Clutch

General

Clutch assembly

Clutch pressure plate assembly Clutch slave disc assembly

 Clutch

Clutch master cylinder

Clutch cylinder
 Clutch

Main technical parameters

Slave disc
Type Dry single diaphragm type with damping spring

Size

Quantity of damping springs 4

Friction disc

ID×OD 160×250

Quantity × thickness 2×3.5

Pressure plate
Type Diaphragm spring

Max. pressing force 6276N

Hydraulic cylinder
Clutch master cylinder bore × stroke

Clutch cylinder bore × stroke

 Clutch

Clutch assembly

Disassembling drawing

Disassembling sequence

1. Transmission assembly; 2. Clutch pressure plate; 3. Clutch slave disc 4. Release sleeve;

5. Disengaging fork; 6. Guide bearing

 Clutch

Steps of disassembling (according to sequence)

Jack up the vehicle and safely support it.

1. Remove transmission (for operations, refer to the transmission part of this manual)

2. Pressure plate assembly;

3. Slave disc assembly.

Use a guide axle to prevent free sipping and fall of slave disc assembly.

Make markings on flywheel and pressure plate, which shall be used for alignment during
reassembling.

4. Remove clutch release fork.

5. Release sleeve assembly.

Remove release sleeve along with return spring.

Caution: Avoid flow of brake fluid onto painted surfaces during disassembling.

Immediately wipe out any such fluid on painted surfaces.

Inspection and repair

In case of excessive wear, damage or other fault found during inspection, make
necessary adjustment and repair, or replace corresponding parts.
 Clutch

Pressure plate assembly

Perform visual inspection of
pressure plate wear, thermal crack,
bending deform. In case of excessive wear
or bending deform, or too deep thermal
crack, replace the pressure plate.
(Pressure plate deformation
planeness of pressure plate friction face;
replace pressure plate assembly if the limit
value is exceeded. Limit: 0.3mm)

Clutch cover

Perform visual inspection of wear, crack or

other damage of the whole clutch cover.
Clutch cover with excessive wear, crack or
other damage must be replaced.

Mounting pressing force

Metal block
1) Put clutch pressure plate
Measuring gauge
upside-down;
2) Place an 8mm thick metal block on
pressure plate;
3) Press pressure plate down till distance
“B” is 0mm.
4) Record pressure reading on the gauge.
Standard pressure: 6276N

Height of diaphragm spring

disengaging finger
1) Place an 8mm thick metal block under
pressure plate
2) Press pressure plate down till distance
“B” is 0mm. 2 methods can be used:
a. press top of pressure plate down;
b. tighten pressure plate mounting bolts.
3) Measure from base plane to disengaging
finger end.

Standard height: 40±1mm

Clutch

Slave disc assembly

Visually check torsion spring

for looseness, softening and cracking; in
case of any of these, replace slave disc
assembly.

Visually check friction surface for crack,

grease or excessive charring; in case of
any of these, clean or replace slave disc
assembly. Check if this assembly can
move smoothly on transmission first shaft
spline.

Deform of slave disc

Insert guide axle in spline hub.

Guide axle must be kept very smooth and

straight. Fit a scale gauge on slave disc
outer circle and slowly rotate slave disc
assembly to obtain reading on the gauge.
If measured value exceeds a limit, replace
slave disc assembly.

Limit value: 1.0mm

Wear of slave disc spline

hub

Clean insides of spline hub.

Fit slave disc on transmission 1st shaft

spline.

Fit a surface measuring instrument on

outer circle of slave disc. Slowly rotate
slave disc and measure change of outer
circle.
Replace slave disc assembly if measured
value exceeds a limit.

Wear limit of slave disc spline hub: 1.0mm

 Clutch

Slave disc rivet head depth

Use a depth gauge to measure

distance from rivet head to friction surface.
Measure both sides. If measured value is
less than a limit. Replace slave disc
assembly.
Rivet head depth limit: 0.2mm

Release yoke and support

Visually check surface of release

yoke in contact with release sleeve and
support.

Replace part in case of excessive wear or

surface roughness.

Release sleeve assembly

Before disassembling release

sleeve assembly, check wear and roughing
of release sleeve assembly.

A. Surface of release bearing is rough or

noise is heard in rotation when being lightly
pressed.

B. Surface is rough or damaged (surface in

contact with release yoke and release
bearing front cover face).

Warning: The release bearing is loaded with lubricant in advance. Do not place this bearing in
solvent for cleaning, as this will dissolve the lubricant. Note that do not disassemble the release
sleeve if there is no problem. Visually check return spring for cracking and softening. Part
replacement is required in case of such situations.
 Clutch

Reassembling

Sequence of reassembling

1. Guide bearing; 2. Clutch release fork; 3. Release sleeve assembly; 4. Slave disc assembly;

5. Pressure plate assembly; 6. Transmission

Clutch

Reassembling steps

1. Release yoke

Apply Supramoly multi-purpose grease

on surface of release yoke in contact
with release sleeve assembly and
support.

2. Release sleeve assembly

it release sleeve with return spring.

3. Slave disc assembly

4. Pressure plate assembly

Apply Supramoly multi-purpose

grease inside slave disc spline hub.

Use guide axle to install slave disc

assembly.

Tighten pressure plate mounting bolts

in the sequence shown by numbers.

Tightening torque for pressure plate

mounting bolts: 18N·m

Warning: After tightening of pressure

plate mounting bolts, remove steel
wire protecting diaphragm spring.
 Clutch

Clutch control equipment

Disassembling

Disassembling sequence

1. Clutch pipe and hose; 2. Clutch pedal; 3. Clutch pedal and support assembly; 4. Clutch switch
 Clutch

or limit bolt; 5. Axle; 6. Pin; 7. Spring; 8. Clutch cylinder

Inspection and repair

In case of excessive wear or damage of part found during inspection, make necessary adjustment,
or repair or replace parts.

Reassembling

9
6
10

8
11
4
5

Reassembling sequence

1. Clutch cylinder; 2. Hose; 3. Clutch cylinder; 4. Clutch pedal; 5. Return spring; 6. Pin; 7. Axle; 8.
Clutch switch or limit bolt; 9. Clutch pedal and support assembly; 10. Master cylinder oil inlet hose;
11. Clutch pipe and hose
 Clutch

Assembling steps

1. Clutch cylinder

Clutch cylinder mounting bolts mounting

torque: 16 N•m

Before assembling clutch cylinder return

spring, first adjust clutch cylinder jogger.

1) Loosen clutch jogger lock nut;

2) Rotate jogger till pushing against

disengaging fork;
3) Rotate jogger back by 1.5 rounds (free travel of the fork is about 2mm)
4) Tighten lock nut (19 N•m)
2. Clutch hose
3. Clutch master cylinder
Install clutch master cylinder on clutch pedal and support. Tightening torque for mounting nut shall
be 13N·m
4. Clutch pedal
5. Return spring
6. Pin
7. Axle
8. Clutch switch or limit bolt
9. Clutch pedal and support assembly
Tightening torque for bolts of clutch pedal and support assembly is 38N·m.
After above assembling, adjust clutch control equipment.

Clutch pedal height and travel

1) Loosen clutch master cylinder jogger lock nut

2) Rotate jogger to adjust pedal

Clutch pedal height A: 160-180mm

Clutch pedal travel B: 160-170mm

3) Clutch master cylinder jogger lock nut tightening

torque is 13N·m

4) Reinstall instrument and adjust clutch pedal free

travel

1) Loosen clutch switch of pedal limit bolt.

