JAC S2 (Chassis). Service Manual — part 4

Clutch

Clutch

37

2. Drain clutch hydraulic oil, refers to clutch hydraulic oil
3. Remove the inlet pipe assembly

1). Remove the clip, disengage inlet pipe assembly
and brake master cylinder.

2). Remove the clip, disengage inlet pipe assembly and
clutch master cylinder.

3) Remove the inlet pipe assembly.

4. Remove the clutch master cylinder

1). Removing the clip, disengage inlet pipe assembly
and clutch master cylinder.

2) Remove the flare nut and disengage the clutch
hard pipe assembly - I and clutch master cylinder.

Clutch

Clutch

38

3). Remove the clamp connecting the clutch pedal and
clutch master cylinders, remove the latch, disengage the
clutch pedal and the clutch master cylinder.

4) Remove the two fixing nuts connecting clutch master
cylinder and clutch pedal body.

5) Remove the clutch master cylinder.

(II) Installation

1. Install the clutch master cylinder

1). Place the clutch master cylinder to the installation
location.

2) Install the two fixing nuts connecting clutch master
cylinder and clutch pedal body.
Tighten torque 20 ~ 28N • m

3) Install the lock pin, install clamp connecting clutch
pedal and the clutch master cylinder.
△ Note Coat low temperature grease Kunlun II on the
outer surface of the front pin.

4). Install nut connecting the clutch hard pipe assembly

- Ⅰ and clutch master cylinder.

Tightening torque 16 ~ 18N • m

Clutch

Clutch

39

5). Install clamps to connecting clutch master
cylinder inlet pipe assembly and the clutch master
cylinder.

2. Install the inlet pipe assembly

1). Install clamp to connect inlet pipe assembly and
brake master cylinder.

2) Install clamp to connect inlet pipe assembly clutch
master cylinder.

3. Fill the clutch hydraulic oil refers to clutch
hydraulic oil
4. Drain clutch system refers to the clutch hydraulic oil
5. Close the engine hatch

VIII Clutch cylinder and the inlet pipe assembly

(I) Remove

1. Open the engine hatch
2. Drain clutch hydraulic oil refers to clutch hydraulic oil
3. Remove the clutch inlet pipe assembly

Clutch

Clutch

40

1) Remove connection nut between the clutch inlet
pipe and the clutch hard tube assembly

2). Remove the fixing nut connecting clutch inlet pipe
and clutch working cylinder.

3). Disengage clutch inlet pipe assembly

4. Remove clutch cylinder

1). Remove bolts connecting the clutch inlet pipe and
the clutch cylinder.

2). Remove the latch and rivets connecting the clutch
cylinder and separation fork.

Clutch

Clutch

41

3) Remove the two fixing bolts connecting the clutch
cylinder and the gearbox.

4) Remove the clutch cylinder.

(II) Installation

1. Install clutch cylinder

1). Connect the latch and rivets to the clutch cylinder
and separation fork

2). Install fixing bolts connecting the clutch inlet pipe
and the clutch cylinder

3). Install two fixing bolts to connect the clutch
cylinder and the gearbox.
Tightening torque 14.7 ~ 21.6N • m

Clutch

Clutch

42

2. Install the clutch inlet pipe assembly

1) Install the fixing bolts to connect the clutch inlet
pipe and the clutch cylinder.

2) Install the connection nut between the clutch inlet

pipe and the clutch hard tube assembly - Ⅰ.

Tightening torque 16 ~ 18N • m

3. Fill the clutch hydraulic oil refers to clutch hydraulic
oil
4. Drain clutch system refers to the clutch hydraulic oil
5. Close the engine hatch

IX Clutch hard pipe assembly

(I) Remove

1. Open the engine hatch
2. Drain clutch hydraulic oil refers to the clutch
hydraulic oil
3. Remove clutch hard tube assembly

1) Remove the connection nut between the clutch inlet
pipe and the clutch hard tube assembly

2) Remove the pipe nut and the connection between the
clutch hard pipe assembly and clutch master cylinder.

