DC7J Transmission

Contents

I. Overview ..........................................................................................................................................3
II. Replacement of Flange Assembly ...............................................................................................13
III. Replacement of Odometer Gears.................................................................................................17
IV. Repair of Roof Cover Assembly...................................................................................................20
V. Repair of Upper Cover Assembly ................................................................................................28
VI. Replacement of Transmission Clutch Housing ..........................................................................45
VII. Replacement of Input Shaft and Bearing ....................................................................................47
VIII. Repair of Output Shaft Assembly ................................................................................................52
IX. Repair of Countershaft and Reverse Idler Assembly.................................................................76
X. Replacement of Transmission Housing ......................................................................................83

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 DC7J Transmission

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DC7J Transmission

Transmission
I. Overview
(I) Technical Parameter
DC7J120T
Model
Direct gear Over-speed gear
Seven forward gears and one reverse gear (2nd to 7th
Type
gears & synchronizer)
Control method Mechanical remote control
Center distance (mm) 165
Rated input power (KW) 220
Rated input torque (N•m) 1176
Maximum output torque (N•m) 12121
Maximum input speed (r/min) 3000
st
1 gear and
Straight tooth
Gear type reverse gear
2nd to 7th gears Helical tooth
st
1 gear 10.307 9.024
nd
2 gear 6.811 6.082
rd
3 gear 4.462 3.984
4th gear 2.807 2.506
Speed ratio
5th gear 2.008 1.586
th
6 gear 1.375 1.000
th
7 gear 1.000 0.829
Reverse gear 10.144 9.059

Overview 3
 DC7J Transmission

DC7J120T
Model
Direct gear Over-speed gear
st
1 gear 47/12 47/12
nd
2 gear 44/17 44/17
rd
3 gear 39/23 39/23
Output shaft/ th
4 gear 32/30 32/30
countershaft
th
5 gear 29/38 27/40
th
6 gear 23/44 --
Number th
7 gear - 18/51
of teeth
Output shaft/
reverse gear Reverse gear 38/23 38/23
shaft
Reverse gear
shaft/ Reverse idler 28/12 28/12
countershaft
Countershaft/ Constant mesh
50/19 47/20
input shaft gear
Designation of lubricating oil GL-4 85W/90 middle load vehicle gear oil
Volume of lubricating oil (L) 11

(II) Repair Standard

Item Standard Dimension (mm) Wear Limit (mm)
Transmission body
Clearance between gears of output shaft
0.08~0.23 0.5
and countershaft
Axial clearance of output shaft gear 0.3~0.50 0.7
Axial clearance of reverse idler 0.3~0.7 1.0
th th
Radial clearance between the sliding tooth 5 /6 gear: 0.07~0.34
sleeve and the fixed toothholder Other gears: 0.2~0.3 0.5

Radial clearance between the sliding tooth 1st/reverse gear: 0.4~0.5

sleeve and the gear mating tooth Other gears: 0.2~0.3 1.0
Axial clearance of ball bearing - 0.5
Transmission roof cover
Clearance between the shift lever and the
0.1~0.5 0.8
selector lever
Radial clearance between the shift shaft
0.15~0.25 0.5
and the selector lever spline
Clearance between the shift lever and the
0.7~1.0 1.5
guide block

4 Overview
DC7J Transmission

Item Standard Dimension (mm) Wear Limit (mm)

Transmission upper cover
Clearance between the shifting rocker and
0.04~0.082 0.2
the shifting rocker shaft of 5th/6th gear
Clearance between the shift fork and the
0.1~0.29 1.0
sliding tooth sleeve
Free length of the shift fork shaft
41~44 --
self-locking spring
Compression force of the shift fork shaft 157~196 (compressed to
127N
self-locking spring 27)
Clearance between the shifting rocker and
0.05~0.4 1.0
the guide block
Synchronizer
Between inside
synchronizer rings (2nd ~3rd
Axial clearance between the synchronizer gear dual-cone 0
ring and the synchronizer conical ring synchronizer):1.7~2.3
4th ~ 6th gears: 1.5~2.5
2nd ~ 3rd gears:6.4~6.8
Axial clearance between the synchronizer 1.0 (maximum wear of
4th gear: 6.9~7.3
ring and the fixed toothholder synchronizer ring)
5 ~ 6th gears: 4.9~5.3
th

Radial clearance between the synchronizer

0.1~0.3
stop block and the fixed toothholder
Free length of the stop block spring 31.3
37.36~41.29N (when
Compression force of stop block spring 35.3N
compressed to 18.52)

(III) Tightening Torque

Tightened Parts Tightening Torque (N·m)
Connecting bolt of clutch housing M16 × 1.5 187~235
Fixing bolt of transmission roof cover M10 × 1 19~25
Fixing bolt of transmission upper cover M10 × 1 33~42
Fixing bolt of transmission reverse gear hole cover M10 × 1 19~25
Reverse switch and neutral switch M18 × 1.5 34~39
th
Connecting bolt of power take-off housing M12 × 1.25 (6 gear
57~75
power take-off hole cover)
Fixing bolt of countershaft rear bearing cap M12 × 1.25 57~75

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 DC7J Transmission

Tightened Parts Tightening Torque (N·m)

M14 × 1.5 93~124
Fixing bolt of output shaft rear bearing
M16 × 1.5 145~190
Fixing bolt of input shaft bearing cap M10 × 1 33~42
Bolts of reverse idler shaft locking plate M10 × 1 19~25
Front locking nuts of output shaft M42 × 1.5 491~686
Draining plug and oil inlet bolt M24 × 2 120~140
Roof cover retainer M10 × 1 19~25
Rear locking nuts of output shaft M42 × 1.5 687~980

(IV) Parts Cleaning

Since the parts and components are always covered by dirty oil and sludge, the cleaning is mandatory.
The applicable cleaning methods include cleaning by steam, pressure, light oil, acid or alkaline solution,
neutral medium, trichoroethylene vapor, magnus solution or others. The part damage may be exposed
during cleaning, thus it is required to take notice and make inspection carefully.
Metal parts
Light oil: Different from other solutions, the light oil is unable to penetrate or dissolve sludge. Therefore, it
is required to remove the sludge with a wire brush or other tools and wash out the parts for two times
with the above-mentioned methods, which, however, is not applicable to the fine finishing surface.
Alkaline solution: Do not use the alkaline solution for alloy parts, if were. The alkaline solution is a better
choice for steel and cast iron cleaning.
Note: When the alkaline solution is used, it is required to prepare the neutralization media
such as boric acid solution to wash the alkaline solution splashed on eyes or skin
accidently.
Rubber parts
Use alcohol or clean wiping rag instead of mineral oil to remove oil and sludge on the rubber parts.
Oil duct
Make a wire pass through the oil duct to check for smoothness, and inject the cleaning solution into it
with a pressure nozzle for cleaning.
Anti-corrosion
After removing the old grease on the parts, a layer of clean grease shall be applied to protect it against
rust.
(V) Parts Inspection
Before the transmission is reassembled, all parts shall be inspected carefully for damage, abnormal
wear or excessive wear to prevent the useless parts from being installed into the transmission and avoid
unnecessary loss. When judging whether the parts can be used continuously, the parts service time,
mileage and service condition shall be comprehensively considered. The recommended inspection
procedures include:

