Gearbox 16jsd220ta.pdf

Transmission (16JSD220TA) Transmission.....................................31A-1 General..........................................31A-1 Cautions ........................................31A-2 Structure and principle of transmission31A-6 List of failure symptoms...............31A-18 Inspection and adjustment ..........31A-20 Shift mechanism assembly............31A-26 Component drawing ....................31A-26 Removal and installation .............31A-27 Transmission assembly..................31A-30 Removal ......................................31A-30 Installation ...................................31A-33 Input shaft assembly.......................31A-36 Component drawing ....................31A-36 Removal ......................................31A-37 Installation ...................................31A-39 Output shaft assembly....................31A-41 Component drawing ....................31A-41 Removal ......................................31A-42 Installation ...................................31A-43

Transmission upper cover..............31A-46 Component drawing ....................31A-46 Removal ......................................31A-48 Installation ...................................31A-51 Main gearbox assembly..................31A-54 Component drawing ....................31A-54 Removal ......................................31A-55 Installation ...................................31A-57 Auxiliary gearbox assembly...........31A-59 Removal ......................................31A-59 Installation ...................................31A-63 Reverse gear countershaft.............31A-68 Component drawing ....................31A-68 Removal ......................................31A-69 Installation ...................................31A-71 Main gearbox countershaft.............31A-72 Component drawing ....................31A-72 Disassembly and assembly .........31A-73

Transmission (16JSD220TA) - Transmission

31A-1

Transmission General The major characteristic of Fast dual-shaft transmission consists in another countershaft provided in addition to the countershaft equipped in an ordinary transmission, to constitute the dual-countershaft transmission. With this auxiliary countershaft, the symmetrical transfer of power is obtained, thus realizing the steady transmission and lower noise. Definition of transmission model: 16

J

(D)

S

220

(T)

A

Gear ratio code All synchromesh transmission X10 nominal input torque (N·m) Double-countershaft structure Single gearbox Mechanical Number of forward gears

31A

Nameplate of transmission:

Model of transmission assembly

16JSD220TA (Production based on American technology)

Input power User ID

Input torque Factory No.

Shanxi Fast Gear Co., Ltd

31A-2

Transmission (16JSD220TA) - Transmission

Cautions I. Cautions for transmission operation Correct and proper operation of the transmission and providing regular maintenance are critical for ensuring the safe and reliable driving of the vehicle and prolonging the service life of the transmission. Please observe the following operation requirements: 1. Before vehicle start, release the parking brake. For vehicles equipped with air cutoff brake, the vehicle can only be started after the air pressure rises to the value necessary for releasing the brake. 2. Start the vehicle at 3-speed and 4-speed according to the road conditions. 3. Where the gearshift lever is located in the high-speed range, the neutral gear is located between 9-speed and 10-speed; where the lever is in the low-speed range, the neutral gear is located between 3-speed and 4-speed. When the vehicle is stopped, the transmission shall be shifted in the Neutral gear of the lowspeed range; in other words, the change-over switch on the control lever is in the low position. 4. In the shifting operation, the clutch must be disengaged thoroughly; otherwise the service life of main transmission synchromesh device will be adversely affected. Furthermore, the gearshift lever shall be engaged in place. 5. To engage the reverse gear, firstly shut down the engine and then engage the gear to avoid damage to the parts inside the transmission. When shifting into R position, apply strong selecting force to overcome the resistance from the re31A verse lock. 6. To shift from 6-speed to 7-speed (or from 7-speed to 6-speed ), a short pause is required intentionally to enable the auxiliary transmission to fulfill the change between high-speed and low-speed ranges. Before disengaging the gear, operate the control handle to the target zone, and then change between different speed ranges. 7. When changing from low-speed range to high-speed range (vice versa), do not skip any gear, otherwise the service life of the auxiliary transmission synchromesh device may be adversely affected. 8. Frequently check the ventilating plug, and if any dirt is found, remove it immediately. 9. Check the air cleaner screen for running every 2,000 Km and clean the screen and cleaner inner wall with soap water and dry them with compressed air. 10. When the vehicle goes downhill, avoid the changeover between high-speed and low-speed ranges as much as possible. 11. If any abnormal symptom, such as abnormal noise or obviously heavy operation in the transmission, is detected, park the vehicle immediately for troubleshooting. 12. The operation of power take-off should strictly observe the regulations, otherwise it may result in fast damage to auxiliary transmission synchromesh device. 13. Transmission within the period of "three guarantees" is not allowed to disassemble and install privately.

Transmission (16JSD220TA) - Transmission

31A-3

Warning: • • • • •

Gear skipping is forbidden when the transmission is shifted from low speed to high speed (vise versa). Shift between high and low speeds is forbidden when going downhill. Never coast at the neutral gear. Never tow the vehicle with the driving wheel in contact with the ground. If any abnormal symptom, such as abnormal noise or obviously heavy operation in the transmission, is detected, park the vehicle immediately for check. Continue driving after troubleshooting.

II. Maintenance issues of transmission Each time the required interval is expired, it is required to perform all service and maintenance inspection items specified in the service and maintenance regulations. 1. Daily inspection (a) Inspection on lubricating oil level Check the transmission lubricating oil level and leakage on a daily basis, and add the oil if necessary. If any leakage is found, repair the transmission immediately to avoid any failure resulting from the loss of lubricating oil.

31A

Oil level

Oil level

Oil level

Incorrect

Incorrect

Incorrect

(b) Pneumatic system 1-2 • •

Remove the water in the vehicle pneumatic system on a daily basis. Check whether there is air leakage by hearing and carry out repairs if necessary on a daily basis. • Confirm whether the air dryer works normally, and carry out repairs if necessary. Inspect and repair the vehicle air compressor as required to prevent the entry of lubricating oil into the pneumatic system. 2. Every 2,000-5,000km’s travel of the new transmission (a) Replacethe lubricating oil; (b) Check the transmission fastening bolts and fasteners for looseness and loss. Especially those bolts used to attach the transmission onto the engine. (c) Lubricate the release bearing;

Transmission (16JSD220TA) - Transmission

31A-4

(d) Lubricate the clutch fork shaft; (e) Clean the air cleaner element; (f) Check and clean the transmission vents; (g) Check the transmission control mechanism for normal operation. 3. Every 10,000 km or two months (a) Check the transmission fastening bolts and fasteners for looseness and loss, especially those bolts used to attach the transmission onto the engine. (b) Lubricate the release bearing; (c) Lubricate the clutch fork shaft; (d) Clean the air cleaner element; (e) Check and clean the transmission vents; (f) Check the transmission control mechanism for normal operation. 4. Replace oil (a) The use of correct lubricating oil is critical for the maintenance of the transmission. You are kindly required to strictly observe the maintenance procedure specified below: •

Purchase lubricating oil from a qualified supplier; the use and maintenance of the rear axle; • Employ the lubricating oil with correct type and class; trademark of the lubricating oil: 31A 85W-90 GL-5; • Replace the oil as per the proper interval; • Maintain a correct oil level. (b) The interval for replacement of lubricating oil shall not exceed the time stipulated in the table below. Road conditions

Off-road conditions

Rigorous conditions

One year (at most) or 5,0000 km

Every 1,000 h

Every 500 h

Note: Rigorous conditions refer to the circumstances where components are required to constantly work at high load or in severely contaminated environment or on a steep slope. Under these circumstances, adopt the replacement interval of lubricating oil required by the rigorous conditions.