3) Remove the clutch hard tube assembly

Clutch

Clutch

43

(II). Installation

1. Install the clutch hard tube assembly

1) Install oil pipe nuts and remove the connection

between clutch hard pipe assembly - Ⅰ and clutch master

cylinder.
Tightening torque 16 ~ 18N • m

2) Install the connection nut between the clutch inlet

pipe and the clutch hard tube assembly - Ⅰ

Tightening torque 20 ~ 28N • m

2. Fill the clutch hydraulic oil refers to clutch hydraulic
oil
3. Drain clutch system refers to clutch hydraulic oil
4. Close the engine hatch

X Clutch cover and pressure plate assembly, clutch driven disc

(I) Remove

1. Remove the transmission assembly refers to gearbox assembly
2. Remove the clutch cover and pressure plate assembly,
clutch driven disc

1). Remove the clutch cover and pressure plate assembly,
6 fixed bolts connecting clutch driven disc and the engine

.

(II) Installation

1. Install the clutch cover and pressure plate assembly,
clutch driven disc

1) Clean the clutch friction plate and the input shaft
keyway to remove grease and wear metals crumbs.

2) Apply grease to the input shaft keyway.

Grease: SAE J310

△ Note ensure that the grease is applied in the

predetermined position, if not may lead to clutch noise,
separation bad or damage. Too much oil can lead to slip
or jitter.

3) Install the clutch cover.

4) Use the special tool to install clutch plates and the

Clutch

Clutch

44

clutch pressure plate.

5) As shown in Figure through 1-2-3-4-5-6 sequence
tighten the clutch fixing bolts successively and evenly.
Tightening torque 20 ~ 28N • m

△ Note tighten each bolt 1 to 2 laps in turn progressively.

2. Install the transmission assembly

Drive shaft

Drive shaft

46

Drive shaft

I. Overview

(I) Structure summary

Drive shaft is located above the front sub frame and combined with left drive shaft assembly and right

drive shaft assembly, who transmit the transmission output torque and speed to the wheels. The inside of
the drive shaft is connected to gearbox differential by spline, by the inside universal joints can slide
axially inside the steering wheel in order to compensate for the change in length caused by turning and
jitter; through the outer universal joint it can have a large rotation angle and through a spline at the end of
the shaft, connect hub inner ring and lock with self-locking nuts.
Drive shaft assembly structure

1. Left front drive shaft assembly 2. Right front drive shaft assembly

Drive shaft

Drive shaft

47

(II) Torque parameters

No

Item

Torque （N·m）

Remark

1

Drive shaft self-locking nuts

240~260

2

Lower arm ball head and knuckle
connection nut

100~120

3

knuckle and shock absorber
assembly connection nut

100~120

4

speed sensors

10~15

(III) Maintenance precaution

1. Maintenance precaution related to the drive shaft

1). Knuckle and other non-repair parts are not removable.

2) Operate in a clean work surface.

3) Clean the outer parts surface before assembling and
disintegration.

4) When working, take care not to contaminate the parts
and prevent outer matter from entering. The disintegrated
components must be carefully reassembled in the correct
order. If the work is interrupted, cover the parts with clean
cover.

5) Use paper cloth to prevent the use of fiber debris
attached to the components.

6) Clean the disintegrated components (except rubber
parts) with kerosene and dry with a paper or cloth.

2. Things to be noted when check, repair system or replace parts.

1) Check whether the fastener torque is specified after
assembly.

2) Carry out necessary position checks after assembly.

3) Do not reuse the disposable parts.

4) Check thoroughly before repair or replace parts.

(IV) Maintenance parameters

Drive shaft

Item

outside

inside

Drive shaft

universal joint type

GI

AC

maximum allowable angle

23°

45°

Lubrication grease

Item

Lubrication grease

quantity

Drive shaft

GI

GRBN-1000

120±10g

AC

CVJM-2008J

120±10g

(V) Special tools

Drive shaft

Drive shaft

48

No

Tool

Outer look

Description

1

Japanese-style
ball puller

Remove ball head

z2

Differential oil
seal installation
tool

JAC-T6B025 S2-0610-9025-HL

II. Fault diagnosis

(I) Fault diagnosis table

No

Failure
Cause

Failure Cause analysis

Solution

Remark

1

Vehicle
deviation

shaft knuckle worn

replace

wheel bearing wear, friction or pop sound

replace

front suspension and steering defect

Adjust and replace

2

Vibration

shaft wear, damaged or bent

replace

shaft and hub splines loose or broke

replace

wheel bearing wear, friction or pop sound

replace

3

Beating

wheel unbalance

Adjust and replace

front axle steering defect

Adjust and replace

4

Loud noise

shaft wear, damaged or bent

replace

hub splines friction

replace

Drive shaft hub end spline wear

replace

wheel bearing wear, friction or abnormal
sound

replace

Wheel hub nut loose

Adjust and replace

front suspension and steering defect

Adjust and replace

III. Drive shaft

(I) Special tools

No

Tool

Outer look

Description

1

Japanese-style
ball puller

Remove ball head

Drive shaft

Drive shaft

49

2

Differential oil
seal installation
tool

JAC-T6B025 S2-0610-9025-HL

(II) Remove

1. Open the engine hatch
2. Remove the wheels refers to the wheels
3. Remove the drive shaft

1). Remove cotter pin and hex slotted nuts connecting to
the knuckle and tie rod.