2) Adjust clutch switch or pedal limit bolt so that clutch pedal free travel is 3-5mm.
Clutch

Venting of clutch pipeline

Follow the steps below:

1. Pull parking brake tight;

2. Add brake fluid in oil storage pot to max. level.

During venting, note brake fluid in the pot.

3. Remove rubber cap on venting screw of clutch

cylinder. Connect one end of a plastic pipe to
this screw and the other end to a transparent
vessel filled with brake fluid.

4. Continuously step down clutch pedal for a

number of times and then keep the pedal down.

5. With the pedal stepped down, loosen venting

screw to vent air. Later, tighten the venting
screw.

6. Repeat above operations till air in pipeline is

completely vented.

After venting operation, add brake fluid in the oil

storage pot to the “MAX” marking.
 Clutch

Clutch master cylinder

Disassembling

Disassembling sequence
1. Jogger and dust sleeve; 2. Piston assembly and return spring; 3. Cylinder body; 4. Clip;
5. Oil inlet hose; 6. Valve seat assembly
Inspection and repair
In case of excessive wear or damage found during inspection, make necessary adjustment, repair
or replacement of parts.

Clutch master cylinder assembly

Use brake fluid to clean clutch master cylinder body.

Check oil return hole for clogging; clean if necessary.

Measure ID of master cylinder body.

Master cylinder ID: 19.050---19.102mm

Clearance between clutch master cylinder piston and

ID of the cylinder: 0.12mm (limit)

Warning: For disassembled clutch master cylinder,

repair pack must be replaced.
 Clutch

Reassembling

Reassembling sequence

1. Cylinder body; 2. Piston assembly and return spring; 3. Jogger and dust sleeve; 4. Clip;

5. Oil inlet hose; 6. Valve seat assembly

Precautions on reassembling:

1. Before reassembling, use clean brake fluid to wet pump body and piston;

2. Apply a thin layer of grease on the rubber cup;

3. Prevent damage of rubber cup lip during assembling.

 Clutch

Clutch cylinder

Disassembling

Sequence of disassembling

1. Jogger; 2. Dust cover; 3. Piston assembly; 4. Venting screw; 5. Cylinder body

Inspection and repair

In case of excessive wear or damage of part found during inspection, make necessary adjustment
or repair/replacement of the part.

Clutch cylinder assembly

Use brake fluid to clean clutch

cylinder body.

Measure master cylinder inner diameter.

Master cylinder ID: 26.99---27.042mm

Clearance between clutch cylinder piston

and cylinder ID: 0.12mm (limit)

Warning: For disassembled clutch cylinder,

repair pack must be replaced.
 Clutch

Reassembling

Sequence of reassembling

1. Push rod; 2. Dust cover; 3. Piston assembly; 4. Venting screw; 5. Cylinder body

Precautions on reassembling:

1. Before reassembling, use clean brake fluid to wet pump body and piston;

2. Apply a thin layer of grease on rubber cup;

3. Prevent damage of rubber cup lip during assembling.

 Clutch

Troubleshooting

Sluggish clutch (noise of gear grinding during shifting)

Check hydraulic circuit

YES Faulty hydraulic circuit Liquid leakage Air in circuit

Replace Repair or replace

Check clutch master cylinder and cylinder

YES NO

Check free clearance Repair or replace

YES Excessive gap

Check clutch plate Adjust

YES Clutch plate warping

Check diaphragm spring Replace clutch plate

YES Weak diaphragm spring or worn pointer tip Faulty spring clamp

Replace pressure plate assembly Replace pressure plate

assy

Check spline shaft

YES Sliding not free

Clean, repair, apply grease

Check guide bearing

Worn or damaged guide bearing

Replace guide bearing

 Clutch

Slipping of clutch

Check master cylinder and slave cylinder

YES NO

Check clutch pedal Repair or replace

YES Clutch switch keeping pedal down

Adjust clutch switch setting

Check clutch pedal free gap & slave cylinder

YES No gap

Check clutch plate Adjust

Hardened friction disc surface Worn clutch plate Engine oil/grease on clutch plate
YES

Repair/replace clutch plate assy Replace clutch plate assy Replace clutch plate assy

Check diaphragm spring

YES Weak spring force

Replace pressure plate assy

Check pressure plate and flywheel

Warping flywheel Warping pressure plate

Repair or replace Repair/replace pressure plate assy

 Clutch

Vibration of clutch (clutch vibration during engaging start of clutch)

Check clutch plate

Clutch/friction disc poor contact Clutch plate warping/wear Hardened clutch plat surface

Replace clutch plate assy Replace clutch plate assy Repair or replace

No engine oil/grease on clutch Weak or broken clutch plate Loose clutch plate rivet
plate surface damping spring

YES
Replace clutch plate assy Replace clutch plate assy Replace clutch plate assy

Check pressure plate and flywheel

Warping or wear of pressure plate Warping or wear of flywheel

YES Repair or replace Repair or replace

Check diaphragm spring

YES Weak diaphragm spring force

Replace pressure plate assy

Check engine support or rubber pad

Loose engine support Deteriorated rubber pad

Tighten Replace rubber pad assembly

 Clutch

Noise of clutch (check clutch noise during engaging and disengaging of clutch
to determine cause of noise)

Check release fork or link rod

NO

YES Repair or replace

Check clutch pedal

Cracked clutch disc or damping Weak damping spring force Exposed rivet head
spring casing or broken spring

YES
Replace clutch plate assy. Replace clutch plate assy. Replace clutch plate assy

Check release bearing

YES Poor lubrication of release bearing Worn release bearing

Replace release bearing Replace release bearing

Check guide bearing

Worn guide bearing

Replace guide bearing

 Gearbox Assembly

General

Technical parameters

Tightening torque

Gearbox disassembling

Inspection and repair

Gearbox reassembling

Trouble shooting

1
 General

1) Direction for use

1. All forward gears of MSB-5M (reinforced) gearbox have clamping ring synchronizer, in order to
reduce abrasion between the gear and the synchronizer and enable the synchronizer and gear to
declutch smoothly so as to prevent the gear being destroyed, the action of shifting the gear must
be gentle. Only after the vehicle has stopped steadily can forward gear be shifted to reverse gear
or reverse gear to forward gear.

2. Special attention must be paid to: The fifth gear of gearbox is overdrive gear; to avoid the
overdrive gear being damaged, the fifth gear can only be used when the vehicle is not overloaded,
the road surface condition is excellent, and the vehicle is running at the speed above 50 km/h.
When at the fifth gear, in case some kind of situation requires the vehicle to slow its speed to
below 50 km/h, it is necessary to shift to lower gear; if it continues to run at the fifth gear, it is
extremely easy to break up the fifth gear.

3. The gearbox uses 80W/90 GL-4 gear oil in winter and 85W/90 GL-4 gear oil in summer.
Generally, the vehicle has to change its gear oil after running every 6,000 km. After draining dirty
oil, put the gearbox at reversing gear, jack up the rear axle, pour kerosene into it, let the gearbox
gear rotate for 2-3 minutes, then after draining the dirty oil again, fill it with pure gear oil.

4. When the vehicle is running downhill, it does not allowed to turn off the engine; and it is
forbidden to start the engine by using the inertia running downhill under the flameout condition, so
as to avoid the gear being damaged.

