SECTION 3 TRANSMISSION

Transcription

1 SECTION 3 TRANSMISSION 1. INTRODUCTION GENERAL DESCRIPTIONS -1. MAIN SPECIFICATIONS GEAR CONTROL PARTS EXPLODED VIEW OF GEARSHIFT CONTROL PARTS INSPECTION AND MAINTENANCE SERVICING TIGHTENING TORQUE DISASSEMBLY AND REASSEMBLY TRANSMISSION CASE QUADRANT BOX TRANSMISSION ASSEMBLY (K805) TRANSMISSION ASSEMBLY (K1406/K806) TRANSMISSION ASSEMBLY (T9S6, T10S6, T15S6, T16S6) TRANSMISSION (T14S10) TRANSMISSION (ZF16S 151/ 1) DIAGNOSIS AND TROUBLESHOOTING PROCEDURES SPECIAL TOOLS

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3 1. INTRODUCTION The transmission is mounted to the rear of the engine and is designed to allow the car to move forward and in reverse. If also has a neutral position. In this position, the engine can run without applying power to the drive wheels. Therefore, although there is input to the transmission when the vehicle is in neutral, there is no output from transmission because the driving gears are not engaged to the shaft. A manual transmission is an assembly of gears and shafts that transmits power from the engine to the drive axle and changes in gear ratios are controlled by the driver. By moving the shift lever on a manual transmission and depressing the clutch pedal, various gear and speed ratios can be selected. The gears in a transmission are selected to give the driver a choice of booth speed and torque. Based on T10 TRANSMISSION Synchromesh (key type) Clutch housing Gear shift rail 3rd rd 5th Reverse 4th Upper 1st gearshift Gearshift fork Lower gearshift Synchromesh (pin type) Parking brake Pilot bearing Drive pinion 5th 4th Reverse 1st 6st 3rd nd Mainshaft 1st 4th 3rd 5th nd Reverse 6th Release fork Constant Counter shaft Reverse shaft Extension housing Synchromesh (key type) TM1490 3

4 . GENERAL DESCRIPTIONS -1. MAIN SPECIFICATIONS Model T9S6 T10S6 K1406 T14S10 T15S6 T16S6 Type Gear mesh type Advance 6 position Reverse 1 position Front: Synchro mesh type Rear: Constant mesh type G e a r r a t P T O Fill capacity (L) Weight (kg) Max. torque Ratio to engine speed 1st nd 3rd 4th 5th 6th 7th 8th Reverse Type (kgf m/rpm) Reduction Speed 1.5(13.5) 07(dump: 40) /1,000 1: (15) 77(dump: 310) :1. 16 (General purpose:16.) 379(mixer: 353) Side type 40/1,000 1: (19) 380(dump:395) L H L (19) 360(dump:380) H Rotating direction Reverse i o 50/1,000 H 1:1.09 L 1: :

5 G e a r r a t P T O Model Type Gear mesh type Fill capacity (L) Weight (kg) 1st nd 3rd 4th 5th 6th 7th 8th Reverse Type Max. torque (kgf m/rpm) Ratio to engine speed Reduction Speed Rotating direction K1406 Advance 6 position Reverse 1 position Front: Synchro mesh type Rear: Constant mesh type 16(PTO:16.) /1,000 1:0.83 ZF16S-151 ZF16S-1 MD3060 HD4560 ZF1AS301 Advance 16 position Advance 16 position Advance 6 position Advance 6 position Advance 1 position Reverse position Reverse position Reverse 1 position Reverse 1 position Reverse position L H L H L H Side type 10/1,500 i o 5

6 -. GEAR CONTROL PARTS --a. TRANSMISSION CONTROL STRUCTURE AND FIXING TORQUE (kgf.m) DE1TIS/ DE08TIS Engine (K805P/ K1406Q/ T10/ T14S10 Transmission) (K805, T15S6, T9S6, K1406Q, T10S6 Transmission) 0.6~1.1 1.~.3 1.4~.6 (K805P, T14S10, T9S5 Transmission) 6.~9.3 (Mixer:13.~0.8) 7.~10.6 DE1TIS Engine (ZF16S151/1 Transmission) TM083 1.~.3 1.4~ ~0.8 7.~10.6 TM085 6

7 (kgf.m) DV15T Engine (K1406 Transmission) 1.~.3 1.4~ ~0.8 7.~10.6 DV15T Engine (ZF16S151/1 Transmission) 0.6~1.1 1.~.3 1.4~ ~0.8 7.~10.6 TM086 7

8 (kgf.m) DV15TIS Engine (ZF16S151/1- Telescopic T/M) 0.6~1.1 3.~5.4 1.~.3 3.~5.4 DV15TIS Engine (T16S6 Transmission) 1.~.3 3.~5.4.8~4.7 TM5860 8