6 Overview
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Bearing
1). Check the steel ball, roller and bearing rolling track for pockmark or falling-off.
2). Check the axial and radial clearances of the bearings and replace the one with an excessively large
clearance.
3). Check the matching condition of the bearing and the housing hole. The housing shall be replaced if
the bearing can rotate freely in the hole.
4). Measure the axial clearance of the ball bearing:
Wear limit 0.5mm
5). Check the radial clearance between the needle bearing and the gear inner race
Repair standard 0.049mm
Wear limit 0.30mm
Gear
1). Check the gear tooth surface for pitting. Replace the gear if any.
2). Check all mesh gears. Replace the gear with abnormal wear, a conical worn part or a reduced
meshing length caused by gearshift impact.
3). Check the axial clearance of the gear. Check whether the snap ring, washer, adjusting shim and
gear hub are worn excessively if any part with an excessively large clearance is found.
4). Check the gear contact traces and the bearing working conditions if the measured clearance
exceeds the wear limit:
Repair standard 0.08~0.23mm
Wear limit 0.5mm
5). Measure the clearance between the fixed toothholder and the mating tooth of the sliding tooth
sleeve (including the output shaft):
Repair standard 5th/6th gear: 0.07~0.34mm, other gears: 0.2~0.3mm;
Wear limit 0.5mm
6). Measure the radial clearance between the sliding tooth sleeve and the gear mating tooth:
Repair standard 1st/R gears: 0.4~0.5mm, other gears: 0.2~0.3mm
Wear limit 0mm
Splines
1). Check all splines on the shaft for abnormal wear. If the spline on shaft is affected due to excessively
worn parts such as the output flange plate and synchronizer, replace the affected shaft.
Thrust washer
1). Check the surface conditions of all thrust washers. Replace the scratched or excessively worn
washer.
Reverse idler
1). Check all reverse idlers and roller bearings for excessive wear.
Gray cast iron parts
1). Check all gray cast iron parts for cracks or damages and replace or repair it when necessary. Apply
the fusion welding or brazing process to large castings for crack repair; Replace the casting if the
crack extends to the bearing hole and bolt connecting surface.
Clutch release parts
1). Check the wear conditions of the clutch release parts and replace the excessively worn release fork
and release bearing.
2). Check the wear condition of the clutch release fork shaft.

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 DC7J Transmission

Transmission upper cover assembly

1). Check all shift forks, guide blocks and fork shaft locating grooves for wear and replace the
excessively worn one.
2). Check all forks for deformation and replace it if any.
3). Check the locking screws of the fork and guide blocks for looseness; tighten the loose one and lock
it tightly by punching and riveting at three points on the thread joint.
4). After disassembling the upper cover assembly, check the wear conditions of the contacting surface
of the interlocking steel ball with the corresponding fork shaft.
Shifting lever
1). The clearance between the shifting lever and the guide block:
Repair standard 0.7~1.0mm
Wear limit 1.5mm
Components for shifting control system
1). Wear resistance of self-locking and interlocking steel ball grooves for the shift fork shaft:
Repair standard 13.3
Wear limit 14.2
2). Measure the free length and rigidity of locking fork shaft spring for the transmission:
Free length 47mm
When compressed to 27mm
Repair standard 157~196N
Wear limit 127N
Bearing cap
1). Check the wear condition of the bearing cap and replace the damaged one due to the thrust from
the bearing cup.
2). Check the wear condition of the bearing cap hole and replace the excessively worn parts.
Seals and oil seals
1). Check the oil seals in the input shaft front bearing cap and the output shaft rear bearing cap.
Replace with a new oil seal in case of ineffective sealing effect.
2). Check the wear condition of the spigot and replace it if necessary.
3). Check the working condition of oil seals. Replace the seal in case of an unsealed lip.
4). Check all O-rings for crack or deformation and replace if necessary.
Synchronizer
1). Check the synchronizer for burrs, deformation and excessive wear.
2). Check the chamfer surfaces of the tooth sleeve and the synchronizer ring splines for excessive
wear.
3). Check whether the contact surface between the synchronizer and the gear is worn excessively.
Replace the gear with a burned contact surface or the burned synchronizer.

8 Overview
DC7J Transmission

4). Check the location dimension between the

synchronizer conical ring and the synchronizer
ring:
A For location dimension of dual-cone
synchronizer (for 2rd~3nd gear).
B For location dimension of single-cone
synchronizer (for 4th~7th gears).
Wear limit A=0mm
Repair standard A=1.7~2.3mm
Wear limit B=0mm
Repair standard B=1.5~2.5mm

5). Wear of sliding gear engagement length: ＜ 15%

Sliding sleeve
1). Check all shift forks and shift fork grooves of the sliding sleeve for excessive wear or discolored due
to overheating.
2). Check whether the contact area of the sliding sleeves is inclined.
3). Measure the clearance between the shift fork and the fork groove of the sliding sleeve.
Note: Measure the fork grooves of the sliding sleeve at three, five or more points.
Repair standard 0.1~0.29mm
Wear limit 1.0mm
(VI) Precautions for assembling
During assembling, thoroughly clean all parts and components to be assembled to prevent the dust and
foreign matters from entering the transmission; or else unnecessary damages may be caused. The
following precautions shall be observed during assembling:
1). Ensure that the gear thrust washer, needle bearing and spacer sleeve are assembled in the correct
direction when assembling the parts.
2). Apply the gear lubricating oil to all running surfaces.
3). Replace all self-locking nuts, oil seals and O-rings according to the repair specifications.
4). Ensure to install the synchronizer ring and the synchronizer conical ring in the same direction and at
the same position during the reassembling.
5). During the reassembling, ensure that the lubricating oil inlet is not blocked and that each gear
working surface is free from dust, sand hole or cracks; clean the synchronizer conical ring and apply
the clean lubricating oil to the working surfaces of the synchronizer conical ring, synchronizer ring,
oil seals and bearings.
Gaskets
New gaskets shall be used and coated with the sealant when the transmission is reassembled. Do not
miss any gasket to prevent oil leakage and inaccurate bearing cap alignment.
Note: The silicon rubber sealant is not required for the mating surface without paper gasket.
Tightening bolts
All tightening bolts shall be coated with the thread sealant before assembling and screwed down as per
the specified tightening torque to prevent oil leakage.
Seals and O-rings
All oil seal cutting edges and O-rings shall be lubricated with the lithium grease before the assembling.
Overview 9
 DC7J Transmission

Assembling
Refer to the assembling diagram provided in this manual when reassembling.
Initial lubrication
All thrust washers, shaft splines, needle bearings and synchronizer ring conical surfaces shall be coated
with gear oil for initial lubrication to prevent scratch or dry wear during the assembling.
Axial clearance
Ensure that the axial clearance of the output shaft gear meets the specification. Tighten the gear to the
specified tightening torque.
Bearing
The bearing puller with flange is recommended for bearing installation, managing to avoid damage to the
steel ball and the bearing cone and bearing cups as well as to ensure the concentricity of bearing and
the shaft hole since the force can be applied to the cone and cup at the same time with the aid of such
puller. You'd better not use the sleeve-type puller, which may cause the bearing damage since the force
can only be applied to either bearing cone or cup.
Output shaft flange plate
Before installing the output shaft flange plate, ensure that the odometer drive gear has been installed in
place, and then tighten the lock nut to the specified tightening torque.
(VII) Malfunction diagnosis
Basic malfunction diagnosis procedures of transmission
Preliminary inspection
1. Observation: checking vital parts such as mounting points, joints and brackets for damage
signs.
2. Enquiring owner or driver: collecting relevant materials such as working conditions and
malfunction history.
3. Preparing relevant files: including maintenance and lubricating interval, malfunctions
occurred, service mileage and time.
Disassembling the transmission
1. Keep the oil sample for measuring the content of foreign matters when necessary.
2. Check whether all parts are installed correctly without missing or counterfeit parts during
the disassembling.
3. Clean and inspect all parts carefully.

