Í EN&CNí+3 ChassisÁÎ+ ÀÍ ß-LE410

WORKSHOP MANUAL
维修手册
HFC1071LK-LE410
Chassis
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底盘分册
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Version No 版本号：JAC-2014110301N3301
江淮汽车部门：客户服务部
Chassis 底盘分册
FORWARD 前言 CONTENT 目录
This Manual is helpful for technical maintenance
staff for JAC and provides effective and correct
Overview & maintenance
概述与保养分册
maintenance and service for JAC vehicle. To ensure
the customer satisfaction of the JAC products, it is
extremely essential that the professional maintenance Engine
technicians for JAC have the friendly service and the 发动机分册
capability of proper operation; therefore, the
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maintenance technicians must fully understand the
Body structure& electrical
contents in this Manual. This Manual shall be
车身结构与电器分册
accessible for reference at any time.
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本手册用于帮助 JAC 授权的专业维修技术人员， Chassis
对江淮汽车提供有效正确的保养及维修。为确保江淮底盘分册
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汽车产品的用户满意，江淮汽车专业维修技术人员的
热情服务和正确操作是十分必要的，因此，维修技术 Circuit
人员必须充分理解本手册内容。本手册应放在便于使电路分册
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用的地方，以便随时用来参考。
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All contents in this Manual, including pictures, technical parameters are the latest. But if product
modification affects maintenance, JAC will provide technical bulletin or supplementary volume.
Therefore, please obtain the latest information about this Manual. JAC reserves the right to make change
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in design, addition or improvement for the product.
本手册的所有内容包括图片、技术参数都是最新的，但是由于产品改进而影响维修时，江淮
汽车将提供技术通报或补充卷。因此，使用本手册应密切注意获取相关信息的最新动态。江淮汽
车保留产品在设计变化、增添或改进方面的权力。
During the process of maintaining JAC vehicle, if genuine parts that are not from JAC or
disqualified oil, the vehicle may be damaged.
在对江淮汽车产品保养及维修过程中，若使用非江淮汽车的纯正配件或不合格油料，有可能
会造成车辆的损坏。
All rights reserved, without the written consent of JAC, it may not be translated all or a part
of this manual.
版权所有，未经江淮汽车公司的同意，不得翻印本手册之全部或一部分。
Tel：0086-551-62296644
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Fax：0086-551-62296633
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ChapterⅠClutch
第一章离合
I Overview 概述
Clutch is located in the flywheel housing between engine and transmission, Fixing clutch assembly
on the surface of fly wheel with screw and the clutch output shaft is the transmission input shaft. In the
process of driving, the operator can press or release the clutch pedal, to let the engine and transmission
temporarily detached and gradually engaged, so as to cut or pass the input power through engine to
transmission.
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离合器位于发动机和变速箱之间的飞轮壳内，用螺钉将离合器总成固定在飞轮的后平面上，离
合器的输出轴就是变速箱的输入轴。在汽车行驶过程中，驾驶员可根据需要踩下或松开离合器踏板，
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使发动机与变速箱暂时分离和逐渐接合，以切断或传递发动机向变速器输入的动力。
Clutch is the common parts in the mechanical transmission, which could make the drive system be
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detached or engaged. The basic requirements are: engage smoothly, disengage quickly and thoroughly;
adjust and repair conveniently; small dimensions; light weight; good ability in wearing and sufficient
cooling capacity; easy and convenient to operate.
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离合器是机械传动中的常用部件，可将传动系统随时分离或接合。对其基本要求有：接合平稳，
分离迅速而彻底；调节和修理方便；外廓尺寸小；质量小；耐磨性好和有足够的散热能力；操作方
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便省力。
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The clutch important parameters
离合系统重要参数
Project 项目 Date 参数
Pressure plate static torque

465.3N
压盘静传递扭矩
Moment of inertia of the clutch assembly

0.137kg.mm
离合器总成转动惯量
Maximum separation form
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11mm
最大分离形成
The clutch pedal free stroke

10-15mm
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离合器踏板自由行程
The clutch pedal work Angle

33°
离合器踏板工作角度 12
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II Location map and exploded 位置图及爆炸图
1、 Location map 位置图
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2、 Exploded figures 爆炸图
□ Clutch assembly 离合器总成
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S/N 序号 Spare parts name description 备件名称
01 brake oil pipe perforation bolt 变速器总成
02 braking oil pipe joint washer 离合器从动盘
03 hexagon flange bolts 分离套筒
04 oil storage boat 分离拨叉
05 hexagon nuts with flange 导向轴承
□ The clutch circuit 离合管路
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01 brake oil pipe perforation bolt 制动油管穿孔螺栓

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02 braking oil pipe joint washer 制动油管接头垫圈
03 hexagon flange bolts 六角法兰面螺栓

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04 oil storage boat 储油壶总成
05 hexagon nuts with flange 六角法兰面螺母
07 clutch master cylinder inlet pipe assembly 离合器总泵进油管总成
08 double steel wire ring hoop 双钢丝环箍
09 clip 管夹
10 clutch master cylinder tubing assembly 离合器总泵出油管总成
11 clutch hose assembly 离合软管总成
13 clutch tube bracket 离合器管固定支架
15 clip 管夹（φ6）
16 hexagon flange nuts 六角法兰面螺母
17 clutch tube assembly 离合器管总成
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18 clutch tube bracket 离合器管支架
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clutch hose assembly 离合器软管总成
22 clutch tube bracket 离合器管支架

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23 clutch tube bracket (I) 离合器管支架(I)
24 clutch booster oil inlet pipe assembly 离合助力器进油管总成

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25 brake oil pipe perforation joint 制动油管穿孔接头
26 cylinder booster assembly 离合助力器总成

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27 cylinder booster bracket assembly 离合助力器支架总成
28 clutch pedal and bracket assembly 离合踏板支架总成
29 clutch master cylinder 离合器总泵总成
30 pipe clip I 管夹 I
□ Clutch pedal 离合器踏板
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01 connecting bracket 连接支架

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02 bolt 六角螺栓
03 nut 六角螺母
04 flat washer 平垫圈
05 spring washer 弹簧垫圈
□ Driven plate of clutch pressure plate 离合器压盘从动盘
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01 Clutch pressure plate assembly 离合器压盘总成

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02 Clutch 离合器从动盘总成
03 Hexagonal bolt and spring washer Combination 六角螺栓和弹簧垫圈组合件