III. Cautions for removal of the transmission 1. Maintenance of the transmission should be carried out in a clean place to avoid the entry of dust or other foreign matters into the transmission. Prior to the removal operation, carefully clean the external surface of the transmission. 2. To remove various assemblies, place all parts on a clean work bench in the sequence of the removal operation. Thus to make the steps of the reinstallation convenient and minimize the possibility of loss of parts. 3. At removing the input shaft , it is unnecessarily to remove the countershaft, output shaft and input shaft gear.

Transmission (16JSD220TA) - Transmission

31A-5

4. Use the special tool to remove the bearing. Carefully clean the bearing and check whether there is pit corrosion on the rolling way and whether the roller is in good conditions.

IV. Cautions for fitting Before fitting, thoroughly clean all parts for fitting and avoid the entry of dust and foreign matters into the transmission; otherwise the unnecessary damages may occur. 1. Liner: Use the new liners to refit the transmission. 2. Bolts: To prevent oil leakage, all bolts must be coated with thread sealant and tightened as per the standard torque. 3. O-ring: Lubricant all the O-rings with the silicon-grease lubricant. 4. Initial lubrication: Coat all thrust washers with the grease for initial lubrication to avoid scratches or wear during fitting. 5. Tighten the output shaft flange plate nuts, and use the torque of 610-680 N•m to fasten output shaft nuts; otherwise severe consequences may be aroused.

31A

Transmission (16JSD220TA) - Transmission

31A-6

Structure and principle of transmission I. Dual countershaft floating structure

1

Main shaft

3

Input shaft gear

2

Input shaft

4

Auxiliary gearbox driving gear

As to the 16-speed transmission, the main and auxiliary transmissions adopt two countershafts, of which structure are completely the same. The power with interval of 180° is 31A transferred to the input shaft, then shunt to two countershafts. At last, the power is output from the main shaft. So does the auxiliary transmission. Theoretically, each countershaft only transfer 1/2 torque. Therefore, the double countershafts could reduce the center distance of transmission, thin the thickness of gear, shorten the axial dimension and decrease the mass. After the adoption of double countershaft, each-speed gear on the main shaft should simultaneously engage the gears of two countershafts. To fulfill the correct engagement and distribute the load as uniformly as possible, the main shaft gear floats in a radial direction on the main shaft which is provided with a hinged floating structure. The main shaft journal is inserted into a hole on the input shaft. An oilbearing guide sleeve is accommodated in this hole, with a sufficient radial clearance between the main shaft journal and the guide sleeve. The rear end of the main shaft is inserted into the auxiliary driving gear hole via an involute spline, and the auxiliary transmission driving gear journal is supported on the ball bearing. As all gears on the main shaft float along the main shaft, the conventional needle bearing is thus canceled to simplify the structure of the main shaft assembly. In the operation, both countershaft gears exert the same radial force on the main shaft gear in opposite directions to offset each other; in such a way, the main shaft will only bear torque, but no bending moment, which has largely relieved the load on both the main shaft and the bearing, and has also significantly improved the transmission’s reliability and durability.

II. Power transfer line Understanding the specific gear positions of the transmission for the engine power drive route can help the technicians to overhaul and maintain the transmission. The 16 JS series

Transmission (16JSD220TA) - Transmission

31A-7

transmission is an insert transmission with 16 forwarding gears and 2 rear gears composed by a main transmission consisting of 4 forwarding gears and 1 reverse gear, an auxiliary transmission consisting of high and low gears and a front auxiliary transmission consisting of half-high gear and half-low gear. For the main transmission, the front auxiliary transmission of half gear and the rear auxiliary are both dual countershafts structure.

1-speed 2-speed 3-speed 4-speed 5-speed 6-speed 7-speed 8-speed 9-speed 10-speed 11-speed 12-speed 13-speed 14-speed 15-speed 16-speed R1-speed R2-speed

31A

31A-8

Transmission (16JSD220TA) - Transmission

Note: This transmission is the type of normally engagement. In the working process, all the gears are rotated although only some of the gears are used to transmit power.

31A

The figure above shows the Fast double shaft transmission power transfer. It can be visually seen that: the power is divided into two and then two parts are combined in the main gearbox. The power that is transmitted to the auxiliary gearbox is also divided into two and then two parts are combined together.

III. Tooth alignment and tooth alignment procedure To ensure the correct engagement between the countershaft gear and main shaft gear, the tooth alignment must be conducted. (1) At first, mark two adjacent teeth of the input shaft gear, and then mark the other side symmetrical to it. (The teeth number of both groups of marks shall be equal.) (2) Mark the tooth on each countershaft driven gear opposite to the gear key groove. (3) During installation, engage the marked teeth on both countershaft driven gears into both marked teeth on left and right sides of the input shaft gear separately. (4) At installing the auxiliary transmission, select the reducer gear for tooth alignment with auxiliary transmission countershaft pinion.

Transmission (16JSD220TA) - Transmission

31A-9

Tooth alignment procedure: 1

1

Left countershaft gear

2

Input shaft gear

2

3

3

Right countershaft gear

Tooth alignment of main gearbox •

At first, mark any two adjacent teeth with paint on the input shaft gear, and then mark another two adjacent teeth on the other side in the corresponding 180° direction. The 31A two groups of teeth shall be of equal numbers. • Apply marking paint on the external teeth top opposite to the hole keyways of the constant mesh gears of two countershafts, and such mark is unique. • During installation, insert the marked teeth separately into the marked grooves of input shaft gear. • If installed correctly, the input shaft rotates flexibly; if the input shaft can not rotate or rotates inflexibly, check if the teeth alignment marks are correct. Teeth alignment for auxiliary gearbox •

At first, mark any two adjacent teeth with paint auxiliary reducer gear, and then mark another two adjacent teeth on the other side in the corresponding 180° direction. The two groups of teeth shall be of equal numbers. • Separately paint the tooth crown top marked with “O” on the auxiliary transmission countershaft gear , and such a mark shall be exclusive. • During installation, insert the marked teeth of both auxiliary gearbox countershaft gear into the marked tooth groove on the auxiliary gearbox reducer gear. Before the installation of the auxiliary transmission assembly onto the main gearbox, carefully check the tooth alignment marks. Perform the installation after confirming that there is no error. • Before the installation of the main gearbox, carefully check the tooth alignment marks. Perform the installation after confirming that there is no error. Note: 16 JS series is designed with serration. Furthermore, the difference of the speed ratio between the adjacent gears is small. So special attention should be paid during

31A-10

Transmission (16JSD220TA) - Transmission

"alignment" installation; Before installation, mark the "alignment teeth" and install in strictly accordance with the alignment marks. Alignment error is prone to occur without carefulness. The installation can be finished without correct alignment sometimes and after the installation, the input shaft can rotate for several circles. However, after the installation of such a transmission on the complete vehicle, as long as the engine starts, severe damage will occur. During installation of the main transmission countershaft, if the countershaft is heavy to move to align with the bearing inner hole, it indicates that there is something wrong with "alignment" installation and careful check is thus required. After the installation of the transmission, it is a must to check whether it runs freely.