10 Overview
DC7J Transmission

Cause analysis and troubleshooting of common faults

Fault
Possible Causes and Analysis Troubleshooting
Phenomenon
The viscosity of the lubricating oil is too low Use the lubricating oil of the proper class
Insufficient lubricating oil Add the specified lubricating oil
Over-large tooth clearance due to damage
Repair or replace faulty parts
Abnormal or excessive wear of gear tooth surface
sound or The bearing is damaged or has crack. Replace the bearing
noise
The engaged position of the shift fork and Check the shift fork and replace the bent
the gear is incorrect one
The synchronizer is worn or damaged Replace the damaged parts
Individual gear is damaged Replace the damaged parts
The bearing wears out or is damaged. Replace the bearing
The synchronizer works abnormally. Replace the synchronizer
It is hard for
The shift fork is deformed or damaged Check, rectify or replace
the
transmission The check screw of the shift fork becomes
Tightening and locking
to engage loose
gear Others: the clutch is not released normally;
Adjust the clutch; Use the lubricating oil of
The viscosity of the lubricating oil is too
the required class
high
Check the shift fork, and rectify or replace
The shift fork is deformed or worn
the bent one
The filling slot on the lock ball or the shift Disassemble and replace the excessively
fork shaft is worn worn part
The lock spring is broken or fatigue Replace the spring
Automatic Adjust the gear clearance or renew the
Gear clearance is too wide
transmission gear
gear shift The mesh tooth or gear sleeve back taper
Check and replace
fails
The sliding part or end surface of the
Replace the shaft sleeve
sliding shaft sleeve is worn
Axial runout due to bearing worn out Replace the bearing
Looseness of flange lock nut Tighten it as per the requirement
Gear
engaged Interlocking ball or pin is missed or worn Remove, check and refit
incorrectly
Too much lubricating oil Drain the excessive oil
The seal is damaged or in failure Replace
Oil leakage The fastener becomes loose Tighten
The breather plug is blocked Dredging
The bolt sealant is not applied fully Reapply the sealant and reassemble.

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 DC7J Transmission

Location Diagram of Shift Lever

Precautions for removal

1. The orientations involved in the manual are specified as follow: take the output end of the
transmission as "back" and the part facing towards the traveling direction of the vehicle as
the "front" of the transmission according the installation position on the vehicle; "left" and
"right" refer to that when looking from the output end of the transmission (back) towards the
traveling direction of the vehicle (front of the transmission);
2. Before dismounting the transmission assembly, park the vehicle on the even and safe place,
shift the transmission to neutral position, shut down the engine, turn off the power master
switch and block the front and rear wheels to ensure security.
3. Before disassembling the transmission assembly, thoroughly clean the transmission
housing.
4. Disassemble the transmission at a clean place to avoid dust or other foreign matters
entering the transmission; or else the wear may be worsened and the bearing may be
damaged.
5. Remove the bearings with special tools to facilitate the removal and avoid bearing damage,
and carefully clean the bearings removed;
6. When disassembling each subassembly, put all removed parts on a clean workbench in the
sequence of removal, to avoid part missing and facilitate the assembling.
7. Remove the snap rings with a snap ring pliers to facilitate the removal and avoid snap spring
damage.
8. When disassembling parts with tools, a special attention shall be paid to the force applied on
the parts such as shafts or housings, to avoid part damage. Some parts are not allowed for
removal. It is strictly forbidden to exert any force on the running driven parts. Use the soft
hammer, rod and mallet for removal

12 Overview
DC7J Transmission

II. Replacement of Flange Assembly

(I) Recommended tools and auxiliary materials
Tools and Auxiliary
Name and Type
Materials
Common tools Hammer
Special tools Special tool for slotted nuts
Inspection tools ——
Auxiliary materials Lubricating grease

(II) Operation steps

Removal
1. Remove the slotted nut.

1). Remove the split pin.

2). Remove the slotted nut with the special tool.

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2. Remove the flange assembly.

1). Remove the plain washer.

2). Take down the O-ring.

3). Take down the flange assembly.

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DC7J Transmission

Installation
1. Install the flange assembly.

1). Install the flange assembly in place.

2). Install and tighten the four butterfly springs.

3). Install the O-ring.

Note: The O-ring must be installed in place;
or else it will be damaged, causing oil
leakage.

4). Install the plain washer.

2. Install the slotted nut.

1). Install and tighten the slotted nut with the
special tool.
Tightening torque 687~980N·m

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 DC7J Transmission

2). Install the split pin.

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DC7J Transmission

III. Replacement of Odometer Gears

(I) Recommended tools and auxiliary materials
Tools and Auxiliary
Name and Type
Materials
Common tools ——
Special tools ——
Inspection tools Torque wrench (0~400N·m)
Auxiliary materials Lubricating grease

(II) Operation steps

Removal
1. Remove the flange assembly.
Refer to Replacement of Flange Assembly.
2. Remove the rear bearing seat assembly of
the output shaft.

1). Remove and take out the tightening bolt of the

rear bearing seat on the output shaft.

2). Take down the rear bearing seat of the output

shaft.

Replacement of Odometer Gears 17

 DC7J Transmission

3. Remove the odometer driving gear

assembly

1). Take down the odometer driving gear.

2). Take down the thrust ring of the odometer

driving gear.

Installation
1. Install the odometer gear assembly.

1). Install the thrust ring of the odometer driving

gear.
Note: The installation of the driving gear
thrust ring is directional with the plane
end towards the front.

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DC7J Transmission

2). Install the odometer driving gear.

2. Install the rear bearing seat assembly of

the output shaft.
1). Install the rear bearing seat and paper gasket
of the output shaft.
Note: Before the installation, apply the
sealant evenly to the inside surface of
the rear bearing seat of the output
shaft.

2). Screw down the tightening bolt of the rear

bearing seat of the output shaft.
Tightening torque 93~124N·m

3. Install the flange assembly.

Refer to Replacement of Flange Assembly.

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 DC7J Transmission

IV. Repair of Roof Cover Assembly

Structure diagram of upper cover and roof cover

1. Skeleton rubber oil seal 20. 5th/6th gear shifting rocker shaft 39. 4th/5th gear shifting fork shaft
2. Control shaft 21. Shifting stop plate 40. Shifting rocker shaft
3. Shaft elastic retainer ring 22. Spacer sleeve 41. 1st/reverse gear shifting rocker
4. Gearshift rocker shaft washer 23. 5th/6th gear shifting rocker 42. Upper cover
5. Oil seal ring for gearshift rocker 24. Nut 42A. Bolt assembly
shaft 25. Plug 42B. Bolt assembly
6. Breather plug assembly 26. 1st gear shifting fork 43. Stud
7. Cylindrical pin 27. 1st/reverse gear shifting shaft 44. Steel ball
8. Roof cover 28. 1st/reverse gear shifting guide 45. Sealing gasket
9. Thin washer of gearshift rocker block 46. Switch assembly
shaft 29. Hexagonal socket conical plug 47. Locking shifting fork shaft spring
10. Gearshift rocker assembly 30. 6th/7th gear shifting fork 48. Steel ball
11. Reverse damping spring 31. 5th/6th gear shifting fork shaft 49. Guide spring of stop guide block
12. Shifting balance spring seat 32. 3rd/4th gear guide block 50. 2nd/3rd/4th/5th gear shifting fork
13. Shift lever 33. Reverse gear guide block 51. Roof cover paper gasket
14. Transposition damping spring 34. Reverse gear shifting fork shaft 52. Upper cover gasket
seat
35. Interlocking cylindrical pin
15. Transposition damping spring
36. Steel ball
16. Nut
37. 1st/2nd gear guide block
17. 5th/6th gear damping spring
38. 2nd/3rd gear shifting fork shaft
18. Bowel plug oil baffle
19. Oil baffle

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DC7J Transmission

(I) Recommended tools and auxiliary materials

Tools and Auxiliary
Name and Type
Materials
Common tools Double offset ring spanner S16/S21, copper rod
Special tools External snap spring pliers
Inspection tools Torque wrench (0~400N·m)
Auxiliary materials Lubricating grease

(II) Operation steps

Removal
1. Remove the roof cover assembly.

1). Remove the roof cover and tighten the bolt.