9 (kgf.m) DDC Engine (ZF16S151/1 Transmission) 1.~.3 1.~.3 3.~5.4 14~18 14~18 TM580 (kgf.m) C Engine & T14S10(RHD) 1.4~.6 1.4~.6 7.~10.6 TM581 9

10 --b. DISASSEMBLY TM Knob. Flange nut 3. Boot 4. Boot, (inner) 5. Retainer cover 6. Flange bolt 7. Change lever assembly 8. Cushion rubber 9. Distance 10. Bolt 11. Washer 1. Spring 13. Rod assembly(shift) 14. Lock nut 15. Rod assembly(select) 16. Lock nut 10

11 ONE-ROD CHANGE LEVER TM Knob assembly. Pattern 4. Flange nut 5. Boot 6. Boot(inner) 7. Retainer cover 8. Flange bolt 9. Change lever assembly 10. Bracket change lever mounting 11. Bracket change lever mounting 1. Bush-change lever 13. Bolt 14. Nut 15. Needle bearing assembly 16. Spring washer 17. Plain washer 18. Bolt-spring(with washer) 19. Plain washer 11

12 -3. EXPLODED VIEW OF GEARSHIFT CONTROL PARTS K805, K1406, T10S6, T14S10 Relay lever assembly - 1st Rod assembly-1st shift Return spring Ball seat Idler assembly Rod assembly-nd shift Rod assembly-1st select Relay lever assembly-nd Rod assembly-nd select Rod assembly-idler shift TM090 1

13 ZF 16S-151/1 TRANSMISSION Relay lever A-1st Rod A- 3rd select Rod A-1st shift Relay lever A-nd Relay lever A-3rd Rod A-1st select Idler A Rod A-nd shift Rod A-nd select Rod A-Idler shift Select lever-zf Bush Lock plate TM

14 TELESCOPIC TRANSMISSION Rod complete-telescopic Spring-release Rod A- inner Rod A-outer Relay lever complete Lever-lock Bracket A- T/M Tip Ball joint A Shift lever A TM

15 -4. INSPECTION AND MAINTENANCE -4-a. POWER TRAIN STEP Tilt center -link type B Shift Select C D T/M Select Shift TM10-4-b. MAINTENANCE OF TRANSMISSION SYSTEM Select Left and right travel of change lever Forward and backward travel of select control rod A Angle motion at bracket B Forward and backward travel of select control rod C Selection of shift rod with rotation angle motion of T/M side. Shift Forward and backward travel of change lever Forward and backward travel of shift control rod A Angle motion at bracket B Forward and backward travel of shift control rod D Gear insertion by forward and backward travel of the fork connected to the selected shift rod of T/M side. Adjust control rod as follows, when the gear control is hard and free play is excessive: NO HOW TO OPERATE Assemble all of the parts for T/M control(however, 8-ton and 39-ton tractors should remain with the return spring removed. Loosen the length adjust nut for the first select rod and first shift rod. Rotate the first shift rod and first select rod from the front of the vehicle to make the same length so that the JIG can be inserted into the JIG check hole on the first relay, and then remove the JIG. Tighten the length adjust nut for the first select rod and first shift. (Assembly of return spring) Position of cab tilt Up Down Up Inserting direction Front View First shift rod First select rod TM131 15

16 JIG check hole Adjust by rotating the rods Length adjust nut Side View TM13 ) Adjust the length of 1st select and shift rod so that the change lever assembly and two levers connecting 1st select and shift rod should be vertical. If these two levers are adjusted vertically, the change lever knob is positioned 30mm at left, rearward(toward driver). Change lever knob adjusting steps are as follows(t/m in neutral) (1) Knob, inclined to left or right: Adjust the length of change lever select rod. () Knob, inclined forward: Shorten the length of change lever shift rod. (3) Knob, inclined reward: Extend the length of change lever shift rod. Knob Change lever select rod Change lever shift rod Lever TM150 Caution 1) Periodically check the tightening condition of ball joint and tightening nuts and retighten them to avoid malfunction of transmission gear shifting because twin-link type has many ball joints and tightening nuts. ) Check and repair wear of related parts frequently to avoid malfunction of transmission gear shifting possibly due to wear of moving parts such as bush, especially in the case of vehicles that are operated many mileage. 16