31A

Transmission (16JSD220TA) - Transmission

31A-11

IV. Structure and working principle of main geabox synchronizer 1

6

2

7

5

8

3

4

1

Synchronizer gear sleeve

5

Synchronizer outer cone

2

Locating block

6

Synchronizer double cone

3

Spring

7

Synchronizer engaging gear

4

Synchronizer gear hub

8

Synchronizer inner cone

The transmission synchronizer enable the easy and rapid gearshift without causing impact or noise, so as to prolong the gear’s useful life, and improve the vehicle’s accelerating performance and save fuel. Therefore, except for the reverse gear, the transmission can be applied at all gears. A large torque range, stable performance and endurance is required. The inertia synchronizer can ensure the gearshift with the synchronizer engaged, being stable and reliable. It is divided into the inertia lock type and inertia servo type, and those of the most widespread use is inertia lock synchronizers, such as the locking ring type, locking pin type etc. The lock ring synchronizer is widely used at present due to its compact structure, good performance, reliable use and low cost. Its defect lies in that the synchronizer friction torque is too small. Double-cone lock ring synchronizer is a new synchronizer device developed and designed on the base of the similar working principle and structural arrangement to the lock ring synchronizer. It inherits the merits of the lock ring synchronizer as well as covers the shortage by improving the friction torque of the synchronizer. The figure above shows the 5-6 speed synchronizer, in which both the 5-speed-speed and 6-speed are provided with a double cone, with the synchronizer gear sleeve, gear hub, sliding block, spring etc. shared by them. In addition, three conical members (5, 6, 8) are provided for these two speeds. For the synchronizer outer cone (5), 6 single keys are connected with these 6 key grooves on the inner cone (8); therefore, the outer cone (5) and inner cone (8) can rotate synchronously with the transmission output shaft, while these 6

31A

Transmission (16JSD220TA) - Transmission

31A-12

lugs on the synchronizing cone (6) are engaged with these 6 holes on the combining ring (7), so the cone (6) rotates with 5-speed. As a result, when the gear is shifted from 4-speed to 5-speed or from 6-speed to 5-speed, a relative angular speed difference is produced between the 5-speed and the output shaft; at this moment, two pairs of sliding friction cones will start to work in the 5-speed synchronizer cone structure. Consequently, the synchronous frictional torque produced on the friction cone due to the axial thrust exerted on the synchronizer gear sleeve is equal to the sum of friction torques between these two pairs of cones, provided that the overall sizes are the same, that’s to say, the synchronous frictional torque produced at the shift to 5-speed is about 2 times of that of a single-cone synchronizer, thus deducting the gear shifting force by approximately 50%. Working precess: To start the gearshift, the engagement sleeve will bring the sliding block, to push the outer cone to move. Next, the synchronizer tooth sleeve, by overcoming the spring force, will be separated from the sliding block to continue to move forward, thus to enable the inclined face of the locking corner at the tooth sleeve tooth end to press against the inclined face of the locking corner at the synchronizing ring tooth end. When the friction torque on the cone overcomes the inertia torque of the jointed part, the speed difference and friction torque disappear. The ring pulling force aligns the external cone, the locking slope is disengaged, and the meshing sleeve overcomes the spring force of the sliding block and crosses the locking ring to synchronously joint with the gear joint teeth, so as to guarantee shock-free shift.

V. 16-speed transmission gearshift operation device 31A High-speed

Black

Low-speed

Red

Compressed air inlet 7-8bar (from air reservoir)

Black

Red

Provided by manufacture of main machine

Transmission (16JSD220TA) - Transmission

31A-13

1

Double H shift valve

4

Clutch switch

2

Auxiliary gearbox gear shift cylinder

5

Clutch pedal

3

Air filter regulator

6

Front auxiliary gearbox shift valve

16 JS series transmission gearshift operation system is composed by two sets of devices. The figure fhwx310009 shows the pneumatic system of two sets of devices. One device is to shift gears of the main and auxiliary gearboxes and adopts single-lever or doublepole remote double H shift device. This device has no difference from the shift device of RT11509C, 8JS transmission. The shift lever controls the shift shaft of the gearbox with the link to make the shift lever swing, later, the shift lever stirs double H shift guide block, thus, the shift lever can directly change the speed of the main transmission gearbox. When the shift lever moves around, it can shift gears and can control double H shift valve 1 (as shown in fhwx310009) to change between high and low speeds through the auxiliary gearbox shift cylinder 2. The control pressure for this set of device is 0.67-0.71 Mpa. The other device is to shift half gears of front auxiliary gearbox with the gear selector switch. This device consists of the preselection valve, front auxiliary gearbox shift valve 6, clutch switch valve 4 and front auxiliary gearbox shift cylinder, as shown in fhwx310009. Figure ifhwx310061 shows the working principle of shift valve of the front auxiliary gearbox. The air filter pressure regulating valve reduces the control pressure to be 0.28-0.32 Mpa and the pressure is transmitted to the shift valve 6 of the front auxiliary gearbox through the clutch switch valve 4. The shift valve 6 is controlled by the preselection valve of the control lever. Two output pipelines of the shift valve 6 are connected with the shift cylinder of the front auxiliary gearbox. 31A When the driver depresses the clutch pedal 5, the clutch switch valve 4 is opened and the compressed air is transmitted to the shift valve 6. At the same time, the compressed air flows into the shift valve 6 and preselection valve. If the preselection valve is turned upward to “even speed” position, the preselection valve is closed, as shown in Figure fhwx310061, and the shift valve element is pushed on the right by the compressed air to the position in Figure fhwx310061 (b). At this moment, the compressed air is connected with the high-speed pipe 3 through the shift valve. Push the front shift cylinder 8 piston to move on the right, input shaft synchronizer engagement sleeve and high half speed gear are engaged, and then the vehicle drives at variable speed in the range of the high half gear. When the clutch pedal is stepped on and the preselection valve switch is turned downward to “odd speed” position, as shown in Figure fhwx310061, the preselection valve is turned on. The compressed air flows into the shift valve “P” joint through the “P pipe 2”, as shown in Figure fhwx310061 (c). The shift valve element is pushed on the left to the limiting position because of the action of the pressure difference. At this moment, the valve element will make the compressed air flow into the pipe 4 of the low speed but the compressed air in the pipe 3 in the high speed is emptied through the shift valve. The piston of the shift cylinder is pushed off forward (left). Input shaft synchronizer and the low half gear are engaged and the gearbox will run at variable speed in the range of low half speed. When the clutch pedal is stepped on and the clutch is thoroughly disengaged, the clutch switch valve is to shift the gears in the front auxiliary gearbox. Thus, it can avoid driver’s false operation and the gearbox can change speeds under full load to cause fault and damage. Figure fhwx310008 shows the gear position of 16JS series of gearbox lever.

31A-14

Transmission (16JSD220TA) - Transmission

Null

Null

Figure fhwx310008 shows that when the preselection valve switch is turned upward to “1” position, the gearbox will appear “2-4-6-8-10-12-14-16” even speed range. When the preselection valve switch is turned downward to “2” position, the gearbox will appear “1-35-7-9-11-13-15” odd speed range. Under general conditions, either a vehicle drives in the 31A even speed range or drives in the odd speed range. At the same time, the driver can operate the preselection valve switch at any speed according to the load change to change between the odd and even speeds. In other words, the odd and even speeds can be changed at any speed. Therefore, 16JS series of transmission, main gearbox and rear auxiliary gearbox are designed into a range-speed transmission but the front gearbox is designed into insert-type speed transmission. Note: •

•

When the main gearbox and rear auxiliary gearbox double H mechanism for 16JS series of transmission change the speeds, the clutch must be thoroughly disengaged, or else the synchronizer will be worn early. This is a common knowledge. When the preselection valve of the front auxiliary gearbox changes the speeds and the clutch is not stepped on thoroughly, the clutch cannot be disengaged thoroughly to cause early fault of the synchronizer. At the same time, as the clutch switch valve is not turned on, the preselection valve cannot change the speeds. Obviously, if the front auxiliary gearbox cannot change speeds, please check the preselection valve and shift valve first and especially check the clutch switch valve.

