Great Wall service chassis and body Manual - part 8

MT-20

Transmission

 Output Shaft Assembly (Components Figure)

Output shaft assembly

Components  figure

synchronizer spring

expansion ring

snap ring

synchronizer

slide block

3th,4th gear synchronizer

meshing sleeve

3th gear needle bearing

synchronizer hub of 3rd

and 4th gear

toothed ring of

synchronizer

gear components of 3rd gear

steel ball

synchronizer sliding block

synchronizer meshing sleeve

of 1st and 2nd gear

gear components

of 1st gear

1st gear shaft sleeve

locking ring of output

shaft rear bearing

spring expansion ring

needle bearing of

2nd gear

gear components

of 2th gear

toothed ring of synchronizer

for 1st and 2nd gear

toothed ring of synchro-

nizer for 1st and 2nd gear

needle bearing of 1st gear

rear bearing of

output shaft

gear of 5th gear

odometer drive gear

drive gear snap ring of odometer

output shaft

snap ring of 5th gear

steel ball

MT-21

Transmission

 Output Shaft Assembly(Disassembly of Output Shaft Assembly)

Disassembly of output shaft assembly

1.

Remove the drive gear of speedometer

(a)  Pry down the two shield rings with open end ring plier

(b)  Dismantle the drive gear of tachometer.

(c)  Take out the steel ball with magnetic stick.

2.

Remove the 5th gear,rear bearing of output shaft,1st

gear assembly,1st gear shaft sleeve and needle bearing

of 1st gear

(a)  Take down the circlip of 5th gear with two screwdrivers

and one hammer.

(b)  Dismantle the rear bearing of output shaft,1st gear assem-

bly and 1st gear sleeve with press machine.

(c)  Remove the needle bearing of 1st gear.

3. 

Remove the synchronized ring

4.

Take down the steel ball

Take out the steel ball with magnetic rod.

5.

Take down the 1st and 2nd gear synchronizer assembly,

2nd gear assembly,and 2nd gear needle bearing.

(a)  Remove the 1st and 2nd synchronizer assembly and 2nd

gear components.

(b)  Take off the needle bearing of the 2nd gear.

6. 

Take down the meshing sleeve ,sliding block and spring.

Remove the three sliding blocks and two springs from the

synchronizer assembly with one screwdriver.

MT-22

Transmission

 Output Shaft Assembly(Disassembly of Output Shaft Assembly)

7. 

Take down the 3rd and 4th gear synchronizer assembly,

3rd gear and needle bearing .

(a)  Remove the snap ring with plier for snap ring.

(b)  Take down the 3rd and 4th gear synchronizer assembly and

3rd gear with press machine.

(c)  Remove the needle bearing .

8.

Take off the meshing sleeve ,sliding block and spring

from 3rd and 4th synchronizer.

Remove the three sliding blocks and spring from the meshing

sleeve  with one screwdriver.

MT-23

Inspection of output shaft assembly

1.

Check the axial clearance of every gear:

For the transmission made by Shang Chi:(0.15

0.33)

mm(1st,2nd,and 3rd gear position)

For the transmission made by Tang Chi:(0.1

0.25)mm

(1st gear position)(0.09

0.26)mm,(2nd and 3rd gear

position)

2. 

Measure the idle clearance of every gear.

Check the radial clearance of every gear with micrometer.

Standard clearance:

For the transmission made by Shang Chi:0.05mm

(1st,2nd,and 3rd gear position)

For the transmission made by Tang Chi:

(0.009

0.033)mm(2nd and 3rd gear position)

(0.009

0.032)mm(1st gear position)

Max clearance

For the transmission made by Shang Chi:0.05mm

For the transmission made by Tang Chi:0.033mm

(2nd,and 3rd gear position);0.032(1st gear position)

If the clearance value exceeds the limit above , the gear,

needle bearing or shaft should be changed.

PK Inspection for output shaft and 1st gear shaft sleeve

(a)  Measure the thickness of output shaft flange with callipers

Min thickness

 For the transmission made by Shang Chi:4.75mm

 For the transmission made by Tang Chi:4.65mm

(b)  Measure the thickness of flange of 1st gear shaft sleeve

with callipers

Min thickness

  For the transmission made by Shang Chi:3.87mm

  For the transmission made by Tang Chi:3.795mm

(c)  Measure the outside diameter of the journal of output shaft

with micrometer.

Min diameter:19.216mm

Gear of 2nd gear:37.984mm

Gear of 3rd gear:34.984mm

Transmission

 Output Shaft Assembly(Inspection of Output Shaft Assembly)

1st gear position

2nd gear position

3rd gear position