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Note: The above picture is the typical part pictures, there is a slight difference in some type vehicles, here is no
longer remark.
备注：上述图片为典型部件图片，部分车型存在细微区别，此处不再标识
III Remove, install and adjust 拆装与调整
1、 Precautions 注意事项
□ When disassemble transmission assembly, please use a hoist to prevent the damage to the parts and
people
拆解变速箱总成时需用吊具，防止造成人员与零部件的损伤
□ Pay attention to collect abandoned clutch hydraulic oil, prevent environmental pollution
注意收集废弃离合器液压油，防止污染环境
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□ Clean the clutch friction plate please use the vacuum cleaner, do not use compressed air to clean
up
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清洁离合器摩擦片请使用吸尘器，切勿使用压缩空气清理
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2、 Disassembly of clutch control assembly 离合器控制总成拆解
□ Before disassembling, vehicle front and rear wheels need

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mask wood will cover, to prevent the slide
拆装前，需用掩木将车辆前后轮掩实，防止溜车
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□ Before disassembling, vehicle front and rear wheels need

mask wood will cover, to prevent the slide
拆装前，拧开离合器放油螺塞，将离合器液放尽
□ Disassemble clutch control assembly and disassembly

sequence: Clutch Oil jug, clutch lines, clutch master
cylinder, clutch pedal.
拆解离合器控制总成，拆解顺序为：离合器储油壶、
离合器链接管路、离合总泵、离合踏板
□ The disassemble oil spout mounting bolts and Lines Link

nuts and remove oil jug
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拆解储油壶固定螺栓及管路链接螺母，取下储油壶
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□ Disassemble clutch master cylinder mounting bolts and
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the clutch lines link nuts and remove the clutch master
cylinder
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拆解离合总泵固定螺栓以及离合管路链接螺母，取下
离合总泵
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□ Disassemble the clutch pedal and bracket nuts, remove

the clutch pedal
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拆解离合踏板与支架固定螺母，取下离合踏板
Assembly: operate in accordance with the removal procedure in reverse order, and note the
following matters
装配：按照拆解相反步骤开展，并注意以下事项
□ Assembling the clutch pedal attaching bolts is critical

operations, and specific torque please see the overview
and maintenance sub-register
装配离合器踏板连接螺栓为关键工序，具体拧紧力矩
请参见《概述与保养分册》
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□ When assembling the clutch pipe mounting bolts, please
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put leak-proof plastic,and refers to the overview and
maintenance sub-register about the specific model
number
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装配离合器管路固定螺栓时需涂防漏胶，具体型号请
参见《概述与保养分册》
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3、 The removal and installation of clutch circuit 离合管路拆装
□ Disassemble clutch circuit, disassemble order: clutch

tubes and hoses, clutch pedal, clutch pedal and bracket
assembly, clutch switch or stop bolt, spring, and
clutch-pump, along the clutch line toward a case-by-case
basis disassemble the parts
拆解离合管路，拆解顺序为：离合器管和软管、离合
器踏板、离合器踏板和支架总成、离合器开关或限位
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螺栓、弹簧、离合器分泵，沿着离合管路走向逐次拆
解各部件
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Assembly: operate in accordance with the removal procedure in reverse order.
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装配：按照拆解相反步骤开展。
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4、Clutch removal 离合器拆装
□ Disassemble the clutch and remove order:

transmission, clutch pressure plate, clutch driven disc,
split sleeve, split fork, pilot bearing
拆解离合器，拆解顺序为：变速箱、离合器压盘、
离合器从动盘、分离套筒、分离拨叉、导向轴承
□ Disassemble transmission and engine, frame, the
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driving shaft link bolts and remove transmission
assembly
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拆解变速箱与发动机、车价、传动轴链接螺栓，取
下变速箱总成
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□ Disassemble clutch pressure plate retaining bolts and
remove clutch pressure plate.
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拆解离合器压盘固定螺栓，取下离合器压盘
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□ Disassemble clutch driven plate retaining bolts and

remove clutch pressure plate. Prevent driven disc
assembly free fall with a guide shaft. Mark on the
flywheel and pressure plate block, and when re-install,
make sure that the marks are aligned.
拆解离合器从动盘固定螺栓，取下离合器从动盘用
一个导向轴来阻止从动盘总成自由滑落。在飞轮和
压盘块上做标记，在复装时，用标记对齐。
□ Disassemble the socket assembly together with the

split sleeve and return spring.
拆解离合器分离套筒总成，把分离套筒和回位弹簧
一起拆下
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Assembly: operate in accordance with the removal procedure in reverse order, and note the
following matters:
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□ Visually check the clutch cover for wear, cracks and

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damage. Clutch cover with excessive wear, cracks and
other damage must be replaced.
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目视检查整个离合器盖的磨损、裂纹和其他损坏。有
过度磨损、裂纹和其他损坏的离合器盖必须更换。
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□ Pilot shaft goes through splined hub. Pilot shaft must be

kept in a straight.Depth measurement platen rivet.If the
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measured value exceeds limits, should be replaced

driven disc assembly
在花键毂内插入导向轴。导向轴必须保持很平直，测
量从动盘铆钉深度，如果测量值超出极限值，应更换
从动盘总成
IV Fault diagnosis and solutions 故障诊断与处理
1、 Clutch drag (gear with gear grinding teeth) 离合器拖滞（换挡时伴随齿轮磨齿声）
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2、 Clutch slip 离合器打滑
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3、 Clutch vibration (partial clutch engaged make the body vibrations)
离合器振动（离合器部分啮合起动时，使本体发生振动）
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4、 Clutch noise (engage and disengage the clutch to check if clutch has noise, and thus determine what
caused the noise)
离合器噪音（啮合和脱开离合器时检查是否离合器发出的噪音，从而确定引起噪音的原因
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ChapterⅡ Front axle
第二章前桥
I Overview 概述
Front axle is usually located in the front of the car, which is an important assembly part. Mainly
includes front axle, bend arm, direct arm, knuckle, kingpin and other parts. There are two main functions
for the front axle in the car, one is to withstand part of the payload of the vehicle, the other is for the
steering of the vehicle, therefore, also known as steering axle. Front axle connects with frame through
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suspension to withstand the vertical load between ground and frame, also bear braking force and lateral
force, as well as the forces that constitute the torque and to ensure that the rotating wheel move correctly.
During the use of vehicle, the forcing condition of steering axle is comparatively complex, and therefore
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should have sufficient strength. To ensure that steering wheel the correct positioning to manipulate light
and reduce tire wear, so steering axle is also expected to have sufficient rigidity. In addition, it should also
be possible to minimize steering axle weight. In sum, when driving, the front axle is under the poor
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working environment, with complex performance, the bearing load mostly is alternating load which make
the parts much more easier to be fatigue cracks and even broken. This requires that the structural design,
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there must be with sufficient strength, stiffness and fatigue resistance capacity to destroy.
前桥一般位于汽车的前部，是汽车上一个重要的总成件。主要包括前轴、弯臂、直臂、转向节、
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转向主销等零部件。前桥在整车上主要有两个功能，其一是承受整车的部分载荷，其二就是实现车
辆的转向，所以也称转向桥。前桥通过悬架与车架相连，用以承受地面与车架之间的垂直载荷外，
还承受制动力和侧向力以及这些力所构成的力矩，并保证转向轮作正确的运动。在汽车使用中，转
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向桥的受力状况比较复杂，因此应具有足够的强度。为保证转向车轮的正确定位角度，使操纵轻便
并减轻轮胎的磨耗，转向桥也应有足够的刚度。此外，还应尽量减轻转向桥的重量。总之，由于在
汽车的行驶过程中，前桥所处的工作环境恶劣，工况复杂，其承受的载荷也多为交变载荷，从而其
零部件易出现疲劳裂纹甚至断裂现象。这就要求其在结构设计上必须有足够的强度、刚度和抗疲劳
破坏的能力。
Front axle important parameters
前桥重要参数
The front wheel camber Angle

