Haima M3. Service Manual - part 8

 

Engine Suspension

 1G-1 

 

Chapter 7  Engine Suspension 

Table of Contents 

 

Engine Suspension ·································································································1G-2 

Engine Dismantling/Mounting ·································································1G-2 

Engine Suspension Dismantling/Mounting···················································1G-2 

Engine Suspension Diagram····································································1G-4 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine Suspension

 1G-2 

 

Engine Suspension   

Engine Dismantling/Mounting 

Warning 

  Fuel vapor is combustible, and keep away the 

spark and naked flame.   

  Fuel leakage and splash are dangerous, which 

will irritate the skin and eye. Due to this, 
follow the “Oil Circuit Safety Inspection 
Procedure” (see Fuel System, Preparatory 
Work before Repair).   

Complete the dismantling work 

  Respectively discharge A/C refrigerant, 

power steering liquid, gearbox oil, and engine 
coolant:  

1.  Disconnect the accumulator’s negative cable.   

2.  Dismantle the left/right driving axles (see 

Driving Axle Dismantling/Mounting).   

3.  Dismantle the air filter (see Intake System 

Dismantling/Mounting).  

4.  Dismantle heat sink(see Heat Sink, Heat Sink 

Dismantling/Mounting).  

5.  Dismantle the throttle cable(see Throttle 

Cable Inspection /Adjustment).   

6.  Dismantle the fuel hose (see  Fuel System, 

Preparatory Work before Repair)(see Fuel 
System, Inspection Work after Repair).   

7. Dismantle three-way catalyst converter 

assembly (see Exhaust System, Exhaust 
System Mounting/Dismantling).   

8.  Dismantle the accumulator and accumulator 

tray (see Engine Electrical System, 
Accumulator Dismantling/Mounting).   

9.  Dismantle PM wiring harness and engine’s 

connector (see PM Wiring Harness 
Dismantling/Mounting).  

10.  Dismantle the reverse switch joint and gear 

shift cable that are connected with the 
gearbox.  

11.  Dismantle power steering pump’s oil pipe 

connection.  

12. 

Dismantle A/C compressor’s pipeline 
connection.  

13.  Dismantle the engine and engine suspension 

according to the sequence illustrated in the 
figure.  

14. Mount parts according to the sequence 

reverse to the dismantling process.   

15. Inject A/C refrigerant and discharge the 

power steering liquid, gearbox oil, and engine 
coolant.  

16.  Correct the driving belt’s tension (see Driving 

Belt, Driving Belt Dismantling/Mounting).   

17.  Star the engine and conduct the following 

inspection work: 

(1) Inspect the belt pulley and driving belt’s 
deflection and interference.   

(2) Inspect if there is engine oil, engine 
coolant, gearbox oil, and fuel leakage.   

(3) Inspect the idling speed (see Engine 
Running, Idling Speed Inspection).   

18.  Confirm the road test.   

19. Inspect the engine oil, engine coolant, 

gearbox oil and power steering liquid’s level 
again.  

Engine Suspension Dismantling/Mounting   

Engine1# Suspension Bracket Dismantling/ 
Mounting  

Dismantle engine1# suspension bolt ①— take off 
engine1# suspension to inspect if the rubber is 
broken, hardened, or damaged --Dismantle 
engine1# Bracket Bolt ② (Engine End).   

Mount parts according to the sequence reverse to 
the dismantling process.   

 

Engine3# Suspension Bracket Dismantling/ 
Mounting  

Dismantle 3# suspension bracket bolt and nut ③ 
(engine end)--Dismantle engine3# suspension bolt 
②

 (body end)—take off engine3# suspension to 

inspect if the resonance block rubber is damaged, 
and inspect if 3# suspension seat suffers oil 
leakage or damage.   

 

Engine Suspension

 1G-3 

 

Mount parts according to the sequence reverse to 
the dismantling process.   

 

 

Engine Suspension

 1G-4 

 

Engine4# Suspension Bracket 
Dismantling/Mounting  

Dismantle 4# suspension bracket bolt ① 
(transmission end)--Dismantle 4# suspension nut ③ 
—take off 4# suspension to inspect if the rubber is 
broken, hardened, or damaged --Dismantle engine4# 
suspension bolt ② (body end). Mount parts 
according to the sequence reverse to the dismantling 
process.  

