2±0.1L

Transmission input shaft

spline

Lubricant oil

Appropriate

The joint surface of

housing and clutch

housing

Tonsan ®1596F

Appropriate

Transmission oil sealing

Lubricant oil

Appropriate

- 249 -

Chapter VIII Quick-wear Part List

No.

Part number

Name

Quantity

D-1701551-00-00

Oil sealing(input shaft）

D-1702241-50-00

Oil seal (Select & shift

shaft)

D-2303011-00-00

Oil seal (differential front)

D-2303011-00-00

Oil seal (differential rear)

H-1701516-79-00

Washer (Drain screw plug)

Q5280624

Resilient cylinder pin (Shift

lever knob, select&shift stop

block)

Q5280424

Resilient cylinder pin