Empty 空载：1°30′ Full 满载：1°15′
前轮外倾角
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Kingpin caster Angle
Empty 空载：2° Full 满载：1°30′
主销后倾角
Kingpin inclination
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Empty 空载：7° Full 满载：7°15′
主销内倾角
Axial load
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轴向负荷
Steering knuckle and front axle surface gap

≤0.1mm
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转向节与前轴面间隙
前束
Oblique tire 斜交胎 3mm-6mm Meridian tire 子午线胎 1mm-3mm
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Front beam
车轮最大内转角
32°
Front wheel maximum amount of corner
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1、 Location Map 位置图
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2、 Exploded diagrams 爆炸图
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S/N 序号 Spare Parts Name 备件名称
00 front axle assembly 前轴总成

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01 wheel hub cover 轮毂罩
02 nut (L) 轮胎外螺母（左）

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03 left&front wheel huband brake drum assy 左轮毂带制动鼓总成
04 right&front wheel huband brake drum assy 右轮毂带制动鼓总成

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05 nut (R) 轮胎外螺母（右）
06 front axle 前轴
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07 nut 转向节螺母
08 lock plate 锁片
09 wheel hub-outer bearing 轴承
10 wheel hub-inner bearing 轴承
11 oil seal 油封
12 oil seal seat 油封座
13 oil retainer plate 挡油盘
14 right steering knuckle with jacket unit 右转向节带衬套总成
14 left steering knuckle with jacket unit 左转向节带衬套总成
15 keen pin dustproof cover 主销防尘罩
16 keen pin 主销
17 bolt 制动器底板螺栓
18 bolt 转向限位螺栓
19 plug
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螺塞
20 nut 螺母
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21 keen pin cover 主销盖
22 lock bolt,king pin 主销锁栓
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steering knuckle-crank arm 转向弯臂
24 tie rod assy 横拉杆总成

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25 Thrust bearings 止推轴承
26 steering straight arm 转向直臂

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27 hexagon bolt 六角头螺栓
28 flat washer 平垫圈

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30 hex nut 六角头螺母
31 hexagon nut 六角螺母
32 spring washer 弹性垫圈
33 cotter pin 开口销
longer remark.
1、 Remove front axle assembly 前桥总成拆卸
□ Before Remove and Install, make sure front and rear

wheels with a mask to prevent it from rolling
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□ Lift the vehicle to safety height with jack
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用千斤顶将车辆举升至安全高度
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□ Remove the tyre retaining bolt and remove the front

wheel vehicles
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拆卸轮胎固定螺栓，拆下车辆前轮
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□ Remove joint nut of steering lever(and power steering

machine
拆卸转向直拉杆与动力转向器连接螺母
□ Remove the front saddle bolts. Remove the front
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bumper blocks
拆卸前骑马螺栓，拆下前缓冲块
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□ Remove the front brake and vehicle connect pneumatic
tubing and remove the front axle assembly
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拆卸前制动器与车辆连接气动管路并取下前桥总成
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2、 Decomposition front axle assembly 前桥总成分解
□ □ Remove the hub caps and remove the front wheel
拆下轮毂罩，拆卸前轮外螺母外螺母
□ Remove the front wheel hub with brake drum assembly
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卸下前轮毂带制动鼓总成
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□ Remove the sleeve and front brake mounting nut and
remove the front brake assembly
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卸下衬套与前制动器固定螺母，取下前制动器总成
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□ Remove the main pin cover

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拆下主销盖
□ Remove the cotter pin and remove steering lever and

bend arm retaining nut and remove steering lever
取下开口销，卸下转向直拉杆与转向弯臂固定螺母，
取下转向直拉杆
□ Remove the cotter pin and remove joint nut of steering

lever and steering arm
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拆下开口销，拆卸转向横拉杆与转向直臂连接螺母
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□ Remove the joint nut of steering lever and steering arm,
and remove steering lever
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拆卸转向横拉杆与转向弯臂连接螺母，取下转向直拉
杆
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□ Remove fixing nut of steering arm and bushing , steering

bend arm and bushing mounting nuts and remove
steering straight arm and steering bend arm
分别拆卸转向直臂与衬套固定螺母、转向弯臂与衬套
固定螺母，拆下转向直臂与转向弯臂
□ Remove the main pin retaining nuts and remove thrust

bearing
拆卸主销固定螺母、取下止推轴承
□ Remove the main pin and bushing
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拆下主销、衬套
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3、 Front axle assembly 前桥装配
□ Multiple steps in contrast to th 复装的步骤与拆解顺序相反
□ Assembly considerations 装配注意事项
 Before assembly parts outside surface should be clean, no rust, burrs, cracks and other defects;
装配前各零部件外表面应清洁，无锈蚀、毛刺、裂纹和其他缺陷；
 Before assembly, front axle and steering knuckle, steering arm straight forgings convex mesa is
convex, dept. of mark to use file file;
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装配前，前轴、转向节、转向直臂等锻件凸台面上有凸起、磕痕处要用锉刀锉平；
 Front axle assembly to make a comprehensive inspection, all nut must be tightened according to the
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specified torque value, the assembly lubrication mouth parts should be injection lubrication, until
from a crack in the parts of extrusion, front axle and steering knuckle end clearance and wheel hub
bearing looseness should carry on the sampling inspection;
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前轴总成要进行综合检查，所有螺母必须按规定扭矩值拧紧，各装配润滑嘴部位应注入润滑脂，
直至从零部件的缝隙中挤出为止，前轴与转向节端面间隙和轮毂轴承松紧度应进行抽样检查；
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 Left and right steering knuckle, thrust bearing, type O sealing ring and adjusting shim, guarantee the
steering knuckle and front axle end single side clearance is not greater than 0.1 mm; Unilateral
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adjusting shim not more than 2 slices.
装左、右转向节、止推轴承、O 型密封圈及调整垫片，保证转向节与前轴端面单侧间隙不大