2) Assembling diagram

2
3) Diagram of gear shifting mechanism

Technical parameters

Rated input torque 254.8N·m

Assembly mass Approx. 78Kg

1st 5.529

2nd 2.782

3rd 1.641
Speed ratio
4th 1

5th 0.785

Rev 5.271

Lube oil amount 2.7L

Use (GL-4) 85W/90 in summer

Lube oil brand
Use (GL-4) 80W/90 in winter

3
II. Tightening torque N·m

4
5
 III. Gearbox disassembling drawing
Disassembling of large parts

Disassembling sequence:
1 Separation bearing 11 Odometer driven gear 20 Secondary axle bearing
2 Separation shifting yoke 12 Rear cover bolt 21 Secondary axle
assembly 13 Rear cover assembly
3 Clutch housing bolt 14 Breather valve 22 Intermediate axle front
4 Clutch housing 15 Odometer driven gear bearing, retaining ring
5 Gearbox side cover bolt driving gear 23 Intermediate axle rear
6 Gearbox gear side cover 16 Odometer driven gear bearing, retaining ring
and side cover gasket driving gear spacer 24 Intermediate axle
7 Gearbox top head bolt 17 Shifting yoke and shifting assembly
8 Top head assembly yoke shaft 25 Reversing gear
9 Second axle nut 18 Primary axle bearing
10 Flange 19 Primary axle assembly

6
 Important operation-- gearbox assembling

When disassembling, do use jack or similar

tool so as to guarantee safety of disassembling
and facilitate disassembling.

Assembling

Gearbox assembly

(1) Align the inclined line of gearbox to the

inclined line of engine.

(2) Adjust the gearbox to the direct gear

position, turn the secondary axle flanged disc
to align it with clutch.

Gearbox cover assembly

Insert a screwdriver to the groove indicated by

the arrow in the picture. Remove the gearbox
cover assembly from the gearbox body. Do not
disassemble it roughly, be careful and put it
down gently.

58
 Clutch housing bolts

Torque (N·M) 68.6-91.3

Intermediate axle front bearing

Use a copper bar and a hammer to strike the

rear end of the axle, move the intermediate
axle for about 3mm.

Use special tool to insert to the stop ring

groove; remove the front bearing.

Primary axle ball bearing

Use a copper bar and a hammer to strike the

rear end of the axle; move the primary axle
for about 3mm.

Use special tool to insert into the brake ring

groove; remove the ball bearing.

59
 Gearbox rear cover bolts

Torque (N·M) 68.6-91.3

Secondary axle ball bearing

Use a copper bar and a hammer to strike the

rear end of the axle; move the secondary
axle for about 3mm.

Use special tool to insert into the brake ring

groove; remove the bearing.

Spring pin, shifting yoke, shifting yoke

shaft

Before disassembling, put all the shifting

yoke axles at neutral position.

After pushing out the spring pin, push the

rear end of the shifting yoke shaft forward.

Then, strike the rear end of the shifting yoke

shaft forward and gently, remove the shifting
yoke and the shifting yoke shaft.

Secondary axle assembly

When disassembling, use strong steel cable,

and pay attention to safety.

60
 Disassembling of small parts
Top head assembly

Disassembling sequence:

1 Oil filling plug 2 Reversing lamp switch 3 Elastic cylindrical pin 4 External selected
gear rocker arm combined part 5 Plain washer 6 Internal selected gear rocker arm 7 External
shifting gear rocker arm combined part 8 Internal shifting gear rocker arm 9 Oil seal

Important operation

Reversing lamp switch

Torque N·m 30-50

61
 Primary axle assembly, secondary axle assembly, intermediate axle assembly,
reversing gear

Disassembling sequence:
1 Primary axle 14 Retaining ring 23 R/5 gear synchronizer gear
ring
2 Primary axle connection gear 15 1/2 gear synchronizer gear
ring ring 24 R/5 gear synchronizer
assembly
3 Needle roller bearing 16 1/2 gear synchronizer
assembly 25 Secondary axle reversing gear
4 Retaining ring
26 Needle roller bearing
17 1/2 gear synchronizer gear
5 3/4 gear synchronizer gear ring
ring 27 Secondary axle
6 3/4 gear synchronizer assembly
18 Secondary axle first gear 28 Intermediate axle fifth gear
7 3/4 gear synchronizer gear ring
19 Needle roller bearing 29 Retaining ring
8 Secondary axle third gear
20 Secondary axle fifth gear 30 Intermediate axle assembly
9 Needle roller bearing
thrust washer 31 Reversing axle pin
10 Retaining ring
21 Secondary axle fifth gear 32 Reversing axle
11 Secondary axle thrust washer
22 Retaining ring 33 Reversing gear
12 Secondary axle second gear
13 Needle roller bearing
62
Essential points for attention
Synchronizer assembly

spring filler block Disassemble the synchronizer assembly altogether;

then disassemble the gear sleeve, slide block, spring
matchin
synchronizer and synchronizer tooth hub.
g sleeve
tooth hub

synchronizer assembly

Ball bearing

When disassembling, use bench press.

Retaining ring

Remove the retaining ring with ring pliers.

Thrust plate

2
IV. Inspection and repair

Gear inner hole

Gear 1, 2, 5 Standard Limit

0.05-0.09mm 0.2mm

Ball bearing radial runout

Limit 0.2mm

Shifting yoke

Standard Limit

10.0mm 9.0mm

3
 Gap between synchronizer tooth hub

and slide block

Standard 0.09-0.31mm

Important operation—Secondary axle

radial runout

Gap between synchronizer gear

ring and connection gear

Gear Standard Limit

Gear 3, 4 1.0mm

Gear 1, 2, 5 1.5mm 0.5mm

Limit spring free length

Standard Limit

39.8mm 38.5mm

4
 V. Gearbox reassembling

Reassembling of small parts

Secondary axle assembly, primary axle assembly, intermediate axle assembly,
reversing axle assembly

Reassembling sequence:
1 Secondary axle 2 Needle roller bearing 3 Secondary axle first gear 4 1/2 gear
synchronizer gear ring 5 1/2 gear synchronizer assembly 6 1/2 gear synchronizer gear ring
7 Retaining ring 8 Needle roller bearing 9 Secondary axle second gear 10 Secondary axle
thrust washer 11 Retaining ring 12 Needle roller bearing 13 Secondary axle third gear 14
3/4 gear synchronizer gear ring 15 3/4 gear synchronizer assembly 16 3/4 gear
synchronizer gear ring 17 Retaining ring 18 Needle roller bearing 19 Secondary axle
reversing gear 20 R/5 gear synchronizer assembly 21 R/5 gear synchronizer gear ring 22
Retaining ring 23 Secondary axle fifth gear 24 Secondary axle fifth gear thrust washer 25
Intermediate axle assembly 26 Retaining ring 27 Intermediate axle fifth gear 28 Primary
axle 29 Primary axle connection gear 30 Reversing gear 31 Reversing axle 32
Reversing axle pin 33 Needle roller bearing
5
 Important operation

Synchronizer assembling

When pressing the synchronizer assembly onto the secondary

axle, take care not to fall off the synchronizer gear sleeve, slide
block, and synchronizer spring.

Retaining ring assembling

Select appropriate retaining ring to insert in, and get a minimum

axial gap.

6
 Top head reassembling

Reassembling sequence:

1 Oil seal 2 Inner shifting gear rocker arm 3 Outer shifting gear rocker arm combined part 4
Plain washer 5 External selected gear rocker arm combined part 6 Inner selected gear
rocker arm 7 Elastic cylindrical pin 8 Reversing lamp switch 9 Oil filling plug

Important operation

Oil seal assembling

Strike the oil seal into place gently with special

tools.