Engine Suspension Diagram   

1 Engine1# 

suspension 

 

2 Engine3# 

suspension 

3 Engine4# 

suspension 

 

1 

2 

3 

 

MF515L Transmission

 1H-1 

 

 

Chapter 8  MF515L Transmission 

Table of Contents 

 

MF515L Transmission·····························································································1G-2 

Overview ······································································································1G-2 

Transmission Troubleshooting and Maintenance ························································1G-3 

Troubleshooting ······························································································1G-3 

Transmission Emits High Noise or Abnormal Sound Reasons and Solutions ·······················1G-3 

Transmission Assembly Dismantling······································································1G-5 

Transmission Components Dismantling, Overhaul, and Remounting ································1G-7 

Differential Unit Dismantling and Mounting·····························································1G-12 

Left/right box body ··························································································1G-14 

Attached Table 1: Special Tools············································································1G-15 

Attached Table 2: Reference List of MF515L   
Transmission Bolt Tightening Torques····································································1G-16 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MF515L Transmission

 1H-2 

 

MF515L Transmission 

Overview  

The transmission, through three synchronizers and 
three transmission shafts (input shaft, intermediate 
shaft, and reverse gear shaft), can provide five 
forward gears and one reverse gear, of which all 
forward gears belong to constant-mesh type, but 
the reverse gear is a sliding idle gear.   

Low-speed synchronizer is mounted onto the 
intermediate shaft, and coupled with the 
intermediate shaft’s first gear and second gear. 
High-speed synchronizer is mounted onto the input 
shaft, and coupled with the input shaft’s third gear 
and fourth gear.   

On the input shaft the fifth-gear synchronizer is 
engaged with the fifth gear on the input shaft.   

Intermediate shaft drives the main reduction gear 
and differential device, so as to rotate the front 
driving axle that is connected with the front wheel.   

As for the maintenance work, sealant or equivalent 
products shall be smeared on gearbox housing 
surface’s corresponding parts, and the gearbox 
housing is made of aluminum. On the housing, the 
fixing bolt shall be tightened to specific torque 
with the torque wrench. Before remounting, all 
parts shall be cleaned thoroughly with cleaning 
agent or liquid and dry air, which is very 
important.  

 

 

Transmission assembly 

 

 

 

 

 

Internal gear shift mechanism 

 

 

 

 

Gearshift Actuator 

 

 

 

 

 

Gear Mechanism 

 

 

MF515L Transmission

 1H-3 

 

Transmission Troubleshooting and 
Maintenance  

The gearshift control lever’s motion is transmitted 
to transmission shaft and shift shaft through the 
transmission control shaft, and then transmitted to 
the transmission and gear shift lever, shaft, and 
fork or arm through the transmission cross arm and 
yoke. In addition, transmission interlocking plate is 
prepared to avoid the gear’s double engagement. In 
the mechanism there are five-gear and reverse-gear 
cams, cam guide spring, and fifth gear-reverse gear 
interlocking guide pin, in order to avoid the gear’s 
direct shifting from fifth gear to reverse gear.   

1)  When the transmission shifts to the fifth gear, 

the fifth gear-reverse gear shift cam will 
rotate with the shift shaft along the clockwise 
direction, and cam return spring will jack the 
cam to shift to the reverse gear.   

2)  Shift from the fifth gear to the neutral gear is 

permitted, but further shift to the reverse gear 
is prohibited.   

3)  Shift position is located at the neutral gear 

position of the fifth gear-reverse gear (see Fig. 
1-4). When the shift shaft moves upwards to 
facilitate the gear shift lever’s shift from fifth 
gear to the reverse gear, shift cam will stop 
due to blockage by the guide rod.   

4)  At this time, the system can shift to the 

reverse gear when there is not interference by 
shift cam.   

