Professional Documents
Culture Documents
Foreword
This service manual mainly covers the removal and refitting process, service technology and
service personnel understand the method of removing and refitting it and to lay a solid technical
Chapter 1 Introduction
This chapter mainly describes precautions for servicing transmission, explains the meaning of each
symbol which are included in the following text and specifies the tightening torque for plain bolts.
This chapter mainly describes the gearshift principle of transmission, the transmission line of each
gear, and the operation and maintenance of oil supply line and transmission.
This chapter describes how to remove each part properly and the relevant precautions in the
process.
This chapter describes how to refit each part properly and the relevant precautions in the process.
This chapter describes special tools required in the process of servicing transmission.
Note
The specifications of parts covered by this Manual may be subject to modification due to the
improvement of this product, and no further notice will be given upon such modification, so
Contents
1 Introduction ................................................................................................................ 1
1.1 Safety precautions ............................................................................................. 1
1.2 Description of signs ........................................................................................... 2
1.3 Tightening torque table for plain bolts .............................................................. 3
2 Transmission system .................................................................................................. 5
2.1 Description of transmission............................................................................... 5
2.2 Basic parameters of transmission & torque converter assembly ...................... 6
2.3 Structure and principle of transmission............................................................. 6
2.3.1 Structure of transmission ........................................................................... 6
2.3.2 Shifting principle of transmission.............................................................. 7
2.3.3 Gear transmission lines .............................................................................. 8
2.3.4 Structure and principle of shifting clutch ................................................ 10
2.3.5 Structure and principle of automatic emptying valve (oil drain valve) ... 11
2.4 Oil supply system ............................................................................................ 13
2.4.1 Structure and working principle of transmission & torque converter oil
supply system .................................................................................................... 13
2.4.2 Introduction to oil supply system main components ............................... 14
2.5 Transmission Operation and Maintenance ...................................................... 18
2.5.1 Installation and Application Notices for Transmission ........................... 18
2.5.2 Maintenance of Transmission .................................................................. 18
3 Removal of Transmission ......................................................................................... 20
3.1 Removal of assembly components .................................................................. 20
3.1.1 Removal of oil filler pipe and filter ......................................................... 20
3.1.2 Removal of parking brake assembly ....................................................... 21
3.1.3 Removal of transmission control valve ................................................... 22
3.1.4 Removal of breather and cover plate ....................................................... 23
3.1.5 Removal of input flange .......................................................................... 23
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BYD4208 Transmission Service Manual
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BYD4208 Transmission Service Manual
1 Introduction
1.1 Safety precautions
Important safety notice
Service and maintenance is essential to the safe operation of vehicle. This Manual mainly
states the related techniques on how to remove and refit the transmission assembly properly.
To prevent relevant personnel from being hurt, this Manual takes as safety sign. With
regard to precautions attached with this sign, it is required to do operation carefully. In case
of potential hazard, first take into account the safety of yourself, and meanwhile take
Safety notice
In the process of refitting and removal, improper operation technique will lead to part damage,
service life reduction and deterioration in operating performance, and in addition, it may cause
unsafe factors. Therefore, please read related content in this manual carefully before refitting and
1. The parameters, figures and content covered by this manual apply to product of standard
2. In repair workshop, a separate or special area shall be set for placing removed parts,
corresponding tools and parts shall be placed at appropriate area, and the operation area shall be
kept clean and free of oil dirt and other contaminant. Do not smoke at any place other than the
specified area. Never smoke during operation, and it is required to have fire extinguishing device.
3. When welding operation is necessary, it shall be done by a trained and experienced welding
worker. During welding, it is required to wear and use appropriate protective equipment such as
4. Before removing transmission & torque converter assembly, make sure to clean the dirt from its
5. During operation, do wear safety shoes and safety helmet. Do not wear inappropriate work coat.
The work coat must be buttoned. When striking parts with a copper rod, safety goggles shall be
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BYD4208 Transmission Service Manual
worn.