17 -5. SERVICING Change of transmission oil Model Fill capacity(l) K (PTO:11.3) Drain plug Supply plug TM0010 K806 K1406 T9S5 T9S6 T10S6 T14S10 T15S6/T16S6 ZF16S-151 ZF16S-1 ZF16AS301 MD3060 HD (PTO:16.) 10 (PTO:11) 1.5 (PTO:13.5) 14 (PTO:15) 18 (PTO:19) 17 (PTO:18) Grease up the gear shift control parts. TM000 Transmission lever Radiator TM0030 OIL SPECIFICATIONS AND VISCOSITY CHART Oil specifications Item Oil specifications Transmission Gearshift control box Gear oil Engine oil API GL-4(SAE80W90) : K805, K806, K1406, T10S6, T9S5, T9S6, T14S10, T15S6, T16S6 API GL-4(SAE85W140) : Thermostat - open 71'c API CD/CE/CF/SF/SG(SAE 30) : ZF T/M Multi-purpose type grease NLGI No. 0 17

18 GEAR OIL VISCOSITY CHART GEAR OIL VISCOSITY CHART - AMBIENT TEMPERATURE Single grade SAE 80W SAE 140 SAE 85W SAE 90 Ambient temperature -30 C (-0 F) -5 C (-10 F) -15 C (0 F) 0 C (3 F) 10 C (50 F) 0 C (70 F) 30 C (90 F) Multi grade SAE 80W-90 SAE 80W-140 SAE 85W-140 SAE 75W-80 TM

19 Gear shift control rod (After cab tilting cab lower port ) MTC0490 Gear shift control rod (Frame port ) MTC0500 Spring pin and shackle pin MTC

20 -6. TIGHTENING TORQUE TIGHTENING TORQUE FOR MAJOR PARTS TM Bolts for clutch housing and flywheel housing. Bolt and nut for clutch housing and transmission case 3. Bolt rear case to transmission case 4. Bolt and nut parking brake to rear cover 5. Front cover lock bolt 6. Reverse gear shaft lock bolt 7. Speedometer driven gear housing lock bolt 8. Flange nut * The above bolts and nuts should be tightened according to the torques as specified on the following page. 0

21 TIGHTENING TORQUE FOR SPECIAL BOLTS (kgf m) Bolt identification 7 9 Bolt diameter x pitch(mm) 6 x x x x x x 1.5 7T High carbon steel 0.6~ ~.3 3.5~ ~ ~ ~0.8 9T Alloy steel.1~ ~ ~ ~ ~4.5 TIGHTENING TORQUE FOR STANDARD BOLTS (kgf m) Bolt identification Bolt diameter x pitch(mm) 4T Low carbon steel 7T High carbon steel 9T Alloy steel 6 x ~ ~1.0 8 x ~1.8 1.~.3 1.7~ x 1.5.1~3.5.8~ ~6.4 * 10 x 1.5.0~3.4.8~ ~6.1 1 x ~7.5 6.~ ~11.6 * 1 x ~ ~ ~ x ~ ~ ~17.4 * 14 x.0 7.3~ ~ ~ x ~ ~ ~4.5 * 16 x.0 10.~ ~ ~ x ~ ~ ~35. 0 x ~ ~ ~48.5 x ~ ~ ~ x ~ ~ ~84.7 * The asterisk * indicates that the bolts are used for female threaded parts that are made of soft materials such as casting. 1

22 -7. DISASSEMBLY AND REASSEMBLY Propeller shaft Disassembly 1. Gearshift control rod(shift and select). Parking brake cable 3. Clutch booster with bracket 4. Yoke flange 5. PTO yoke flange and control cable or rod 6. Transmission assembly IMPORTANT OPERATIONS (DISASSEMBLY) 4 TM0060 Reassembly 6. Transmission assembly 5. PTO yoke flange and control cable or rod 4. Yoke flange 3. Clutch booster with bracket. Parking brake cable 1. Gearshift control rod(shift and select) Transmission E/G Cross member TM Gearshift control rod Unbolt the control rod fixing bolt and remove the control rod at the point as shown. (1)Transmission relay lever(lock nut: M8x1.5) ()Idler(Lock nut: M10x1.5) (3)Transmission shift lever(lock nut: M10x1.5) (4)Idler(Lock nut: M10x1.5) (5)Engine flywheel housing(lock nut: M10x1.5) (6)Cross member(lock nut: M10x1.5) Parking brake drum Connecting point Important operations (1) For assurance of safety, park the vehicle on level ground and brace the front or rear wheels when lifting the vehicle. ()Remove the propeller shaft at the parking brake drum Propeller shaft TM0071 Caution Check the connecting point before disassembly.