2). Take down the roof cover assembly.

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Disassembling

1. Remove the roof cover breather plug

assembly.

2. Remove the stop plate and oil baffle of the

roof cover.
1). Knock the locking plate to make it flat and
remove the bolts of the roof cover stop plate.
2). Remove the stop plate and oil baffle of the
roof cover.

3. Remove the 5th/6th gear shifting rocker.

4. Remove the gearshift rocker assembly.

1). Remove the snap spring on the gearshift
rocker with a snap spring pliers.

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DC7J Transmission

2). Take out the gearshift rocker.

3). Take out the gearshift rocker shaft washer.
4). Take out the gearshift rocker shaft oil seal.

5. Remove the control shaft assembly.

1). Remove the large nut of the shift lever.
Note: Do not lose the gearshift damping
spring and its seat.

2). Remove the cylindrical pin of the control shaft

with a special tool (thimble).

3). Pull out the control shaft.

Repair of Roof Cover Assembly 23

 DC7J Transmission

Assembling
1. Install the shifting balance spring seat
assembly.

1). Install the shifting balance spring seat.

2). Install the shifting spring.
Note: When installing the shifting spring,
make the end near to the bowel plug
shorter and the other end longer.

2. Install the control shaft assembly.

1). Install the control shaft.
Note: Rotate the control shaft during the
installation.

2). Install the shift lever.

Note: Install the shift lever to the correct
position in the correct direction during
the assembling.

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DC7J Transmission

3). Install the gearshift damping spring seat.

4). Install the damping spring.

5). Apply the sealant to the shifting lever.

6). Install and tighten the nut.

7). Install the stop cylindrical pin of the control

shaft.

3. Install the gearshift rocker assembly.

1). Apply the sealant to the end surface.
2). Install the bowel plug.

Repair of Roof Cover Assembly 25

 DC7J Transmission

3). Install the gearshift rocker.

Note: Pay attention to the four gaskets and
the oil seal on the upper plane of the
roof cover.

4). Install the gearshift rocker washer.

Note: Make the washer surface with chamfer
upwards.

5). Install the snap spring of the gearshift rocker.

4. Install the stop plate and oil baffle of the

roof cover.
Note: Install the 5th/6th gear shifting rocker to
the correct position.

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DC7J Transmission

5. Install the roof cover breather plug.

6. Install the roof cover assembly.

1). Install the roof cover assembly.

2). Install and tighten the tightening bolt of the

roof cover.
Tightening torque 19~25N·m

On-board inspection
Check whether each gear can be engaged orderly
and the transmission can work normally when
each gear is engaged in sequence in a road test.

Repair of Roof Cover Assembly 27

 DC7J Transmission

V. Repair of Upper Cover Assembly

(I) Recommended tools and auxiliary materials
Tools and Auxiliary
Name and Type
Materials
Common tools M16 spanner, copper rod, hammer
Special tools External snap spring pliers
Inspection tools ——
Auxiliary materials Steel locking wire, lubricating grease, hair brush

(II) Operation steps

Removal
Note: Ensure that the shifting fork of each gear is at the neutral position when removing the
upper cover assembly. If not, the shifting fork will be locked and the fork shaft will be
unable to be pulled out.
1. Remove the roof cover assembly.

1). Remove the eight M16 tightening bolts of the

roof cover.

2). Take down the roof cover assembly.

28 Repair of Upper Cover Assembly

DC7J Transmission

2. Remove the upper cover assembly.

1). Take out the four springs locking the

transmission fork shaft.
Note: Do not lose the self-locking spring.

2). Take out the four steel balls.

Note: Do not lose the self-locking steel ball.
3). Take out the upper cover assembly.

3. Remove the 5th/6th gear shifting fork and

the 6th/7th shifting fork shaft assembly.

1). Remove the hexagonal socket conical plug

tightening the 6th/7th shifting fork with a special
tool.

Repair of Upper Cover Assembly 29

 DC7J Transmission

2). Knock the rear end of the 5th/6th gear shifting

fork shaft with a copper rod to take out the
plug.

3). Take down the 5th/6th gear shifting fork shaft

plug.

4). Continuously knock the rear end of the 5th/6th

gear shifting fork shaft to take it out along with
the 6th/7th gear shifting fork.
Note: Do not lose the interlocking cylindrical
pin and the steel ball.

4. Remove the 1st/reverse gear shifting fork

and the shifting fork shaft assembly.

1). Remove the hexagonal socket conical plug

securing the 1st/reverse gear shifting fork with
a special tool.

30 Repair of Upper Cover Assembly

DC7J Transmission

2). Remove the hexagonal socket conical plug

securing the 1st/reverse gear shifting guide
block with a special tool.

3). Knock the front end of the 1st/reverse gear

shifting fork with a copper rod to take out the
plug from the rear end.

4). Take down the plug of the 1st/rever gear

shifting fork shaft.

5). Continuously knock the front end of the

1st/reverse gear shifting fork shaft to take out
the shifting guide block.

Repair of Upper Cover Assembly 31

 DC7J Transmission

6). Continuously knock the front end of the

1st/reverse gear shifting fork shaft to take out
the shifting fork and the shifting fork shaft.
Note: Do not lose the interlocking cylindrical
pin and the steel ball.

5. Remove the 4th/5th gear shifting fork and

shifting fork shaft assembly.

1). Remove the hexagonal socket conical plug

securing the 3rd/4th gear guide block with a
special tool.

2). Remove the hexagonal socket conical plug

securing the 4th/5th gear shifting fork with a
special tool.

3). Knock the rear end of the 4th/5th gear shifting

fork shaft with a copper rod to take out the
plug from the front end.

32 Repair of Upper Cover Assembly

DC7J Transmission

4). Continuously knock the rear end of the 4th/5th

gear shifting fork shaft to take out the 4th/5th
gear shifting fork.

5). Continuously knock the rear end of the 4th/5th

gear shifting fork shaft to take out the 3rd/4th
gear guide block and the 4th/5th gear shifting
fork shaft.

6. Remove the 2nd/3rd gear shifting fork shaft

assembly.

1). Remove the hexagonal socket conical plug

securing the 1st/2nd guide block with a special
tool.

2). Remove the hexagonal socket conical plug

securing the 4th/5th gear shifting fork with a
special tool.

Repair of Upper Cover Assembly 33

 DC7J Transmission

3). Knock the rear end of the 2nd/3rd gear shifting

fork shaft with a copper rod to take out the
plug from the front end.

4). Continuously knock the 2nd/3rd gear shifting

fork shaft to take out the 4th/5th gear shifting
fork and the 2nd/3rd gear shifting fork shaft.

5). Continuously knock the 2nd/3rd gear shifting

fork shaft to take out the 1st/2nd gear guide
block and 2nd/3rd gear shifting fork shaft.
Note: Do not lose the interlocking cylindrical
pin and the steel ball.

7. Remove the reverse gear shifting fork

shaft assembly.
1). Remove the hexagonal socket conical plug
securing the reverse gear guide block with a
special tool.

34 Repair of Upper Cover Assembly

DC7J Transmission

2). Remove the hexagonal socket conical plug

securing the 1st/reverse gear shifting guide
block with a special tool.

3). Knock the rear end of the reverse gear shifting

fork shaft with a copper rod to take out the
1st/reverse gear shifting guide block.

4). Continuously knock the reverse gear shifting

fork shaft to take it out along with the reverse
gear guide block.

8. Remove the shifting rocker assembly.

1). Remove the lock nuts of the shifting rocker
shaft.
2). Take down the gasket.
3). Take down the shifting rocker shaft.
4). Take down the reverse gear shifting rocker.

Repair of Upper Cover Assembly 35

 DC7J Transmission

9. Remove the reverse switch assembly.

1). Reverse the reverse switch assembly and

take it down along with the sealing washer
and the steel ball.