6. Petrol, kerosene and water-based oil cleaner can be used to clean the removed parts.
7. To use a crane or other hoisting equipment, first check the slings for damage. It is required to use
hoisting equipment with sufficient lifting capacity. During lifting operation, do lift slowly at
appointed position so as to prevent parts from striking against each other. Do not work under the
lifted parts.
8. When two or more people are required to work simultaneously, they shall be in agreement with
the same operation procedure in advance to avoid accident due to out of step conditions.
9. Make sure to keep all tools properly and get familiar with their operating methods.
10. To align one hole with another, do not get your hand or finger into the holes. As regards to parts
requiring direct assembly with hand, always pay attention to the holding position and check it for
risk of crushing.
11. Make sure to perform inspection on the removed parts. The part of which the defect has already
13. When assembling the oil seal and seal ring, if they have to pass key groove, screw hole and step,
14. In the process of refitting parts, the tools used shall match corresponding threaded fasteners so
15. To tighten joint body and plug screw, do not use pneumatic wrench. Be sure to rotate them to
some extent with hand, and then tighten them with torque wrench of corresponding specification to
16. When draining oil from transmission, be sure to unscrew the drain plug slowly so as to prevent
To make this manual fully play its roles, the signs in Table 1-1 are used in respect of critical safety
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BYD4208 Transmission Service Manual
Table 1-1
Oil and water Add a certain amount of oil, water and fuel.
Table 1-2
Yield Nominal diameter of bolt (mm)
Strength
strength 6 8 10 12 14
class
(N/mm2) Tightening torque (Nm)
8.8 640 9~12 22~30 45~59 78~104 124~165
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BYD4208 Transmission Service Manual
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BYD4208 Transmission Service Manual
2 Transmission system
2.1 Description of transmission
BYD4208 transmission is a fixed shaft, constant mesh and power gearshift transmission, which is
mainly used for LG933L and LG936L loader. In the transmission system of LG933L and LG936L,
the engine is directly connected to the torque converter via an elastic plate so as to realize output
power, and torque converter is connected via the propeller shaft to front input flange of the
transmission where speed change and torque increase happens such that the power can be
transmitted to front and rear drive axles via front and rear propeller shafts respectively.
BYD4208 transmission mainly consists of input shaft assembly, countershaft assembly, and reverse
gear shaft assembly, high-low gear sliding sleeve as well as its control mechanism and many pairs
Fig. 2-1
1.Breather 2.Transmission control valve 3.Reverse gear shaft 4. Input shaft 5.Countershaft
6.Oil drain plug 7.High-low gearshift fork 8.Output shaft 9.Filter 10.Oil filler pipe
11.Parking brake
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BYD4208 Transmission Service Manual
Table 2-1
Item Parameters/description
Single-stage three-element turbine hydraulic
Type
torque converter
Torque ratio 3.25
Torque
Oil pressure at torque converter inlet
converter 0.2~0.6
(MPa)
Oil pressure at torque converter
0.05~0.15
outlet (MPa)
Type Fixed-shaft power shift
Gears 4 gears in front and 2 in the rear
Transmission
Transmission working pressure
1.1~1.5
(MPa)
BYD4208 transmission includes three sets of normally opened clutches, which are closed by
hydraulic fluid, and they control the 1st gear, 2nd gear, 1st reverse gear respectively, or the 3rd gear,
4th gear and 2nd reverse gear when the shift fork is set to a higher gear. The one installed on the
input shaft is the 1st gear clutch; the power from torque converter is transmitted to input shaft via a
connecting flange and the input shaft is the total input of transmission. The one installed on the
countershaft is the 2nd gear clutch, and the countershaft can transmit the power from the 1st gear
and the reverse gear to the output gear. The one installed on the reverse gear shaft is the reverse gear
clutch which can make the loader drive backwards when it is engaged.