Transmission (16JSD220TA) - Transmission

31A-15

The even gears

The odd gears

Low-speed air pipe High-speed air pipe

31A

Low-speed air pipe High-speed air pipe

fhwx310061

1

Preselection valve

5

Intake pipe

2

P air pipe

6

S air pipe

3

High-speed air pipe

7

Front auxiliary gearbox shift valve

4

Low-speed air pipe

8

Front auxiliary gearbox shift cylinder

31A-16

Transmission (16JSD220TA) - Transmission

Note: • •

The air circuit control valve is switched on only in the neutral gear. The air circuit is cut off in the air circuit control valve when engaging a shift. That is, the high-low speed switching can be realized only in neutral gear. There is air in the outlet pipe of control air circuit (preselection valve) at low speed and there is no air in the control air circuit at high speed.

VI. Working principle of parking PTO In order to meet the demand for some special vehicles, PTO can be installed below transmission and between the clutch housing and transmission. Power taken off from the extended countershaft of auxiliary gearbox at the right bottom of transmission rear end is called “rear power take-off”. This way of taking off the power is widely applied at present. Power taken off from the clutch housing and transmission is called “front power take-off” or “full power take-off”. When “rear power take-off” is adopted, the rear auxiliary gearbox synchronizer must be set in the Neutral gear to realize power take-off power on stop. In order to solve this problem, you just need to remove the transmission range cylinder head and to add one neutral gear cylinder. The orifices A and B are separately connected with low-speed pipe and high-speed pipe of transmission and further connected with single H valve of transmission. The pressure is 0.57-0.6 Mpa. The orifice C is the inlet of compressed air when the transmission is set in the N (neutral) position and the pressure is 0.7-0.8 Mpa. During power taking-off on stop, 31A disengage the clutch and set the shift lever in the Neutral gear of low-speed range to tightly press the range cylinder piston 15 on the positioning ring. Then, operate the Neutral gear cylinder control valve and make 0.7-0.8 Mpa compressed air flow into the Neutral gear cylinder 7. As the cylinder has pressurization function, the Neutral gear cylinder pistons 10 and 13 move towards the left and will stop until reaching the locating ring. As a result, the transmission range cylinder piston 15 is set in the Neutral gear. At the moment, shift the main gearbox into the appropriate speed, connect the air circuit of PTO, engage the clutch, and then PTO can realize power taking-off on stop.

Transmission (16JSD220TA) - Transmission

A

5

4

B

6

31A-17

7

3

8

2

7 1

15

14

13

12

11

10

9

31A 1

Range gear shift fork shaft

9

Cylinder head

2

Range gear cylinder

10

Middle-position cylinder piston

3

Rear cover housing

11

O-ring

4

O-ring

12

Hollow shaft

5

Hexagon nylon locking nut

13

Middle-position cylinder piston

6

Air vent plug

14

Bolt

7

Middle-position cylinder

15

Range gear cylinder piston

8

Shaft snap ring

31A-18

Transmission (16JSD220TA) - Transmission

List of failure symptoms The following list will help you to locate the fault. Serial number means the sort of possible reason. Check each section according to that sequence, and replace if necessary. Failure symptom

Suspected part

Refer to

1. Poor quality of lubricating oil

Replace with the lubricating oil 85W-90 GL5 specified by the manufacturer.

2. Improper lubricating oil level

Add lubricating oil

3. The tooth surface of the gear Chapter 31 Transmission (16JSis damaged or worn excesD220TA) – Transmission, Testing sively to generate large backand Adjustment lash. Abnormal sound or noise

Chapter 31 Transmission (16JS4. Bearing is damaged or has D220TA) – Transmission, Testing cracks and Adjustment Chapter 31 Transmission (16JS5. The jointing position of fork D220TA) – Transmission Control and gear is improper. Mechanism, Testing and Adjustment

31A

Chapter 31 Transmission (16JS6. Synchronizer wear or damD220TA) – Transmission, Testing age and Adjustment 7. Gear damage

Chapter 31 Transmission (16JSD220TA) – Transmission, Testing and Adjustment

1. Bearing wear or damage

Chapter 31 Transmission (16JSD220TA) – Main Gearbox, Disassembly and Assembly

Chapter 31 Transmission (16JS2. The shift fork and shaft bend D220TA) – Transmission Upper or have burrs. Cover, Disassembly and Assembly Chapter 31 Transmission (16JSThe shift of the main gearbox is 3. The check screws of fork are D220TA) – Transmission Upper difficult or fails. loose. Cover, Disassembly and Assembly Replace with the lubricating oil 4. The viscosity of lubricating oil 85W-90 GL5 specified by the is too high. manufacturer. 5. Main shaft twist

Chapter 31 Transmission (16JSD220TA) – Main Shaft Assembly, Disassembly and Assembly

Transmission (16JSD220TA) - Transmission Failure symptom

Suspected part

31A-19 Refer to

1. Defective pressure regulator Replace the regulator valve valve Chapter 31 Transmission (16JSD220TA) – Double H Control Mechanism, Removal and Installation

2. Failure of air pipe or joint Off-gear of the high-speed and low-speed sections of the auxil3. The shaft is distorted, and the Chapter 31 Transmission (16JSiary gearbox gear leaves the teeth align- D220TA) – Transmission, Testing ment position. and Adjustment Chapter 31 Transmission (16JS4. The engaging teeth or gear D220TA) – Transmission, Testing sleeve back taper fails. and Adjustment The gears are in disorder.

Chapter 31 Transmission (16JS1. The interlock steel ball or D220TA) – Transmission Upper interlock pin is not installed or Cover, Disassembly and Assemworn. bly 1. Too much lubricating oil

Oil or air leakage

Adjust the lubricating oil level to the specified value

Chapter 31 Transmission (16JS2. The seals are damaged or D220TA) – Transmission, Testing failed. and Adjustment 3. Fasteners are loose.

Fasten the loose components

4. The air vent plug is clogged.

Clean or replace the air vent plug.

5. The bolt is not coated with Coat with sealant, and re-install sealant. the bolt.

31A

Transmission (16JSD220TA) - Transmission

31A-20

Inspection and adjustment 1. Testing of the axial clearance of the main shaft gears (a) Place the output shaft vertically, install the reverse gear snap ring, and install the auxiliary gearbox drive gear assembly and snap ring. (b) Check the clearance between the reverse gear and drive gear by a feeler gauge. Standard clearance: 0.3-0.9 mm (c) Check the axial clearance between the lowspeed and reverse gear and between the 2-speed and 3-speed gears of the output shaft. Standard clearance: 0.13-0.3 mm

2. Testing of double H air valve (a) Appearance testing: The housing shall be free from defects, and the plunger shall move flexibly and have no heavy wear.

4

31A

2 1 3

fhwx310162

(b) Channel testing: When the pin is in the original position, the compressed air introduced in shall flow out from the outlet 4 only; when the pin backs to the lowest position due to force carrying, the compressed air introduced in shall flow out from the outlet 2 only. Note: Replace the air valve if any of the fault phenomena appears.

Transmission (16JSD220TA) - Transmission 3.

31A-21

Testing of air filter regulator

(a) Appearance testing: The part shall be free from defects and leakage.

Air outlet

(b) Pressure testing: When the air pressure of the vehicle reaches 0.7-0.8 Mpa, the barometer is installed at the outlet, and the pressure valve displayed by the barometer shall be 0.41-0.44 Mpa. Note:

Air inlet

Replace the air filter regulator if the reading doesn't meet the requirement.