10. Remove the neutral switch assembly.

1). Remove the neutral switch assembly and take
it down along with the sealing gasket and the
steel ball.

Assembling
1. Install the 1st/reverse gear shifting rocker.

1). Install the 1st/reverse gear shifting rocker, its

shaft gasket and the rocker shaft lock nut in
the reverse order of removal and tighten the
nut as per the specified torque.
Tightening torque 19~25N·m

36 Repair of Upper Cover Assembly

DC7J Transmission

2. Install the reverse switch assembly.

1). Install the reverse switch assembly in the

sequence of steel ball, sealing washer and the
reverse switch assembly.

3. Install the neutral switch assembly.

1). Install the neutral switch assembly in the
sequence of steel ball, sealing washer and the
neutral switch assembly.

4. Install the reverse gear shifting fork shaft

assembly.
1). Install the interlocking cylindrical pin.

2). Install the shifting fork shaft and guide block of

the reverse gear.
Note: Do not lose the interlocking cylindrical
pin.

Repair of Upper Cover Assembly 37

 DC7J Transmission

3). Knock the front end of the reverse gear

shifting fork shaft with a copper rod and install
the 1st/reverse gear shifting guide block.

4). Install and tighten the hexagonal socket

conical plugs securing the 1st/reverse gear
shifting guide block and the reverse gear
guide block with a special tool.
Tightening torque 19~25N·m

5. Install the 2nd/3rd gear shifting fork

assembly.
1). Install the interlocking cylindrical pin.

2). Install the 1st/2nd gear guide block and the

2nd/3rd gear shifting fork shaft;
Note: Do not lose the interlocking cylindrical
pin.

38 Repair of Upper Cover Assembly

DC7J Transmission

3). Install the steel ball.

4). Knock the 2nd/3rd gear shifting fork shaft to

install the shifting fork and the shifting fork
shaft.
Note: Do not lose the interlocking cylindrical
pin and the steel ball.

5). Install the hexagonal socket conical plugs

securing the 1st/2nd gear guide block and the
2nd/3rd shifting fork with a special tool.

6. Install the 4th/5th gear shifting fork

assembly.
1). Install the interlocking cylindrical pin.

Repair of Upper Cover Assembly 39

 DC7J Transmission

2). Knock the 4th/5th gear shifting fork shaft to

install the 3rd/4th gear guide block.
Note: Do not lose the interlocking steel ball.

3). Install the steel ball.

4). Knock the 4th/5th gear shifting fork shaft to

install the shifting fork.
Note: Do not lose the interlocking cylindrical
pin and the steel ball.

5). Tighten the hexagonal socket conical plug

securing the 4th/5th gear shifting fork with a
special tool.

40 Repair of Upper Cover Assembly

DC7J Transmission

6). Tighten the hexagonal socket conical plug

securing 3rd/4th gear guide block with a special
toll.
Tightening torque 19~25N·m

7. Install the 5th/6th gear shifting fork shaft

and the 6th/7th gear shifting fork.

1). Knock the 5th/6th gear shifting fork shaft to

install it along with the 6th/7th gear shifting fork.

2). Install the steel ball.

3). Remove the hexagonal socket conical plug

securing the 6th/7th gear shifting fork with a
special tool.
Note: Do not lose the interlocking cylindrical
pin and the steel ball.

Repair of Upper Cover Assembly 41

 DC7J Transmission

8. Install the 1st/reverse gear shifting fork assembly.

1). Knock the 1st/reverse gear shifting fork shaft

to install it along with the shifting fork.

2). Continuously knock the front end of the

1st/reverse gear shifting fork shaft to install the
1st/reverse gear shifting guide block.

3). Tighten the hexagonal socket conical plugs

securing the 1st/reverse gear shifting fork and
shifting guide block with a special tool.
Tightening torque 19~25N·m

9. Install the neutral switch assembly.

1). Install the (large) steel ball of the neutral
switch assembly.

42 Repair of Upper Cover Assembly

DC7J Transmission

2). Install the plain gasket and the neutral switch

assembly.

3). Install the (small) steel ball of the neutral

switch assembly.

10. Install the reverse switch assembly.

1). Install the plain washer and the reverse switch
assembly.

11. Install the shifting fork shaft locking spring

assembly.
1). Install the (four) self-locking steel balls.

Repair of Upper Cover Assembly 43

 DC7J Transmission

2). Install the (four) springs locking the shifting

fork shaft.

12. Install the roof cover assembly.

1). Apply the sealant and install the paper gasket.

2). Install the roof cover assembly.

3). Screw down the tightening bolt of the roof

cover.
Tightening torque 19~25N·m

On-board inspection
Check whether each gear can be engaged orderly
and the transmission can work normally when
each gear is engaged in sequence in a road test.

44 Repair of Upper Cover Assembly

DC7J Transmission

VI. Replacement of Transmission Clutch Housing

(I) Recommended tools and auxiliary materials
Tools and Auxiliary
Name and Type
Materials
Common tools copper rod
Special tools ——
Inspection tools Torque wrench (0~400N·m)
Auxiliary materials ——

(II) Operation steps

Removal
1. Remove the transmission assembly
Refer to Replacement of Transmission Assembly.
2. Remove the clutch housing assembly.

1). Remove the fixing bolts of the clutch release

fork; pull out the release fork shaft and fork
arm assembly.

2). Take down the clutch release bearing

assembly, release bearing lubricating hose
assembly and the clutch release fork & pin
assembly.

Replacement of Transmission Clutch Housing 45

 DC7J Transmission

3). Remove the clutch housing fixing bolts, and

knock the clutch housing with a copper rod to
take it down when loose.

Installation
1. Install the clutch housing assembly.

1). Install the clutch housing.

2). Install the release fork shaft and release fork
arm assembly.
3). Install the square key and the clutch release
bearing assembly.
4). Install the release bearing lubricating hose
assembly.
5). Install the clutch release fork & pin assembly
and tighten the fixing bolt of the clutch housing
and the clutch release fork.
Tightening torque 187~235N·m

2. Install the transmission assembly.

Refer to Replacement of Transmission Assembly

46 Replacement of Transmission Clutch Housing

DC7J Transmission

VII. Replacement of Input Shaft and Bearing

Structure Diagram of Input Shaft

1. Shaft elastic retainer ring 3. Input shaft of the transmission

th
2. Input shaft bearing & stop ring 4. 5 gear synchronizer

(I) Recommended tools and auxiliary materials

Tools and Auxiliary
Name and Type
Materials
Common tools copper rod, slotted screwdriver
Special tools External snap spring pliers
Inspection tools Torque wrench (0~400N·m)
Auxiliary materials hair brush, Lubricating grease

(II) Operation steps

Removal
1. Remove the transmission assembly
Refer to Replacement of Transmission Assembly.
2. Remove the clutch housing
Refer to Replacement of Clutch Housing.
3. Remove the roof cover assembly.
Refer to Repair of Roof Cover Assembly
4. Remove the upper cover assembly
Refer to Repair of Upper Cover Assembly.

Replacement of Input Shaft and Bearing 47

 DC7J Transmission

5. Remove the input shaft bearing cap

assembly.

1). Remove the tightening bolt of the input shaft

bearing cap.

2). Knock the input shaft bearing with a copper

rod and take down the bearing cap when
loose.

6. Remove the input shaft assembly.

1). Pull out the transmission input shaft assembly
with a special tool.

2). Remove the shaft elastic retainer ring with a

snap spring pliers.

48 Replacement of Input Shaft and Bearing

DC7J Transmission

3). Remove the stop ring with a snap ring pliers.

(140/149.2)

4). Remove the input shaft bearing with a special

tool.

Installation
1. Clean the removed parts and components.
1. Install the input shaft assembly.

1). Knock the input shaft bearing uniformly with a

copper rod to install it in place.

