JAC HFC4DA1-2C engine. Service Manual — part 32
MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-19-
Removal/Installation
Removal/Installation
Removal/Installation
Removal/Installation
Manual
Manual
Manual
Manual transmission
transmission
transmission
transmission
1.
Remove manual transmission.
●
Oil drainage
Attention:
Remove oil drain plug with
wrench and drain oil through this plug instead
of other parts.
2.
Remove release bearing from input shaft front cap.
3.
Remove input shaft front cap from transmission.
4.
Remove clutch housing.
Attention: If the transmission housing is assembled
tightly with clutch housing, a rubber hammer or
copper rod can be applied to knock on the housing
edge to make them become loose.
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-20-
Removal/Installation
Removal/Installation
Removal/Installation
Removal/Installation (Continued)
(Continued)
(Continued)
(Continued)
Manual
Manual
Manual
Manual transmission
transmission
transmission
transmission
5.
Remove clutch housing.
�
Place
it
upside
down
on
cardboard
horizontally.
6.
Remove input shaft oil seal from transmission.
7.
Remove top cover from transmission.
Attention: If the transmission housing is assembled
tightly with clutch housing, a rubber hammer
or copper rod can be applied to knock on the
housing edge to make them become loose.
8.
Remove gear shift rocker arm assembly from
transmission.
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-21-
Removal/Installation
Removal/Installation
Removal/Installation
Removal/Installation (Continued)
(Continued)
(Continued)
(Continued)
Manual
Manual
Manual
Manual transmission
transmission
transmission
transmission
9.
Use pneumatic gun or wrench to remove output
shaft bolt of transmission and knock out flange nut.
10. Remove rear cover of transmission.
Attention: If the transmission housing is assembled
tightly with clutch housing, a rubber hammer
or copper rod can be applied to knock on the
housing edge to make them become loose.
11. Remove vehicle speed sensor.
12. Remove vehicle speed sensor gear and bushing.
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-22-
Removal/Installation
Removal/Installation
Removal/Installation
Removal/Installation (Continued)
(Continued)
(Continued)
(Continued)
Manual
Manual
Manual
Manual transmission
transmission
transmission
transmission
13. Remove side cover from transmission.
�
Turn over the transmission.
�
Remove bolts from side cover.
14. Remove side cover from transmission.
15. Remove gear shift fork from transmission.
16. Remove gear shift block from transmission.
�
Punch out the spring pin by using punch and
remove each shift fork, shift block and shift
fork shaft.
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-23-
Removal/Installation
Removal/Installation
Removal/Installation
Removal/Installation (Continued)
(Continued)
(Continued)
(Continued)
Manual
Manual
Manual
Manual transmission
transmission
transmission
transmission
17. Remove gear selector fork from transmission.
Attention:
Attention:
Attention:
Attention:
Please notice the position of steel balls. This
transmission has 7 steel balls and 1 steel locking
piece, among which, 3 steel balls are self-locking
devices and the others are interlocking devices.
18. Remove all bearing circlips by using circlip pliers.
19. Pull out bearings except for input shaft bearing cap
with SST.
20. Remove input shaft of transmission.
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-24-
Removal/Installation
Removal/Installation
Removal/Installation
Removal/Installation (Continued)
(Continued)
(Continued)
(Continued)
Manual
Manual
Manual
Manual transmission
transmission
transmission
transmission
21. Remove output (input) shaft of transmission and
place it on cardboard horizontally.
22. Remove output shaft of transmission.
23. Remove output shaft of transmission.
Assemble
the
output
shaft
and
input
shaft
of
transmission together and place them on clean
cardboard horizontally.
24. Remove reverse gear shaft pin of transmission.
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-25-
Removal/Installation
Removal/Installation
Removal/Installation
Removal/Installation (Continued)
(Continued)
(Continued)
(Continued)
Manual
Manual
Manual
Manual transmission
transmission
transmission
transmission
25. Use a rubber hammer or copper rod to knock on the
reverse gear shaft gently.
26. Pull out the reverse gear shaft pin and punch out
the reverse gear shaft.
27. Remove reverse gear of transmission.
Place it on clean cardboard horizontally.
28. Assemble the reverse gear and reverse gear shaft as
a whole.
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-26-
Removal/Installation
Removal/Installation
Removal/Installation
Removal/Installation (Continued)
(Continued)
(Continued)
(Continued)
Manual
Manual
Manual
Manual transmission
transmission
transmission
transmission
29. Loosen the 5
th
gear circlip with circlip pliers and
remove the fixed circlip from the 5
th
driving gear.
30. Adjust the position of 5
th
gear of countershaft and
remove countershaft of transmission.
31. Transmission gearing diagram
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MT
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MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-27-
Instruction
Instruction
Instruction
Instruction and
and
and
and Operation
Operation
Operation
Operation
Exploded
Exploded
Exploded
Exploded View
View
View
View of
of
of
of Reverse
Reverse
Reverse
Reverse Gear
Gear
Gear
Gear Shaft
Shaft
Shaft
Shaft
Reverse Gear Shaft Parts List
S/N
Name
Qty.
1
Reverse gear assembly
1
2
Reverse gear shaft
1
3
Reverse gear shaft pin
1
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MT
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MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-28-
Instruction
Instruction
Instruction
Instruction and
and
and
and Operation
Operation
Operation
Operation
Exploded
Exploded
Exploded
Exploded View
View
View
View of
of
of
of Output
Output
Output
Output Shaft
Shaft
Shaft
Shaft Assembly
Assembly
Assembly
Assembly
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MT
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MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-29-
Output
Output
Output
Output Shaft
Shaft
Shaft
Shaft Parts
Parts
Parts
Parts List
List
List
List
S/N
Name
Qty.