于 0.1mm；要求单侧调整垫片不多于 2 片；
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 Section will turn to dust cover in the steering knuckle (lower) king pin hole hole steps, a flat surface
rung up tight, along the circumferential and rivet rivet at three.
将转向节防尘盖放入转向节（下端）主销孔台阶孔内，将曲面敲平涨紧后，沿周向冲铆三点
铆紧。
 Both inside and outside the front wheel hub bearing race between roller and thoroughly lithium base
grease, fitting within the hub, two bearing between the inner surface, end face and hub bearing block
filling 190 + 10 g lithium grease (unilateral), fill inside hubcap;
在前轮毂内外轴承座圈和滚柱之间充分涂抹锂基润滑脂，合件轮毂内、两轴承挡内表面、端
面及轮毂轴承挡之间填充 190±10g 锂基润滑脂（单侧），轮毂罩内填充；
 Front wheel hub oil seal, use special tools by the oil seal pressure into the front wheel hub oil seal
seat inside the hole, the pressure of the oil seal pressure into the 2.94 x 106 n/m2, oil seal face shall
not be higher than that of wheel hub face;
装前轮毂油封，用专用工具经油封压入前轮毂内油封座孔内，油封压入的压力为
2.94×106N/m2，油封端面不得高出轮毂端面；
 From the steering knuckle small end into the oil seal seat, the wheel hub and brake drum and woolly
steering knuckle petiole, in turn into the lock, nut, screw the nut, nut tightening torque: 147 ~ 176 N ·
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m, to turn 50 ° ~ 80 ° make nut notches on the recent split pin hole, again into the split pin;
从转向节小端套入油封座，将轮毂及制动鼓合件套转向节柄部，依次装入锁片、螺母、拧紧
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螺母，螺母拧紧力矩：147～176 N·m，再回转 50°～80°使螺母槽口对准最近的开口销孔，再
装入开口销
Requirements: brake drum can be moved freely, check its axial load is 10 ~ 25 n, but there is no
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obvious axial channeling and oscillating phenomenon; Inspection method: use a spring balance hook
outside the tire bolts of twisting the tangent direction of fine line, tension within the scope of the 10 ~ 25
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n, brake drum assembly can free uniform rotation is unqualified, less than 10 n rotation for loose, greater
than 25 n turns too tight. Turn the brake drum assembly 10 ~ 20 times before inspection, make the bearing
grease evenly distributed.；
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要求：制动鼓能够自由转动，检查其轴向负荷为 10～25N,但不允许有明显的轴向窜动和摆动

现象；检查方法：用弹簧秤钩挂在缠绕轮胎螺栓外圆切线方向的细线上，拉力在 10～25N 范围
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内，制动鼓总成能够自由匀速转动为合格，小于 10N 转动为过松，大于 25N 才转动为过紧。检

查前转动制动鼓总成 10～20 圈，使轴承润滑脂均匀分布。
4、 Front Axle Adjustment 前桥调整
 Front wheel toe-in measurement and adjustment 前轮前束测量和调整
□ Let front wheel on a flat position
将前轮置于平坦的位置
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□ Mark in the middle of tire and tread , and place the
equipment of toe-in measuring in the center of the wheel
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用笔在轮胎轮距中心部位做标记，放置测量前束装置
在车轮的中心位置
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□ In front of the vehicle measured center-to-center of tires

of the distance (A), push the vehicle to the rear or
Forward to let each wheel rotate 180 degrees, in
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accordance with the original mark measure the distance

between rear side tire center distance of front-wheel(B).
The toe-in is equal to the B subtract A
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在车辆前面测量轮胎中心线之间的距离(A)，把车辆
向后或向前推，将每个车轮转动 180°，按照原标记
测量前轮后侧的轮胎中心线之间的距离(B)。前束等于
B减A
□ If the toe-in does not match. Release clamp bolts of the

rod end. Use a wrench reverse link to adjust the front
harness
如果前束不符。松开连杆端头的夹紧螺栓。用扳手扭
转连杆以调整前束
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 Turn radius adjustment 转向半径调整
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□ Put the front wheels on a flat position and put wooden
block under the rear wheels,and its thickness and
measuring instruments thickness are the same. Put the
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front wheel on the instruments, and to ensure it is in the
center of instruments. Turn the front wheels in clockwise
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and counter-clockwise separately to the maximum

position.
将前轮置于平坦的位置在后轮下加木垫块，其厚度和
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测量仪器的厚度相同。把前轮放置在仪器上，并保证
置于仪器的中央。分别以顺时针和逆时针方向转动前
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轮到最大位置。
□ Note: when turn the front wheels, depress the brake

pedal
注意：在转动前轮时，要踩下制动踏板
 The inner and outer wheels angle adjustment 内轮和外轮转角调整
□ The put the front wheels on a flat position loosen the