4. Testing of neutral gear switch (a) Appearance testing: The part shall be free from defects and leakage. (b) Resistance testing: Measure the resistance between the two wiring terminals of the switch by a multimeter. fhwx310164

. Gear position

Contact resistance (Ω)

Neutral gear

<1

Other positions

∞

5. Testing of range gear switch (a) Appearance testing: Free from defects such as deformation, damage or contact looseness. (b) Resistance testing: Measure the resistance between the two wiring terminals of the switch by a multimeter. fhwx310165

Resistance range

Contact resistance (Ω)

Low range

1

High range

∞

31A

31A-22

Transmission (16JSD220TA) - Transmission 6. Testing of reverse gear switch (a) Appearance testing: Free from defects such as deformation, damage or contact looseness. (b) Resistance testing: Measure the resistance between the two wiring terminals of the switch by a multimeter. fhwx310166

Gear position

Contact resistance (Ω)

Low range

1

Other positions

∞

7. Testing of auxiliary shift cylinder (a) Test whether the O-ring or other seals are damaged, deformed, lubricated poorly or installed not ineutral gear.

31A

8. Inspection of high low speed synchronizer (a) Check the fit state between the synchronizer and auxiliary gearbox output shaft.

Transmission (16JSD220TA) - Transmission

31A-23

(b) Check whether the synchronizer keyway and lock pin are worn.

fhwx310169

(c) Check whether there are cracks, deformation, etc. on the synchronizer ring gear.

fhwx310170

9. Bearing inspection (a) Place all bearings in clean solution and wash them. Check whether the steel balls, rollers and ball track have pits or fall off. 31A (b) Measure the bearing inner diameter. (c) Replace the bearing if the measured value exceeds the limit value.

10. Measurement of reverse shaft diameter (a) Measure the diameter of the reverse shaft by a micrometer. (b) Replace the reverse shaft if the measured value exceeds the limit value.

fhwx310172

31A-24

Transmission (16JSD220TA) - Transmission 11. Adjustment of transmission shift control mechanism (a) The technician A in the cab holds the shift lever in the center. (b) The technician B releases the adjusting nut of the expansion link assembly or shift lever assembly, and adjusts the gears to the best position. (c) Tighten the nut.

12. Measure the fit clearance between the ring gear and fork. (a) Measure the size of the ring gear with a micrometer.

31A

(b) Measure the size of the shift fork with a micrometer. Note: Replace the corresponding ring gear and fork if the fit clearance exceeds the limit value.

13. Gear inspection (a) Check whether there is pitting on the tooth surface of the gears, and replace the gears if any. (b) Check all mesh gears, replace the gears which are worn into a cone or have a decreased mesh length due to impact. (c) Check the axial clearance of gears, and check whether the gear split ring, washer, adjusting gasket and gear flange are worn excessively if detecting the part with excessive clearance. The axial gap of forward gear of main shaft should be kept between 0.13

Transmission (16JSD220TA) - Transmission

31A-25

and 0.30 mm. The axial clearance of reverse gear: 0.30-0.90 mm. 14. Spline inspection (a) Check the wear degree of splines on all shafts, and replace if the sliding gear sleeve and output flange incline to one side of the spline due to wear. 15. Inspection of thrust washer (a) Check the surface condition of all thrust washers. Replace the washers with scratches or thinned depth. 16. Inspection of gray cast iron parts (a) Check whether there are cracks or damages on all gray cast iron parts. Fusion welding or braze welding can be conducted for large castings, but the heat generated shall not extend to the bearing hole or bolt connecting surface. 17. Inspection of bearing cover (a) Check the seam for wear. (b) Check the oil seal in input shaft bearing cap and the oil seal in the odometer housing, replace if the sealing function of the lip fails. 18. Inspection of sliding sleeve (a) Check whether all forks and fork grooves on the sliding sleeves are overworn or discolored due to overheating. (b) Check whether the contact area of the engaging teeth of the sliding sleeve deflects. 19. O-ring inspection (a) Check all O-rings for cracking and deformation conditions. Replace the O-rings which are worn and aged.

31A

Transmission (16JSD220TA) - Shift mechanism assembly

31A-26

Shift mechanism assembly Component drawing

32 34

35

33

31

9

20 28

30

22

29

17

3 1

25

27

16

18

15

5

8

10

19

13

26 24

14 16

2

4 11

23

31A

12

6

7

21

1

Air vent plug

18

Dust cover

2

Air pipe assembly

19

End cover lining

3

Shift mechanism housing

20

Spring seat

4

Gear shift shaft

21

Low and reverse gear cam

5

Slide block

22

Bolt

6

Air circuit bend

23

Bolt

7

Air line control valve

24

Cheese head screw

8

Stop collar

25

Nut, style 1

9

Compression spring

26

Spring washer

10

Cylindrical pin

27

Spring washer

11

Air pipe tee joint

28

Shaft elastic snap ring

12

Elastic cylindrical pin

29

Bowl-shaped plug

13

Shift shaft bushing

30

Neutral gear switch

14

Control valve gasket

31

Travel top pin

15

Oil seal

32

Washer

16

Shift crank

33

Reverse lamp switch

17

End cover

Transmission (16JSD220TA) - Shift mechanism assembly

31A-27

Removal and installation 1. If the oil seal is removed, put the shift mechanism assembly vertically, and install the oil seal.

fhwx310134

2. Install the transverse shift shaft and assemble the elastic cylindrical pin of the reverse control block with the small end facing up.

fhwx310135

3. Install the cylindrical pin of the shift guide block, and bind with wires.

fhwx310136

4. Install the spring, spring seat and snap ring

fhwx310137

31A

31A-28

Transmission (16JSD220TA) - Shift mechanism assembly 5. Install the limiting sleeve and the side panel.

fhwx310138

6. Install the reversing lamp switch and neutral switch.

fhwx310139

7. Install dust cover and shift rocker to guarantee the rocker and block are in the same straight line. 31A

fhwx310140

8. Install the shift mechanism on the upper cover.

fhwx310141

9. Fasten the four bolts

fhwx310142

Transmission (16JSD220TA) - Shift mechanism assembly

31A-29

10. Install the air circuit reversing valve, air circuit control valve and air pipeline.

fhwx310143

31A

31A-30

Transmission (16JSD220TA) - Transmission assembly

Transmission assembly Removal 1. Lift the rear gearbox 2. Disconnect the negative cable of battery 3. Unscrew the oil drain plug at the bottom of the transmission, drain transmission oil, and tighten the oil drain bolt. Torque: 54.5±7 N•m

fhwx310077

4. Remove the intermediate drive shaft. Refer to Chapter 33 Drive shaft – Intermediate Drive Shaft, Overhaul. 5. Remove the drive shaft of the power take-off. Refer to Chapter 34 Power Take-off – QH50 Power Take-off, Removal and Installation. 6. Remove the transmission accessory (a) Remove the air pipe assembly of the air filter regulator.

31A

fhwx310063

(b) Remove the grounding cable of the transmission.

fhwx310064

Transmission (16JSD220TA) - Transmission assembly

31A-31

(c) Remove the air inlet of PTO.

fhwx310065

(d) Disconnect the combined plug of the transmission.

fhwx310066

7. Remove transmission shift control mechanism assembly 8. Remove the cover plate of the clutch observation hole. (a) Remove four bolts and take down the cover plate.

fhwx310067

9. Pick off the spring clamping wire hook of the clutch release bearing. 10. Remove the clutch slave cylinder. Refer to Chapter 32 Clutch – Clutch Slave Cylinder, Overhaul.

fhwx310068

31A

31A-32

Transmission (16JSD220TA) - Transmission assembly 11. Disconnect the connection of transmission and engine (a) Remove the lower connecting bolts of the transmission and engine.

fmwx010001 fhwx310069

(b) Remove the upper connecting bolts of the transmission and engine.

fhwx310070

12. Remove the subframe 13. Remove the transmission assembly (a) Jack up the transmission assembly by a transmission hydraulic jack.