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BYD4208 Transmission Service Manual
Countershaft
Output shaft
Fig. 2-2
1. Reverse gear shaft clutch 2. Input shaft clutch 3. Intermediate gear shaft clutch
The transmission’s gearshift mechanism is a mechanically-operated one, with the gear controller of
BYD4208 transmission shown in Fig.2-3. This gear controller includes two gearshift levers: 1.
direction control handle (see Fig. on the left), which connects to the gearshift control valve stem on
the transmission via a flexible shaft; 2. high/low speed control handle (see Fig. on the right), which
connects to the shift fork on the transmission via a flexible shaft. The gear controller operates the
clutches of different gears by controlling the speed change valve. The working conditions of
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BYD4208 Transmission Service Manual
Ⅰ Ⅱ Ⅲ Shift fork
Ⅰ √
Ⅱ √
Ⅲ √
Ⅳ √
Ⅰ √
Ⅱ √
The power of the hydraulic torque converter is transmitted to the transmission via the input shaft
flange installed on the part of the right end of the input shaft that extends outside the transmission
box. The input shaft assembly, reserve gear shaft assembly and immediate shaft assembly connects
with the transmission box in the same way. Both ends of them are supported on the transmission
box and big end cap by conical bearings. Adjust the clearance of conical bearing during assembly,
to avoid damage to the bearing. The gears on the output shaft assembly, reverse gear shaft assembly,
countershaft assembly and output shaft are constantly meshed with each other. There are three stop
positions (HI, N, LO) in the high-low gear sliding sleeve which is refitted on the output shaft. The
high gear position corresponds to a high speed; the low gear position corresponds to a low speed.
When the sliding sleeve stays at the neutral position, no power will be output by the transmission.
Caution: Never shift the high-low gear sliding sleeve before the transmission is in the
neutral gear after the loader is stationary, otherwise, impacting and crashing of the gears may
occur.
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BYD4208 Transmission Service Manual
input→Z3→Z4→Z7→Z5→Z8→Output
Output shaft
Fig. 2-4
output
Output shaft
Fig. 2-5
Z5→Z8→output
Input shaft
2nd reverse gear (when the fork is set to the
Z4→Z7→Z9→output
Output shaft
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BYD4208 Transmission Service Manual
Fig. 2-6
1. Structure
The housing and gear of the hydraulic clutch is fixed together with bolts, and the gear connects to
the external spline of the propeller shaft via the internal spline, all of which consist of the driving or
driven part of the clutch. The inner part of the clutch consists of piston, outer friction lining, inner
friction lining, oil seal ring, return spring, outer end cover, retaining ring, etc. The driving friction
lining of the clutch connects to the clutch housing via the external spline, and the driven friction
lining of the clutch connects to the external spline of the gear via the internal friction lining.
Another gear is supported on the propeller shaft by the bearing and can rotate with respect to the
propeller shaft.
The outer friction linings in three sets of clutches are copper based powder metallurgy friction
linings (6 PCS for each). The internal friction linings are made of 65Mn (5 PCS for each), with 0.5
mm concavity. When assembling, the convex surface shall face the piston end and make sure to
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BYD4208 Transmission Service Manual
Fig. 2-7
1. Constant mesh gear 2. Centrifugal emptying valve 3. Clutch housing 4. Piston
5. Driving friction lining 6. Driven friction lining 7. Driven gear 8. Spring 9. Piston ring
10. Cylinder oil inlet passage 11. Lubricating oil passage 12. Seal ring
2. Working principle
When working: the transmission oil from the transmission control valve flows through the oil
passage in the transmission box and the big end cap and to the cylinder via the inlet end cover and
clutch shaft that will make the piston move forward, compress the driving and driven clutch plates,
and output the power via the driven gear that has been integrated with the clutch housing.