23 Harness Select rod (3) Remove the control rod, harness-switch, parking brake cable, speedometer cable at the transmission. Harness Shift rod P.T.O TM007 Clutch booster (4) Remove the drain plug and check plug from the transimission to drain out gear oil. TM0073 (5) Remove the drain plug and check plug from the transmission to drain out gear oil. Check plug Drain plug TM0074 (6) When the gear oil drain out check the state of oil and chip. TM0075 3

24 (7) Seperate the oil cooler hose from the transmission and pump. Oil cooler pump TM0076 Clutch housing (8)To remove clutch housing-mouting bolts, support the transmission with transmission jack. Mounting bolt Transmission jack TM0077 IMPORTANT OPERATIONS (REASSEMBLY) Guide bar Apply molybdenum disulfide (MoS) grease Horizontal line Engine slope TM0080 (1)Transmission assembly 1) Remove the transmission assembly using a special tool-transmission jack. ) Align the transmission inclination with the engine slope. 3) Shift the gear in 5th position. 4) Mount the transmission to the engine carefully. ()Clutch booster with bracket For adjustment operation, refer to Section CLUTCH. (3)Parking brake cable For adjustment operation, refer to Section 9 BRAKE. Important operations (1)Lubricate rotating and sliding faces of the parts with oil or grease before installation. TM0081 4

25 Clutch housing () Fit the transmission assembly using a special transmission jack. Fixing bolt Transmission jack TM008 (3) Mount the oil cooler hose to ther transmission and oil pump. Oil cooler pump TM0083 (4) Check the drain plug fixing torque and refill the level plug with the specified new gear oil. Level plug 5.5~8.5kgf m Drain plug 5.5~8.5kgf m TM0084 Clutch booster (5) Fix the clutch booster. (6) Connect the transmission P.T.O control. TM0085 5

26 Harness Select rod (7) Fit the control rod, harness-witch, parking brake cable, speedometer cable to the transmission. Harness Shift rod TM0086 Parking brake drum Connecting point (8) Install the propeller shaft to the parking brake drum then check the maching point. Fix the nut. Propeller shaft TM0087 6

27 3. TRANSMISSION CASE * * 8 1 T14S10 T9S6/T10S6/T15S6/T16S6 Repair kit * TM009 T9S6/T10S6/T15S6/T16S6 1. Flange bolt. Front bearing retainer 3. Oil seal 4. Gasket 5. Bolt/ Washer 6. Gasket 7. Magnetic plug 8. P.T.O Cover 9. P.T.O Gasket * 10. Oil seal 11. Dust plug 1. Speedometer gear 13. Speedometer connector 14. L-joint T14S10 1. Flange bolt. Front bearing retainer 3. Taper plug 4. Oil seal 5. O-ring 6. Oil intake plate 7. Drain plug/ Gasket 8. Magnetic plug/ Gasket 9. P.T.O Cover * 10. P.T.O Gasket 11. Seal bolt 1. Oil seal 13. Speedometer/ L-joint 14. Speedometer bushing 15. Speedometer gear 16. Rear cover 7

28 ZF16S151/ TM Housing. Screw plug 3. Filler neck 4. Lock screw 5. Gasket 6. Cylindrical pin 7. Gasket 8. Clutch housing 9. Lock screw 8

29 4. QUADRANT BOX 4-1. UPPER QUADRANT BOX DISASSEMBLY K805, K * 10 1 * * : Apply liquid gasket. TM0111 Disassembly 1. Upper quadrant box. Link rod assembly 3. Select fix pin 4. Select lever 5. Snap ring 6. Washer 7. Selection lever 8. Oil seal 9. Relay lever bolt 10. Select relay lever * Reassembly is inverse of disassembly. 11. Washer/ Bush 1. Relay lever insert boss 13. Relay lever bracket 14. Spring pin 15. Shift lever shaft 16. Side cover 17. Shift lever 18. Cap 19. Oil seal 0. Air breather 9

30 T9S6, T10S TM011 Disassembly 1. Air breather. Interlock switch 3. Lock pin 4. Gear selecting lever(b) 5. Gear selecting lever(a) 6. Washer 7. Shim 8. Oil seal 9. Spring pin * Reassembly is inverse of disassembly. 10. Gearshift sliding lever 11. Power shift 1. Gearshift lever 13. Dust plug 14. Spring retainer 15. Return spring 16. Interlock plate 17. O-ring 18. Select lever case 30

31 T14S TM0131 Disassembly 1. Bolt. Bolt 3. Bolt 4. Sub unit 5. Spring pin 6. Nut 7. Lock pin 8. Gear shift sliding lever 9. Washer 10. Shim 11. Oil seal * Reassembly is inverse of disassembly. 1. Select lever assembly 13. Dust plug 14. Air breather 15. Interlock switch 16. Gasket 17. Gear shift lever 18. O-ring 19. Retainer and spring 0. Gear shift sliding lever 1. Interlock plate 31