31A

fhwx310071

(b) Remove the connecting nut of the transmission mounting, and take down the lower spring beam.

fhwx310072

(c) Separate the transmission from the engine by a flat crowbar. (d) Remove the transmission assembly.

fhwx310073

Transmission (16JSD220TA) - Transmission assembly

31A-33

Installation 1. Install the transmission assembly (a) Connect the transmission assembly with the engine assembly.

fhwx310074

2. Tighten the connecting bolts of the transmission and engine. (a) Tighten the upper connecting bolts of the transmission.

fhwx310075

(b) Tighten the lower connecting bolts of the transmission.

fmwx010001 fhwx310069

3. Install the spring beam of the transmission, and tighten the connecting nut of the mounting. Torque: 240 N•m 4. Install the transmission shift control mechanism assembly. fhwx310072

31A

31A-34

Transmission (16JSD220TA) - Transmission assembly 5. Install the transmission accessory (a) Connect the combination plug of the transmission.

fhwx310066

(b) Install the intake pipe of the power take-off.

fhwx310065

(c) Install the grounding cable of the transmission, and tighten the bolts. Torque: 54.5±7 N•m 31A

fhwx310064

(d) Install the air pipe assembly of the air filter regulator.

fhwx310063

6. Install the clutch slave cylinder, refer to Chapter 32 Clutch - Clutch Slave Cylinder, Overhaul Note: Before installing the clutch slave cylinder, tie the end of the release bearing crank by a rope through the window of the clutch slave cylinder, and strongly pull the crank outward to force the release bearing into the release ring and make it jammed by spring clamping wire, which shows that the release bearing is installed ineutral gear.

Transmission (16JSD220TA) - Transmission assembly

31A-35

7. Install the cover plate of the clutch observation hole (a) Install the cover plate of the clutch observation hole, and tighten the four bolts.

fhwx310067

8. Remove the drive shaft of the power take-off. Refer to Chapter 34 Power Take-off – QH50 Power Take-off, Removal and Installation. 9. Install the intermediate drive shaft. Refer to Chapter 33 Drive Shaft – Intermediate Drive Shaft, Overhaul. 10. Install the negative cable of the battery. 11. Unscrew the oil filler plug in the middle of the transmission, fill transmission oil 85W/90GL-5, and tighten the oil filler bolt. Note: Run the transmission for several minutes after filling oil, and then check the transmission oil 31A level again. fhwx310076

12. Put down the rear gearbox 13. Transmission running-in specification and test (a) The environment is that the speed is about 1,500 r/min; the oil temperature is not lower than 15℃ ; with no load, the transmission is running at Neutral gear for not less than 15min, and at other gears for not less than 20 min. (b) Check whether the shift is flexible, the gears are meshed fully, and there is a gear impact sound during shift. (c) The shift lever of the transmission shall be free from obvious vibration. (d) There shall be no abnormal friction sound or impact sound during testing of the transmission. (e) The transmission shall have no oil-leakage. (f) After running-in, drain transmission oil for running-in, clean the transmission inside completely, and fill transmission oil as specified.

Transmission (16JSD220TA) - Input shaft assembly

31A-36

Input shaft assembly Component drawing 10

9

31A 1

2

3

4

5

6

5

5

7

8

7

5

1

Input shaft nut

6

Front auxiliary gearbox synchronizer

2

Input shaft bearing

7

Input shaft gear spline cushion

3

Spacer ring

8

1-speed high splitter group gear

4

Primary shaft low splitter group

9

Guide bush, output shaft

5

Snap ring

10

Input shaft

Transmission (16JSD220TA) - Input shaft assembly

31A-37

Removal 1. Remove the transmission input shaft gear assembly.

fhwx310010

2. Remove the snap ring in the internal hole of input shaft gear.

fhwx310011

3. Remove input shaft gear and spline gasket of both sides

fhwx310012

4. Remove the snap spring in front of the synchronizer meshed gears

fhwx310013

31A

31A-38

Transmission (16JSD220TA) - Input shaft assembly 5. Remove components at the one side of the odd/even speed synchronizer.

fhwx310014

6. Direction of sliding block and cone ring on synchronizer. Remove the snap ring at one side of synchronizer. Note: Cone rings on both sides and normally meshed gears 16-speed odd-even speed synchronizer cannot be changed mutually. fhwx310015

31A

Transmission (16JSD220TA) - Input shaft assembly

31A-39

Installation 1. Put input shaft vertically, install input shaft high splitter group gear, and assemble input shaft gear spacer with the concave side down.

fhwx310026

2. Install input shaft bearing

fhwx310027

3. Put the input shaft levelly, install components at one side of the odd and even speed synchronizer and install one snap 31A ring

fhwx310028

4. Install the gear hub of synchronizer and install one snap ring

fhwx310029

31A-40

Transmission (16JSD220TA) - Input shaft assembly 5. Install the components on the other side of synchronizer and a snap ring

fhwx310030

6. Install the spline gasket on the input shaft

fhwx310031

7. Assemble the input shaft low splitter group gear and spline gasket, and install one snap ring. 31A

fhwx310042

8. Apply anaerobic adhesive on the threads of the input shaft nut, and assemble the input shaft nut and rivet it. Make the teeth alignment marks on two groups of teeth that are selected freely and are 180° adjacent on input shaft gear. fhwx310043

Transmission (16JSD220TA) - Output shaft assembly

31A-41

Output shaft assembly Component drawing

7

8 3

3 6

5 4

3

1

1

9

3

3 2

10

1

1

11 12

31A

1

Snap ring

7

1-speed gear, output shaft

2

3-speed/4-speed synchronizer assembly

8

1-speed/reverse mesh sliding sleeve

3

Output shaft gear spacer

9

Reverse gear, output shaft

4

3-speed gear, output shaft

10

Output shaft

5

2-speed gear, output shaft

11

Output shaft hexagon long key

6

1-speed/2-speed synchronizer

12

Elastic cylindrical pin

31A-42

Transmission (16JSD220TA) - Output shaft assembly

Removal 1. Remove the baffle at the front end of output shaft assembly, input shaft gear and components on one side of 5/6-speeds synchronizer

fhwx310175

2. Remove the snap ring on the main shaft fixing 5/6-speeds synchronizer, and take down the 5/6-speeds synchronizer.

fhwx310176

3. Remove the spring pin on the main shaft, pull out the long key and then remove gears and gaskets in order

31A

fhwx310177

Transmission (16JSD220TA) - Output shaft assembly

31A-43

Installation 1. Put the output shaft vertically on the workbench, install the output shaft reverse gear gasket and insert the long key after turning a tooth pitch.

fhwx310044

2. Install the reverse gear of the output shaft into the reverse sliding sleeve with the engaging teeth down, and the tooth space groove faces the output shaft keyway with hole.

fhwx310046

3. Install the gear spacer of the output shaft, and insert the long key upward after turn31A ing a tooth pitch.

fhwx310032

4. Install the engaging teeth of the output shaft 1-speed gear downward in the output shaft, put the output shaft gear spacer in, and insert the long key after turning a tooth pitch.

fhwx310033

31A-44

Transmission (16JSD220TA) - Output shaft assembly 5. Install the components at one side of the 1/2-speeds synchronizer, and install one snap ring

fhwx310034

6. Install the gear hub of the 1/2-speeds synchronizer, and install a snap ring

fhwx310035

7. Install the components at the other side of the 1/2-speeds synchronizer, and install the spline gasket of the output shaft with the convex side facing down, and insert the long key after turning a tooth pitch.