When stop working: The pressure oil will be cut off; the transmission oil in the cylinder returns via
the oil port; the piston returns via the return spring; the driving and driven clutch plates separates
2.3.5 Structure and principle of automatic emptying valve (oil drain valve)
After the clutch cylinder cut off the oil supply, the clutch housing will continue to rotate with the
shaft under the action of inertia force, and the transmission oil in the cylinder will move from the
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BYD4208 Transmission Service Manual
inside to the outside under the action of centrifugal force which will generate pressure at the
circumferential edge of the cylinder and a thrust for the poison return, therefore hindering the rapid
separation of the clutch. In order to remove the centrifugal pressure from the oil inside the rotating
Fig. 2-8
The pressure oil flows into the cylinder and flows out from the oil drainage hole via the pore
passage between the steel ball and the pore. At this point, pressure difference will be formed at the
front and the back of the steel ball. Under the action of this pressure difference, the steel ball will be
pushed to the oil drainage hole to cover it. When the oil drainage stops, the oil pressure in the
The cylinder connects with the return oil passage to release the pressure. At this point, the steel ball
will no longer be pushed by the pressure oil and will move outward under the action of the
centrifugal force, then, the oil drainage hole will open. The oil in the cylinder flows out from the oil
drainage hole via the pore passage between the steel ball and the pore, which will help the quick
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BYD4208 Transmission Service Manual
The oil supply system is an important component of the hydro-mechanical transmission system,
which generally consists of transmission pump, transmission control valve, oil filter, radiator, oil
When the pump impeller of the torque converter is running, the driving gear will drive the operation
of the oil pump to suck oil from the tank and output the pressure oil, which will flow into the torque
converter combination valve. The torque converter combination valve consists of transmission
pressure valve, inlet pressure valve and constrictor. The working oil to the combination valve
ensures sufficient oil for operation first and then is transmitted to the torque converter via the
transmission pressure valve under the action of the transmission pressure valve. The oil pressure for
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BYD4208 Transmission Service Manual
transmission control and the oil pressure at torque converter inlet are controlled by the transmission
pressure valve and inlet pressure valve, with oil pressure of 1.1~1.5 MPa and 0.5~0.6 MPa
respectively. If the oil pressure at torque converter inlet exceeds the setting value of the inlet
pressure valve, the valve port will open and the oil will spill out for oil spray of the transmission
and the torque converter. Torque converter outlet pressure valve will keep the pressure at torque
converter outlet within 0.05~0.15 MPa. The oil from the outlet pressure valve will flow through the
Transmissi
on pressure
Torque converter valve
Reverse gear
Neutral gear
1st and 3rd gear
2nd and 4th gear
Cooler
Lubrication Shower
1st and 3rd gear clutch 2nd and 4th gear Reverse gear clutch
clutch
Fig. 2-10 Schematic diagram for the oil supply of transmission & torque converter system
converter. This series of torque converter as shown in Fig. 2-11 consist of energy conversion
elements (impeller, turbine, guide pulley), power input/output elements (elastic plate,wheel cover,
turbine shaft, output flange), fixed supporting element (housing), hydraulic parts and other
accessories, etc.
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BYD4208 Transmission Service Manual
The drive plate, wheel cover and impeller constitute the power input part of the torque converter.
The wheel cover connects with the drive plate via rubber damping block or elastic plate, and the
drive plate connects with the engine flywheel housing via screws.
When the engine is running, the flywheel will drive the rotation of wheel cover via the drive plate.
The wheel cover is firmly connected to the impeller with bolts and sealed at the joint surface with
O-rings. One end of the input part is supported on the center hole of the diesel engine flywheel
housing by the shaft end of the wheel cover, and the other end is supported on the guide pulley seat
YJ315LG-1 torque converter has also been equipped with PTO port. A part of power from the diesel
engine is directly transmitted to the pump shaft gear via the transfer gear refitted on the impeller
and drives the operation of gear pump by the pump shaft, etc.
The turbine, driving shaft, driving gear, output gear and output shaft together constitute the power
output part of the torque converter. The turbine output shaft is supported at two points. That’s, the
left end is supported on the torque converter wheel cover by needle roller bearing, and the right end
is supported on the torque converter housing by ball bearing. The power from turbine output shaft is
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BYD4208 Transmission Service Manual
transmitted via driving gear to the output gear with which the driving gear is meshed, and then to
Guide pulley is fixed on the guide pulley seat via the splined joint, and the guide pulley seat is fixed
● O-ring is used at the joint of wheel cover and impeller to prevent the leakage of liquid in the
● Alloy cast iron seal ring is used between the impeller hub and the guide pulley seat to prevent
● Skeleton oil seal is used at the middle part of flywheel housing and the impeller hub. Note that
the lips of the skeleton oil seal shall face to the incoming flow when assembling.