S/N
Name
Qty.
1
Output shaft head needle
roller bearing
1
27
Thrust washer of 5
th
gear
1
2
Circlip
1
28
Ball bearing
1
3
3rd/4th gear synchronizer
spring
2
29
Stop ring
1
4
3rd/4th gear synchronizer
gear hub
1
30
Front spacer bush of odometer
driving gear
1
5
3rd/4th gear synchronizer
gear sleeve
1
31
Odometer driving gear
1
6
needle roller bearing
1
32
Rear spacer bush of odometer
driving gear
1
7
3rd/4th gear synchronizer
ring
1
33
Flange
1
8
3
rd
gear assembly of output
shaft
1
34
O-ring
1
9
Circlip
1
35
Conical spring washer
1
10
Thrust washer of 2
nd
gear
1
36
Output shaft nut
1
11
2
nd
gear assembly of output
shaft
1
37
Steel ball
1
12
Needle roller bearing
2
38
3rd/4th gear synchronizer spring
2
13
1st/2nd gear synchronizer
ring
1
39
1st/2nd gear synchronizer spring
2
14
Circlip
1
40
3rd/4th gear synchronizer slider
3
15
1st/2nd gear hub
1
41
Reverse/5th
gear
synchronizer
slider
3
16
1st/2nd gear sleeve
1
42
Reverse/5th
gear
synchronizer
gear hub
1
17
1st/2nd gear synchronizer
ring
1
43
18
1st gear assembly of output
shaft
1
44
19
3rd/4th gear synchronizer
slider
3
45
20
Output shaft
1
46
21
Needle roller bearing
1
47
22
Reverse gear assembly of
output shaft
1
48
23
Circlip
1
49
24
Reverse/5th
gear
synchronizer gear sleeve
1
25
3rd/4th gear synchronizer
ring
1
26
5
th
gear assembly of output
shaft
1
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-30-
Instruction
Instruction
Instruction
Instruction and
and
and
and Operation
Operation
Operation
Operation
Exploded
Exploded
Exploded
Exploded View
View
View
View of
of
of
of Top
Top
Top
Top Cover
Cover
Cover
Cover Assembly
Assembly
Assembly
Assembly
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-31-
Top
Top
Top
Top Cover
Cover
Cover
Cover Assembly
Assembly
Assembly
Assembly Parts
Parts
Parts
Parts List
List
List
List
S/N
Name
Qty.
S/N
Name
Qty.
1
Transmission cover
1
14
Hexagon bolt
2
2
Outer gear selector rocker arm assembly
1
15
Large washer
2
3
Flat washer
1
16
Spring washer
8
4
Oil seal
1
17
Hexagon bolt
1
5
Inner gear selector rocker arm
1
18
Flat washer
6
Spring pin
1
19
Washer
1
7
Reverse/5th gear damping spring
1
20
Knurled pin
1
8
Oil seal
1
21
Oil filler plug assembly
1
9
Flat washer
1
22
1st/2nd gear damping spring
1
10
Reversing lamp switch
1
23
Flat washer
1
11
Hexagon bolt
8
24
Outer gear shift rocker arm assembly
1
12
Inner gear shift rocker arm
1
13
Spring washer
8
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-32-
Instruction
Instruction
Instruction
Instruction and
and
and
and Operation
Operation
Operation
Operation
Exploded
Exploded
Exploded
Exploded View
View
View
View of
of
of
of Input
Input
Input
Input Shaft
Shaft
Shaft
Shaft Assembly
Assembly
Assembly
Assembly
S/N
Name
Qty.
S/N
Name
1
Circlip
1
5
3rd/4th gear synchronizer ring
2
Stop ring
1
3
Ball bearing (input shaft)
1
4
Input shaft assembly
1
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-33-
Instruction
Instruction
Instruction
Instruction and
and
and
and Operation
Operation
Operation
Operation
Exploded
Exploded
Exploded
Exploded View
View
View
View of
of
of
of Transmission
Transmission
Transmission
Transmission Rear
Rear
Rear
Rear Cover
Cover
Cover
Cover
Instruction
Instruction
Instruction
Instruction and
and
and
and Operation
Operation
Operation
Operation
S/N
Name
Qty.
S/N
Name
Qty.
1
Rear cover
1
9
Odometer guide sleeve
1
2
Vent plug
1
10
O-ring
1
3
Hexagon bolt
1
11
Spring pin
1
4
Spring washer
1
12
Hexagon bolt
5
5
Hexagon bolt
2
13
Spring washer
7
6
Oil seal
1
7
Oil seal
1
8
Odometer gear
1
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-34-
Exploded
Exploded
Exploded
Exploded View
View
View
View of
of
of
of Countershaft
Countershaft
Countershaft
Countershaft Assembly
Assembly
Assembly
Assembly
S/N
Name
Qty.
S/N
Name
Qty.
1
Circlip
1
6
Circlip
1
2
Cylinder roller bearing
1
7
5th gear of countershaft
1
3
Main gear of countershaft
1
8
Cylinder roller bearing
1
4
3rd gear of countershaft
1
9
Stop ring
1
5
Countershaft
1
10
Circlip
1
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