32 T15S TM3336 Disassembly 1. Air breather. Interlock switch 3. Lock pin 4. Gear selecting lever(b) 5. Gear selecting lever(a) 6. Washer 7. Shim 8. Oil seal 9. Spring pin * Reassembly is inverse of disassembly. 10. Gearshift sliding lever 11. Power shift 1. Gearshift lever 13. Dust plug 14. Spring retainer 15. Return spring 16. Interlock plate 17. O-ring/dust seal 18. Select lever case 3

33 T16S TM3337 Disassembly 1. Air breather. Boot 3. Plug screw 4. Spring pin 5. Gear shift shaft 6. Spring 7. Return spring retainer 8. spring 9. Return spring retainer 11. Oil seal 1. Bushing 13. Selecting lever case * Reassembly is inverse of disassembly. 33

34 4-. LOWER QUADRANT BOX DISASSEMBLY K805 1 A 3 4 c b a 19 9 A c c c a b a b a b Section: A-A a: Interlock ball b: Rod cover c: Detent spring and ball TM Neutral lamp switch. Back lamp switch 3. Shift rod cover 4. 1st and reverse shift block(front) 5. 1st and reverse shift block rod 6. 1st and reverse shift block(rear) 7. nd and 3rd shift block 8. nd and 3rd shift rod 9. nd and 3rd shift fork 10. 4th and 5th shift fork 11. 4th and 5th shift arm rod 1. 4th and 5th shift block rod 13. 4th and 5th shift block 14. 1st and reverse shift rod 15. 1st and reverse shift fork 16. Washer 17. 1st and reverse relay lever 18. 1st and reverse shift spindle 19. 4th and 5th shift pinion/ Bearing / Bolt/ Cover/ Washer 34

35 K1406 c c c Section: A-A a: Interlock ball b: Rod cover c: Detent spring and ball a b a b a b 1 A b 6 3 a A 0 1 C TM Neutral lamp switch. Back lamp switch 3. Shift rod cover 4. 1st and reverse shift block(front) 5. 1st and reverse shift block rod 6. 1st and reverse shift block rod(rear) 7. nd and 3rd shift block 8. nd and 3rd shift rod 9. nd and 3rd shift fork 10. 4th and 5th shift rod 10. 4th and 5th shift fork 1. 6th shift fork 13. 6th shift fork rod 14. 6th shift lever/ Spindle / Bolt/ O-ring 15. 6th shift block 16. 6th shift fork rod 17. Shift rod stopper 18. 1st and reverse shift fork rod 19. 1st and reverse shift fork 0. Washer 1. 1st and reverse relay lever. 1st and reverse shift spindle 35

36 T9S6/T10S6/T15S6/T16S b 3 4 A 5 a A c c c C Section: A-A a: Interlock ball b: Rod cover c: Detent spring and ball a b a b a b TM Neutral lamp switch. Gasket 3. Spring 4. Interlock pin 5. Dust plug 6. Flange nut 7. 1st and reverse shift lever shaft 8. O-ring 9. 1st and reverse lever 10. Thrust washer 11. Bolt 1. Bolt 13. Clip bracket 14. Set bolt 15. 1st and reverse shift rail 16. 1st and reverse shift jaw 17. 1st and reverse shift rail jaw 18. nd and 3rd shift rai assembly 19. nd and 3rd shift rail jaw 0. Steel ball 1. nd and 3rd gear shift fork. 1st and reverse shift B rail 3. 1st and reverse gearshift fork 4. 4th and 5th shift rail assembly 5. 4th and 5th gearshift fork 6. Overdrive shift rail 7. 6th and 7th gear shift jaw 8. Overdrive shift shift rail fork 9. Overdrive shift lever shaft 30. Overdrive shift lever 31. Spring washer 3. Jaw nut 33. Over drive shift(b) rail 34. Over drive shift(c) rail 35. Over drive gearshift 36. Gasket 37. Case 36

37 T14S TM Neutral lamp switch. Gasket 3. Spring 4. Interlock pin 5. Rod cover 6. Nut 7. 1st and reverse shift lever shaft 8. O-ring 9. 1st and reverse shift lever 10. Washer 11. Bolt and Washer 1. Bolt 13. Bolt 14. Nut 15. Bolt 16. Air band clip 17. Bolt 18. Bolt 19. 1st and reverse shift jaw 0. 1st and reverse shift rail jaw 1. Steel ball ( 5/8" ). 1st and reverse shift (A) rail 3. nd and 3rd shift rail jaw 4. nd and 3rd shift rail fork 5. nd and 3rd shift rail 6. 4th and overdrive shift rail 7. 4th and overdrive shift fork 8. 1st and reverse shift (B) rail 9. 1st and reverse gear shift fork 37