2) Separate connection between the knuckle and steering
tie rod.

3) Remove the cotter pin and slotted nut connecting the
lower arm and knuckle.

4) Detach the lower arm and knuckle connection with a
special tool.

△ Note avoid violent demolition.

5) Remove the front brake hose and connect to the front
strut assembly bracket bolts. Disengage the connection of
the front brake hose and the front pillar.

Drive shaft

Drive shaft

50

6) Remove the drive shaft self-locking nuts

7) Tap the shaft with a hammer (or a suitable tool) and
wood, make the drive shaft and front wheel hub
assembly do relative activity.

△ Note if the hub and the drive shaft cannot be separated,

use puller (or a suitable tool).

8). Disengage the drive shaft and the front hub assembly.

△ Note avoid pulling the brake hose.

9) Insert a lever between the transmission housing and
the joint housing; separate the drive shaft from the
transmission.

△ Note support housing (joint assembly), shafts and other

components of the drive shaft before putting down.

△ Note Do not place a too big angle with the drive shaft

universal joint. Avoid excessive stretching, prevent cage
shedding.

(III) Check

1. Check all parts of the drive shaft

1) Check whether there is damage on left and right drive
shaft splines.

2) Check whether there is damage around the drive shaft
dust cover or securely installed.

3) Check whether there is clamp damage or missing on
the moving ends of the left and right shaft.

4) Universal joint should be able to ride in any direction
around the drive shaft.

(IV) Installation

1. Install the drive shaft

1). Apply gear oil on the drive shaft splines.

Drive shaft

Drive shaft

51

2) Slightly rotate the drive shaft

3) Match mobile end outer spline with the differential inner spline movement, then further push,
install the drive shaft mobile end to the transmission differential.

△ Note the clamp of the mobile end must be assembled in position.

△ Note the clamp open side should be downward.

4) Install the shaft fixed end of on the front hub
assembly.

△ Note self-locking nuts of the fixed end must be

assembled in position.

5) Install the shaft self-locking nuts. Tightening Torque
240 ~ 260N • m

6) Install the front brake hose to the front shock absorber
welded bracket bolts. Tightening torque 20 ~ 25N •

7) Install the cotter pin and slotted nut connecting the
lower arm and knuckle.
Tightening torque 60 ~ 72N • m

Drive shaft

Drive shaft

52

8) Install the cotter pin and hex slotted nuts connecting
the steering and knuckle tie rod.
Tightening torque 50 ~ 55N • m

2. Install the wheel
3. Check the wheel alignment refers to the wheel
alignment
4. Close the engine hatch

IV. Drive shaft seal

(I) Remove

1. Open the engine hatch
2. Remove the wheels refers to the wheels
3. Remove the drive shaft refers to the shaft
4. Remove the drive shaft seal

1). By using a pry bar to pry the outer seal lip,
disassemble the differential oil seal.

△ Note when use a pry bar to pry the seal, it should be

particularly careful not to damage the transmission
casing and seals.

(II) Check

1. Check the seal for cracks, damage and grease leakage.
2. Check the dust cover for cracks, damage and grease
leakage.
3. If there is non-compliance situation, replace the seals.

(III) Installation

1. Install the shaft seals

1). Apply the transmission oil on the new differential
lip seal assembly.

△ Note replace a new seal

2). By using special tools to install the new
differential seal components.

2. Install the drive shaft
3. Install the wheel
4. Close the engine hatch

Front suspension

Front suspension

53

Front suspension

I. Overview

(I) Structure Summary

1. The left lower arm assembly
2. The right lower arm assembly
3. The left front shock absorber and coil spring support assembly
4. The right front shock absorber and coil spring support assembly
5. The sub-frame assembly
6. The left front wheel hub assembly
7. The right front wheel hub assembly
8. Stabilizer bar
9. Left ball pin rod assembly
10. Right-ball rod assembly