Replacement of Input Shaft and Bearing 49

 DC7J Transmission

2). Install the shaft elastic retainer ring with a

snap spring pliers.

3). Install the stop ring (140/149.2).

4). Install the transmission input shaft assembly

with a special tool.

5). Knock the front end surface of the

transmission input shaft with a copper rod if
there is no special tool to install the input shaft
bearing in place.
Note: After the installation, rotate the input
shaft to check whether the input shaft
rotates smoothly and whether each
gear is correctly engaged. If not
smooth, make adjustment until it
rotates smoothly and the gear is
correctly engaged.

50 Replacement of Input Shaft and Bearing

DC7J Transmission

2. Install the input shaft bearing cap

assembly.

1). Check whether the oil seal in the input shaft

bearing cap is normal. Replace the damaged
oil seal, if any.

2). Install the input shaft bearing assembly. Apply

the sealant evenly to the inside of the input
shaft bearing cap; install the input shaft
bearing cap and paper gasket and screw
down the tightening bolt.
Tightening torque 33~42N·m

3. Install the upper cover assembly

Refer to Repair of Upper Cover Assembly
4. Install the roof cover assembly
Refer to Repair of Roof Cover Assembly
5. Install the clutch housing
Refer to Replacement of Clutch Housing
6. Install the transmission assembly
Refer to Replacement of Transmission Assembly

On-board inspection
Check whether each gear can be engaged orderly and the transmission can work normally when each
gear is engaged in sequence in a road test.

Replacement of Input Shaft and Bearing 51

 DC7J Transmission

VIII. Repair of Output Shaft Assembly

Structure Diagram of Output Shaft

th
1. Shaft elastic retainer ring 17. 6 gear needle bearing race 34. 2nd gear needle bearing ring
2. Input shaft bearing 18. 5th gear thrust ring 35. 2nd gear bearing race
3. Transmission input shaft 19. 5th gear bearing race 36. 2nd gear assembly
4. 7th gear synchronizer conical ring 20. 3rd/4th/5th gear needle bearing 37. Reverse gear thrust ring
5. Shaft steel wire retainer ring 21. 5th gear assembly 38. Reverse driven gear
6. Output shaft front bearing 22. 4th gear synchronizer ring 39. 1st/reverse gear needle bearing
7. Output shaft lock nut 23. 3rd/4th gear sliding tooth sleeve 40. 1st/reverse gear tooth sleeve
7A. Lock nut plate 24. 3rd/4th gear fixed toothholder 41. Transmission output shaft
8. Lock nut washer assembly 42. 1st gear
th
9. 5th/6th gear synchronizer ring 25. 4 gear assembly 43. 1st gear thrust ring
10. 5th/6th gear sliding tooth sleeve 26. 4th gear needle bearing race 44. Output shaft rear bearing
11. 5th/6th gear fixed toothholder 27. 3rd gear thrust ring 45. Output shaft flange assembly
12. Synchronizer locking piece 28. 3rd gear assembly 46. O-ring (65*5.7)
13. Synchronizer locking piece 29. 3rd gear needle bearing race 47. Plain washer
spring 30. 2nd needle bearing spacer sleeve 48. Hexagonal slotted nut
14. Synchronizer locking piece seat 31. 2nd/3rd gear synchronizer conical
15. 7th gear assembly ring assembly
nd rd
16. 6th gear needle bearing 32. 2 /3 gear sliding tooth sleeve
33. 2nd/3rd gear fixed toothholder
assembly

52 Repair of Output Shaft Assembly

DC7J Transmission

(I) Recommended tools and auxiliary materials

Tools and Auxiliary
Name and Type
Materials
Common tools ——
Disassembling tool for output shaft rear bearing, External snap spring
Special tools
pliers, Bearing puller
Inspection tools Torque wrench (0~400N·m)
Auxiliary materials hair brush, Lubricating grease

(II) Operation steps

Removal
1. Remove the transmission assembly
Refer to Replacement of Transmission Assembly
2. Remove the roof cover assembly
Refer to Repair of Roof Cover Assembly
3. Remove the upper cover assembly
Refer to Repair of Upper Cover Assembly
4. Remove the clutch housing assembly
Refer to Replacement of Clutch Housing
5. Remove the input shaft assembly
Refer to Replacement of Input Shaft and Bearing
6. Remove the output shaft rear bearing cap
Refer to Replacement of Skeleton Oil Seal
Assembly
7. Remove the output shaft assembly.

1). Remove the rear bearing retainer ring of the

output shaft with a snap spring pliers.

Repair of Output Shaft Assembly 53

 DC7J Transmission

2). Remove the output shaft rear bearing with a

special tool to take out the output shaft
assembly.

Disassembling

1. Take down the 5th gear synchronizer

conical ring.
1). Fix the output shaft front end upwards on the
workbench to take down the 5th gear
synchronizer conical ring.

2. Take down the 5th/6th gear synchronizer

ring.

3. Remove the output shaft front bearing.

1). Remove the shaft steel wire retainer ring and
the output shaft front bearing with a special
tool.

54 Repair of Output Shaft Assembly

DC7J Transmission

4. Remove the 5th/6th gear synchronizer

assembly.

1). Press the lock plate turnup of the lock nut flat
and remove the output shaft lock nut with the
corresponding special tool.

2). Take down the lock plate of the lock nut.

3). Take down the 5th/6th gear synchronizer

assembly.

5. Remove the 6th gear assembly.

1). Take down the 5th/6th gear synchronizer ring.

Repair of Output Shaft Assembly 55

 DC7J Transmission

2). Take down the 6th gear assembly.

6. Remove the 5th gear assembly.

1). Take down the 6th gear needle bearing.

2). Take down the 6th needle bearing race.

3). Take the 5th gear thrust ring.

56 Repair of Output Shaft Assembly

DC7J Transmission

4). Take down the 5th gear assembly.

7. Remove the 3rd/4th gear synchronizer

assembly.
1). Take down 4th gear synchronizer ring.

2). Take down 3rd/4th gear needle bearing.

3). Take down the 4th gear needle bearing race.

Repair of Output Shaft Assembly 57

 DC7J Transmission

4). Take down the 3rd/4th gear synchronizer

assembly.

8. Remove the 4th gear assembly.

1). Take down 4th gear synchronizer ring.

2). Take down the 4th gear assembly.

9. Remove the 3rd gear assembly.

1). Take down the 3rd/4th gear needle bearing.

58 Repair of Output Shaft Assembly

DC7J Transmission

2). Take down the 4th gear needle bearing race.

3). Take down the 3rd gear thrust ring.

4). Take down the 3rd gear assembly.

10. Take down the 2nd/3rd gear synchronizer

conical ring assembly.

Repair of Output Shaft Assembly 59

 DC7J Transmission

11. Remove the 2nd/3rd gear synchronizer assembly.

1). Take down the 3rd/4th gear needle bearing and

2nd gear needle bearing spacer sleeve.

2). Take down the 3rd gear needle bearing race.

3). Take down the 2nd/3rd gear synchronizer

assembly.

12. Take down the 2nd/3rd gear synchronizer

conical ring assembly.

60 Repair of Output Shaft Assembly

DC7J Transmission

13. Take down the 2nd gear assembly.

14. Remove the reverse gear assembly.

1). Take down the 2nd gear needle bearing.

2). Take down the 2nd gear bearing race.

3). Take down the reverse gear thrust ring.

Repair of Output Shaft Assembly 61

 DC7J Transmission

4). Take down the reverse driven gear.

15. Remove the output shaft assembly.

1). Take down the 1st/reverse gear needle
bearing.

2). Take down the 1st/reverse gear tooth sleeve.

3). Pull out the output shaft.

62 Repair of Output Shaft Assembly

DC7J Transmission

16. Remove the 1st/reverse gear assembly.

1). Take down the 1st/reverse gear needle

bearing.

