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Transmission
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Disassembling the Output Shaft Subassembly................... 60
Disassembling the Shift Cover Subassembly...................... 64
Disassembling the Differential Subassembly...................... 68
Transmission 43
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oil level can lead to ineffective lubrication, as well as burning of the bearings and gears. Excessive high oil
level, however, can overheat the transmission or cause oil to leak. In addition, during the first level of main-
tenance, the breather plug should be checked and cleaned. If the breather plug is clogged, internal pressure
will build up and oil will leak from the transmission.
4.2 Transmission level-two maintenance: The transmission's lubricant should be replaced the first time that the
vehicle undergoes the second level of maintenance. Clean the transmission with kerosene. The quality of the
lubricant should be inspected during the future second level of maintenance practises. The lubricant should
be replaced if diluted, gummy, or dirty.
4.3 Transmission level-three maintenance: During the third level of maintenance, it should be removed for in-
spection, cleaning, and oil changing.
Inspect the axial play (δ) between the synchronizer ring and the gear shaft
Gear (δ1) (δ2) (δ3) (δ4) (δ5)
Standard axial play (mm) 0.7-1.7 0.7-1.7 0.7-1.7 0.7-1.7 0.7-1.7
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Transmission case × hexagon head plug 037-1701016 M18 × 1.5 2 39.2
Transmission case × reverse gear switch
037-1701022 M18 × 1.5 1 40.2
subassembly
Transmission case × cable bracket 037-1701019 M8 × 1.25 4 11.3
Clutch housing × clutch slave cylinder
037-1601019 M8 × 1.25 2 11.3
subassembly
Select lever assembly × gear shifting
037-1702027 M8 × 1.25 1 38.0
block
Clutch housing × release fork support
037-1601011 M10 × 1.25 1 36.8
nail
Counterweight component × shift lever
037-1702030 M8 × 1.25 2 20.0
component
Release fork support nail 1 29.4
Areas of Importance
Removal
During removal, all components should be gently handled to avoid knocking, especially the joint surface.
All components should be placed in the proper order to avoid misplacing and mistaking.
Installation
1. Clean all parts before installation (except rubber pieces and gaskets).
2. All oil seals, shaft retainers, and elastic pins should not be reused.
3. All rubbing surfaces should be coated with lubricant, and the lips of all oil seals should be coated with
grease.
4. During installation of the bearings, do not use any kind of rolling element to transmit pressure, and
make sure not to tilt it.
5. During the installation of synchronizer components, the two sides of the spring piston's openings
should alternate.
6. When the transmission is operating under normal working conditions, there should be no lubricant
leakage from any of the parts.
Transportation and storage
1. When transporting a transmission, make sure the conditions are dustproof and rainproof, as well as
take proper care not to damage it due to jolting, shaking, removal, or installation.
2. Transmission assembly should be stored in a ventilated, dustproof, and dry place.
3. Users with special transportation or storage requirements should have another discussion to reach an
agreement on this matter in the supply contract.
46 GWFLORID Maintenance Manual
Troubleshooting
Common problems Possible causes Solving methods
Difficult gear Not applying clutch Use correct driving methods
engagement Insufficient clutch separation Inspection & adjustment
Serious abrasion of the synchronizer ring Replace component
Positioning spring is too hard Replace component
Noise is too loud or Oil level is too low Fill oil to the specified level
abnormal Lubricant is of poor quality Replace the specified oil
Untimely oil changes Replace oil and damaged part
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lations.
