Dongfeng DFA1101GZ5AD6J-907. Manual - part 34

 

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Dongfeng DFA1101GZ5AD6J-907. Manual - part 34

 

 

Transmission

MT-18

5.Make use of tools to take out the gear shift fork of the

reverse gear, 5th and 6th speed gear, and the spring pin
of every guide block;

6.Knock down the 5th and 6th speed or reverse gear shift

shaft, and then take down the interlocked pin, reverse
gear or 5th and 6th speed gear shift fork and steel ball;

7.Knock out the 1st and 2nd gear shift fork spring pin,

and then the 1st and 2nd gear shift fork and 3rd and 4th
speed gear guide block shaft.

Transmission top cover

1.Take down the elastic ring, and then remove the select

rocker arm and O-ring;

Transmission

MT-19

2.Loose the screw and remove the locking spacer, then

take out the spring and steel ball from the gear shift
lever;

3.Make marks on the same place of the gear shift lever

and gear shift shaft spline;

4.Knock out the straight pin by a hammer and then pull

the gear shift shaft.

Transmission

MT-20

Cleaning

Cleaning is compulsive because parts and components are often covered up with dirty oil and slurry. Appli-

cable washing methods include vapor wash, Light oil wash, acid wash or alkaline wash, neutral agent wash,
trichloroethylene wash, Magnus solution wash, etc. Some damages may be exposed during washing, so keep an
eye on the parts and components during washing.

Metal parts

Light oil

 Unlike other solutions, light oil is not able to osmose into and solute slurry. So except for the finish surface,

clear the slurry with metal brush or other tools, and then wash twice as specified above.

Alkaline solution

Don't wash with alkaline solution if the part or component is of alloyed metal, alkaline solution is an ideal

washing agent for steel or cast iron.

Note:
 If wash with alkaline solution, prepare some neutralizing agent such as boric acid solution. In case alkaline

solution splash into eyes or onto skin, wash it off with neutralizing solution.

Rubber parts

Don't wash with mineral oil. Get rid of slurry or filth with alcohol or clean cloth.

Oil channel

Let a wire go through the oil passage to unclog the passage, then wash the passage by injecting washing solu-

tion into it with pressurized nozzle.

Anticorrosion

After getting rid of the dirty oil on the component, apply a layer of clean grease to prevent corrosion.

Check

Check parts and components with special gauges or tools. Decide whether a component can continue to

serve according to specified maintenance standards. Damaged components should be repaired or replaced as
required.

 If one of a pair of components fitted together is so worn that the fit clearance exceeds the specified range,

replace the pair of components together.

Out of consideration of preventive maintenance, some components should be replaced before reaching ser-

vice limit.

Carefully inspect the surface of components by eye looking or red check method. Repair or replace the com-

ponent if its surface has the following abnormal signs: 

uneven wear,

biased wear, 

scratch, 

crack, 

distortion, 

malfunction or becoming weak (spring), 

bent, 

Transmission

MT-21

loose, 

abnormal noise (bearing), 

discolored, 

eroded, 

deteriorate (friction lining), etc.

All the rubber pieces, such as O-rings, oil seals, washers, cannot be further used after disassembled.

Transmission top cover

1.Measure the clearance between gear shift lever and

gear select rocker arm;

Repair standard: 0.1~0.4mm

Wear limit: 0.8mm

2.Measure the clearance between gear shift shaft and

gear shift lever spline;

Repair standard: 0.05~0.11mm

Wear limit: 0.5mm

3.Measure the clearance between gear shift lever and

every guide block.

Repair standard: 0.1~0.4mm

Wear limit: 1.0mm

 

 

 

 

 

 

 

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