The transmission control valve is mainly composed of speed change valve and power shut-off valve,
etc. When pulling the speed change valve lever outwards to the limit, the reverse gear will be
engaged, and when pushing it inwards, neutral gear, 1st gear and 2nd gear will be engaged
successively. The valve body has also been equipped with power shut-off valve, which will shut off
the power oil to the transmission during braking to ensure more reliable braking performance.
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BYD4208 Transmission Service Manual
1. Power shut-off valve 2. Main pressure measuring port 3. Speed change valve oil inlet
4. Speed change valve lever 5. 1st and 3rd gear lubricating oil passage 6. 1st and 3rd gear
pressure oil passage 7. 2nd and 4th gear pressure oil passage 8. 2rd and 4th gear lubricating oil
passages 9. Reverse gear lubricating oil passage 10. Reverse gear pressure oil passage
11. Oil sprayer port 12. Cooling oil port
(2) Relief valve
The relief valve is mainly composed of transmission pressure valve and torque converter inlet
pressure valve, etc. The speed change valve controls the transmission control pressure (1.1~1.5
MPa); the torque converter inlet pressure valve controls the torque converter inlet oil pressure
(0.3~0.6 MPa). The relief valve is equipped with an oil passage which can be used to lubricate the
torque converter internal gear. When the oil supply pressure in the system is too high, the overflow
valve in the relief valve will open and release pressure via the pressure relief vent.
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BYD4208 Transmission Service Manual
(1) When installing transmission, ensure the input share the same axis with the torque converter
output and the transmission output share the same axis with the input of front/rear axle.
(2) Transmission, after installed to the vehicle, shall be filled with about 45L of 6# hydraulic
transmission oil from oil filler, and the oil level shall be checked 5 min after starting the engine,
which shall reach to the level of oil dipstick. Before and after working every shift, always check the
gear or vice versa as well as between high and low gears must be
carried out after parking, but the change between 1st and 2nd gear or
105°C and will not exceed 115°C in the short run, together with the Fig. 2-14
oil temperature at the transmission oil sump not larger than 100°C.
(6) When depressing the brake pedal with engine throttle full open,
(1) Change oil in the transmission of new vehicle for the first time after the vehicle travels for 100 h
and thereafter perform this operation every 500 h. The oil to be filled shall be 6# (8#) hydraulic
transmission oil with filling amount of about 38L; the oil level shall be checked within 5 min after
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BYD4208 Transmission Service Manual
the engine is started and then runs at idling, and the level of oil dipstick shall apply. Before and after
working every shift, always check the oil level in the transmission carefully.
(2) Attention shall be paid to maintain the operating oil pressure at 1.1~1.5MPa during transmission
operation, and the outlet oil temperature of torque converter shall be generally not more than 105°C
(3) New transmission, after installed to the vehicle, shall experience 12 h running-in, 2 h for each
gear, and the load during which shall not exceed 70% of rated load. Meanwhile, note the oil
temperature, oil level and the fastening of bolts. After the period of running-in, wash transmission
(4) The gear change in transmission from forward gear to reverse gear or vice versa as well as
between high and low gears must be carried out after the vehicle is stopped, but the gear change
between 1st and 2nd gear or between 3rd and 4th gear can be done while the vehicle is running.
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BYD4208 Transmission Service Manual
3 Removal of Transmission
3.1 Removal of assembly components
Preparation for removal:
NOTE:
Protect O-ring.
Fig. 3-1
3 Bolt
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BYD4208 Transmission Service Manual
Fig. 3-2
1 Filter
3. Take filter element out.
Fig. 3-3
1 Filter element
parking brake.
Fig. 3-4
1 Parking brake
2 Fixing bolt
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BYD4208 Transmission Service Manual
Fig. 3-5
1 Lock plate
2 Bolt
3. Remove output shaft flange, brake caliper &
seal cover.