31A

fhwx310036

8. Install the engaging teeth of the output shaft 2-speed gear downward in the main shaft, install the output shaft gear spacer, and insert the long key after turning a tooth pitch.

fhwx310037

9. Install the engaging teeth of the output shaft 3-speed gear downward in the main shaft, install the output shaft gear spacer, and insert the long key after turning a tooth pitch.

fhwx310038

Transmission (16JSD220TA) - Output shaft assembly

31A-45

10. Assemble the spring pin on the output shaft.

fhwx310039

11. Install the components on one side of the 3/4-speeds synchronizer and install a snap ring. Note: The opening of the snap ring towards the output shaft groove with hole. fhwx310040

12. Install the gear hub of the 3/4-speeds synchronizer, and install one snap ring Note: The opening of the snap ring avoids the output 31A shaft groove with hole. fhwx310041

13. Install the components at the other side of the 3/4-speeds synchronizer.

fhwx310046

31A-46

Transmission (16JSD220TA) - Transmission upper cover

Transmission upper cover Component drawing 24 23

21

25

20

27 6 1

7

5 30

29 28

31A

2 8

5

9

13

14

10

4

22

5

5 11

5 16

5 18 15

26

3

19

17

17

12

Transmission (16JSD220TA) - Transmission upper cover

31A-47

1

Steel ball

16

3/4-speeds shift shaft

2

Steel ball

17

Y-shaped seal ring

3

O-ring

18

Y-shaped seal ring

4

Fork shaft interlock pin

19

End cover

5

Fork lock pin screw

20

Compression spring

6

Stud bolt

21

Compression spring

7

Upper cover

22

3/4-speeds, 7/8-speeds guide block

8

Reverse gear guide block

23

Thin nut

9

Reverse gear shift fork

24

Z-nut

10

1/2-speeds shift fork

25

Spring washer

11

3/4-speeds fork

26

Snap ring for hole

12

Front auxiliary gearbox fork

27

Nut

13

Reverse gear shift fork shaft

28

Reverse pin plunger

14

1/2-speeds shift shaft

29

Reverse pin spring

15

Front auxiliary gearbox fork piston rod

30

Reverse pin plug screw

31A

31A-48

Transmission (16JSD220TA) - Transmission upper cover

Removal 1. Remove the slave valve and pipe of oddeven speed cylinder.

fhwx310016

2. Remove the upper cover bolt.

fhwx310017

3. Push the upper cover out with bolts and remove the upper cover assembly. 31A

fhwx310018

4. Take out three locating springs and steel balls from the housing hole.

fhwx310019

Transmission (16JSD220TA) - Transmission upper cover

31A-49

5. Remove the reverse fork shaft, guide block and reverse fork.

fhwx310020

6. Remove 1/2-speeds fork shaft and fork, and take out interlock steel ball from the housing. Note: The 1/2-speeds fork shaft hole has interlock pin. fhwx310021

7. Remove 3/4-speeds fork shaft, guide block and fork, and take out interlock steel ball from the housing. 31A

fhwx310022

8. Remove the snap spring of odd-even speed shifting cylinder on the upper cover housing.

fhwx310023

9. Knock the piston and fork shaft, take out the spring and steel ball from the housing, and remove the piston and fork shaft.

fhwx310024

31A-50

Transmission (16JSD220TA) - Transmission upper cover 10. Remove the Y-ring on the piston form shaft and O-ring on the side cover.

fhwx310025

31A

Transmission (16JSD220TA) - Transmission upper cover

31A-51

Installation 1. Y-ring in the bore of odd/even gear shift cylinder on upper cover housing

fhwx310048

2. Apply a layer of grease on the Y-ring of piston shaft, and install the shaft into the odd/even speed gear cylinder on the upper cover housing. Note: Direction of Y-ring. fhwx310049

3. Install the locating steel ball in the bore of odd/even gear shift cylinder. Note: Spring upside, steel ball downside

fhwx310050

4. Install side cover with the plane facing outward

fhwx310051

31A

31A-52

Transmission (16JSD220TA) - Transmission upper cover 5. Install the snap ring of shift cylinder

fhwx310052

6. Assemble bolts on the fork of odd/even speed shift cylinder, and fasten with iron wire.

fhwx310053

7. Install the 3/4-speeds fork shaft, guide block and fork, fastening bolts, and install one interlock steel ball. 31A

fhwx310053

8. Install the 1/2-speeds fork shaft, interlock pin.

fhwx310055

9. Fasten bolts on the 1/2-speeds fork and guide block, bind with iron wire and install one interlock steel ball.

fhwx310056

Transmission (16JSD220TA) - Transmission upper cover

31A-53

10. Install the reverse fork shaft, guide block and reverse fork, and fastening bolts.

fhwx310057

11. Install the upper cover assembly

fhwx310058

12. Assemble three locating steel balls and spring in the upper cover holes Note: The spring in the hole of the 3/4-speeds fork 31A shaft is thicker.

fhwx310059

13. Screw up bolts on the upper cover, and connect the air pipes of shift device and upper cover.

fhwx310060

Transmission (16JSD220TA) - Main gearbox assembly

31A-54

Main gearbox assembly Component drawing 2

9

16

13

31A

5

12

4

3 14 7

15

6

10

8

1

17

11

1

Side power take off window lining

10

Hexagon head bolt and spring washer assembly

2

Round magnet

11

Pregluing hexagon head bolt and spring washer assembly

3

Bottom power take-off window cover

12

Slotted lock screw with flat end

4

Bottom power take-off window gasket

13

Hexagon nut, type-1

5

Transmission housing

14

Flat washer

6

Stud bolt

15

Flat washer

7

Hexagon nylon locking thin nut

16

Spring washer

8

Power take-off window cap

17

Slotted cone screw plug

9

Stud bolt

Transmission (16JSD220TA) - Main gearbox assembly

31A-55

Removal 1. Remove the snap ring on the back of the main gearbox countershaft.

fhwx310121

2. Install the driven gear bearing to locate the output shaft rear end.

fhwx310122

3. Remove the countershaft rear bearing with the soft rod.

fhwx310123

4. Knock the countershaft backward by approximately 10 mm with the copper rod and remove the two countershaft front bearings with special tools.

fhwx310124

31A

31A-56

Transmission (16JSD220TA) - Main gearbox assembly 5. Remove the driven gear bearing for one more time.

fhwx310125

6. Take the output shaft assembly out from the main gearbox.

fhwx310126

7. Take the countershaft assembly and the reverse idle gear from the main gearbox housing. 31A

fhwx310127

Transmission (16JSD220TA) - Main gearbox assembly

31A-57

Installation 1. Put the two countershafts of main gearbox into the main gearbox housing.

fhwx310128

2. After making the teeth aligning marks on a pair of teeth which are 180° adjacent on input shaft gear, put the output shaft assembly into the main gearbox, and install the drive gear bearing to locate the rear end of the output shaft. fhwx310126

3. Insert the marked teeth on the lower side countershaft into the two marked teeth on input shaft gear, and install the lower side 31A countershaft rear bearing.

fhwx310130

4. Assemble the front bearing of lower side countershaft.

fhwx310132

31A-58

Transmission (16JSD220TA) - Main gearbox assembly 5. Align and assemble the rear and front bearing of upper side countershaft with the same method.

