Haima S5 1.5T. Service Manual - part 8

 

Engine Suspension

 1G-3 

 

 

1 Engine1# 

suspension 

 

3 Engine3# 

suspension 

4 Engine4# 

suspension 

 

1.1.1 Engine1# Suspension Bracket Dismantling/ Mounting   

1. Dismantle the engine # 1 bracket bolts 1 and 2 (transmission side) ; 

2. Remove the engine mounts bolt # 1 flat washer 5 ,3, 4 flat washers and bolts to remove the engine 1# 6; 

3. Check rubber mounts broken, hardening or damage. 

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

 

 

Engine Suspension

 1G-4 

 

1.1.2 Engine3# Suspension Bracket Dismantling/ Mounting   

1. Dismantle the engine mounts bolt 3 # 3 and nuts 1 and 2 (engine side); 

2. Dismantle the engine mounts bolt 3 # 4, 5 and 6 (body side) ; 

3. Whether to remove the engine mounts Check rubber damaged # 3 check 3 # suspended base oil leaks or 

damage. 

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

 

1.1.3 Engine4# Suspension Bracket Dismantling/Mounting 

1. Dismantle 4 # 3 and 4-- suspension nut; 

2. Dismantle 4 # suspension bolts 1 and 2 (body side); 

3. Dismantle the four # mount bracket nut 6 and 7; 

4. Dismantle the four # suspended inspection rubber is broken, hardening or damaged.   

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

 

 

 

 

 

MF515L Transmission

 1H-1 

 

 

Chapter 8  6MT Transmission 

Table of Contents 

 

MF515L Transmission·······················································································1H-2 
1. Overview ·································································································· 1H-2 
2. Transmission Troubleshooting and Maintenance ···················································· 1H-3 

2.1 Troubleshooting······················································································ 1H-3 
2.2 On-spot Maintenance ··············································································· 1H-4 
2.3 Transmission Assembly Dismantling ····························································· 1H-5 
2.4 Transmission Components Dismantling, Overhaul, and Remounting ······················· 1H-7 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MF515L Transmission

 1H-2 

 

6MT Transmission 

1. 

Overview

   

The transmission, through 

4 

synchronizers and 

three transmission shafts (input shaft, intermediate 
shaft, and reverse gear shaft), can provide 

6 

forward gears and 1 reverse gear, of which all 
forward gears belong to constant-mesh type, but 
the reverse gear is a sliding idle gear.   

1-2-gear synchronizer is mounted onto the 
intermediate shaft, and coupled with the 
intermediate shaft’s first gear and second gear. 
3-4-gear synchronizer is mounted onto the input 
shaft, and coupled with the input shaft’s third gear 
and fourth gear.   

Five or six gear synchronizer assembly is mounted 
on the input shaft, and with the input shaft 5th gear 
and six-gear linked in. Reverse synchronizer 
assembly is mounted in the reverse gear shaft 
associated with the reverse gear. 

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.  

 

 

Fig. 1-1    Transmission assembly 

 

 

 

Fig. 1-2    Gear Mechanism 

 

 

 

Fig. 1-3    Internal gear shift mechanism 

 

 

 

Fig. 1-4    Gearshift Actuator 

 

 

 

MF515L Transmission

 1H-3 

 

1.1 Shifting mechanism 

Gear shift lever movement transmitted by the shift 
power to the shift shaft rotating arm, the pendulum 
is transmitted to the shift by shift shaft, then 
through the shift rocker pin to transmit the power 
to shift head, and finally delivered to the fork 
assembly. With a transmission gear interlock plate 
to prevent double engagement. 

When put up a gear shift interlock plate to lock the 
other, it can not be linked to other gear shift 
operation between each gear interlock avoid while 
hang two or more file archives. 

2. Transmission Troubleshooting 
and Maintenance 

 

2.1 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   

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   

 

MF515L Transmission

 1H-4 

 

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.   

2.2 On-spot Maintenance   

2.2.1 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, before installing 
the application on a certain amount of drain 
plug thread sealant.   

Sealant: Suzuki 1215   

Tightening torque:12～18N·m 

Gear oil:GB13895-1992 heavy-load vehicle gear 

oil (GL-4) grade:75W-90.   

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.   

2.2.2 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) 

Differential limit end face seal in place. 

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.   

 

Fig. 2-1 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.   

2.3

 

Transmission Assembly Dismantling   

2.3.1 Dismantle Gearshift Actuator   

 

MF515L Transmission

 1H-5 

 

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

 

Fig.3-1    Dismantle Gearshift Actuator 

1 

Gearshift box components 

2 

Gearshift box bolt M8×25(five) 

Notice 

  Make sure the gearshift box’s components are 

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

2.3.2 Dismantle the assembling bolt to split the 

box   

1)  Dismantle the assembling bolt from internal 

and external sides of the transmission; 

2) Dismantle 

the 

Left bearing plate 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). 