Troubleshooting  

Transmission’s main faults and troubleshooting 
methods: 

Out of Gear   

Reasons and Solutions: 

a.  Reason: shift rod suffers serious abrasion and 

distortion  

Solution: calibrate the shift rod manually. If the 
shift rod bends or suffers serious abrasion, replace 
it in time.   

b.  Reason: shift rocker suffers serious abrasion 

and distortion   

Solution: replace the shift rocker in time.   

c.  Reason: Self-locking spring’s elasticity is 

weakened  

Solution: Replace the self-locking spring in time.   

d.  Reason: Gear’s axial clearance is too large, 

which should be mainly attributed to the gear 
check ring’s serious abrasion   

Solution: Replace the gear check ring.   

e.  Reason: shift fork’s abrasion and distortion   

Solution: Calibrate the shift fork manually when it 

suffers distortion. Replace it when suffering 
serious abrasion.   

f.  Reason: Synchronizer gear housing, gear 

sleeve, or gear ring suffer abrasion   

Solution: If there is out of gear, replace the 
wear-out parts.   

g.  Reason: After being adjusted, transmission 

fails to reach the “Neutral Gear” position, or 
the adjusting mechanism is loosened.   

Solution: Place it to the “Neutral Gear”’ position 
again, and adjust the clearance.   

h.  Reason: the engine’s connection with the 

transmission and complete vehicle is too loose, 
or the clearance adjustment is inappropriate.   

Solution: Adjust the clearance   

Transmission Emits High Noise or Abnormal 
Sound Reasons and Solutions   

a.  Reason:Transmission has insufficient oil or the 

oil is not clean   

Solution: Inject sufficient oil or replace the oil.   

b.    Reason: Gear’s axial clearance is too large   

Solution: Replace gear or gear check ring.   

c.  Reason: Gear suffers abrasion or gear teeth is 

broken  

Solution: If the gear backlash exceeds the specified 
range, replace the gear. Standard backlash of the 
five-gear transmission is 0.1mm, and the operating 
limit is 0.3mm.   

d. Reason: synchronizer’s gear ring suffers 

abrasion or the gear is broken   

Solution: Replace the gear ring.   

e.  Bearing suffers damage or abrasion 

Solution:Replace bearing.   

f.  Bearing press plate suffers damage or 

abrasion.  

Solution: Replace the gear check ring.  

Shifting Difficulty   

 

MF515L Transmission

 1H-4 

 

Reasons and Solutions   

a.  Shift rod or shift fork incurs distortion or 

uneven abrasion   

Solution: Replace parts.   

b.  Self-locking steel ball and shift fork shaft’s 

groove suffer abrasion   

Solution: Replace parts.   

c.  Synchronizer’s gear ring gets stuck on the 

gear’s conic section   

Solution: Replace the gear ring.   

d.  Synchronizer spring is damaged   

Solution: Replace the synchronizer spring.   

e.  Gear sleeve and gear end suffer abrasion or 

abrasion of gear ring’s key groove becomes 
wider.  

Solution: Replace corresponding parts.   

Oil Leakage   

a.  Oil leakage at the drain plug 

Solution: first, the plug’s tightening torque is less 
than the specified value, and so inspect the tightening 
torque. If the tightening torque does not comply with 
requirements, tighten the plug. Second, there is 
deflection in engagement or thread teeth damage, 
replace corresponding parts.   

b.  Oil Leakage at Sealing Parts 

Solution: Replace sealing parts while abiding by 
operation specifications.   

c.  Oil Leakage at the Bonding Surface   

Solution: Conduct inspection and make all 
connection bolt’s tightening torques accord with 
specifications.  

d.  Oil Leakage at the Input Shaft’s Seal Ring 

Solution: first, inspect if the seal ring is damaged. 
If damaged, replace the sealing parts. Second, 
inspect if the right tank body’s supporting port 
suffers excessive abrasion. If it suffers, replace 
right tank body.   

On-spot Maintenance   

Replace Oil   

1)  While replacing and inspecting the lubricating 

oil, be sure to stop the engine and lift the 
automobile steadily.   

2)  Oil level and leakage cannot be inspected 

until the automobile has been lifted. If there is 
leakage, remedial actions shall be taken in 
time. 

3)  Drain original lubricating oil and inject new 

and specified lubricating oil.   

4)  Drain plug and oil filler plug’s torque 

specifications are as follows, and the drain 
plug itself has sealant.   

Tightening torque:12～18N·m 

Gear oil:GB13895-1992 heavy-load vehicle gear 
oil (GL-4) grade:75W.   

Oil filling volume:1.8～2.0L 

Notice 

  When the automobile is jacked for other 

maintenance work besides the lubricating oil 
replacement, inspection to leakage of 
lubricating oil shall be conducted as well.   

Differential Right/Left Oil Seal Replacement   

1) Jack the automobile and drain the 

transmission lubricating oil.   