38 IMPORTANT OPERATIONS (DISASSEMBLY) Dial gauge Check the shift rail for bending.if bending, damage or any other abnormal conditions are replace. Lathe TM0061 If the inner diameter of shift rail hole and outer diameter are beyond the standard valve, replace the parts a new one. TM006 Screw driver Shifter rod Interlock ball 6th shifter rod and block Install rod in place. Install and lock the shift arm or shift block using bolt and wire, then set the rod to neutral position. When reassembling parts NO. 6, 1, or 13 as in the previous page, refer to the above instructions. TM040 Fit the shift rail set bolts to the quadrant box. Then punch of min. 3 point of tread. Set bolt 5.0~6.8kgf m TM063 38

39 5. TRANSMISSION ASSEMBLY (K805) 5-1. MAJOR COMPONENTS DISASSEMBLY STEPS * * : Apply liquid gasket. * TM Upper quadrant box assembly. Oil seal 3. Speedometer driven gear, Oil seal, Bushing and O-ring 4. Rear cover 5. Gasket 6. Stud bolt 7. Clutch housing 8. Front cover, Oil seal and Gasket 9. Counter shaft front bearing cover 10. Plug and Packing * Reassembly is inverse of disassembly. 11. Cover, Gasket and Bolt 1. Bracket and Bolt 13. Plug and O-ring 14. Top gear shaft 15. Bearing, Snap ring and Protector 16. Main shaft assembly 17. Counter shaft assembly 18. Reverse shaft assembly (Gear, Bearing, Piece, Washer and O-ring) 19. Reverse shaft 39

40 IMPORTANT OPERATIONS (DISASSEMBLY) 3. Speedometer driven gear, Oil seal, Bushing and O-ring Use a remover to disassemble these parts as required. TM Counter shaft front bearing cover Grip the knob with pliers tightly to remove the counter shaft front bearing cover. TM Counter shaft front bearing Use a remover to disassemble these parts as required. (Special tool: CA1031) Counter bearing puller TM Counter shaft rear bearing and Snap ring Use a remover to disassemble these parts as required. (Special tool: CA1031) Counter bearing puller TM

41 14. Top gear shaft assembly and Circlip The dog gear installed to the top gear shaft with the circlip can be separated from the top gear shaft by pulling it strongly. With the top gear shaft taken out, the top gear shaft dog gear will remain in the gear case. TM0340 Wire 16. Main shaft rear bearing and Snap ring Use a remover to disassemble these parts as required. (Special tool: CA1031) 16. Main shaft assembly and thrust washer Remove the main shaft assembly from the case using a suitable hook or wire. TM0350 Caution The main shaft assembly can be easily separated from the gear case by using a dummy collar as shown. TM Reverse shaft assembly Use a remover to disassemble these parts as required. (Special tool: CA101) TM

42 IMPORTANT OPERATIONS (REASSEMBLY) Thrust washer 18. Thrust washer Make necessary replacement if wear damage or any other abnormal conditions are found through assembly. TM0630 Reverse gear 18. Reverse gear shaft and O-ring Align the lock bolt hole in the shaft with the hole in the case. The adjusting groove on the shaft should be turned rearward and aligned in the vertical direction. TM0640 Lock bolt 1. Reverse gear shaft lock bolt Apply liquid gasket to the lock bolt. (kgf m) Torque 1.5 ~.8 TM Thrust washer Note the direction of installation. Forward TM0660 4

43 16. Main shaft rear bearing and snap ring Be careful for damage. When installing it to the bearing and snap ring using jig. (Special tool: CA1041 or CA1011) TM0670 Top gear shaft Dog gear 14. Top gear shaft assembly Fit the top gear shaft to the place where the end of the dog gear has been partially cut out. Drop the counter shaft assembly into the transmission case, then install the top gear shaft assembly. TM Connector shaft rear bearing, snap ring Be careful for damage when installing it to the bearing and snap ring. (Special tool: CA1101,CA1031,CA1061) Bearing puller TM0690 Toward transmission case 16. Speedometer drive gear Note the direction of installation. Toward rear cover TM Gasket 4. Reverse cover. Oil seal Apply liquid gasket to lock bolt. (kgf m) Torque 5.8~8.7 43

44 Speedometer driven gear 3. Speedometer driven gear, Oil seal, Bushing and O-ring (kgf m) Torque 0.4~0.6 TM0710 Rear cover or extension housing Fit the speedometer gear bushing to extension housing using round bar (diameter: 40mm) Round bar Speedometer gear bushing TM0711 Round bar Fit the Oil seal to the speedometer gear bushing using round bar (diameter: 15mm) Caution Apply grease to packing inside Packing Speedometer gear bushing TM Quadrant box assembly Fill the transmission case with gear oil and then assembly the quadrant box. 44