 

Fig. 3-2-a Dismantle assembling bolt 

1 Assembling 

bolt 

M8×40(

five)

 

 

Fig. 3-2-b Dismantle assembling bolt 

1 

Assembling bolt M8×40(twelve) 

2 

Left bearing plate bolt M8×25(six) 

3 Left 

case 

 

Fig. 3-2-c Split the Box 

2.3.3 

Dismantle the input shaft assembly, the 

intermediate shaft assembly and into the gear 
shift mechanism.

 

1)  Use the soft hammer to knock input shaft 

lightly; 

2)  Take out the input shaft components, 
intermediate shaft components, first /second gear 
shift components, third/fourth gear shift 
components,

 fifth/sixth

 gear shift components from 

the box once for all. 

 

Fig. 3-3-b    Dismantle Gear Mechanism and Gear 

Shift Mechanism 

 

MF515L Transmission

 1H-6 

 

1 

Input shaft components 

2 

Intermediate shaft components 

3 

into the gear shift mechanism 

3) The reverse shaft assembly, reverse fork 

assembly and differential assembly box in the 
right time overall removal; 

 

Fig. 3-3-c    Take off the gear mechanism and gear 

shift mechanism 

2.3.4 Dismantle left box’s other components   

 

Fig. 3-4-a    Take off other components   

1 

Intermediate shaft oil tray   

2 

Intermediate shaft’s right bearing
outer ring   

3 Magnet 
4 Close 

box 

pin（two） 

 

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.   

 

Fig. 3-4-b    Dismantle the input shaft’s oil seal   

1 

Input shaft oil seal   

2 

Intermediate shaft’s right bearing
outer ring   

 

2.4 Transmission Components 
Dismantling, Overhaul, and Remounting 

2.4.1 Dismantle input shaft’s components   

◆ 

Disassembly 

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, 

fourth gear, third gear speed 

synchronizer and together with the sleeve out 
together.

   

Notice: 

  To prevent the gear teeth from being damaged, 

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

 

1.Input shaft 

2.Right bearing

3.Bearing puller

 

MF515L Transmission

 1H-7 

 

Fig.4-1-a Dismantle the input shaft’s right bearing   

 

1 

Input shaft 
bearing left 

5 High-speed 

synchronous 

2 

Five-speed 
synchronous 

6 Third 

gear 

gear 

assembly 

3 

  5th gear gear 
assembly 

7 Input 

shaft 

4 

4th gear gear 
assembly 

8 Bearing 

puller 

 

Fig.4-1-b    Dismantle the input shaft’s left bearing, 

each gear

 synchronizer unit 

◆ 

Assembly 

Assemble Input Shaft Components   

 

 

Fig.4-1-d    Input Shaft Components     

1 

Left input shaft bearing lock nut 

2 

Input shaft left bearing 

3 

Input shaft 6th gear assembly 

4 

5th/6th gear synchronizer gear ring 

5 

Shaft snap ring 

6 

5th/6th gear synchronizer components

7 

Input shaft 5th gear assembly 

8 

Input shaft 4th gear assembly 

9 

3th/4th gear synchronizer gear ring 

10 

3th/4th gear synchronizer components

11 

Input shaft third gear assembly 

12 Input 

shaft 

 

13 

Input shaft right bearing   

14 

Right gear input shaft bearing ring 

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

: 1.0- 1.2mm 

Ultimate value: 0.5mm 

3)  Ensure the lubrication, and blow air to every 

oil port to make sure that there is not 
blockage.  

 

Fig.4-1-e 

1 Gear 

wheel 

2 Gear 

ring 

 

 

Fig.4-1-f 

 

MF515L Transmission

 1H-8 

 

4)  Mount the high-speed synchronizer onto the 

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

 

Fig.4-1-g 

1 

High-speed synchronizer spring   

2 Slide 

block 

 

3 

High-speed synchronizer gear hub 

4 

High-speed synchronizer gear 
sleeve 

5 

3rd gear input shaft 

5)  Use special tool and hammer to mount the 

right bearing.   

Special tools(A):bearing erector 

 Fig.4-1-h 

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 

 Fig.4-1-i 

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.   

 Fig.4-1-j 

1 Shaft 

sleeve 

 

2 Needle 

bearing 

3 Gear 

ring 

4 Fourth 

gear 

5 Input 

shaft 

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 

2.4.2 Intermediate Shaft Components   

◆ 

Disassembly 

1)  Use the puller and holding-down device to 

 

 

MF515L Transmission

 1H-9 

 

pull out the left conical bearing.   

Caution 

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

Fig.4-2-a 

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） Take the pressure with a pull and pull out 

together with all gear and low speed 
synchronous assembly. 