2)  Dismantle the driving shaft from the 

differential.  

3)  Use the special tool and hammer to dismantle 

the oil seal and mount a new part. special 
tools(A): oil seal erector1(right); oil seal 
erector2(left) 

Oil seal’s mounting degree “a” on the differential 
side: 1.0-1.5mm 

4)  Smear lubricating grease on the oil seal’s rim, 

in addition to inspecting the contacting part 
between the driving shaft and oil seal, as well 
as ensure the smoothness.   

“A”: Suzuki Lubricating Grease A.   

 

 

MF515L Transmission

 1H-5 

 

Differential oil seal replacement 

5)  Mount driving shaft into the differential.   

Caution 

  When inserting the driving shaft’s bolt, do not 

scratch the oil seal’s rim. Make sure the 
driving shaft’s bolt has been inserted 
sufficiently, and the elastic check ring is fixed 
as original.   

6)  Inject transmission oil according to the 

requirements, and make sure the oil has been 
sealed tightly by the oil seal.   

Transmission Assembly Dismantling   

Dismantle Gearshift Actuator   

Dismantle the locking bolt assembly and the 
gearshift box’s assembling bolt, in addition to 
taking off the gearshift box’s components.   

Dismantle Gearshift Actuator 

 

 

 

1 Locking 

bolt 

assembly 

 

2 Assembling 

bolt 

M8×20(four) 

3 

Gearshift box components 

4 

Gearshift stop pin   

Notice 

  Make sure the gearshift box’s components are 

dismantled when the transmission stays at the 
“Neutral Gear” position   

1.  Dismantle the assembling bolt to split the box   

1)  Dismantle the assembling bolt from internal 

and external sides of the transmission; 

2)  Dismantle the reverse gear shaft bolt from 

lateral side of transmission; 

3)  Use the soft hammer to knock the left box’s 

rim and dismantle the left box.   

Special tool: Box splitter (A). 

 

 

Dismantle assembling bolt 

1 Assembling 

boltM8×40(nine) 

2 Assembling 

boltM8×40(five) 

 

Dismantle assembling bolt 

1 

Assembling boltM8×40(fourteen) 

2 Left 

box 

 

3 

reverse gear shaft bolt(one) 

 

Split the Box 

 

MF515L Transmission

 1H-6 

 

Dismantle Reverse Gearshift Mechanism and 
Reverse Gear   

1)  Take off input shaft’s oil tray and shim, and 

the intermediate shaft’s left bearing adjusting 
shim; 

2)  Dismantle the reverse shift fork bolt, and take 

off reverse shift fork assembly; 

 

Dismantle the reverse gear shift mechanism and 

reverse gear 

1  Internal gear shift mechanism 
2  Input shaft’s oil tray 
3  Input shaft’s shim 

4 

Intermediate shaft’s left bearing adjusting
shim 

5  5. reverse shift fork bolt 
6  6. reverse shift fork assembly 

3)  Take off reverse idler gear shaft and reverse 

idler gear assembly.   

4)  Dismantle gear mechanism and gear shift 

mechanism 

 

Dismantle Gear Mechanism and Gear Shift 

Mechanism 

1 Differential 

unit 

2 Intermediate 

shaft 

components 

3 

Input shaft components 

4 

Reverse gear shaft 

5 Reverse 

gear 

assembly 

 

5)  Use the soft hammer to knock input shaft 

lightly; 

6)  Take out the input shaft components, 

intermediate shaft components, first /second 
gear shift components, third/fourth gear shift 
components, fifth/reverse gear shift 
components from the box once for all.   

 

Take off the gear mechanism and gear shift 

mechanism 

1 

Internal gear shift mechanism 

2 

Input shaft oil tray 

3 

Input shaft shim 

4 

Intermediate shaft’s left bearing
adjusting shim 

5 

Reverse gear shaft bolt 

6 

Reverse gear shift fork assembly 

7 

Reverse gear fork spacer block 

Dismantle left box’s other components   

 

Take off other components   

1 Right 

box 

 

2 Magnet 

 

3 

Intermediate shaft’s right bearing
outer ring   

4 

Intermediate shaft oil tray 

 

 

MF515L Transmission

 1H-7 

 

1)  Take off other components   

2)  Dismantle differential unit from the right box   

3) Dismantle 

bolt, 

 

4)  Use special tools to dismantle the 

input shaft’s oil seal   

Special tools: (A): Slide shaft; 

(B): Oil seal ejector 

5) Use special tools to dismantle the 

intermediate shaft’s ring bearing outer ring.   