Fig. 3-6
1 Oil seal cover 2 Oil seal
3 Output shaft flange 4 Dust cover
5 Brake caliper & disc
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BYD4208 Transmission Service Manual
Fig. 3-8
1 Bolt 2 Cover plate
3 Breather
Fig. 3-9
1 Round nut 2 Round nut washer
3 Washer
Fig. 3-10
1 Bolt
2 Oil sump
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BYD4208 Transmission Service Manual
Fig. 3-11
1 Iron wire 2 Fastening screw
3 Fork shaft
2. Unscrew screw plug and washer, remove steel
Fig. 3-12
1 Bolt
NOTE:
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BYD4208 Transmission Service Manual
Fig. 3-14
1 Bolt
2 Output rear end cover
3. Remove bearing, gear, high/low gear sliding
shaft.
NOTE:
Fig. 3-15
1 Output shaft 2 Thrust ring
3 Gear (output shaft high gear) 4 High/low
gear sliding sleeve
5 Gear (output shaft low gear)
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BYD4208 Transmission Service Manual
cover.
Fig. 3-17
1 External oil seal sleeve
3. Firstly use jackscrew to jack up big end cap,
About 15kg.
NOTE:
Fig. 3-18
The hoisting operation shall be done slowly.
1 End cover 2 Hoisting bolt
3 Bearing cup
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BYD4208 Transmission Service Manual
NOTE:
Fig. 3-19
1 Input shaft assembly
5. Take out countershaft assembly and reverse
Fig. 3-20
1 Reverse shaft assembly
2 Countershaft assembly
6. Erect transmission body, disassemble hexagon
Fig. 3-21
1 Stop plate 2 bolt
3 Adjusting screw
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BYD4208 Transmission Service Manual
separately.
Fig. 3-22
1 Bolt 2 End cover
3 Adjusting ring 4 Paper washer
ball.
Fig. 3-23
1 Plug
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BYD4208 Transmission Service Manual
Fig. 3-24
1 Snap ring
stem.
Fig. 3-25
1 Oil seal 2 Adjusting washer
3 Valve stem
Fig. 3-26
1 Screw plug
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BYD4208 Transmission Service Manual
Fig. 3-27
1 Screw plug 2 O-ring
3 Leather cup 4 Brake sliding valve
be repeated here.
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BYD4208 Transmission Service Manual
Fig. 3-28
1 Bolt 2 Stop pad
3 Shaft end baffle
2. Remove internal oil seal sleeve and 2 piston
rings on it.
Fig. 3-29
1 Piston ring
2 Internal oil seal sleeve
3. Remove bearings from both ends of the shaft
Fig. 3-30
1 Shaft sleeve
2 Bearing
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BYD4208 Transmission Service Manual
as a gear wheel.
Fig. 3-31
1 Clutch external drum 2 Bolt
3 Stop pad 4 Gear wheel
5. Disassemble automatic emptying valve (oil
housing.
Fig. 3-32
1 Emptying valve
6. Disassemble retainer ring and take out external
Fig. 3-33
1 Retainer ring
2 External end cover
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BYD4208 Transmission Service Manual
Fig. 3-34
1 Special tools 2 Shaft elastic retainer ring
3 Spring 4 Piston
9. Disassemble oil seal ring from the piston.
Fig. 3-35
1 Oil seal ring
11. Press pinion out from the shaft and
bearings.
Fig. 3-36
1 Pinion
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BYD4208 Transmission Service Manual
4 Refitting of Transmission
4.1 Refitting of assembly
NOTE:
NOTE:
Three sets of clutch assemblies are of similar structure. Take input shaft assembly as example
to introduce refitting procedure and the others will not be repeated here.
Fig. 4-1
NOTE:
1 Oil seal ring ● The opening width of piston ring shall be within
0.05~0.1mm.
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BYD4208 Transmission Service Manual
retainer ring.
Fig. 4-3
refitting.
Fig. 4-4
NOTE:
1 Outer friction lining ● The number of outer friction linings for the
2 Internal friction lining
three sets of clutches is 6.