fhwx310133

31A

Transmission (16JSD220TA) - Auxiliary gearbox assembly

31A-59

Auxiliary gearbox assembly Removal 1. Enable the two synchronizers in the main gearbox to engage with the gear separately.

fhwx310082

2. Use the special force-saving spanner to loose the output shaft flange nut.

fhwx310083

3. Remove the three air pipes on the auxiliary 31A gearbox cylinder and the two bolts on the air filter.

fhwx310084

4. Remove the connecting bolt of rear cover and main gearbox.

fhwx310085

31A-60

Transmission (16JSD220TA) - Auxiliary gearbox assembly 5. Push the auxiliary gearbox backward for approximately 10 mm with three bolts.

fhwx310086

6. Take the auxiliary gearbox assembly off with the auxiliary gearbox hanger.

fhwx310087

7. Remove the flange nut and the flange.

31A

fhwx310088

8. Remove the two output bearing cover and the snap ring on the auxiliary gearbox shaft with the snap ring plier.

fhwx310089

9. Knock the output shaft backward to separate it from the bearing and take down the countershaft bearing.

fhwx310090

Transmission (16JSD220TA) - Auxiliary gearbox assembly

31A-61

10. The two countershaft and bearing of the auxiliary gearbox.

fhwx310091

11. Remove the connecting bolt of auxiliary gearbox gearshift cylinder and the auxiliary gearbox gearshift fork.

fhwx310092

12. Remove the four bolts on the auxiliary gearbox gearshift cylinder and take the cylinder assembly down. 31A

fhwx310093

13. Take the cynchronizer assembly down form the output shaft.

fhwx310094

14. Knock the output shaft backward until it is off the bearing hole.

fhwx310095

31A-62

Transmission (16JSD220TA) - Auxiliary gearbox assembly 15. Block up the output shaft assembly and knock off the bearing.

fhwx310096

16. Each part of the output shaft assembly.

fhwx310097

17. Remove the bolt of the output bearing cover and and take down the bearing cover. Remove the odometer connector and the master and slave gear of odometer.

31A

fhwx310098

18. Take the combined bearing outer ring out from the rear cover hole.

fhwx310099

Transmission (16JSD220TA) - Auxiliary gearbox assembly

31A-63

Installation 1. Put the low speed ring of synchronizer flat and put it into the synchronizer sliding sleeve.

fhwx310100

2. Put the synchronizer high-speed ring, and add one rotating force to assemble the high-speed ring ineutral gear in place.

fhwx310101

3. Put the low-speed ring of the synchronizer up on a wood block 50 mm high, and insert 31A the output shaft.

fhwx310102

4. Install the gasket of the auxiliary gearbox main shaft, with the rabbet facing down.

fhwx310103

31A-64

Transmission (16JSD220TA) - Auxiliary gearbox assembly 5. Nest the auxiliary gearbox reduction gear into the output shaft with the plane facing upward, and put the pressure plate of the auxiliary gearbox main shaft gear. Note: Apply the lubricating grease on the pressure plate of auxiliary gearbox main shaft gear 6. Put the one side of the combination bearing into the output shaft, and make the teeth aligning mark in the 180° direction of the auxiliary gearbox reduction gear.

7. If the bearing inner rings of auxiliary gearbox has been removed, install the bearing inner rings into two countershafts. 31A

fhwx310106

8. Make teeth alignment mark on the marked tooth top of countershaft of auxiliary gearbox.

fhwx310107

9. Put the marked teeth of the two countershafts into the marked grooves of the reduction gear.

fhwx310108

Transmission (16JSD220TA) - Auxiliary gearbox assembly

31A-65

10. Put down the rear cover housing Note: Install the extended countershaft of power take-off on the lower right of rear cover housing.

fhwx310109

11. Install two countershaft bearings and output shaft outer bearing on the rear cover.

fhwx310110

12. Install the snap ring on the countershaft bearing of auxiliary gearbox. 31A

fhwx310111

13. Install two countershaft end caps.

fhwx310112

14. Install the output shaft bearing cap, and put the odometer drive and driven gears and joint in.

fhwx310113

31A-66

Transmission (16JSD220TA) - Auxiliary gearbox assembly 15. Insert the shift fork of the auxiliary gearbox into the synchronizer sliding sleeve, with the plane facing outward, install the connecting bolt of the fork and fork shaft, and lock with iron wires.

fhwx310114

16. Assemble shift cylinder of auxiliary gearbox

fhwx310115

17. Tighten the flange nut with a special socket. 31A

fhwx310116

18. Place the auxiliary gearbox synchronizer in the low-speed range.

fhwx310117

19. Apply grease evenly on the front bearing inner holes of two countershafts at the rear end of main gearbox (this step is very important).

fhwx310118

Transmission (16JSD220TA) - Auxiliary gearbox assembly

31A-67

20. Assemble the auxiliary gearbox assembly with lifting appliance.

fhwx310119

21. Tighten the connecting bolt of the rear cover and main gearbox housing.

fhwx310120

31A

31A-68

Transmission (16JSD220TA) - Reverse gear countershaft

Reverse gear countershaft Component drawing

5 1 2

4

3

31A

1

Cupped reverse gear washer

4

Reverse gear countershaft

2

Reverse countershaft gear

5

Slotted lock screw with flat end

3

Needle bearing

Transmission (16JSD220TA) - Reverse gear countershaft

31A-69

Removal 1. Remove the snap ring in the output shaft reverse gear.

fhwx310147

2. Take out the output shaft gear washer in the main shaft reverse gear.

fhwx310148

3. Remove the countershaft front bearing of auxiliary gearbox by a special tool.

fhwx310149

4. Remove the screw plug in the reverse idle gear shaft with the screwdriver.

fhwx310150

31A

31A-70

Transmission (16JSD220TA) - Reverse gear countershaft 5. Loosen the self-locking nut on the reverse idle gear shaft.

fhwx310151

6. Remove the reverse idle gear shaft by a special shaft puller.

fhwx310152

7. All components of reverse idle wheel assembly 31A

fhwx310153

Transmission (16JSD220TA) - Reverse gear countershaft

31A-71

Installation 1. Fit the reverse idle gear with the convex surface facing forward.

fhwx310145

2. Fit the reverse idle shaft and tighten the self-locking nut.

fhwx310146

31A

31A-72

Transmission (16JSD220TA) - Main gearbox countershaft

Main gearbox countershaft Component drawing

9

31A

8

7

6

5

3

4

3

2

1

1

Countershaft snap ring

6

Countershaft square key

2

Countershaft differential gear

7

Elastic cylindrical pin

3

Spacer sleeve

8

Woodruff key

4

Countershaft drive gear

9

Countershaft

5

3-speed gear, countershaft

Transmission (16JSD220TA) - Main gearbox countershaft

31A-73

Disassembly and assembly Note: Do not remove the countershaft gear, except for severe wear or tooth collision. 1. Disassemble the left countershaft (a) Remove the left countershaft snap ring.

31A

(b) Remove the countershaft differential gear, spacer sleeve, countershaft driven gear, countershaft 3-speed gear, countershaft square key and woodruff key in order.

31A-74

Transmission (16JSD220TA) - Main gearbox countershaft 2. Assemble the left countershaft. (a) Fit the woodruff key, countershaft square key, countershaft 3-speed gear, countershaft driven gear,countershaft differential gear and spacer sleeve in order.

(b) Install the countershaft snap ring.

31A

Note: As for the disassembly and assembly of the left countershaft, refer to the disassembly and assembly of the right one.