7
 Reversing lamp switch

Torque N·m 30-50

Internal/external shifting gear rocker arm

Assembling of internal/external shifting gear

rocker arm

8
 Large parts reassembling

1 Housing 2 Intermediate axle assembly 3 Reversing gear 4 Secondary axle assembly 5

Secondary axle bearing 6 Primary axle assembly 7 Primary axle bearing 8 Intermediate axle
rear bearing, retaining ring 9 Intermediate axle front bearing, retaining ring 10 Inner driven
gear and driving gear spacer 11 Inner driven gear driving gear 12 Rear cover and oil seal
13 Rear cover bolt 14 Flange 15 Secondary axle nut 16 Breather valve 17 Inner driven
gear 18 Side cover and side gasket 19 Side cover bolt 20 Shifting yoke, shifting yoke shaft
21 Top head assembly 22 Top head bolt 23 Clutch housing 24 Clutch housing bolt 25
Separation bearing 26 Separation shifting yoke assembly

9
 Important operation

Secondary axle assembling

Use strong steel cable while assembling, and

pay attention to safety.

Interlocking pin, steel ball

Put the steel ball into the housing, insert the

interlocking pin into pin hole of shifting yoke,
make it arrive at the other side of the housing
through the case hole, 3/4 gear shifting yoke,
and 3/4 gear shifting block in sequence.

Spring pin

Do not reuse the disassembled spring pin;

Incorrect Correct replace it with a new one.

Primary axle bearing

Please assemble it with special purpose

sleeve.

10
 Clutch housing

Apply the connection surface of the clutch

housing with liquid sealant.

Primary axle

Assemble primary axle into the gearbox; and

make sure the primary axle turns flexibly.

Gearbox rear cover bolt

Torque (N·m) 68.6-91.3

11
 VI. Trouble shooting

1. Gearbox noises
If there is noise coming from the gearbox area during idling, inspect the clutch first. If the noise
stops when treading down the clutch pedal, it shows the noise is coming from the gearbox.

Check gear oil level

Fill the Check gear oil quality....type,

recommend Too low YES pollution, foreign matters, viscosity
ed gear oil

Fill the
Sufficient recommended gear Insufficient
lube oil

Gearbox overhaul

Gear worn or damaged Bearing/spline worn or damaged Axial clearance too

large

Replace Replace Replace

12
 II. Gear out-of-gear

Clearance too big, loosened or Check control parts for clearance,

maladjusted loosening or mal-adjustment

Check whether each YES

Adjust or replace
connection is loosened

Loosened Loosened

Gear change
Tighten
mechanism overhaul

Connecting Shifting arm worn Gear change Circlip elastic YES (

piece or bent lever groove force
loosened worn weakened

Gearbox
Replace Replace Replace Replace
overhaul

Gear sleeve and connection Spline has excessive

Bearing worn Gear worn
gear worn excessively clearance at rotating
excessively excessively
direction

Replace Replace Replace Replace

13
III. Gear cannot shift smoothly (having noise when shifting)

Check free clearance of clutch pedal

Adjust to
Check gear oil level YES Incorrect
specified value

Fill the
Check control rod
YES Too low recommended
moving and length
lube oil

Gear change
Adjust to
YES mechanism NO
specified value
overhaul

Check whether the shifting yoke

shaft and shifting arm are bent Bent too much Replace

Gearbox
Not bent Check axial clearance of parts
overhaul

YES Synchronizer parts worn out or Clearance

damaged too big

Replace Replace

14
 Drive shaft

General

Technical parameters

Fixed torque

Disassembling and reassembling

Trouble-shooting
General
 Technical parameters

Bearing fixing mode Outer spring ring

Cross length Mm 71

Cross length outside diameter Mm 18.44

Shaft tube specification Diameter × thickness Mm 69×2.5

Flange bolt specification 10

Flange dimension Reference diameter Mm 85

Max. unbalance g·cm/rpm Not exceeding 35/3200

 Fixed torque

N·m

Gearbox side

Rear axle side

 Disassembling

Disassembling steps

1. Differential end nut

2. Middle suspension

3. Transmission end nut

4. Drive shaft assembly

Important operation

As the drive shaft requires good balance, assembly

mark should be made on the universal joint during the
disassembling.
 Disassembling

Universal joint

Disassembling sequence

1. Cross grease nipple 4. Cross

2. Universal bearing retaining ring 5. Flange yoke

3. Needle bearing

Importance operation - disassembling

1. Needle bearing

Knock on the flange yoke to remove the

bearing and then tap on the cross to remove the
needle bearing. Remove the other bearings in the
same way.
 Center bearing

Disassembling sequence

1. Nut 5. Center bearing

2. Washer 6. Dust shield

3. Yoke

4. Middle rubber

Inspection and repair

If wearing or other faults are found on the

components during the inspection, repair or
replacement should be carried out.

Cross

Needle bearing
Visual inspection
Flange yoke
Check the following components for wearing,
Yoke
damage and other abnormal conditions.
Center bearing

Vibration isolating rubber bearing

Bracket
 Cross pin diameter
Cross pin
diameter
(mm)

Dimension Limit

18.44 18.34

Hj Spline side play

Spline housing

(mm)

Standard Limit
Spline shaft
0.1 0.3

Side play

Unbalance inspection (for reference only)

Measure the unbalance value of certain

point in cross.

Speed at measurement Unbalance

(rpm) (g·cm)

3200 35
 Reassembling

Center bearing

Disassembling sequence

1.. Middle rubber 5. Washer

2. Center bearing 6. Nut

3. Dust shield

4. Yoke

Important operation

Apply grease on oil seal lip and middle

bearing

Grease. Recommended grease type:

Fuchs EPT-2.5 grease

Filling-up quantity 20 - 25g.

 Important operation

Staking on the nut after the middle nut is

tightened.

Two symmetrically on circumference.

Universal joint

1. Flange yoke 4. Universal bearing retaining ring

2. Cross 5. Cross grease nipple

3. Needle bearing
 Important operation - - - reassembling

1. Flange yoke

The flange yoke of the drive shaft must be installed

as shown in the figure. The spline spindle and spline
yoke should be assembled in alignment as shown by
the arrow.

2. Needle bearing

Apply Fuchs EPT - 2.5 grease on the oil

seal and needle bearing. Use cross as
the guide to fit needle bearing in the flange yoke by
knocking with soft face hammer.

3. Cross grease nipple

Install the grease nipple to the specified

angle on the cross. Make sure that the
grease nipples face upward.

4.Universal bearing retaining ring

Do not use worn universal bearing retaining ring.

After the bearing is installed, select and fit the
appropriate universal bearing retaining ring to make
the cross end play not exceed 0.1mm.
 Assembly

Gearbox side

Rear axle side

Assembling steps

1. Drive shaft assembly 3. Middle suspension

2. Transmission end nut 4. Differential end nut

 Importance operation - Assembly

1.Transmission side nut

Torque N·m 46-56

2. Differential end nut

Torque N·m 46-56

3. Middle support nut

Torque N·m 41-51

 Trouble-shooting

Noise

Check middle spline shaft

YES Worn

Replac

Check cross bearing

YES Worn or stuck

Replac

Check middle bearing

YES Worn

Replac
 Vibration

Check shaft run-out

YES NO

Replace

Check shaft

YES Unbalance

Adjust

Check gearbox rear shell bushing

YES Worn

Replace

Check sliding yoke spline shaft

YES Stuck

Replace
 Rear Axle

Rear Axle Assembly

Chapter I Introduction of Rear Axle Structure

Chapter II Disassembling, inspection, and reparation

Chapter III Assembly and adjustment of rear axle assembly

Chapter IV Use and maintenance of rear axle assembly

Chapter V Trouble shooting of rear axle

63
 Rear Axle

Chapter I Introduction of Rear Axle Structure

I. General description of the structure

Types of Rear Axle Structure (Table 1)

Item Content

Type of axle case Press-welding integral type

Type of axle shaft support Full floating type

Type of reduction gear Single-stage hypoid spiral bevel gear

Number of planetary gears 4 planetary gears

Rated axle load 4 tons

Maximum output torque 8500N·m

This series of rear axle is the drive axle for two-wheel drive vehicle, and the rear suspension is of
the rigid-axle type suspension structure. It is composed of the final gear, differential and axle case
etc., which is the final reduction and driving mechanism in the automotive power transmission
system. The final gear can both change the power transmission direction, and reduce the rotation
speed and increase the torque. It is composed of the drive gear and the driven gear. The end with
spline of the drive gear is jointed to the propeller shaft universal joint assembly through the drive
gear flange, and the middle of it is supported by two conical bearings which are installed in
opposite direction, so as to bear the axial force and the tangential force. The small face neck of the
drive gear is installed on the conical roller bearing, which only bears the radial force. The driven
gear is fixed on the differential left casing by the bolts.

