Dongfeng DFA1063DJ10 (14)-301/303. Manual - part 8

Transmission

MT-7

Transmission cover

1.Cover
2.Straight pin
3.Bell cap
4.Balancing spring--selecting shaft
5.Circlip for shaft
6.Oil seal--transmission cover
7.Control shaft and gear shift arm assy
8.Transmission shift lever
9.Steel ball
10.Damping spring--reverse gear
11.Lock shim--spring seat
12.Damping spring seat--reverse gear
13.Washer
14.O-ring
15.Gear selecting rotating arm assy
16.Switch assy
17.Sealing ring

18.Steel ball
19.Gasket spacer--cover
20.Transmission upper cover
21.Gasket spacer--upper cover
22.Spacer
23.Vent plug assy
24.Guide block--1st, reverse gear
25.Locking gear shift fork shaft spring
26.Steel ball
27.Gear shift fork shaft --1st, reverse gear
28.Gear shift fork --1st, reverse gear
29.Straight pin--interlock
30.Gear shift fork shaft--2nd, 3rd gear
31.Gear shift fork--2nd, 3rd gear
32.Gear shift fork--4th, 5th gear
33.Locking bolt--gear shift fork
34.Gear shift fork shaft--4th, 5th gear

Transmission

MT-8

Transmission Disassembly

Disassembly procedure

Before disassemble assembly, park the truck on the flat ground, shift the transmision in neutral position,

switch off the power and wedge up the front and rear wheel to ensure the safety.

1.Tilt the cab.

2.Screw off the drain plug screw, drain off the lubricant oil from transmission when the vehicle is warm.

3.Disassemble the propeller shaft assembly and  intermediate support bearing.

4.Screw off four tightening bolts of transmission and clutch housing.

5.Remove speedometer flexible shaft, reverse speed switch, and separate the parking brake steel wire and rocker.

6.Disassemble transmission control system.

7.Remove the return spring and dowel pin of the clutch's slave cylinder then put the clutch's slave cylinder assem-

bly onto frame safety.

8.Remove wire and tube.

9.Disassemble transmission with transmission jack and steel wire.

Disassembly

1.Remove transmission upper cover assembly, gasket,

power-take-off hole cover, reverse gear inspect hole
cover and output shaft rear bearing cover.

2.Disassemble input shaft bearing cover and gasket from

front end of transmission, tap input shaft slightly from
right to left with copper bar, take out the input shaft
with bearing from front end.

Take out main shaft front bearing and input shaft

rear bearing.

Transmission

MT-9

3.Take off speedometer drive gear and spacer, hold up

and sway up and down the front end of mainshaft with
hands, tap the rear end of mainshaft from right to left
with copper bar to move it backward out of the rear.
Take off mainshaft rear bearing snap ring, remove the
rear bearing form mainshaft with puller.

4.Slope the front end of mainshaft assembly upward to

take out the mainshaft assembly from transmission
casing.

Take out the 4th and 5th speed synchronizer assem-

bly locating tooth seat lock loop and thrust ring. Take off
the 2nd and 3rd speed synchronizer assembly and all the
parts in front of synchronizer in turn from mainshaft.

Take off 1st and reverse speed gear from rear end of

mainshaft, depress the thrust ring locking pin with screw-
driver, turn the thrust ring and remove it.

Note: When removing the thrust ring avoid the

rebound of the locking pin by the spring.

5.Remove reverse speed gear shaft lock plate, pull out

the reverse speed gear shaft with extractor, and take
out the reverse speed gear, bearing and spacer through
inspection hole of reverse speed.

6.Take off the countershaft front and rear bearing cover,

countershaft lock plate and nut, put the copper rod
against the front end of the countershaft and knock the
copper rod to move out the countershaft assembly a lit-
tle, remove the rear bearing from countershaft with
extractor.

Transmission

MT-10

7.Slop the front end of countershaft assembly upward to

take out the countershaft assembly from transmission
casing.

Put a copper rod against the countershaft front bear-

ing outer ring and then tap the copper rod to take out the
bearing outer ring. Remove the bearing inner ring and
nap ring from countershaft, press the engagement gear
out with press machine, then take off another snap ring,
press the other gears and spacers out with press machine
in turn.

Check

1.Check the backlash of each pair of gears.

Standard dimension    0.15~0.26mm

Service limit                0.50mm

2.Check the axial clearance of each gear.

The axial clearance of mainshaft 2nd speed gear:

Standard dimension       0.05~0.37mm

Service limit                   0.40mm

The axial clearance of mainshaft 4th speed gear:

Standard dimension       0.10~0.35mm

Service limit                   0.40mm

The axial clearance of mainshaft and input shaft

gears:

Standard dimension      <0.30mm