Breather plug fails Replace
Damaged seal Replace
Synchronizer is damaged Excessive gear shifting force Replace synchronizer
Not applying clutch Use correct driving methods
Synchronizer's spring expan-
Replace
sion ring is damaged
Gear disengagement Control mechanism malfunction Inspect and adjust
Retaining spring or steel ball missing Additional assembly
Retaining spring malfunction Replace
Fork groove of the gear sleeve is worn out Replace
Shifting fork is worn out. Replace
Bearing and gear are burnt Oil level is too low Replace part and fill oil
Lubricant is of poor quality. Replace part and lubricant
Untimely oil replacement causes
Replace part and lubricant
the oil to be too dirty
Mixed use of different oils
Replace part and lubricant
or use of additives
Difficulty shifting gears Synchronizer spring malfunction Replace
The internal groove of the syn-
Replace
chronizer ring is worn out
The synchronizer ring is seized
Replace
into the conical surface
Deformed shifting fork or
Replace
shifting fork shaft
Shifting fork is worn out Replace
Transmission 47
1
2
3
4
5 9
6 10
7 11
8 12
76 13
75 14
74 15
73 16
17
72 18
71 19
70 20
21
22
69 23
68 24
67 25
66 26
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65
64
63
27
28
29
62 30
31
61 32
60 33
59
58
57
56
55 34
54 35
53 36
52 37
38
51 39
50 40
49 41
48 42
47 46
45
44
43
1. No. 2 gear sleeve 2. Shaft retainer 3. No. 2 Slider (3) 4. Spring expansion ring (2) 5. No. 2 gear hub 6. 3rd gear synchronizer ring
7. 3rd gear gear assembly 8. Needle bearing 9. With washer bolt 10. Clutch slave cylinder subassembly 11. Release fork protective
cover 12. Release fork spring 13. Bolt for flange face (3) 14. Release fork 15. Clutch housing 16. Release fork support nail 17. Ball
bearing 18. 2nd gear synchronizer ring 19. T oil seal 20. No. 1 gear sleeve 21. No. 1 Slider 22. 1st gear synchronizer ring 23. 1st gear
gear components 24. Needle bearing 25. Release bearing subassembly 26. Tapered roller bearing 27. Guide nozzle 28. 2nd gear gear
assembly 29. No. 1 gear hub 30. Spring expansion ring (2) 31. Bolt for flange face (6) 32. Straight pin 33. Odometer driver 34. T oil
seal 35. Tapered roller bearing 36. Adjusting shim (2) 37. Axle shaft gear (2) 38. Planetary gear (2) 39. Gasket (2) 40. Differential
case 41. Planetary gear shaft 42. Differential ring gear 43. Bolt for flange face (8) 44. Tapered roller bearing 45. Adjusting shim 46.
T oil seal 47. Shaft retainer 48. Retaining ring 49. Needle bearing 50. 3rd driven gear 51. Spacer 52. 4th driven gear 53. 5th driven
gear 54. Shaft retainers 55. Tapered roller bearing 56. Adjusting shim 57. Output shaft 58. 5th gear gear assembly 59. Shaft retainer
60. Retaining ring 61. Spring expansion ring (2) 62. Needle bearing 63. Input shaft 64. Adjusting shim 65. Ball bearing 66. 3rd gear
gear hub 67. 3rd gear Slider (3) 68. 3rd gear gear sleeve 69. 5th gear synchronizer ring 70. Steel ball 71. 5th gear thrust washer 72.
Needle bearing 73. 4th gear components 74. Retaining ring 75. 4th gear synchronizer ring 76. Transmission case
48 GWFLORID Maintenance Manual
Clutch
Components
Release bearing
Cable bracket
Release fork
Bolts with
washer
×5
11.3
Cable bracket
Release fork support nail
29.4
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11.3
Release fork dust cover
Differential assembly
Clutch housing Magnetic body
Guide nozzle
Tapered roller
bearings
T oil seal
Output shaft assembly
Clutch housing
Shaft retainers
Elastic
cylindrical pin
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retainers
Elastic
cylindrical pin
Lock pin No. 1
guide block
Pressure spring
No. 3 gear shift
Reverse gear fork shaft
gear shift fork No. 3 guide block Lock pin
No. 2 gear shift fork shaft
No. 3 gear shift fork
Reverse gear
idler assembly
Reverse gear
idler shaft Output shaft assembly
Bolt for flange face
29.4
Gasket
Input shaft assembly
Transmission Case
Components
Clip
Clip
Clip
Reverse gear
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Shift lever assembly
switch subassembly
Adjusting shim
Position mechanism
assembly
36.8 39.2
Hexagon head plug
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3. Separate the clutch housing and the transmission
case.