Differential allows the left wheel and the right wheel to generate different rotation speed, it is
composed of such components as the differential right casing and left casing, cross shaft, four
planetary gears, and two axle shaft gears etc.

One end of the rear-axle shaft is jointed to the axle shaft gear with spline, the flange on other end
is connected to the hub and brake drum assembly by the bolts.

64
 Rear Axle

II. Explosion diagram and details of rear axle assembly:

1. Drive gear flange 2. Drive gear 3. Dust fender 4 Oil seal-drive
self-lock nut flange gear
5 Drive gear inner and 6 Bearing seat bolt 7 Spring washer 8 Drive gear
outer bearing bearing seat
9 Adjusting 10 O-ring 11 Compressible 12 Drive gear
washer-bearing seat spacer
13 Guide bearing spring 14 Guide bearing 15 Type 1 Hex nut 16 Spring washer
collar guard assembly
17 Drive gear guide 18 Differential 19 Differential 20 Differential
bearing bearing bearing casing (right)
adjusting nut
21 Axle shaft gear thrust 22 Axle shaft gear 23 Planetary gear 24 Planetary gear
washer shaft
25 Driven gear 26 Differential 27 Bolt-driven gear 28 Bolt-differential
casing (left) casing
29 Nut-differential casing 30 Spring washer 31 Flat washer 32 Bearing cap
33 Bearing cap bolt 34 Spring washer 35 Reduction 36 Spring washer
casing bolt
37 Reduction casing bolt 38 Reduction 39 Spring washer 40 Final drive
casing nut casing
41 Hex bolt 42 Locking 43 Spring washer 44 Rear axle
plate-adjusting casing
nut assembly
45 Normally open vent 46 Filler plug 47 Filler plug 48 Drain plug
plug sealing ring
49 Drain plug sealing ring 50 Find thread hex 51 Type 1 fine 52 Spring washer
bolt thread hex nut
53 Rear brake assembly 54 Axle shaft nut 55 Taper sleeve 56 Spring washer
(left and right)
57 Axle shaft bolt 58 Axle shaft 59 Axle shaft oil 60 Lock washer
seal
61 Bearing nut 62 Rear hub outer 63 Hex bolt 64 Spring washer
bearing
65 Tyre bolt 66 Tyre outer nut 67 Tyre inner nut 68 Rear hub inner
nut
69 Rear hub 70 Rear hub inner 71 Rear brake drum 72 Rear hub inner
bearing oil seal
73 Hex bolt 74 Spring washer 75 Oil catcher

65
 Rear Axle

III. Sealant and Adhesive Applied on Rear Axle Table 2

Item Specified sealant and adhesive

Installation surfaces of the rear axle casing 515 Anaerobic sealant

assembly and final reduction assembly

Driven gear bolt GY-340 Anaerobic sealant

Differential casing bolt GY-340 Anaerobic sealant

Reduction casing bolt Mechanical sealant 605

Hub inner cavity ZL-2 GB5671-85 Automobile General purpose

Lithium Base Grease.

Installation of the final reduction assembly No. 10 motor oil

components

VI. Detailed List of Rear Axle Wearing Parts Table 3

Description Quantity

Drive gear oil seal 1

Rear hub inner oil seal 2

Rear hub inner bearing 2

Rear hub outer bearing 2

Drive gear inner bearing 1

Drive gear outer bearing 1

Axle shaft oil seal 2

Drive gear nut 1

Differential bearing 2

Left and right plate friction lining 2 pieces for each

O-ring 1

Drive gear, bearing seat adjusting washer According to actual need

66
 Rear Axle

V. Table of Main Bolts Tightening Torque Table 4

Bolt (nut) Name HF15015 (N.m)

Drive gear nut 250~280

Drive gear bearing seat bolt 75~113

Bolt –driven gear 108~161

Differential casing bolt 45~79

Reduction casing bolt 45~79

Guide bearing guard plate bolt 16~26

Bearing cap bolt 122~185

Adjusting nut locking plate bolt 16~26

Rear brake back plate nut 78~115

Axle shaft bolt 45~79

Hub inner nut 287~346

Lock washer small hex bolt 6~12

Filler plug 44.1~53.9

Drain plug 44.1~53.9

67
 Rear Axle

Chapter II Disassembling, Inspection and Reparation of Rear Axle

I. Disassembling
Remove the rear axle

1. Put wooden wedges under the wheel in the front and

behind, to hold the wheel in position.

2. Loosen the wheel nuts of the outer side wheel.

3. Jack up the rear axle.

Remove the axle shaft

1. Loosen the axle shaft nuts.

2. Remove the axle shaft. If it is difficult to remove the

axle shaft, use copper hammer to slightly knock on the
axle shaft flange, until the axle shaft is loosen off.

Disassemble the wheel hub

1 Remove the lock washer.

2. Remove the nub bearing lock nut.

Note:

Use the hub bearing adjusting nut spanner to

remove the adjusting nut.

3. Remove the wheel hub assembly.

Note: use rear hub extractor to remove the hub.

68
Rear Axle

4. Remove the axle shaft oil seal from the end of the
axle sleeve.

Note: when assembling, the outer ring of the axle shaft

oil seal shall be applied with lithium base grease and
then pressed into the rear hub.

5. Remove the oil seal from the hub assembly.

6. Remove the bearing cup of the inner and outer

bearing.

7. Remove the brake drum and oil retainer.

69
Rear Axle

Disassemble the axle case and the final

reduction gear
1 Bleed out the final reduction gear lubricating oil.
2 Disassemble the connection between the propeller
shaft and main reduction gear.
3 Use jack to remove the final reduction gear
assembly.
4 Remove the hose, steel pipe, and wire cluster.
5 Remove the brake assembly.
6 Remove the rear axle.
·Jack up the axle casing.
·Remove the U bolt and upper and lower base plates,
lower down the jack, and pull out the axle casing.

Disassemble the main reduction gear assembly

1 Before disassembling, measure and record the

tooth clearance of the drive gear and the driven gear.

Note: After adjustment, check the engagement of the

gears.

2 Remove the locking plate;

3 Make assembly marks on the bearing cap and

casing;

The disassembled bearing cap and reduction casing

shall be placed separately per left and right
according to the matching number, in order to avoid
mismatching during re-assembling.

70
Rear Axle

4 Loosen the fixing bolts of the bearing cap, use

differential spanner to remove the adjusting nut;

5 Remove bearing cap and bolt;

6 Remove the differential assembly;

7 Use stripper to remove the drive gear assembly,

at the same time remove the adjusting washer;

71
Rear Axle

Disassemble the differential assembly

1 Remove the differential right casing;

2 Remove the axle shaft gear and washer;

3 Measure and record the tooth clearance of the

planetary gear;

Note: when measuring the tooth clearance, make

sure to press down the planetary gear cross
shaft.