45 GEAR SHAFT DISASSEMBLY TM Protector, Snap ring and Bearing. Top gear shaft 3. Snap ring 4. Pilot bearing 5. 4th blocker ring 6. Snap ring 7. 4th and 5th synchronizer assembly 8. 5th blocker ring 9. 5th gear (over drive) 10. Needle roller bearing 11. Snap ring 1. Collar 13. 3rd gear 14. Needle roller bearing 15. nd and 3rd synchronizer assembly 16. nd gear 17. Piece and speed drive gear 18. Washer and bearing 19. 1st gear, Needle roller bearing and Collar 0. Sleeve and clutch hub 1. Reverse gear and needle roller bearing. Main shaft 3. Bearing and snap ring 4. Counter shaft drive gear and key 5. PTO gear and key 6. 5th gear and key (Over Drive) 7. Snap ring 8. Bearing 9. Shaft 30. Reverse shaft assembly (Gear, Bearing, Piece, Washer, and O-ring) 31. Reverse shaft * Reassembly is inverse of disassembly. 45

46 IMPORTANT OPERATIONS (DISASSEMBLY) 4. Pilot bearing Use a remover to disassemble these parts as required. (Special tool: CA111) Pilot bearing puller TM0390 Plunger 6. Snap ring Be careful for damage when disassemble. Snap ring Block 7. 4th and 5th synchronizer assembly Disassemble the synchronizer assembly into blocker rings, springs, sleeve, inserts, plungers, springs and clutch hub. Spring TM Collar Remove all the parts of item 33 at a time using a bench press. TM0410 IMPORTANT OPERATIONS (REASSEMBLY) 15. nd and 3rd synchronizer assembly Assemble the sleeve to the rear longer plunger. Longer plunger Rearward TM

47 1. Collar Install the collar using a bench press. TM th and 5th synchronizer assembly Install the blocker by matching it with the circular direction of clutch hub. Clutch hub TM0580 Pilot bearing 4. Pilot bearing Note the direction of installation. Forward Rearward Snap ring TM0590. Top gear shaft assembly To install, attach a brass bar and use a bench press. Brass bar TM

48 5-. INSPECTION AND MAINTENANCE Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection. Visual check Inspect all disassembled parts for wear, damage or any other abnormal conditions. Inspect the following parts paying particular attention to the points as shown. Liquid gasket Front and Rear cover oil seal replacement 1) Note the direction of oil seal installation. ) Apply liquid 4 to fitting face of oil seal. 3) Insert oil seal until it is properly seated in position. 4) Fill the cavity between felt and lip of oil seal with grease. TM040 Contact completely Grease TM0430 Shoulder groove Shoulder of shifter rod groove As shoulder part rounded due to wear can cause gear slipping, this part is required to be thoroughly checked. TM

49 Shift arm (mm) Shift arm Thickness Standard 11 Limit 10 Micrometer Make necessary parts replacement if wear, damage or any other abnormal conditions are found through inspection. TM0450 Detent spring Free length Standard 43.5 Limit 40.5 (mm) Make necessary parts replacement if wear, damage or any other abnormal conditions are found through inspection. TM0460 Fine groves Blocker ring Clearance Standard.0 (mm) Limit 0.3 Clearance between gear and blocker ring If the fine grooves on the inner face have worn out completely, replace the blocker ring with a new one. TM0470 TM0480 Clearance Clutch hub Standard (mm) Limit Clearance 1. ~ TM0490 Make necessary parts replacement if wear, damage or ony other abnormal conditions are found through inspection. 49

50 Plunger spring Free length Standard 18.7 (mm) Limit 17.7 TM0500 Plunger block If the plunger block is wear or damage, replace the plunger block with a new one. TM0510 Clutch sleeve Check the clutch sleeve for wear or damage. If the clutch sleeve is wear or damage, replace the clutch sleeve with a new one. TM050 A Clearance Outer ring nd and 3rd synchronizer inner and Outer rings (mm) Standard Limit Clearance.4 ~.5 0 Inner ring TM0540 If the fine grooves on the face A are found to have worn out completely, replace the synchronizer assembly with a new one. 50

51 5-3. TRANSMISSION P.T.O SYSTEM 5-3-a. MAJOR COMPONENTS(BASE: K805) Air shaft rod Control cylinder Idle gear shaft Air chamber return spring Idle gear Spring gear cover Front cover Output shaft Output gear Oil seal TM070 51

52 5-3-b. FIXING TORQUE (kgf.m) Thick collar Gear oil Thin collar 16.1~3.5 Grease Grease Apply liquid gasket Apply liquid gasket..1~3.5 Gear oil Apply liquid gasket. Grease LOCTITE Gear oil Apply liquid gasket..1~ ~ ~4.5 TM0731 5