adjusting screw lock nut of the steering section and
adjust the screws height, till steering angle meeting
requirement and tighten the lock nut
将前轮置于平坦的位置拧松转向节上的调整螺栓的
锁紧螺母，调整螺栓的高度，知道转向角达到要求，
拧紧锁紧螺母
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Front axle bearing anti-competitiveness in vertical direction surface from the ground, horizontal
direction braking force, inertial force, braking resistance and torque resulted from braking and so on. As
front axles long endure the serious impact load, following may occur:
前桥承受来自地面的垂直方向反力、水平方向制动力、惯性力、制动阻力和制动时引起的转矩
等。汽车前桥长期承受这些交变冲击载荷，可能发生以下故障：
1、 Front axle fatigue damage, cracks or broken fault
前桥疲劳损伤、裂纹或断裂故障
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 Fault symptom: Find front axle fatigue damage, cracks or broken fault
故障现象：发现前桥疲劳损伤、裂纹或断裂。
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 The failure repair: Parts should be replaced in a timely.
故障维修：应及时更换新件。
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2、 The front axle happens bent failure in the vertical direction
前桥在垂直方向产生弯曲变形故障
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 Fault symptom: Find front axle happens bent failure in the vertical direction
故障现象：发现前桥在垂直方向上弯曲变形。
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 Fault cause: As front axle bear large anti-competitiveness in the vertical direction from the ground
and it is easy to cause bent, will change the pin pitch, outside of the wheel angle, the diesel vehicle
steering heavy, wheel hub bearing load increases, and reduce its life.
故障原因：前桥在垂直方向上承受来自地面的反力很大，易产生弯曲变形，会改变主销内倾角、
车轮外倾角，会使柴油车转向沉重，轮毂轴承负荷增大、降低使用寿命。
 The failure repair. There should be timely correction beams.
故障维修：应及时校正横梁。
3、 The front axle happens bent failure in the horizontal direction
前桥在水平方向产生弯曲变形故障
 Fault Symptom: Find front axle horizontal bent.
故障现象。发现前桥水平方向弯曲变形。
 Fault cause: Front axle bear the braking force in the horizontal direction from under
ground ,which is easy to cause bent, will change Front Wheel toe-in and increase tire wear.
故障原因：前桥在水平方向承受来自地面的制动力易产生弯曲变形，会改变前轮前束，增大轮
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胎磨损。
 The failure repair: There should be timely correction front beams.
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故障维修：应及时校正前横梁。
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4、 The front axle has distorted fault
前桥产生扭曲变形故障
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 Fault symptom: Find front axle has a reverse deformation.
故障现象:发现前桥产生扭转变形。
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 Fault cause: Front axle with a reverse deformation will change the caster angle, and impact
front-wheel driving stability.
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故障原因:前桥产生扭转变形会改变主销后倾角，影响前轮行驶稳定性。
 The failure repair: Adapter, replace the front beam or to correct repair.
故障维修：适情更换前横梁或进行校正修理。
5、 The front axle shaft with Thermal fault
前桥轴头发热故障
 Fault symptom: The front axle shaft with Thermal fault when driving
故障现象:行驶中发现前桥轴头发热。
 Fault cause: Shaft hair hot typically occurs after maintenance, and often resulted from bearing
pre-pressure too tight to seat bearings with too tight when assembly wheel hub. Wheel hub bearing
damage or pitting will not only result in heat but also with some noise. Wheel hub bearing lacking oil
can also cause shaft thermal failure.
故障原因：轴头发热一般发生在修理保养之后，往往是在装配轮毂时，轴承预压过紧使轴承配
合过紧所致。轮毂轴承损坏或点蚀不仅会发热而且还会有噪声。轮毂轴承缺油也会造成轴头发
热的故障。
 The failure repair: Check the bearings for tightness and wheel hub bearings for the oil
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故障维修：检查轴承配合松紧和轮毂轴承是否缺油。
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6、 The front axle brake drums heat failure
前桥制动鼓发热故障
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 Fault symptom: The front axle shaft with Thermal fault when driving
故障现象:行驶中发现前桥制动鼓发热
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 Fault cause: the main reason of brake drum heat is air brake chamber diaphragm do not return to
the original place or return too slow; brake shoe return spring broken or weak will cause brake drum
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heat.
故障原因:制动鼓发热的主要原因是气制动室膜片不回位或回位太缓慢所致；制动蹄回位弹簧
断裂或弹力不足也会造成制动鼓发热。
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 The failure repair: There is no gap between brake shoes and brake drum, which will obviously cause
brake drum heat. At this time except check adjust clearance, should check the problem of air chamber
diaphragm without returning, and when the brake air chamber diaphragm does not return, the air
problem should check and check whether the brake camshaft stocked.
故障维修:制动蹄片与制动鼓没有间隙，显然也会造成制动鼓发热。此时除检查调整间隙外应
检查气室膜片不回位的问题，制动气室膜片不回位除检查气路故障外应检查制动凸轮轴是否
发卡。
7、 The master pin bushing, main pin, Thrust Bearing Wear-out failure
主销衬套、主销、止推轴承磨损故障
 Fault symptom: Heavy direction, manipulation is unstable.
故障现象:方向沉重，操纵不稳。
 Fault cause: The pin bushing, the main pin, thrust bearings are worn, the absenteeism, will affect the
wheel alignment, lower the lever stability.
故障原因:主销衬套、主销、止推轴承磨损、松旷，会影响前轮定位，降低操纵杆稳定性。
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 The failure repair: Replace worn parts and re-front wheel alignment.
故障维修:应更换磨损件并重新进行前轮定位。
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8、 Step brake lightly with the front wheels failure
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轻踩制动时前轮发摆故障
 Fault symptom: when the brakes are applied in full load, front axle work normally, often rock when
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brake step lightly.
故障现象:汽车在全负荷制动时，前桥工作正常，往往在轻踩制动时前轮发摆。
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 Fault cause: This is mainly caused by the drum round error value, while the two front wheels in
part-load when the brakes are applied, since the brake force is a little, the two front wheels have a
braking effect are not in sync, and some times in the left brake, and sometimes in right brake
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resulting front wheel wiggle.
故障原因:这主要是制动鼓圆度误差超值所致，当两前轮在部分负荷制动时，由于制动力小，
两前轮产生制动效果不同步，时而左刹、时而右刹从而造成前轮摆动。
 The failure repair: Removal brake drum checks and makes the cut. Tire rims deformed sometimes
will also cause this problem.
故障维修:此时应将制动鼓拆卸检查并进行光削修理。轮胎钢圈变形有时也会产生这种故障。
9、 The steering failure
转向沉重故障
 Fault cause: Front Axle Steering System mechanical failure; steering hydraulic power system failure.
故障原因:前桥转向系统机械部分故障；转向液压动力系统的故障。
 The failure repair: Steering heavily owing to the mechanical portion of the burden is mainly due to
the steering joint pin lacking of the oil. Long-term without maintenance, not apply grease to steering
joint pin, which cause the pin-to-Bushing dry friction, not only increase steering resistance heavily,
and can be as severe as the pin-to-Bushing sintered. Therefore, the service require apply grease to
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steering joint pin, generally first, lift up the I frame of front axle ,apply oil with a grease gun to oil
mouth which is installed on the camshaft holder until the beam with pin holes, the flat extruder oil.
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故障维修:由于机械部分造成的转向沉重主要原因是转向节主销缺油。长期不保养，不向转向
节主销内加注润滑脂，造成主销与衬套干燥摩擦，不仅增加转向阻力，使转向沉重，而且严重
时会造成主销与衬套烧结。因此，要求在保养中应向转向节主销中加润滑脂，一般先讲前桥工
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字辆顶起，用黄油枪向安装在凸轮轴座上的黄油嘴注油，直到工字梁与销孔上、下平面挤出油
为止。
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10、 The front brake drum rotor oil