4 Remove the planetary gear cross shaft assembly,

and then remove the planetary gear and washer
from the cross shaft;

72
Rear Axle

5 Take out the axle shaft gear and the thrust

washer on the axle shaft/
shaft;

6 Remove the driven gear;

7 Remove the differential bearing from the

differential casing;

Disassembling of the drive gear

1 Remove the drive gear flange.

3 Remove the stopper elastic ring for shaft and

take off the drive gear guide bearing;

73
Rear Axle

4 Press out the drive gear from the bearing seat;

5 Remove the adjusting washer and the bearing

spacer;

6 Remove the bearing from the drive gear;

7 Remove the oil seal from the bearing seat;

8 Remove the bearing cone, remove the bearing

cup.

74
 Rear Axle

Key points for check-up during disassembling

1. Check the drive gear flange for any wearing or damage.

2. Check the bearing for any wearing or color change

3. Check the gears for any crack.

4. Check the drive gear and driven gear for any wearing or crack.

5. Check the axle shaft gear, planetary gear, and planetary gear shaft for any wearing or crack.

6. Check the axle shaft spline for any wearing or damage.

II. Table of Rear Axle Maintenance Parameters Table V

Item Value

Drive and driven gear clearance 0.18 0.23mm

Planetary, axle shaft gear clearance 0-0.15 mm

Without oil seal

Drive gear rotational torque
Apply gear oil 10-20 Kgf·cm

Hyperbolic gear oil: GL-5 85W/90

Rear axle gear oil
Volume: 3.5 L

Oil applied on the outer rim and lip of the ZL-2 GB5671-85
axle shaft oil seal, and drive gear oil seal
Automobile General Purpose Lithium Base Grease.

Clearance between friction lining and 0.4-0.7 mm Hydraulic brake

brake drum

III. Rear axle inspection and reparation

1. Special measuring instrument or tools shall be used for the inspection of components.

Judgment on whether a component can continue in service shall be made according to the
specified maintenance standard table. The broken parts shall be repaired and replaced according
to the requirements. In case one of a pair of matching parts is worn out, which causes the
clearance go beyond the specified value, this part and the other matching part shall all be replaced
as per the corresponding requirements.

2. From the view of preventive maintenance, some of the parts which are still within the reparation
limit or wearing limit shall also be replaced before they exceed the limit.

3. Carefully check the appearance of all the components, through the assigned methods as visual
inspection or red pigment penetration etc. If the outside appearance of the component has the
following abnormal signs, the said component shall be repaired or replaced as per the

75
 Rear Axle

requirements.
Abnormal signs:
Uneven wear Eccentric wear Scrape
Crack Distortion dead or weaken refer to spring
Bending deflection Abnormal noise refer to bearing
Loosen Color change or seize up Rust
Deterioration refer the brake friction lining
4. All the rubber pieces, such as O-ring, oil seal, and gasket etc. shall be discarded after removal,
and they are not allowed to be re-used.
5. In case the transmission system generates abnormal sound or vibrates, first check the total free
play of the rear axle, and then determine whether it is necessary to disassemble the final reduction
gear assembly.
Place the vehicle on the level ground, put the transmission gear and transfer gearbox on neutral
position, pull up the parking brake lever and jack up the vehicle. Turn the flange clockwise to the
end, and make matching marks on the flange dust fender and the reduction casing, and then turn
the flange counter clockwise to the end, measure the moving distance of the two matching marks,
the ultimate free play is 6mm, if the free play exceed that limit, it indicates excessive gear
clearance of the rear axle, and the rear axle shall be disassembled to make adjustment.
Abnormal sound is also one type of noise, it mainly appears as the abnormal sounds generated
under different service conditions (such as vehicle speed, road conditions), like knocking sound or
screeching sound some of the sounds will gradually disappear through breaking-in, while some of
the sounds will get louder and louder. This is mainly because of the improper assembly and
adjustment. Under the precondition of good quality components, most of such problems can be
solved through adjusting the assembling clearance.
6. Failure of brake return mainly is the problem that the brake seized up after being stepped down
and cannot continue the brake operation. This problem mainly can be solved by adjusting the
brake assembly clearance.
Item Reparation Standard Wearing Limit Remarks
Wear of rear axle leaf spring 1mm
location hole
Radial jumping of left, right — 0.1mm
axle shaft sleeve outer bearing
journal
Radial jumping of axle shaft — 1.5mm
middle un-machined surface
End surface jumping of the hub — 0.15mm
and axle shaft flange coupling
surface

76
 Rear Axle

Chapter III Assembling and Adjustment of Rear Axle Assembly

I. Assembling and adjustment of rear axle assembly

I The assembling of the final reduction gear assembly is following the reverse procedure of the
above disassembling procedure, before assembling all the components shall be kept clean, free of
such foreign substances as oil dirt, iron dust etc. Apply NO.10 motor oil for lubrication during
assembling, and make adjustment as per the following requirements:

1. Drive gear inner and outer bearing preloading

1.1 When assembling the final reduction gear, the conical roller bearing shall have certain
assembly preload, that is, to give certain preloading force on the basis of eliminating the bearing
clearance. The purpose of it is to reduce the axial replacement caused by the axial force
generated during the transmission process of conical gear, so as to increase the supporting rigidity
of the shaft, and ensure the normal engagement of the conical gear pair. But it also shall not be too
tight, if it is too tight, it will cause low transmission efficiency, and speed up the wearing of the
bearing.

1.2 Adjustment of the drive gear bearing preloading force: under the condition of drive gear flange
nut tightening torque, install the drive gear oil seal, the drive gear is not engaged with the driven
gear, and ensure the drive gear bearing preloading torque (see Table 5). The adjustment of
preload is made by increasing and reducing the drive gear bearing adjusting washers in between
the drive gear inner and outer bearings (for specifications, see Table 6). Reduce the number of
adjusting washers; the preloading torque is increased; while increase the number of adjusting
washers, the preloading torque is decreased.

2. Differential bearing preload adjustment

2.1 Adjustment of differential bearing: the differential bearing shall be adjusted to have certain
preloading force, so as to obtain 0.01-0.02 interference on both sides of it, apply gear oil to the
bearing rotating part under the condition of no engagement between drive gear and driven gear,
the start up friction torque is 0.686-1.586N.m. The differential bearing preload adjustment is
realized through the tightening of the differential bearing nut. When adjusting, first put on the
bearing cap freely, when the adjusting ring can be turned smoothly, then tighten the bearing cap
bolt, and after that adjust the preloading force. The locking slot on the adjusting nut after the
adjustment shall be aligned with the locking plate. After adjustment, the driven gear shall not have
end float misalignment.