Special tools: (A): slide shaft; 

(B):Bearing ejector 

6)  Dismantle the differential’s right oil seal from 

right box.   

 

Dismantle the input shaft’s oil seal   

1 

Input shaft oil seal   

2 

Intermediate shaft’s right bearing
outer ring   

 

Transmission Components Dismantling, 
Overhaul, and Remounting 

Dismantle input shaft’s components   

1)  Use the bearing puller and extrusion device to 

dismantle the input shaft’s right bearing.   

2)  Use the puller and extrusion device to extrude 

left bearing, fifth gear synchronizer unit, and 
fifth gear once for all.   

3)  Take off the fifth gear needle bearing.   

4)  Take off the fifth gear shaft sleeve, fourth 

gear shaft sleeve, fourth gear synchronizer 
gear ring, fourth gear assembly, fourth gear 
needle bearing, third gear synchronizer gear 
ring, third gear assembly, and high-speed 
synchronizer unit.   

Notice: 

  To prevent the gear teeth from being damaged, 

make the teeth lean against the smooth and 
straight side of the bearing puller.   

Caution  

  Be sure to use the puller’s flat surface, in 

order to avoid the damage to third gear   

6)  Take out the third gear needle bearing from 

the shaft.   

 

Dismantle the input shaft’s right bearing   

1 Input 

shaft 

 

2 Right 

bearing 

 

3 Bearing 

puller 

 

 

Dismantle the input shaft’s left bearing, fifth gear, 
and fifth-gear synchronizer unit 

 

Dismantle the fifth gear shaft sleeve, four gear 
shaft sleeve, four gear synchronizer gear ring, 
fourth gear assembly, fourth gear needle bearing, 
third gear ring, third gear assembly, and 
high-speed synchronizer unit 

Assemble Input Shaft Components   

1.Input shaft 

2.Right bearing

3.Bearing puller

 

MF515L Transmission

 1H-8 

 

 

 

Input Shaft Components     

1 

Input shaft right bearing   

2 Input 

shaft 

 

3 

Input shaft third gear needle bearing   

4 

Input shaft third gear assembly 

5 

Third gear synchronizer gear ring   

6 Synchronizer 

spring 

 

7 

High-speed synchronizer gear hub   

8 

High-speed synchronizer slide block 

9 

High-speed synchronizer gear sleeve 

10 

Input shaft fourth gear shaft sleeve     

11 

Input shaft fourth gear needle bearing 

12 

Four gear synchronizer gear ring 

13 

Input shaft fourth gear assembly 

14 

Input shaft fifth gear shaft sleeve   

15 

Input shaft fifth gear needle bearing   

16 

Input shaft fifth gear assembly   

17 

Fifth gear synchronizer gear ring   

18 

Fifth gear synchronizer gear hub   

19 

Fifth gear synchronizer slide block   

20 

Fifth gear synchronizer gear sleeve   

21 

Input shaft left bearing   

1)  Clean all parts thoroughly and inspect if there 

is abnormal situation. Then mount the new 
one according to demands.   

  Notice  

Before assembling, clean every component 
and smear designated gear oil to slide the gear 
and the bearing surface. During the 
remounting process, use new gear ring on the 
shaft, and application of used gear ring is 
prohibited.  

2)  If the synchronizer’s components will be 

repaired, inspect the clearance “a” between 
the gear ring and the gear ring, and then 
inspect every gear’s crowned teeth, ring, and 
sleeve. After that, determine if the 
replacement shall be conducted.   

Clearance a: Theoretical value: 0.95- 1.45mm 

Ultimate value: 0.5mm 

3)  Ensure the lubrication, and blow air to every 

oil port to make sure that there is not 
blockage.  

 

1 Gear 

wheel 

2 Gear 

ring 

 

 

 

4)  Mount the high-speed synchronizer onto the 

hub, insert three slide blocks, and then mount 
the spring according to the illustration.   

 

1 

High-speed synchronizer spring   

2 Slide 

block 

 

3 

High-speed synchronizer gear hub 

 

 

MF515L Transmission

 1H-9 

 

4 

High-speed synchronizer gear 
sleeve 

5)  Use special tool and hammer to mount the 

right bearing.   