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前制动鼓甩油故障
 Fault symptom: The front brake drum rotor oil when driving
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故障现象:行驶中发现前制动鼓甩油。
 Fault cause: Front brake drum swings oil, which is clearly because of hub oil seal damage. Wheel
Hub Oil Seal Leak not only caused shaking oil, but will also enable brake failure.
故障原因:前制动鼓向外甩油显然是轮毂油封损坏所致。轮毂油封漏油不仅造成甩油，而且会
使刹车失灵。
 The failure repair: Replace it with a new oil seal to troubleshooting.
故障维修:更换新油封才能将故障排除。
11、 The front tire wear and tear are not normal fault
前轮胎磨损不正常故障
 Fault symptom: Driving found that front-wheel wear is not functioning properly.
故障现象:行驶中发现前轮磨损不正常。
 Fault cause: The reason of that front tire wear and tear are not are much complex, and toe-in value is
not right clearly will worn front tire, Steel ring deformation, shaft and the absenteeism, the beam is
deformed, the main pin clearance, and so on, all of which can cause wear front tire failure
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故障原因:前轮磨损不正常的因素较为复杂，前束值不对显然会磨损前轮胎，钢圈变形、轴头
松旷、工字梁变形、主销间隙过大等都会造成磨损前轮胎的故障。
 The failure repair: Troubleshooting the issue is a complex work, it is necessary to take into account
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the front wheel alignment of the parameters of the change, but also to take into account other factors.
故障维修:排除此故障是一项复杂的工作，既要考虑到前轮定位各项参数的变化，又要考虑其
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他方面因素的影响。
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12、 The front-wheel brake drift .
前轮制动跑偏故障
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 Fault symptom: Find front-wheel brake drift when driving.
故障现象:行驶中发现前轮制动跑偏。
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 Fault cause there are two reasons for front wheel brake deviation. The clearance difference between
left and right brake make the braking starting time is not synchronized; left and right brake shoes and
brake drum to contact different size or the oil causing contact friction torque of the differences, which
results in different brake torque to the brake run in deviation.
故障原因:前轮制动跑偏有两个方面的原因。左、右制动蹄片间隙不同，使开始投入的制动时
间不同步而造成的；左右制动蹄片与制动鼓接触面积不同或由于油污造成接触摩擦力矩的差
异，从而产生不同的制动力矩导致制动跑偏。
 The failure repair: When the vehicle's braking drift, by adjusting brake shoes clearance cannot be
excluded when it is, and should be remove brake drum inspection and the mill.
故障维修:当汽车制动跑偏、通过调整制动蹄片间隙不能排除故时，应拆卸制动鼓进行检查和
光磨。
13、 The brake failure doesn't work .
制动不灵故障
 Fault symptom: Driving found that brake does not work.
故障现象:行驶中发现制动不灵。
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 Fault cause: Brake inefficiency is the problem of braking drum and braking shoe except the reason of
braking control system. In the actual repair, Check brake effection often using the brake drum and
brake shoes contact area, and the general requirements for brake shoes and brake drum contact area
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should be more than 70 per cent. From the practical experience, two end-engaged of the brake shoes
are much more productive than the median engage.
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故障原因:制动不灵除制动控制系统原因外，就是制动鼓与制动蹄片的问题。在实际维修中，
往往用制动鼓与制动蹄片接触面积来检查制动效果，一般要求制动蹄片与制动鼓接触面积应在
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70%以上。从实践经验看来，制动蹄片两端啮合要比中间啮合效果好的多。
 The failure repair: In the mill foot-and-mouth, its diameter should be slightly larger than the diameter,
in order to ensure that shoes engage both ends, in order to get the most recent braking effectiveness.
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故障维修:在光磨蹄片时，其直径应略大于鼓的直径，以保证制动蹄片啮合两端，以便获得最
近制动效果。
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Chapter Ⅲ Transmission
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Chapter 1 Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3
Chapter 2 Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Chapter 3 Instructions for Use - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - 6
Chapter 4 Diagnostic Table for Common Faults- - - - -- - - - - - - - - - - - - - 6
Chapter 5 Transmission structure - - - - - - - - -- - - - - - - - - - - - - - - - - - - 7
Chapter 6 Disassembly and assembly of transmission - - - - - - - - - - - - - 15
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Chapter 7 Transmission maintenance - - - - - - - -- - - - - - - - - - - - - - - - - 36
Chapter 8 Easy-to-wear Directory - - - - - - - -- - - - - - - - - - - - - - - - - - - - 37
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Chapter 9 Special Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - 37
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Chapter 1 General precautions:

1. Do not reuse the drained transmission gear oil.
2. When check or replace the transmission gear oil, you should keep your
vehicle at level.
3. Maintain the internal clean when removing and installing Transmission.
4. Please check to determine the correct location for the installation before
removing or disassembling. If you need to make the installation mark, make
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sure that there is no affection on the function of marked part.
5. In accordance with the regulations, first tighten the center, and then
tighten outside the bolts and nuts in accordance with the diagonal order in
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multi-step. If the tightening sequence is required, then do in accordance
with requirements.
6. Be careful not to damage the slide surface with the fitting surface.
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7. Apply the lubricant in the circular surface before needle bearing
assembly.
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8. Apply grease in the lip area before assemble oil seal.