2). Remove the 1st gear and its thrust ring.

Assembling
1. Clean and inspect the removed parts and
components.
2. Install the 1st gear assembly.

1). Put the 1st gear and its thrust ring onto the
workbench for installation.
Note: The installation of 1st gear and its
thrust ring is directional with the gear
hub surface having teeth upwards.

Repair of Output Shaft Assembly 63

 DC7J Transmission

2). Install the 1st/reverse gear needle bearing.

3. Install the output shaft assembly.

1). Install the output shaft front end upwards onto
the workbench. Ensure that the 1st gear thrust
ring, 1st gear and the 1st/reverse gear needle
bearing are installed in place on the output
shaft.

4. Install the reverse driven gear assembly.

1). Install the 1st/reverse gear tooth sleeve.

2). Install the 1st/reverse gear needle bearing.

64 Repair of Output Shaft Assembly

DC7J Transmission

3). Install the reverse driven gear assembly.

Note: The installation of the reverse driven
gear is directional with the driven gear
hub surface having teeth downwards.

5. Install the 2nd gear assembly.

1). Install the reverse gear thrust ring.

2). Install the 2nd gear bearing race.

3). Apply the gear oil evenly to the outside

surface of the 2nd gear bearing race.

Repair of Output Shaft Assembly 65

 DC7J Transmission

4). Install the 2nd gear needle bearing.

5). Install the 2nd gear assembly.

Note: The installation of the 2nd gear is
directional with the surface having
mesh teeth upwards.

6. Install the 2nd/3rd gear synchronizer conical

ring assembly.
Note: The installation of the 2nd/3rd gear
synchronizer conical ring is
directional with the flatter surface
downwards.

7. Install the 2nd/3rd gear synchronizer

assembly.

1). Apply the gear oil evenly to the surface of the

2nd/3rd gear synchronizer conical ring
assembly to make the oil penetrate into the
inside and outside conical surface.
Note: The installation of the 2nd/3rd gear
synchronizer conical ring is
directional with the flatter surface
downwards.

66 Repair of Output Shaft Assembly

DC7J Transmission

2). Install the 2nd/3rd gear synchronizer.

8. Install the 2nd/3rd gear synchronizer conical

ring assembly.
1). Install the 2nd/3rd gear synchronizer conical
ring assembly in place.
Note: The installation of 2nd/3rd gear
synchronizer conical ring is
directional with the flatter surface
upwards.

9. Install the 3rd gear assembly.

1). Install the 3rd gear needle bearing race.

Repair of Output Shaft Assembly 67

 DC7J Transmission

2). Apply the gear oil evenly to the outside

surface of the 3rd gear needle bearing race
and the surface of the 2nd/3rd gear
synchronizer assembly to make the oil
penetrate into the inside and outside conical
surface.

3). Install the 3rd/4th gear needle bearing and the

3rd gear needle bearing spacer sleeve.
Note: Notice that the 3rd gear needle bearing
spacer sleeve shall be placed at the
middle of the two 3rd/4th gear needle
bearings.

4). Install the 3rd gear assembly.

Note: The installation of the 3rd gear
assembly is directional with the hub
surface having boss upwards.

5). Install the 3rd gear thrust ring.

Note: The installation is not directional.

10. Install the 4th gear assembly.

68 Repair of Output Shaft Assembly

DC7J Transmission

1). Install the 4th gear needle bearing race.

2). Apply the gear oil evenly to the outside

surface of the 4th gear needle bearing race.

3). Install the 3rd/4th gear needle bearing.

4). Install the 4th gear assembly.

Note: The installation of the 4th gear
assembly is directional with the hub
surface having the boss upwards.

11. Install the 3rd/4th gear synchronizer

assembly.

Repair of Output Shaft Assembly 69

 DC7J Transmission

1). Install the 4th gear synchronizer ring.

Note: The installation of 4th gear
synchronizer is directional with the
surface having mesh teeth
downwards.

2). Install the 3rd/4th gear synchronizer assembly.

3). Install the 4th gear synchronizer ring.

Note: The installation of the 4th synchronizer
is directional with the surface having
mesh teeth upwards.

12. Install the 5th gear assembly.

1). Install the 4th gear needle bearing race.

70 Repair of Output Shaft Assembly

DC7J Transmission

2). Apply the gear oil evenly to the outside

surface of the 4th gear needle bearing race.

3). Install the 3rd/4th gear needle bearing.

4). Install the 5th gear assembly.

5). Install the 5th gear thrust ring.

Note: Make the small end upwards.

13. Install the 6th gear assembly.

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 DC7J Transmission

1). Install the 6th gear needle bearing race.

2). Apply the gear oil evenly to the outside

surface of the 6th gear needle bearing race.

3). Install the 6th gear needle bearing.

4). Install the 6th gear assembly.

Note: The installation of 6th gear assembly is
directional with the hub surface having
boss upwards.

14. Install the 5th/6th gear synchronizer

assembly.

72 Repair of Output Shaft Assembly

DC7J Transmission

1). Install the 5th/6th gear synchronizer ring.

Note: The installation of 5th/6th gear
synchronizer ring is directional with
the surface having mesh teeth
downwards.

2). Install the 5th/6th gear synchronizer assembly.

15. Install the output shaft front bearing.

1). Install the washer and the lock plate of the
lock nuts.

2). Tighten the lock nut of the output shaft and

then turn over the lock plate turnup with a
special tool.
Tightening torque 687~980N·m

Repair of Output Shaft Assembly 73

 DC7J Transmission

3). Install the shaft steel wire retainer ring and the
output shaft front bearing with a special tool.

16. Install the 5th/6th gear synchronizer

assembly.

1). Install the 5th/6th gear synchronizer ring.

Note: The installation of the 5th/6th gear
synchronizer ring is directional with
the surface having mesh teeth
upwards.

2). Install the 5th/6th gear synchronizer conical

ring.
Note: The installation of the 5th/6th gear
synchronizer conical ring is
directional with the surface having
boss downwards.

17. Install the output shaft rear bearing.

74 Repair of Output Shaft Assembly

DC7J Transmission

1). Lift the transmission output shaft assembly

with a steel wire rope and then take out the
rope.

2). Knock the output shaft rear bearing cup

uniformly with a copper rod to install the rear
bearing in place.

18. Install the clutch housing assembly

Refer to Replacement of Clutch Housing
19. Install the upper cover assembly
Refer to Repair of Upper Cover Assembly
20. Install the roof cover assembly
Refer to Repair of Roof Cover Assembly
21. Install the transmission assembly
Refer to Replacement of Transmission Assembly

On-board inspection
Check whether each gear can be engaged orderly and the transmission can work normally when each
gear is engaged in sequence in a road test.

Repair of Output Shaft Assembly 75

 DC7J Transmission

IX. Repair of Countershaft and Reverse Idler Assembly

Structure Diagram of Countershaft

1. Countershaft front bearing 8. Key 15. Shaft elastic retainer ring

2. Countershaft front retainer ring 9. Key 16. Roller bearing ring
3. Countershaft constant mesh gear 10. Key 17. Spacer sleeve
4. Countershaft spacer sleeve 11. Countershaft 18. Reverse constant mesh gear
th
5. Countershaft 7 gear 12. Output shaft/countershaft rear 19. Reverse gear shaft
th bearing
6. Countershaft 5 gear 20. O-ring
th 13. Stop ring (120/129.7)
7. Countershaft 4 gear
14. Countershaft adjusting washer

(I) Recommended tools and auxiliary materials

Tools and Auxiliary
Name and Type
Materials
Common tools copper rod
Special tools External snap spring pliers, Bearing puller
Inspection tools Torque wrench (0~400N·m)
Auxiliary materials hair brush, Lubricating grease

76 Repair of Countershaft and Reverse Idler Assembly

DC7J Transmission

(II) Operation steps

Removal
1. Drain out the transmission gear oil
2. Remove the transmission assembly
Refer to Replacement of Transmission Assembly
3. Remove the clutch housing assembly
Refer to Replacement of Clutch Housing
4. Remove the input shaft assembly
Refer to Repair of Input Shaft Assembly
5. Remove the output shaft assembly
Refer to Repair of Output Shaft Assembly
6. Remove the countershaft rear bearing cap.

