JAC HFC4DA1-2C engine. Service Manual - part 32

MT

MT

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MT Manual

Manual

Manual

Manual Transmission

Transmission

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Transmission

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Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

Manual

Manual

Manual

Manual transmission

transmission

transmission

transmission

1.

Remove manual transmission.

●

Oil drainage

Attention:

Remove oil drain plug with

wrench and drain oil through this plug instead
of other parts.

2.

Remove release bearing from input shaft front cap.

3.

Remove input shaft front cap from transmission.

4.

Remove clutch housing.

Attention: If the transmission housing is assembled
tightly with clutch housing, a rubber hammer or
copper rod can be applied to knock on the housing
edge to make them become loose.

 

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Manual Transmission

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Removal/Installation

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Removal/Installation (Continued)

(Continued)

(Continued)

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Manual

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5.

Remove clutch housing.

�

Place

it

upside

down

on

cardboard

horizontally.

6.

Remove input shaft oil seal from transmission.

7.

Remove top cover from transmission.

Attention: If the transmission housing is assembled

tightly with clutch housing, a rubber hammer
or copper rod can be applied to knock on the
housing edge to make them become loose.

8.

Remove gear shift rocker arm assembly from
transmission.

 

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Removal/Installation (Continued)

(Continued)

(Continued)

(Continued)

Manual

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Manual transmission

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transmission

transmission

9.

Use pneumatic gun or wrench to remove output
shaft bolt of transmission and knock out flange nut.

10. Remove rear cover of transmission.

Attention: If the transmission housing is assembled

tightly with clutch housing, a rubber hammer
or copper rod can be applied to knock on the
housing edge to make them become loose.

11. Remove vehicle speed sensor.

12. Remove vehicle speed sensor gear and bushing.

 

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Removal/Installation (Continued)

(Continued)

(Continued)

(Continued)

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13. Remove side cover from transmission.

�

Turn over the transmission.

�

Remove bolts from side cover.

14. Remove side cover from transmission.

15. Remove gear shift fork from transmission.

16. Remove gear shift block from transmission.

�

Punch out the spring pin by using punch and
remove each shift fork, shift block and shift
fork shaft.

 

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(Continued)

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17. Remove gear selector fork from transmission.
Attention:

Attention:

Attention:

Attention:

Please notice the position of steel balls. This

transmission has 7 steel balls and 1 steel locking
piece, among which, 3 steel balls are self-locking
devices and the others are interlocking devices.

18. Remove all bearing circlips by using circlip pliers.

19. Pull out bearings except for input shaft bearing cap

with SST.

20. Remove input shaft of transmission.

 

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Removal/Installation (Continued)

(Continued)

(Continued)

(Continued)

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Manual transmission

transmission

transmission

transmission

21. Remove output (input) shaft of transmission and

place it on cardboard horizontally.

22. Remove output shaft of transmission.

23. Remove output shaft of transmission.

Assemble

the

output

shaft

and

input

shaft

of

transmission together and place them on clean
cardboard horizontally.

24. Remove reverse gear shaft pin of transmission.

 

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(Continued)

(Continued)

(Continued)

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25. Use a rubber hammer or copper rod to knock on the

reverse gear shaft gently.

26. Pull out the reverse gear shaft pin and punch out

the reverse gear shaft.

27. Remove reverse gear of transmission.

Place it on clean cardboard horizontally.

28. Assemble the reverse gear and reverse gear shaft as

a whole.

 

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Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation (Continued)

(Continued)

(Continued)

(Continued)

Manual

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Manual transmission

transmission

transmission

transmission

29. Loosen the 5

th

gear circlip with circlip pliers and

remove the fixed circlip from the 5

th

driving gear.

30. Adjust the position of 5

th

gear of countershaft and

remove countershaft of transmission.

31. Transmission gearing diagram

 

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Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Exploded

Exploded

Exploded

Exploded View

View

View

View of

of

of

of Reverse

Reverse

Reverse

Reverse Gear

Gear

Gear

Gear Shaft

Shaft

Shaft

Shaft

Reverse Gear Shaft Parts List

S/N

Name

Qty.

1

Reverse gear assembly

1

2

Reverse gear shaft

1

3

Reverse gear shaft pin

1

 

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Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Exploded

Exploded

Exploded

Exploded View

View

View

View of

of

of

of Output

Output

Output

Output Shaft

Shaft

Shaft

Shaft Assembly

Assembly

Assembly

Assembly

 

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Output

Output

Output

Output Shaft

Shaft

Shaft

Shaft Parts

Parts

Parts

Parts List

List

List

List

S/N

Name

Qty.

S/N

Name

Qty.