Notice 

  To prevent the gear teeth from being damaged, 

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

 

Fig.4-2-b 

1 

Intermediate shaft 5th gear 

2 

Intermediate shaft 5th gear ring 

 

Fig.4-2-c 

1 Intermediate shaft 5 3

rd

 gear 

2 5th gear 

6  2

nd

 gear   

3 4

th

 gear 

7 

Low-speed 
synchronizer unit 

4 3

rd

/4th gear 

spacer bush

 

8 1st 

gear  

4)  Dismantle the synchronizer unit.   

5)  Take out needle bearing from the shaft.   

6)  Use the puller to dismantle right conical 

bearing.  

 

Fig.4-2-d 

1

Metal  rod   

2

Intermediate shaft’s right conical bearing 
puller 

◆ 

Assembly 

Mount Intermediate Shaft Components   

1)  Clean all parts thoroughly, inspect if there is 

abnormal situation, and mount new parts 
according to demands.   

 

                                  Fig.4-2-e 

1

.Left intermediate shaft bearing lock nut 

2

. 

Intermediate shaft’s left bearing assembly 

3

. 

Intermediate

 

 shaft 6th gear 

 4.

 5th/6th gear 

spacer bush

 5.

 Intermediate shaft 5th gear

 6.

 

Intermediate shaft 4th gear

 7.

 3

rd

/4th gear spacer 

bush

 8.

 Intermediate shaft 3rd gear

 9.

 Intermediate 

shaft 2nd gear

 10.

 1st/2nd gear synchronizer gear 

ring

 11.

 Shaft snap ring

 12.

 1st/2nd gear 

 

MF515L Transmission

 1H-10 

 

synchronizer

 13. 

needle bearing 

14.

 Intermediate 

shaft first gear spacer bush 

15. 

Intermediate shaft 

first gear assembly

 16.

 Intermediate shaft

 17. 

Intermediate shaft right bearing assembly 

18.

 

Intermediate shaft right bearing ring

   

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:

1.0-1.2mm

 

Ultimate value:0.5mm 

Fig.4-2-f 

1 Gear 
2 Synchronizer 

ring 

3)  Ensure the lubrication, and blow air into 

every oil port to inspect if there is blockage.   

Fig.4-2-g 

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:  

Not to slow-sync the tooth shell or each slide in a 
predetermined direction 

, but slide blocks are 

defined as an assembled unit.   

Caution 

  If the extrusion force exceeds 5t, release the 

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

 

 

         Fig.4-2-h 

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 

 

Fig.4-2-i 

1 

Right conical bearing 

2 Intemrmediate 

shaft 

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; 

1. Right conical bearing
2. Intermediate shaft 

 

 

 

MF515L Transmission

 1H-11 

 

(B):bearing erector2; 

(C):bearing erector5 

Fig.4-2-j 

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   

8)  Mount 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  

 

                                                Fig.4-2-k

 

1 

Intermediate shaft first gear 

2 

1st gear synchronizer gear ring 

3 Low-speed 

synchronizer 

unit 

4 

2

nd

 gear bushings

 

5 Needle 

bearing 

6 

2nd gear synchronizer gear ring 
components 

7 

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   

 

Fig.4-2-l 

1 

Third/fourth gear spacer bushes 

2 Third 

gear 

3 Second 

gear 

10)  Press and mount the fourth gear and fifth 

gear ditto.   

11)  Installation 5th gear collar with a special tool 

(collar clamp). 

12) Installation left intermediate shaft bearing 

with special tools and hammers.   

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 

 

Fig.4-2-m

 

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

 

MF515L Transmission

 1H-12 

 

1 

Intermediate shaft left bearing 

2 5th 

gear 

3 4th 

gear 

4 

Third/fourth gear spacer bushes 

5 

Intermediate shaft right bearing 

2.4.3 Reverse gear shaft assembly   

(1)

 

Installation 

 

Fig.4-3-1

 

1 

Reverse gear shaft left bearing 6207P53

2 

Reverse gear synchronizer snap ring 

3 

Reverse gear synchronizer components

4 Reverse 

gear synchronizer gear ring 

5 Reverse 

gear 

gearwheel 

6 Needle 

bearing 

 

7 

Reverse gear shaft sleeve   

8 

Reverse gear shaft 

9 

Reverse gear shaft right bearing 6306E

(2)

 

1

st

/2

nd

 gear shift assembly, 3

rd

/4th gear shift 

components and 5th reverse gear components.

 

1)

 

Using the gap between the plug, check the fork 

and synchronizer sets, if it exceeds the limit 
1.0mm, the need to replace such parts. 

Note: 
To achieve the right to judge whether the parts 
need to be replaced, it is necessary to carefully 
check the contact position of the fork and the 
ring gear. 

 

Fig.4-3-2 

1 Shift 

fork 

2 Synchronizer 

sleeve 

Clearance “a”: standard value:1.0mm 

2)

 Use special tools and a hammer to remove parts. 