Special tools(A):bearing erector 

 

1 Right 

bearing 

 

2 Input 

shaft 

 

6)  Mount the third gear needle bearing, smear 

the lubricating grease, and mount the third 
gear and synchronizer gear ring.   

7)  Use special tool and hammer to drive in the 

high-speed synchronizer assembly.   

Note: when pressing and mounting the gear hub 
and gear sleeve, make sure the synchronizer gear 
ring’s teeth groove aligns with the synchronizer 
unit’s slide block.   

After pressing and mounting the synchronizer 
unit, inspect the third gear’s free rotation.   

Special tools(B):bearing erector1 

 

1 Input 

shaft 

 

2 Third 

gear 

 

3 Gear 

ring 

4 Synchronizer 

unit 

 

7)  Mount the four gear shaft sleeve and needle 

bearing, smear lubricating grease on the 
bearing, and then mount synchronizer gear 
ring and fourth gear.   

Notice 

  Make sure the four gear shaft sleeve is 

properly mounted.   

 

1 Shaft 

sleeve 

 

2 Needle 

bearing 

3 Gear 

ring 

4 Fourth 

gear 

9)  Mount the fifth gear shaft sleeve and needle 

bearing, smear lubricating grease on the 
bearing, and the mount the synchronizer gear 
ring and fifth gear synchronizer.   

10)  Press and mount the left bearing with special 

tool and hammer.   

special tools(C):bearing erector4 

Dismantle Intermediate Shaft Components   

1)  Use the puller and holding-down device to 

pull out the left conical bearing.   

Caution 

Use the puller and holding-down device that can 
support at least 5t load.   

 

1 Holding-down 

device 

2 

Intermediate shaft’s left bearing 

3 Puller 

2)  Use special tool to dismantle the fifth gear 

snap ring   

Special tools(A):snap ring plier 

3)  Use puller and holding-down device to pull 

out the fifth gear and fourth gear together.   

Notice 

  To prevent the gear teeth from being damaged, 

 

MF515L Transmission

 1H-10 

 

make the teeth lean against the smooth and 
straight side of the bearing puller.   

4)  Use the puller to operate the second gear and 

make use of the holding-down device to pull 
out the third gear and the second gear 
together. After that, pull out the needle 
bearing and third/ fourth gear spacer bushes.   

Caution 

  If the extrusion force exceeds 5t, release the 

extrusion immediately, and remount the 
puller bracket. Then, continue the push and 
compression.  

 

 

1 Intermediate 

shaft 

2 

Third/fourth gear spacer bushes 

3 Third 

gear 

 

4 Second 

gear 

 

3)  Take out the second gear synchronizer gear 

ring.  

4)  Use the puller to operate the first gear, and 

make use of the holding-down device to pull 
out the low-speed synchronizer unit, and first 
gear and second gear shaft sleeves.   

 

1 Low-speed 

synchronizer 

unit 

2 First 

gear 

 

3 

Puller(with plane facing upward)

5)  Dismantle the synchronizer unit.   

6)  Take out first gear needle bearing from the 

shaft.  

7)  Use the puller to dismantle right conical 

bearing.  

 

1

Metal  rod   

2

Intermediate shaft’s right conical bearing 
puller 

Mount Intermediate Shaft Components   

1)  Clean all parts thoroughly, inspect if there is 

abnormal situation, and mount new parts 
according to demands.   

 

1. Intermediate shaft’s left bearing assembly  2. 
Intermediate shaft snap ring 3. Intermediate shaft 
fifth gear  4. Intermediate shaft fourth gear 5. 
Third/fourth gear spacer bush 6. Intermediate shaft 
third gear  7. Intermediate shaft second gear 
assembly  8. Second gear needle bearing  9. 
Second gear shaft sleeve  10. low-speed 
synchronizer gear ring components 11. low-speed 
synchronizer unit 12.intermediate shaft second 
gear needle bearing 13. intermediate shaft first 
gear assembly 14. intermediate shaft right bearing 
assembly 15. intermediate shaft 

2)  If the synchronizer’s components will be 

repaired, inspect the clearance “a” between 
the ring and the gear, and then inspect every 
gear’s crowned teeth, ring, and gear ring. 
After that, determine if the replacement shall 
be conducted. 