2.2 Differential gear clearance adjustment

Use dial gage to measure the differential gear meshing backlash on the planetary gear. Note: take
measurement from more than three points, the standard value is: 0 0.15mm; limit value: 0.3mm

77
 Rear Axle

3. Adjustment of drive and driven gear backlash, and meshing mark

3.1 Adjustment of gear backlash
The normal meshing backlash and the gear backlash variables of the drive and driven gear is
shown in table 5. When adjusting the gear backlash, the measurement shall be taken on four
positions which are evenly distributed along the circumference of the driven gear, the measuring
head of the micrometer shall be perpendicular to the surface of the measured point.
3.2 Adjustment of drive and driven gear meshing mark
First apply red lead to the teeth of drive gear, and then turn the drive and driven gear repeatedly by
hand, there will be red marks on the two working sides of the driven gear, if the marks on the
standard rotation and reverse rotation working sides of the driven gear are on the middle of the
tooth depth and closer to the small end, and occupies 60% of the tooth face, then it is a correct
meshing. See attached Figure (I). The position of correct meshing marks is adjusted through the
adjustment of the drive gear bearing adjusting washer (for specifications, see Table 6) and the
differential bearing adjusting nut.
In order to keep the adjusted differential bearing preload from being changed, the number of
circles of the adjusting nut being turned in on one side shall be equal to the number of circles of
the adjusting nut being turned out on the other side. Check and confirm the clearance again, and
then lock up the locking plate.
II The assembling of the rear hub with brake drum assembly is as per the reverse procedure of
disassembling, and the adjustment to be made during assembling is as follows:
1. Adjustment of rear hub bearing backlash
Tighten the bearing nut until the brake drum is no possible or difficult to move, and then slightly
loosen the bearing nut by 1/6-1/8 circle, turn the brake drum, under the condition of no contact
between brake friction disc and the brake drum, the tangent tensile force measured at the tyre bolt
shall be 3-5kg , or the brake drum can be turned freely by hand.
III Rear brake braking clearance adjustment:
1. Liquid brake: for the two-way balanced type brake, first move the two brake chamber adjusting
gears respectively as per the arrow direction indicated at the back plate adjusting hole, so that the
brake drum is tightly against the brake lining, and then turn the brake chamber adjusting gear back
by 5-9 teeth, to allow the brake drum to move freely.
In the actual maintenance process, adjustment shall be made strictly according to the above
procedures and requirements.

Table 6 Washer Specifications mm

Drive gear bearing
Drive gear bearing seat adjusting washer
adjusting washer

0.10 0.18 0.05 0.20

0.12 0.20 0.08 0.25
0.14 0.35 0.12 0.35
0.16 0.50 0.15 1.00

78
 Rear Axle

Tooth depth

Tooth length

Contact status of driven Causes Adjusting method A-Adjust tooth face contact
gear working tooth face area

1. Driven gear away from

the drive gear
Drive gear to too far
2. Drive gear closer to
from the driven gear
driven gear to achieve
Deviate correct backlash (add
to crest washer)

1. Driven gear closer to the

drive gear
Drive gear is too 2. Drive gear away from the
close to the driven driven gear to achieve
gear correct backlash (reduce
Deviate
to root washer)

1. Driven gear away from

the drive gear
Driven gear is too 2. Drive gear away from the
close to the drive driven gear to achieve
Deviate gear correct backlash(reduce
to small washer)

1. Driven gear closer to the

drive gear
Driven gear is too far 2. Drive gear closer to
from the drive gear driven gear to achieve
Deviate correct backlash (add
to big end washer)

Figure I

Adjustment Method of Gear Meshing Backlash

79
 Rear Axle

Chapter IV Use and Maintenance

I. Hyperbolic gear has strict requirement on the lubricating oil, the axle casing is only allowed to be
filled with specified hyperbolic gear oil. It is not allowed to use normal gear oil as substitution or to
be mixed with normal gear oil, otherwise it will cause tooth face early wearing, and even the gear
is “shaved bald”.

II. The conical gear of the rear axle final reduction gear has been selected and adjusted before
ex-work, therefore, under normal condition, it is necessary to be disassembled and adjusted. It can
be disassembled and adjusted only when the gear is worn out, the gear clearance exceeds the
specified value or the bearing axial clearance is too big, and the component is damaged and need
to be replaced.

III. The dirt and dust layer on the vent plug of rear axle casing shall be frequently cleaned off. In
primary maintenance, it shall be removed and washed clean, to ensure that the vent pipe is
unblocked. Blocked vent pipe will cause the pressure in the rear axle casing rising up, and lead to
oil leakage at oil seal and joint place of the drive gear, at the same time, and the lubricating oil
level inside of the casing shall also be checked.

1. In the first time of secondary maintenance for a new car, the lubricating oil shall be replaced.
After a new car has been driven for 40000Km or 24 month, the real axle lubricating oil shall be
replaced. First bleed out the gear oil in the rear axle casing, fill in kerosene, and drain it out after
cleaning, and then fill in GL-5 85W/90 lubricating oil. It is not allowed to substitute with normal
gear oil. After the lubricating oil has been replaced when the car has been driven for 80000Km or
48 month, it will be replaced once every 50000Km of driving.

After that, check the lubricating oil quality every four times of the secondary maintenance, if there
are deteriorations such as color change or getting thinner, it shall be replaced with new oil.

2. Check the wearing conditions of the brake shoe lining and the brake drum. After a new car is
driven for 40000Km or 24 month, check the wearing status of the brake shoe lining and the brake
drum, measure the thickness of the place on the brake lining with the severest wearing, the
standard value is 4.6mm, and the limit value is 1.0mm. When the thickness of the brake lining is
smaller than the limit value, the brake lining shall be replaced.

IV. In the third maintenance, the rear axle can be disassembled, and inner cavity and final
reduction gear assembly can be cleaned. After that, tighten the bolts and nuts for each part as per
the specified torque.

V. Points of attention:

1. The vehicle shall not be loaded with the weight that exceeding its maximum loading capacity.

2. During the driving process of the vehicle, in order to avoid impact damage to the gears, it is not
allowed to improve the obstacle crossing capacity of the vehicle by releasing the clutch abruptly.

80
 Rear Axle

Chapter V Trouble Shooting

I. Hub bearing dragging

Hub bearing
dragging

Excessive hub Bearing lack of Bearing is

preloading force lubrication or use wrong contaminated with
type of lubricating dust
grease

Adjust preload Add or replace Clean and add

lubricating grease lubricating grease

II. Unsmooth wheel

Unsmooth
wheel

Bad lubrication of camshaft or Brake shoe or air chamber return

adjusting arm does not return spring broken or fatigue
back

Add grease or rectify the faulty Replace the faulty

parts parts

81
 Rear Axle

III. Abnormal transmission sound

Abnormal transmission
sound

Improper Excessive Drive gear Wear or damage of Too low oil

differential clearance bearing axle shaft gear, surface
gear between drive preload too planetary gear,
clearance and driven small cross shaft thrust
gears washer etc.

Replace the Replace the Adjust the Rectify or replace Add

washer or washer or gear preloading the faulty parts enough
gear force lubricating
oil

IV. Lubricating oil leakage

Lubricating oil
leakage

Oil seal Final reduction Bearing Drain screw Axle Vent plug
worn, fixing bolt seat fixing loosen or casing blocked or
loosen or loosen or bolt the lining deformed damaged
damaged sealant loosen damaged due to
damaged. overload

Replace Tighten the bolt Tighten Tighten the Rectify or Clean or

the oil or re-apply the the bolt as screw or replace the replace
seal sealant per replace the axle the vent
specified lining casing plug
torque

82
 Rear Axle

V. Insufficient brake force

Insufficient brake force

Unsmooth Improper Brake Improper Water in Oil on the

camshaft adjustment of the lining contact of brake contact
rotation brake air overheat brake surface of
chamber push or lining brake lining or
rod stroke degrade brake drum

Check Adjust the stroke Replace Rectify Step the Clean off the
the the the lining pedal oil or replace
working friction contact slightly in the brake
status of lining position driving, lining
the drain out
camshaft the water

83
VI. Abnormal brake sound
Abnormal brake sound

Brake Brake lining Uneven Loose Brake Hub Brake Improper Brake lining Damage
lining surface wearing or contact shoe bearing drum installation with oil or on
worn out hardened loose between fixing worn deformed of brake degraded. brake
and or installation brake pin shoe or plate
cause the deteriorated of the brake shoe and loosen return
rivet drum brake spring
projecting lining damaged
out