1). Unscrew the tightening bolt of the

countershaft rear bearing cap and take the
rear bearing cap out.

7. Remove the countershaft rear bearing.

1). Remove the shaft elastic retainer ring and the
countershaft bearing stop ring with a snap
spring pliers.
Note: The number of the countershaft
bearing stop ring to be installed is
determined according to the actual
requirements.

Repair of Countershaft and Reverse Idler Assembly 77

 DC7J Transmission

2). Remove the stop ring with a snap spring

pliers.

3). Remove the countershaft rear bearing with a

special tool.

8. Remove the countershaft assembly.

1). Move the countershaft assembly backwards
and take its front end out of the housing.

2). Press the countershaft with the countershaft

5th gear as the supporting surface.
Note: The countershaft assembly shall be
disassembled with a puller or on the
press.

78 Repair of Countershaft and Reverse Idler Assembly

DC7J Transmission

3). Take down the countershaft front bearing

cone.

4). Take down the countershaft front retainer ring.

5). Take down the countershaft constant mesh

gear.

6). Taking down the spacer sleeve and the 7th

gear of the countershaft.

Repair of Countershaft and Reverse Idler Assembly 79

 DC7J Transmission

7). Then, press out the 5th and 3rd gears of the
countershaft and take down the three keys.

Installation
9. Install the countershaft assembly.
1). Install the keys and press in the countershaft
3rd gear.

2). Install the spacer sleeve and keys; press in

the 5th and 7th gears of the countershaft.

3). Install the spacer sleeve and keys; press in

the countershaft constant mesh gear.

80 Repair of Countershaft and Reverse Idler Assembly

DC7J Transmission

4). Install the countershaft front retainer ring.

5). Press in the countershaft front bearing cone.

6). Install the countershaft assembly.

10. Install the countershaft rear bearing.

1). Knock uniformly the countershaft rear bearing
cup with a copper rod and install the
countershaft rear bearing.
Note: Do not install the countershaft rear
bearing in place, so as to assemble the
stop ring.

Repair of Countershaft and Reverse Idler Assembly 81

 DC7J Transmission

2). Install the stop ring with a snap spring pliers.

3). Knock uniformly the rear bearing cup of the

countershaft with a copper rod and install the
rear bearing in place.

4). Install the bearing stop ring and the shaft

elastic retainer ring of the countershaft.
Note: The countershaft bearing stop ring to
be installed which varies in size shall
be determined as per the actual
requirements

11. Install the output shaft assembly.

Refer to Repair of Output Shaft Assembly
12. Install the input shaft assembly
Refer to Repair of Input Shaft Assembly

13. Install the clutch housing assembly

Refer to Replacement of Clutch Housing
14. Install the transmission assembly
Refer to Replacement of Transmission Assembly
On-board inspection
Check whether each gear can be engaged orderly and the transmission can work normally when each
gear is engaged in sequence in a road test.

82 Repair of Countershaft and Reverse Idler Assembly

DC7J Transmission

X. Replacement of Transmission Housing

Transmission accessories and structure diagram

1. Input shaft bearing cap 10. Output shaft rear bearing seat 19. Reverse gear power take-off hole
cap
2. Input shaft bearing cap paper 11. Sealing gasket
gasket 20. Sealing gasket
12. A odometer driven gear
3. Input shaft oil seal ring 21. ScrewpPlug assembly – drain
13. Odometer cable connector
hole
4. Sealing washer
14. Output shaft oil seal assembly
22. 6th gear power take-off hole cap
5. Screw plug
15. Stud liner
6. Housing
16. Countershaft rear bearing cap 23. 6th gear power take-off hole cap
7. Oil collector plate assembly
17. Reverse gear shaft lock plate 24. Radial oil seal
8. Odometer driving gear thrust ring
18. Power take-off hole cap liner 25. Output shaft rear bearing seat
9. Odometer driving gear paper gasket

Replacement of Transmission Housing 83

 DC7J Transmission

(I) Recommended tools and auxiliary materials

Tools and Auxiliary
Name and Type
Materials
Common tools copper rod, slotted screwdriver, hammer
Special tools External snap spring pliers, Bearing puller
Inspection tools Torque wrench (0~400N·m)
Auxiliary materials hair brush, Lubricating grease

(II) Operation steps

Removal
1. Drain out the transmission gear oil
2. Remove the transmission assembly
Refer to Replacement of Transmission Assembly
3. Remove the upper cover assembly
Refer to Repair of Upper Cover Assembly
4. Remove the clutch housing
Refer to Repair of Clutch Housing
5. Remove the input shaft assembly
Refer to Repair of Input Shaft Assembly
6. Remove the output shaft assembly
Refer to Repair of Output Shaft Assembly
7. Remove the countershaft and the reverse
idler
Refer to Repair of Countershaft and Reverse Idler
8. Remove the reverse gear power take-off
hole cap

1). Remove the tightening bolt for the reverse

gear power take-off hole cap.

84 Replacement of Transmission Housing

DC7J Transmission

2). Take down the reverse gear power take-off

hole cap.

9. Remove the 6th gear power take-off hole

cap
1). Remove the tightening bolts of the 6th gear
power take-off hole cap.

2). Slightly knock the 6th gear power take-off hole

cap with a copper rod to take it down.

10. Remove the oil collector plate assembly.

1). Remove the tightening bolts of the oil collector
plate.

Replacement of Transmission Housing 85

 DC7J Transmission

2). Remove the oil collector plate assembly.

11. Remove the countershaft front bearing

assembly.
1). Remove the countershaft front bearing cap.

2). Knock the countershaft front bearing cup

uniformly with a copper rod to take the front
bearing assembly out.

12. Remove the oil filling and draining plug.

Installation
1. Clean the housing.
2. Install the oil filling and draining plug.
Tightening torque 120~140N·m

86 Replacement of Transmission Housing

DC7J Transmission

3. Install the countershaft front bearing

assembly.

1). Knock the countershaft front bearing cup

uniformly with a copper rod to install the front
bearing assembly.

4. Install the oil collector plate assembly.

1). Install the oil collector plate assembly.

2). Install and screw down the tightening bolt of

the oil collector plate assembly.
Tightening torque 19~25N·m

Replacement of Transmission Housing 87

 DC7J Transmission

5. Install the reverse gear power take-off hole

cap.

1). Apply the sealant evenly to the inside surface

of the reverse gear power take-off hole cap;
install the reverse power take-off hole cap and
the paper gasket and screw down the
tightening bolts.
Tightening torque 19~25N·m

6. Install the 6th gear power take-off hole cap.

1). Apply the sealant evenly to the inside surface
of the 6th gear power take-off hole cap; install
the 6th gear power take-off hole cap and the
paper gasket and screw down the tightening
bolts.
Tightening torque 57~75N·m

7. Install the countershaft and the reverse

idler
Refer to Repair of Countershaft and Reverse Idler
Assembly
8. Install the output shaft assembly.
Refer to Repair of Output Shaft Assembly

9. Install the input shaft assembly.

Refer to Repair of Input Shaft Assembly
10. Install the clutch housing Assembly
Refer to Replacement of Clutch Housing
11. Install the upper cover assembly
Refer to Repair of Upper Cover Assembly
12. Install the transmission assembly
Refer to Replacement of Transmission Assembly
On-board inspection
Check whether each gear can be engaged orderly and the transmission can work normally when each
gear is engaged in sequence in a road test.

88 Replacement of Transmission Housing