Clearance “a”: standard value:1.45-2.35mm 

Ultimate value:0.5mm 

Puller (with plane 

facing upward) 

 

MF515L Transmission

 1H-11 

 

 

1 

Right conical bearing 

2 Intermediate 

shaft 

3)  Ensure the lubrication, and blow air into 

every oil port to inspect if there is blockage.   

 

1 intermediate 

shaft 

2 Oil 

port 

 

4)  Mount the low-speed synchronizer onto the 

gear sleeve, insert three slide blocks, and the 
mount the spring according to the illustration.   

Notice: Direction will not be specified to slide 
blocks, but slide blocks are defined as an 
assembled unit.   

 

1 

Low-speed synchronizer snap ring   

2 Slide 

block 

 

3 

Low-speed synchronizer gear hub   

4 

Low-speed synchronizer gear sleeve 

 

5)  Use special tool and hammer to tighten the 

right conical bearing.   

Special tools(A):bearing erector3 

 

 

1 

Right conical bearing 

2 Synchronizer 

gear 

ring 

6) Mount the needle bearing, smear the 

lubricating grease, and then mount the first 
gear and first gear synchronizer’s gear ring 
components.  

7)  Use special tool and hydraulic pressure to 

drive in the low-speed synchronizer unit.   

Notice 

  Lean the shaft against special tool according 

to the illustration, in order to prevent the 
conical bearing retainer from being extruded.   

  When pressing and mounting the 

synchronizer assembly, make sure the 
synchronizer slide block groove is aligned 
with the slide block   

  After pressing and mounting the 

synchronizer assembly, inspect the first 
gear’s free rotation. 

Special tools(A):bearing erector3; 

(B):bearing erector2; 

(C):bearing erector5 

 

1 Low-speed 

synchronizer 

unit 

2 

First-gear synchronizer gear ring components 

3 

Intermediate shaft first gear 

4 

Intermediate shaft right bearing 

A 

Key groove aligned with slide block   

1. Right conical bearing
2. Intermediate shaft 

 

 

 

MF515L Transmission

 1H-12 

 

8)  Mount second gear shaft sleeve and needle 

bearing, smear lubricating grease on the 
bearing, and then mount second gear 
synchronizer ring and second gear.   

Caution 

  Make sure the shaft sleeve is properly 

mounted  

 

1 

Intermediate shaft first gear 

2 Low-speed 

synchronizer 

unit 

3 Shaft 

sleeve 

4 Needle 

bearing 

5 

Second gear synchronizer gear ring 
components 

6 

Intermediate shaft second gear 

9)  Use special tool and holding-down device to 

press and mount the third gear and spacer 
bush.  

Notice 

  It is recommended that bush and third gear 

shall be firstly pressed and mounted before 
the fourth gear pressing and mounting, which 
can prevent the intermediate shaft from being 
excessively extruded.   

Special tools (A):bearing erector3 

(D): bearing erector   

 

1 

Third/fourth gear spacer bushes 

2 Third 

gear 

3 Second 

gear 

10)  Press and mount the fourth gear and fifth 

gear ditto.   

11)  Mount the intermediate shaft snap ring with 

special tool and the left conical bearing with 
hammer.  

Notice 

  To protect the conical bearing, make the shaft 

lean against the special tool according to the 
illustration.   

Special tools (A):bearing erector3 

(E):bearing erector4 

 

1 

Left conical bearing 

2 Fourth/fifth 

gear 

3 

Right conical bearing 

Differential Unit Dismantling and 
Mounting  

Differential Unit Dismantling   

1)  Use special tool to dismantle the right 

bearing.  

Special tools(A)bearing puller;(B) bearing puller 
accessories 

Notice 

  As for the bearing dismantling, if semilune 

puller is used together with holding-down device, 
the main reduction gear shall be dismantled in 
advance.  

2)  Use the puller to dismantle the left bearing, 

during which protect well the bearing.   

3)  Use the soft bench clamp to clamp the 

differential housing, and dismantle eight 
differential bolts. After that, take off the main 
reduction gear.   

4)  Use the snap ring plier to dismantle the 

differential planet gear shaft check ring, and 
then dismantle components and parts.   

1. Third/fourth gear spacer bushes 
2. Third gear 
3. Second gear 

1. Left conical bearing 
2. Fourth/fifth gear 
3. Right conical bearing