1

Output shaft head needle
roller bearing

1

27

Thrust washer of 5

th

gear

1

2

Circlip

1

28

Ball bearing

1

3

3rd/4th gear synchronizer
spring

2

29

Stop ring

1

4

3rd/4th gear synchronizer
gear hub

1

30

Front spacer bush of odometer
driving gear

1

5

3rd/4th gear synchronizer
gear sleeve

1

31

Odometer driving gear

1

6

needle roller bearing

1

32

Rear spacer bush of odometer
driving gear

1

7

3rd/4th gear synchronizer
ring

1

33

Flange

1

8

3

rd

gear assembly of output

shaft

1

34

O-ring

1

9

Circlip

1

35

Conical spring washer

1

10

Thrust washer of 2

nd

gear

1

36

Output shaft nut

1

11

2

nd

gear assembly of output

shaft

1

37

Steel ball

1

12

Needle roller bearing

2

38

3rd/4th gear synchronizer spring

2

13

1st/2nd gear synchronizer
ring

1

39

1st/2nd gear synchronizer spring

2

14

Circlip

1

40

3rd/4th gear synchronizer slider

3

15

1st/2nd gear hub

1

41

Reverse/5th

gear

synchronizer

slider

3

16

1st/2nd gear sleeve

1

42

Reverse/5th

gear

synchronizer

gear hub

1

17

1st/2nd gear synchronizer
ring

1

43

18

1st gear assembly of output
shaft

1

44

19

3rd/4th gear synchronizer
slider

3

45

20

Output shaft

1

46

21

Needle roller bearing

1

47

22

Reverse gear assembly of
output shaft

1

48

23

Circlip

1

49

24

Reverse/5th

gear

synchronizer gear sleeve

1

25

3rd/4th gear synchronizer
ring

1

26

5

th

gear assembly of output

shaft

1

 

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Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Exploded

Exploded

Exploded

Exploded View

View

View

View of

of

of

of Top

Top

Top

Top Cover

Cover

Cover

Cover Assembly

Assembly

Assembly

Assembly

 

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Top

Top

Top

Top Cover

Cover

Cover

Cover Assembly

Assembly

Assembly

Assembly Parts

Parts

Parts

Parts List

List

List

List

S/N

Name

Qty.

S/N

Name

Qty.

1

Transmission cover

1

14

Hexagon bolt

2

2

Outer gear selector rocker arm assembly

1

15

Large washer

2

3

Flat washer

1

16

Spring washer

8

4

Oil seal

1

17

Hexagon bolt

1

5

Inner gear selector rocker arm

1

18

Flat washer

6

Spring pin

1

19

Washer

1

7

Reverse/5th gear damping spring

1

20

Knurled pin

1

8

Oil seal

1

21

Oil filler plug assembly

1

9

Flat washer

1

22

1st/2nd gear damping spring

1

10

Reversing lamp switch

1

23

Flat washer

1

11

Hexagon bolt

8

24

Outer gear shift rocker arm assembly

1

12

Inner gear shift rocker arm

1

13

Spring washer

8

 

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-32-

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Exploded

Exploded

Exploded

Exploded View

View

View

View of

of

of

of Input

Input

Input

Input Shaft

Shaft

Shaft

Shaft Assembly

Assembly

Assembly

Assembly

S/N

Name

Qty.

S/N

Name

1

Circlip

1

5

3rd/4th gear synchronizer ring

2

Stop ring

1

3

Ball bearing (input shaft)

1

4

Input shaft assembly

1

 

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Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Exploded

Exploded

Exploded

Exploded View

View

View

View of

of

of

of Transmission

Transmission

Transmission

Transmission Rear

Rear

Rear

Rear Cover

Cover

Cover

Cover

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

S/N

Name

Qty.

S/N

Name

Qty.

1

Rear cover

1

9

Odometer guide sleeve

1

2

Vent plug

1

10

O-ring

1

3

Hexagon bolt

1

11

Spring pin

1

4

Spring washer

1

12

Hexagon bolt

5

5

Hexagon bolt

2

13

Spring washer

7

6

Oil seal

1

7

Oil seal

1

8

Odometer gear

1

 

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Exploded

Exploded

Exploded

Exploded View

View

View

View of

of

of

of Countershaft

Countershaft

Countershaft

Countershaft Assembly

Assembly

Assembly

Assembly

S/N

Name

Qty.

S/N

Name

Qty.

1

Circlip

1

6

Circlip

1

2

Cylinder roller bearing

1

7

5th gear of countershaft

1

3

Main gear of countershaft

1

8

Cylinder roller bearing

1

4

3rd gear of countershaft

1

9

Stop ring

1

5

Countershaft

1

10

Circlip

1