Replac Replace Rectify the Replace Tighte Replace Replac Tighten Clean or Replac
e the the brake brake the rivet n the the hub e the the locking replace e the
brake lining drum or lockin bearing brake screw of the brake brake
lining tighten the g drum the fixing lining back
bolt screw pin or plate
of the replace
fixing the return
pin spring
 Front Suspension

Front suspension
General
 Front Suspension

Specifications

HFC1042K2

Front suspension

Spring type Semi-elliptic blade type leaf spring

Length mm 1140

Width mm 60

Front fixing part Rubber bushing with flange pin

Pin type

Rear fixing bushing type Metal rubber bushing with flange

Pin type

Shock absorber type Double-acting hydraulic cylinder type

 Front Suspension

Tightening torque

(Unit:N·m)

34-46

15-25

27-46
157-216

157-196

51-71

126-154
21-34
 Front Suspension

Disassembling

5
1

Disassembling sequence

1. Front shock absorber 2.U-bolt 3.Lifting lug pin 4. Fixed pin 5. Leaf spring

Preparations

First, block well the rear wheels, then jack up

the vehicle, and then jack up the front axle with
a screw jack.
Front Suspension

Important operation-Disassembling

1. Front shock absorber

Disassemble the shock absorber assembly, nut, washer

and bearing bush by following the sequence indicated in
the diagram.

2. U-bolts

(1) Loosen U-bolts and nuts (not remove them)

(2) Lift up the vehicle and rest it on the chassis bracket

(3) Remove U-bolts and nuts

3. Lifting lug pin

Take care not to damage the thread and leaf spring

pin cylindrical surface.

4. Retainer pin

Take care not to damage the thread and leaf spring

pin cylindrical surface.
 Front Suspension

Inspection and repair:

If excessive wearing or damage is found during

Leaf spring assembly Buffer block
inspection, it is necessary to repair or replace the
Leaf spring clamp Shock absorber parts.
Center bolt Rubber bushing
U-bolt
Visual inspection
Retainer pin
Inspect the parts listed on the left side visually; if they
Lifting lug pin are damaged or out of use, replace them.
Shock absorber
1. Inspect leakage of shock absorber; little
leakage is allowed.
2. After the vehicle has been running for certain
amount of distance, inspect whether the
temperature of shock absorber has risen; if the
temperature has not risen, it means it does not
work; so it must be replaced.
3. Stretch the shock absorber; if no resistance is
felt, it means the shock absorber does not work;
so it must be replaced.
4.Inspect the bushing at both ends of the shock
absorber; if they are excessively worn, replace
them.

Replacing of leaf spring

Mark

1. Before disassembling the leaf spring, make an

assembling mark on the side surface.
2. Apply grease on both sides of the leaf spring.
3. When disassembling and reassembling, use
bench press.
4. Do not reuse the disassembled center bolt;
replace it with a new one.
When replacing leaf spring, use the leaf spring
marked with “A,B,C”that means the same
camber.
Front Suspension

Center bolt

Tightening torque of center bolt: 34-44N.m

Measure the gap between leaf spring bushing and

leaf spring pin.

If the gap is more than 1mm, replace the leaf

spring bushing or the leaf spring pin.

Replacing of leaf spring bushing

Screw out leaf spring bushing with hand and

screw in a new one.
 Front Suspension

Reassembling

2
1
5

Disassembling sequence
1. Leaf spring2. Retainer pin 3. Lifting lug pin 4. U-bolt 5. Front shock absorber
 Front Suspension

Front Rear
Important operation - assembling

Leaf spring assembly

The assembling direction of leaf spring must be the

same as that of the original state.

Nut

U- bolt

(1) Park the vehicle on a level surface, install the U-bolt

at the corresponding position of the leaf spring

(2) Lift up the vehicle.

(3) Align the front axle holes and the U-bolt.

(4) Apply machine oil to the nuts before tightening them

so as to avoid damaging the thread.

(5) Tighten the nuts.

Install the leaf spring pin; tighten it to the

specified torque.

Front shock absorber assembly

Nut, washer and rubber bearing bush

Disassemble the shock absorber assembly, nut,

washer and bearing bush by following the sequence
indicated in the diagram.

Tighten the nut until the washer contacts the end fitting
surface.
 Front Suspension

Front shock absorber assembly

Main data and specification

Types Two-way hydraulic cylindrical shock
absorber
Max. outer diameter of liquid storage cylinder (mm) 45
Max. outer diameter of boot (mm) 53
Main stroke (mm) 220
Compression length (mm) 335
Extension length (mm) 555
Rear Suspension

Rear suspension
General
HFC1042K2
 Rear Suspension

Specifications

HFC1042K2
Rear suspension
Spring type Semi-elliptic blade type leaf spring
Length mm 1250
Width mm 70
Front fixing bushing type Metal bushing with flange pin

Pin type

Rear fixing bushing type Metal rubber bushing with flange

Pin type

Shock absorber type Two-way hydraulic cylindrical shock absorber

 Rear Suspension

Tightening torque

(Unit:N·m)

157-196

157-216
157-196

Disassembling

2
4

5
1

Disassembling sequence

1. Rear shock absorber 2. U-bolt 3. Lifting lug 4. Leaf spring pin 5. Leaf spring
Rear Suspension

Preparations
First, block well the front wheels, then jack up the
vehicle, and then jack up the rear axle with screw jack.

1. Rear shock absorber

Remove the shock absorber by loosening the shock

absorber mounting nut.

Important operation

2. U-bolt

After loosening U-bolt and nut, lift up the vehicle;

remove the U-bolt by resting the vehicle on the chassis
bracket; then remove the rear axle assembly.

Important operation

3. Lifting lug

Loosen lifting lug nut; remove the lifting lug plate and
pin.
 Rear Suspension

4. Leaf spring pin

Jack up leaf spring assembly with a screw jack,
remove the nut, and then pull out the bolt.

Take care not to damage the thread and leaf

spring pin cylindrical surface.

Inspection and repair:

Visual inspection: If wearing, damage or any other abnormality is found
during inspection, repair or replace the parts according to the actual condition.

Visual inspection
Leaf spring assembly Shock absorber
Leaf spring clamp Buffer block
Center bolt Rubber bushing Inspect the parts listed on the left side visually
U-bolt Auxiliary spring rubber cushion for any wearing, damage or abnormality.
Leaf spring pin
Lifting lug pin
Other inspection and repair steps are the
same as that of the front suspension.

Mark Replacing of leaf spring assembly

1. Before disassembling the leaf spring, make
an assembling mark on the side surface of the
leaf spring.
2. Apply grease on both sides of the leaf
spring.
3. When disassembling and reassembling, use
the bench press.
4. Do not reuse the disassembled center bolt; replace it with a new one.
When replacing leaf spring, use the leaf spring marked with “A,B,C”that means the
same camber.
Rear Suspension

Center bolt

Torque (N.m) 90-110

Clamping bolt
Torque (N.m) 20

Measure the gap between leaf spring bushing

and leaf spring pin.
If the gap is more than 0.4mm, replace the leaf
spring bushing or the leaf spring pin.
Replacing of leaf spring bushing
Disassemble and reassemble the leaf spring
bushing with special equipment.
 Rear Suspension

Reassembling

5
1

Reassembling sequence
1. Leaf spring 2. Leaf spring pin 3. Lifting lug 4. U-bolt and nut 5. Rear shock
absorber