  Special tool (A): the spring pin puller (5mm) 

3)

 

The shift shaft inserted into each shell and 

check the smoothness of movement, if the 
movement is not flexible, be corrected on the 
reamer or similar tool. 

4)

 

Replace or correct as needed and installed shaft 

parts to ensure the correct order of parts, as 
shown in FIG.

 

 

Fig.4-3-3 

1 1

st

/2nd gear shift fork assembly 

2 

3rd/4th gear shift fork assembly 

3 

5th/6th gear shift fork assembly 

4 

Reverse gear shift fork assembly 

5 

Ball gear lock assembly 

 

 

MF515L Transmission

 1H-13 

 

2.4.4 Differential Unit   

◆ 

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.   

 

Fig.4-4-1 

◆  

Differential Unit Adjustment and 

Remounting  

Dismantling shall be determined according to the 
fault denoted in preceding content. After the 
dismantling, use naked eyes to inspect if the parts 
have problems, and prepare spare parts for the 
replacement and remount these parts, during 
which make sure all parts are clean.   

 

                                    Fig.4-4-2 

1.

 

Tapered Roller Bearings 

 2.Differential housing  

3. Planet gear  4. Differential spacer  5.Planet 
gear shaft  6.

 A type shaft circlip 

 7. Main 

reduction gear  8.Differential bolt  9.

 Induction 

ring gear 

 10.Differential half shaft 11.

 

Differential Adjusting washer

 

1)  Mount the differential gear according to the 

illustration and follow method below to 
measure the differential’s pushing clearance.   

Special tools(A): dial gauge;(B): magnet base 
differential gear pushing clearance: 0.03-0.40mm 

Left side: use the soft bench clamp to clamp the 
differential assembly, and also insert the dial feeler 
gauge’s measuring terminal onto the gear’s upper 
surface. Use two screwdrivers to move the gear 
upwards and downwards, in addition to reading the 
gauge feeler gauge’s pointer travel.   

Right side: use similar method and insert the dial 
feeler gauge’s measuring terminal onto the gear’s 
shoulder. Use the hand to move the gear upwards 
and downwards and read the feeler gauge’s 
reading.  

 

 

Fig.4-4-3 

 

MF515L Transmission

 1H-14 

 

1 Screwdriver 

 

2 Half 

axle 

gear 

 

2)  If the pushing clearance exceeds the specified 

value, select appropriate thrust washer from the 
following sizes for mounting, and inspect again 
if specified gear clearance range has been met.   

Thickness of thrust washers:0.9, 0.95, 1.0, 1.05, 
1.15, and 1.2mm 

3)  Drive in the spring from right side till the pin 

keeps even with differential housing surface.   

4)  Use special tool and hydraulic pressure to press 

and mount the left bearing. Special tool: 
bearing erector 6 

5)  Follow the Step 4, to press and mount the right 

bearing.  

6)  Use soft bench clamp to clamp the differential 

assembly, mount main reduction gear, and then 
use eight bolts to tighten the differential 
assembly according to required torque.   

Notice 

  Other bolts beyond requirements shall not be 

used.  

Tightening torque 

(a):80-100N·m 

 

Fig.4-4-4 

1 Differential 

bolt 

2 

Final reduction gear   

3 Torque 

wrench 

 

4 

Soft bench clamp   

2.4.4 Right box body   

1)  Mount the input shaft’s oil seal and keep the 

spring side upward. During the mounting 
process, use special tool and hammer.   

Special tool(A):bearing erector6 

 

1

Intermediate shaft’s right bearing outer ring 

2

Input shaft oil seal   

2)  Use special tool and hammer to mount the 

intermediate shaft’s right bearing outer ring 
and intermediate shaft’s oil tray.   

Special tools (B): Mounting connection rod   

(C): Bearing outer ring erector 

Special tools (D):Seal ring erector 

3)  Use special tool and hammer to mount the 

differential’s right oil seal till it keeps even 
with the housing surface.   

Notice 

  Make differential oil seal’s spring side face 

inward 

Special tools (E): Oil seal erector1 

Differential gear oil seal’s mounting depth: 
“a”:1.0-1.5mm 

2.4.5 Left Box Body   

1) 

With a special tool with a hammer on the 
differential left side oil package, until the 
surface is flush with the housing. 

 

Notice 

  Make the oil seal’s spring side face inward   

Special tools(A):Oil seal erector2: differential oil 
seal’s mounting depth: “a”: 1.0-1.5mm 

   

2) 

Intermediate shaft with a plastic hammer, 
gently knock on the left side of the bearing 
outer ring into the housing chamber.

 

Oil seal

 

1. Main reducer gear bolt 
2. Final reduction gear 
3. Torque wrench 
4. Soft bench clamp