NOTE:
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BYD4208 Transmission Service Manual
correct.
Fig. 4-6
1 Retainer ring
2 External end cover
8. Assemble the pinion with snap ring and 2
Fig. 4-7
1 Bearing
2 Retainer ring
9. Align gear wheel with the cylindrical pin on the
looseness.
Fig. 4-8
1 Gear wheel 2 Bolt
3 Stop pad
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BYD4208 Transmission Service Manual
with a screwdriver.
Fig. 4-9
1 Pinion
11. Turn left and right the pinion continuously until
NOTE:
pinion.
sleeve.
NOTE:
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BYD4208 Transmission Service Manual
3 Internal oil seal sleeve passage.
NOTE:
100~150°C.
Fig. 4-13
1 Shaft end baffle 2 Stop pad
3 Bolt
countershaft assembly.
NOTE:
Fig. 4-14
1 Reverse gear shaft assembly When refitting, clutch shall be installed by
2 Countershaft assembly
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BYD4208 Transmission Service Manual
rotating.
NOTE:
Fig. 4-15
transmission body.
About 41.5kg.
NOTE:
Fig. 4-16
Fig. 4-17
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BYD4208 Transmission Service Manual
transmission body.
NOTE:
Fig. 4-18
1 Input shaft end cover 2 Reverse shaft
end cover
3 Countershaft end cover
● Three oil inlet end covers have the same
Fig. 4-19
1 1st/reverse gear end cover
2 Neutral gear end cover
1. Install oil seal into input shaft oil seal seat, install
input shaft.
Adjusting method:
Fig. 4-20
Use depthometer to measure the depth H from
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BYD4208 Transmission Service Manual
Fig. 4-21
1 Round nut washer 2 Washer
3 Round nut
Adjusting methods:
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BYD4208 Transmission Service Manual
NOTE:
Fig. 4-25
1 Bolt 2 Output rear end cover
3 Pressure plate 4 Bolt
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BYD4208 Transmission Service Manual
Fig. 4-27
1 High/low gearshift fork 2 Screw plug
3 Steel ball 4 Spring
5 Oil seal
NOTE:
steps.
Fig. 4-28
1 Bolt
valve.
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BYD4208 Transmission Service Manual
steps.
NOTE:
Fig. 4-31
1 Oil seal cover 2 Oil seal
3 Output shaft flange 4 Dust cover
5 Brake caliper disc
2. Install O-ring and pressure plate.
Fig. 4-32
1 Pressure plate
2 O-ring
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BYD4208 Transmission Service Manual
Fig. 4-33
1 Lock plate
2 Bolt
4. Install parking brake and fasten connecting bolts.
Fig. 4-34
transmission body.
Fig. 4-35
1 Filter 2. Install oil filler pipe and O-ring, and fasten
2 Oil filler pipe connecting bolts.
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BYD4208 Transmission Service Manual
If not available, a
Transmission mounting To support and tilt
disassembly and assembly
bracket transmission
platform can be set up.
Disassembly and
Three sets of clutch
assembly tool of clutch
springs
spring
Spec: 0.02/0~200
Depth meter Input shaft
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BYD4208 Transmission Service Manual
Low oil level, and empty pump Check if the oil level is below
Oil suction filter element falls Check, wash and replace after
low pressure
1. Weak traveling and gear The oil drain pipe of torque Check, wash and replace
removal
or damage
2. High oil temperature Low oil level, and empty pump Check oil level and add oil
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BYD4208 Transmission Service Manual
Oil suction filter element falls Check, wash and replace after
Low oil level, and empty pump Check oil level and add oil
off or is blocked up
3. Low oil pressure Piston oil seal ring has abrasion Replace
or damage
broken
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BYD4208 Transmission Service Manual
wrong direction
abrasion
5. High/low gear is out of
Spring is damaged Check and replace
mesh
The depth of positioning hole Check and replace
7. Only one gear is The clutch of one gear is burnt Check and repair
gear
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BYD4208 Transmission Service Manual
50