(a) Remove 8 bolts for flange face from the transmission
case and clutch housing.
(b) Remove 5 bolts for flange face from the clutch housing
and transmission case.
(c) Pound the housing's protruding parts with a soft ham-
mer to remove the transmission case.
6. Remove the No. 1 gear shift fork shaft and the set
bolts.
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7. Remove the elastic cylindrical pin from the No. 1 guide
block.
8. Remove the No. 1 gear shift fork, No. 1 gear shift fork
shaft, and No. 1 guide block.
Transmission 53
10. Remove the elastic cylindrical pin from the No. 3 guide
block.
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11. Remove the No. 3 gear shift fork, compression spring,
and No. 3 guide block.
12. Remove the set bolts from the No. 2 gear shift fork
shaft.
54 GWFLORID Maintenance Manual
13. Remove the No. 2 gear shift fork shaft, No. 2 gear shift
fork, and No. 2 guide block.
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15. Remove the differential subassembly.
17. Remove the oil drain slot from the inside of the transmis-
sion case.
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19. Remove the release fork and the release bearing from
the clutch housing.
20. Remove the set bolts of the release fork from the
clutch housing.
56 GWFLORID Maintenance Manual
Retaining ring
Spring expansion
ring Shaft retainer
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No. 3 gear hub
No. 2 gear sleeve/No. 2
gear hub
5th gear
synchronizer ring No. 2 Slider
Spring expansion ring
Spring expansion
ring
5th gear gear
subassembly Needle bearing 3rd gear
synchronizer ring
Retaining ring
Steel ball
Front ball bearing
5th gear thrust washer
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4. Remove the retaining ring.
7. Remove the steel balls from the 5th gear thrust washer
of the input shaft.
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8. Remove the 4th gear subassembly, 4th gear needle
bearing, 4th gear synchronizer ring, and the 4th gear
bearing washer (4 types of part).
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12. Remove the needle bearing from the 3rd gear of input
shaft.
60 GWFLORID Maintenance Manual
Rear tapered
1st gear roller bearing
synchronizer ring
Shaft retainer
Needle bearing
Spacer
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3rd driven gear
Retaining ring
Shaft retainer
Needle bearing
Output shaft
2nd gear gear subassembly
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4. Remove the output shaft spacer.
5. Remove the output shaft's 3rd driven gear and the 2nd
gear subassembly spacer.
62 GWFLORID Maintenance Manual
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8. Remove the output shaft's No. 1 synchronizer compo-
nents and the 1st driven gear.
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64 GWFLORID Maintenance Manual
Dust cover
T oil seal
38.0 Set bolt
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Pressure spring
Manipulation lid
Shaft retainer
T oil seal
2. Remove the shaft retainer on the shift lever and the se-
lect lever.
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4. Remove the pressure torsion spring.
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8. Remove the shaft retainer on the shift shaft and the se-
lect lever.
Caution: Use a cord to fasten the shift lever in order to
Cord make the operation convenient.
9. Remove the shift shaft and the shift shaft dust cover.
Transmission 67
11. Remove the shift shaft T oil seal from the manipulation
lid.
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12. Remove the T oil seal from the manipulation lid.
68 GWFLORID Maintenance Manual
T oil seal
Clutch housing
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Gasket
Planetary gear
Adjusting shim Differential ring gear
Gasket
T oil seal
Adjusting shim
Transmission case
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3. Remove the tapered roller bearings of the right differen-
tial.
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7. Remove 2 planetary gears, 2 axle shaft gears, 2 ad-
justing shims, and 2 gaskets from the inside of the dif-
ferential case.