53 5-3-c. DISASSEMBLY MAJOR COMPONENT DISASSEMBLY STEPS ** 13 8 ** 9 * * ** * 16 * * 1 * ** : Apply liquid gasket. : Repair kit TM Switch and Flange. Control cylinder 3. Spring pin 4. Idle gear shaft 5. Idle gear 6. Needle bearing collar 7. Needle bearing 8. Spring 9. Air shaft rod 10. O-ring 11. Air chamber return spring 1. Shaft rod stopper 13. Shift arm 14. Shaft rod cover 15. Front cover 16. Rear cover 17. Oil seal 18. Output shaft 19. Bearing 0. Bearing collar 1. Output shaft gear 53

54 IMPORTANT OPERATIONS (DISASSEMBLY) 5. Idle gear Remove the idle gear shaft pin to separate the shaft, then disassemble the idle gear and bearing collar. Idle gear TM0750 Shaft rod stopper 13. Shift arm Remove the shift arm pin to separate the shaft, then disassemble the shift arm. Shift arm TM Output shaft Tap on the output shaft lightly with a brass hammer to separate it to the front direction. At the same time, separate the front bearing. Front Hammer TM

55 IMPORTANT OPERATIONS (REASSEMBLY) 18. Output shaft Align the key hole in the shaft with the key hole in the output shaft, then tap lightly on the shaft forward with a brass hammer. Front Hammer TM0880 Bearing collar 19. Bearing Grease the bearing, then install it in the front direction. To install, insert the bearing collar in the rear direction. Front Grease fitting Grease fitting TM0890 Inner Grease fitting 17. Oil seal Grease the inside of lip, direct the lip inward, then install the cover to the plate. Grease the outside of oil seal. TM Rear cover Apply liquid gasket before installing the rear cover. (kgf m) Torque.1 ~ 3.5 Apply liquid gasket TM

56 15. Front cover Apply liquid gasket before installing the front cover. (kgf m) Torque.1 ~ 3.5 Apply liquid gasket. TM090 Front Shaft rod stopper Grease fitting Shaft rod Spring 1. Air shaft rod Grease the O-ring before installing it to the shaft rod. Pre-assemble the stopper spring, then assemble it to the case. Note the direction of shaft arm. After completion of installation, tap and insert the pin, then fix both the upper and lower points. TM0930 Grease fitting 14. Needle bearing Grease the bearing before installing it to the idle gear. Idle gear TM0940 Thick collar Pin Shaft 16. Idle gear Fit the bearing collar to the idle gear, then insert it into the case. Tap and insert the bearing gear shaft. Fix the bearing pin. Grease the bearing collar for easy operation. Thin collar Bearing collar TM0950 Front Rear Thin collar Thick collar 56

57 Control cylinder Grease(0.5g). Control cylinder Apply liquid gasket to the packing, then grease(0.5g) the inside of cylinder. (kgf m) Torque.1 ~ 3.5 TM Shaft rod cover Apply LOCTITE, then tap and install the shaft rod cover to the case. Grease fitting TM0970 Check the functions of the idle gear. Inject air(4kg/cm ) into the nipple to check if the shaft rod operates smoothly. TM0980 Apply liquid gasket. Install the PTO assembly to the transmission case. Apply liquid gasket to the packing and assemble the P.T.O assembly. (kgf m) Torque 3.0 ~ 4.5 TM

58 5-3-d. INSPECTION AND MAINTENANCE Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection. Check the inside and tip of control cylinder for wear. TM0780 Idle gear Check the gear tooth face for damage, and measure abrasion if required. Overhaul diameter(pin φ 8mm) (mm) Standard Limit TM0790 Make necessary parts replacement if wear, damage or ony other abnormal conditions are found through inspection. Bearing collar thickness Item Standard (mm) Front.5 Rear 4.5 TM0800 Make necessary parts replacement if wear, damage or ony other abnormal conditions are found through inspection. Free length Standard Limit (mm) Make necessary parts replacement if wear, damage or ony other abnormal conditions are found through inspection. TM080 58

59 Shift arm Shift arm tip thickness Standard Limit (mm) TM0830 Output shaft Output shaft Check the output shaft oil seal for wear. TM0840 TM0850 Needle bearing Check the output shaft oil seal for wear. Check the bearing for deformation, wear, or unusual sound. - To identify any damage or deformation, rotate the race and check clearance of holes. - Check the holes and race for abnormal conditions. - To identify unusual sound, rotate the bearing to check if it transfers any abnormal feel through the hand. Overhaul diameter of gear tooth face (pin φ 8mm) Standard Limit (mm) TM