Dongfeng DFA1101GZ5AD6J-907. Manual - part 30

Transmission

MT-2

Tightening Torque

Transmission Dismount

Before disassemble the assembly, switch the ignition key to OFF, and wedge up the front and rear wheel to

ensure the safety.

1.Screw off the drain plug screw, drain off the lubricant oil from the underpart of the transmission;

2.Disassemble the driving shaft assembly and central support bearing;

3.Remove the speedometer flexible shaft;

4.Disassemble transmission control system

5.Remove the return spring and dowel pin of the clutch slave cylinder then safely put the clutch slave cylinder

assembly onto the frame;

6.Remove wire and tube.

7.Disassemble the transmission with transmission jack and steel wire.

Item

Tightening Torque （N.m）

Clutch housing connecting bolt

142~186

fasten nut of propeller shaft connecting flange

333~549

Transmission upper cover fixed bolt and nut

32~42

Transmission cover fasten bolt

20~26

Reversing lamp switch and neutral position switch

20

Power take-off housing connecting bolt

Standard

47~63

Countershaft rear bearing cover fixed bolt

59~79

Fixed bolt of mainshaft rear bearing seat 

M12

59~79

M14

93~124

Fixed bolt of drive gear shaft bearing cover

33~44

Reverse gear shaft locking plate bolt

20~26

Mainshaft front locking nut

300

Oil drain screw plug and filler port screw plug

120~140

Gear shift guide bolt

40

Countershaft rear locking nut

300

Transmission

MT-3

Transmission Disassembly

Transmission housing and drive gear shaft

Set the transmission on the working table carefully. If there is not a working table, make use of a simple table

to support the transmission housing first, and then carefully do the disassembly.

1.Small hex guide bolt
2.Spring washer
3.Bearing cover--drive gear shaft
4.Bearing cover spacer--drive 
gear shaft
5.Oil seal --transmission drive 
gear shaft
6.Snap ring for shaft
7.Staved steel ring for shaft
8.Rear bearing--transmission 
drive gear shaft
9.Transmission drive gear shaft
10.Spring washer
11.Hex bolt

12.Cover board--power take-off 
hole
13.Cover board spacer--power 
take-off hole
14.Oil screw plug assy
15.Sealing washer
16.Transmission housing
17.O-ring--transmission counter-
shaft
18.Rear bearing seat spacer--
mainshaft
19.Speedometer oil seal assy
20.Speedometer flexible joint
21.Sealing washer

22.Speedometer driven gear
23.Rear bearing seat--mainshaft
24.Skeleton oil seal assy
25.Small hex guide bolt
26.Spring washer
27.Bolt--for bearing cover
28.Spring washer
29.Countershaft rear bearing 
cover
30.Spacer--countershaft rear bear-
ing cover
31.Sealing washer
32.Oil screw plug assy

Transmission

MT-4

Disassembly of transmission accessories

1.Remove the clutch housing assembly;

2.Remove the transmission upper cover assembly and

spacer;

3.Dismantle the power take-off cover and spacer;

4.Measure the backlash of every pair of gear and take the records;

Note: Take three points of every pair of gear to mea-

sure.

Transmission

MT-5

5.Measure the axial clearance of every gear and take the

records.

Check point

1.Clearance between 6th speed gear and 6th speed gear thrust ring;

2.Clearance between 4th speed gear and 6th speed gear thrust ring;

3.Clearance between 3rd speed gear and 3rd and 4th speed gear fixed seat;

4.Clearance between reverse gear and reverse gear fixed seat;

5.Clearance between 2nd speed gear and 3rd speed gear thrust ring;

6.Clearance between 1st speed gear and reverse gear seat. 

Transmission body

1.Remove the rear bearing cover of the mainshaft;

2.Remove the speedometer drive gear and spacer;