9. When press the synchronize server components, you should synchronize the
slider toward the slider bin on synchronizer gear ring before the Assembly.
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Chapter 2 Overview
●Transmission products LC6T55 is a high-end and self-development
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transmission for light commercial vehicle, which absorbs the technology of

transmission MSH61A from Japan Nissan Company. Automotive transmission
LC6T55 with 6 forward gears and one reverse gear is in a compact structure
it is easy to be operated.
●Meaning of transmission Name:
LC 6 T 55
The maximum input torque

With synchronization.
6 forward shift
Registered
Trademarks: Liuchi
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●Technical parameters
Form 6 gear speeding type
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operating pattern Long-distance control
The maximum input torque 539N·m
Center distance 115mm
Assembly quality 130Kg
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shift 1(1st) 6.482
shift 2 (2nd) 3.654
shift 3 (3rd) 2.263
Speed ratio shift 4 (4th) 1.477
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shift 5 (5th) 1.000

shift 6 (6th) 0.77
Reverse (Rev) 5.996
Lubricating oil type
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75W/90GL-4
Oil level 5.2L
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●The transmission profiles:
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● Manipulation:
Ultimately operate the choosing shift lever and shift changing lever to
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shift through controlling the in-cab control lever. The different directions
of control lever ball shows the corresponding display different options and
shift position. The controlling lever will automatically return to neutral
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position after shift; it could select the shift only when returning to the
neutral position.
1. When shifting, please press the pedal fully down to make the transmission
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out of engine torque to operate the control lever quickly. When you start,
please use shift 1.
2. When going up, down hills and turning, please use the slow speed, and do
not allow disengage clutch coasting.
3. When operating the transmission lever is in difficulty, please stop and
check reasons, shall not be subjected to excessive force.
Shift principle:
In the forward mode, the transmission shift principle requires the

following: increased speed shift should be from 1 to 6 at each level shift
and reducing the speed shift should be 6 to 1 at each level down; when in
forward, forbidden shift to the reverse gear. Reverse gear in principle
requires the whole car still depressing the clutch for 3 seconds; it should
not be moving forward in the reverse gear; at the same time, do not shift
in the forward gear when in the reverse state .
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Note: when the car is running, in the case of an emergency, you cannot comply
with the transmission shift principle.
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●tightening torque:
Technical Requirements (N * (torque wrench) examinin
Site
12 m) specifications g State
Clutch joint with housing 68.6～93.2 20～200 N·m Process
reversing light switch 29.4～39.2 5～50 N·m Process
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The back cover, cap

screws of the 19.6～29.4 5～50 N·m Process
transmission cover
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The cover cap screws 14～24.5 5～50 N·m Process

Vent plug 10.8～18.6 5～50 N·m Process
Plus, oil drain plug 39.2～58.8 20～200 N·m Process
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2 shaft nut 156.8～205.8 30～280 N·m Process

bolt of Shift shaft dowel
9.8～14.7 5～50 N·m Process
pin holes
Odometer shaft sleeve 9.8～14.7 5～50 N·m Process
Chapter 3, Instructions for Use

1. There are synchronizations for every shift of transmission LC6T55. In order to reduce
gear wearing and tearing, prevent broken gears, shifting action shall be mild, which make
the sync server and gear successfully engaged and disengaged. it could shift from forward
gear to reverse gear or from reverse gear to forward gear only after the car stops steadily.
2. Particular attention should be given to: The transmission of shift 5 is the shift of
overdrive. To avoid excessive speed gear is damaged, you could use shift 5 under the
condition that the entire vehicle is not overloaded, road condition is good, and speed of the
vehicle reaches 40 km/h or more. When in shift 5, in a case of the vehicle speed drops
below 40 km/h, you should shift to a lower gear.
3. when the car on the downhill coasting, it is not allowed to shut off the engine, and will
28
not allow to start the engine taking use of the downhill slide of the inertia in the state of
shut-off to avoid damage the gear.
27
Chapter 4 Common Failure Diagnosis
(When there is abnormality of the transmission, please contact with authorized service
station or the professional, please see Service Manual for detailed disassembly of legend
12
and part number)
Failure condition: reason analysis Measures Remark

The gap of multi-phase Replace
20
This issue is mainly

transmission assembled in early synchronizer
happens in shift 3,
period, has not adjusted well assembly,
shift with noise clearance between sync
which make the synchronization dual-cone
ring and pinion is too
wear and without affection as synchronization
small
lack of experience. rings
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Responsibility in the
report is JAC, note the
JAC Exhaust Bracket is
leakage here is resulted
The contacting equipped on the cover; heavily JAC has changed
from the bracket
surface of up vibrating causes the oil spill in this bracket
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position in the upper

cover spill oil. the contacting surface of the assembly location
cover, which is no
upper cover.
relation with clutch
housing.
The gap of multi-phase Replace

transmission assembled in early synchronizer
period, has not adjusted well assembly, This issue is mainly
difficult to shift
which make the synchronization dual-cone happens in shift 3
wear and without effection as synchronization
lack of experience. rings
without Clutch Disengage the fork arm Re-stack solder Our company will
desoldering split rocker arm or strengthen the split fork
replace the arm welding

separator rocker
arm
thrust washers Chamfer of shift 5

Replace the axis 2,
is too large, causing shim going
shift 5 burned to the teeth 5 and This type of fault repair
into the high-speed gear bore so
death thrust washers of must change spacers.
that burned to death when shift 5
shift 5
gear tooth spin at high speed.
Chapter 5 Transmission structure

1、The shaft 1 and clutch group:
28
27
12
20
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Quanti
No. Code Name Remark
ty
1 M-1605126 hex nut 2
2 M-1605125 fixed screw 2
3 M-1605516 Spring 2
Separation shaft
4
B-1605120-00-00 assembly. 1
needle roller
5
M-1605622 bearings 2
6 Q700B01 Grease fitting 3
7 M-1605122 Disengage fork 1
8 M-1605150-03 tube assembly 1
9 M-1605623 Release bearing 1
Release bearing
10
M-1605124-A9-01 housing 1
inner hex cylinder
11
Q218B0612 head screws 6
28
front cover of shaft
12
M-1601310-A2 1 1
13 X-1601310-13-07 oil seal of shaft 1 1
M-1605115 screws 6
27
14 Q40112 Flat washer 6
Q40312 spring washer. 6
15 B-1605111-M1-01 Clutch Housing 1
Q150B0612 screw 2
16
12
Q40306 spring washer. 2
17 M-1605142 Top cover 1
18 M-1701301-01 ring 1
19 Q433100 Bearing snap ring 1
20
20 M-1701601 Roller Bearing 1

composition of shaft
21
B-1701110-00-04 1 1
synchronization
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22
B-1701112-00-10 rings of shift 5/6 1
2、total composition group of axis 2:

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28
27
12
20
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Quanti
ty
1 M-1701304 ring 1
synchronization
2 1
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M-1701141 gear kit of shift 5/6

synchronization
3 1
M-1701142 gear hub of shift 5/6
synchronization
4 2
M-1701511 ring of shift 5/6
5 M-1701143 Slider 3
6 M-1701305 ring 1
synchronization
7 1
M-1701112 rings of shift 5/6
8 B-1701260-10-00 main6 teeth 1
10
main 4 ring gear

9 1
M-1701146 thrust washer
10 M-1701306 ring 1
11 B-1701131-10-00 2nd axis 1
needle roller
12 bearings of main 1
M-1701605 four-teeth
The composition of
13 1
B-1701240-10-00 4-tooth.
synchronization
28
14 1
synchronization
15 1
M-1701151 gear hub of shift 3/4
synchronization
27
16 1
M-1701152 gear kit of shift 3/4
17 M-1701143 Slider 3
synchronization
18 2
M-1701512 ring of shift 3/4
12
synchronization
19 1
The composition of
20 1
B-1701230-10-00 main 3-tooth
20
needle roller
21 bearings of main 1
M-1701611 three-teeth
The composition of
22 1
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B-1701220-10-00 2-tooth
dual-cone ring
23 1
B-1708050-00-00 assembly
synchronization
24 B-1708012-00-00 1
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gear kit of shift 1/2

synchronization
25 B-1708011-00-00 1
gear hub of shift 1/2
synchronization
26 B-1708014-00-00 3
slider of shift 1/2
synchronization
27 B-1708017-00-00 slider rings of 1
shift 1/2
needle roller
28 M-1701611 1
bearings of main
11
one-teeth
29 B-1701210-10-00 main one-tooth 1
30 M-1701219 Reverse Gear Kit 1
31 M-1701218 Reverse Gear hub 1
needle roller
32 M-1701616 1
bearings of reverse
33 B-1701270-10-00 The barb 1
rear bearing of
34 M-1701601 1
shaft 2
35 M-1701222-A6 The primary teeth 1
28
36 M-1701229-00-00 Dust cover 1
37 M-1701224-A6 shaft 2 flange 1
38 M-1701228 nut of shaft 2 1
Mounting Flange
27
39 X-1701373-23N 4
screw
3, the intermediate shaft grouping:

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20
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No. Code Name Quantity Remark

Snap Ring
1 1
M-1701311 (intermediate
12
shaft)
cylindrical roller
2 1
NUP308E bearing
Counter shaft Drive
3 1
B-1701305-00-00 Gear
4 B-1701306-10-00 middle 6-teeth 1
5 B-1701304-10-00 middle 4-teeth 1
6 M-1701246 spacer of shaft 3/4 1
7 B-1701303-10-00 middle 3-teeth 1
8 M-1701247 Flat type (short) 1
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9 M-1701248 Flat type (long) 1
10 M-1701242 Woodruff key 1
11 B-1701301-10-01 intermediate shaft 1
12 M-1701619 Roller Bearing 1
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13 N-1701133-00 ring 2
4、Rear cover group: 12

20
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13
Quantit
y
hex bolts (rear
1 8
M-1703126 cover)
2 B-1703111-10-01 rear cover 1
3 M-1703116-A6 The teeth 1
4 M-1703114 guide bushings 1
5 M-1703406 Rear Oil Seal 1
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5、shell group:
27
12
20
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14
28
27
12
Quanti
20

ty
hex bolts (side
1
Q150B1018 cover) 6
The power vent door
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2
M-1701511-00-00 cover 1
3 M-1705103 The oil drain plug 1
4 B-1705101-10-01 Housing 1
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Reverse gear spacer

5
B-1701814-10-00 ring 1
needle roller
6 bearings (reverse
M-1701621 gear) 1
7 B-1701807-10-00 reverse gear hub 1
8 B-1701811-10-00 Reverse gear shaft 1
9 M-1701402 O-ring (reverse) 1
bolt(reverse gear
10
M-1701258 shaft) 1
11 M-1701257 Reverse gear shaft 1
15
lock
hex bolts (rear
12
M-1703126 cover) 8
13 M-1705104 Oil Fill Plug 1
6、total composition group of upper cover:
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27
12
20
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No. Code Name Quantity Remark

1 M-1702172 5/6gera shift 1
2 M-1702171 5/6shift yoke shaft 1
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3 M-1702174 shift fork fixed screw 7

4 M-1702173 5/6shift block 1
5 M-1702175 Line Lock 7
6 M-1702166 3/4shift yoke shaft 1
7 M-1702168 3/4gera shift 1
8 B-1702514-00-00 1/2shift yoke shaft 1
9 M-1702165 1/2shift block 1
10 B-1702515-00-00 1/2gear shift 1
11 M-1702165 reverse dial block 1
12 M-1702161 Reverse the fork axis 1
13 M-1702159 reverse fork 1
16
14 M-1702158 safety lever-2（right） 1

15 M-1702156 screw 4
16 M-1702179 Steel ball 10
Detent Ball Spring (yoke
17 M-1702524-01 4
shaft)
18 M-1702154 safety lever-1（left） 1
19 M-1702210 guide assembly 1
Detent Ball Spring
20 M-1702525-01 1
(right resistance pin)
Latch Spring (left
28
21 M-1702527-A5 1
resistance pin)
22 M-1702123 steel ball 3
resistance spring-1
23 M-1702521 1
（right）
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24 M-1702144 resistance pin 2
resistance spring-2
25 M-1702522-00-00 1
（left）
26 M-1702176 Supplies cover 1
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27 M-1702185 cover cap screws 9
28 M-1702186 hex bolts 1
29 N-1701011-20-01 plug 1
30 M-1702178 internet lock pin 2
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31 M-1702146 plug 2
32 M-1702124 Plug (top) 1
33 M-1702518-A5 Spring 1
34 M-1702123 steel ball 1
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35 M-1702411 Shift shaft oil seal 1

36 M-1702528-00-00 1/2resistance spring 1
37 M-1702188-A5 Flat washer 1
38 M-1702121 Shift. 1
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39 M-1702125 bowl-shaped filler 1

40 Q150B0850 Hexagon bolt 1
Selected shift rocker
41 1703010E30-08 1
arm assembly.
42 B-1702182-00-00 reversing light switch 1
43 J-1702188-00-00 small fixing bracket. 1
44 1019352 hook 1
45 Q43117 Shaft with circlips 1
46 M-1702129 flat pad 1
17
The optional arm

48 M-1702184-A5 1
assembly
49 1703012E306 connector pins 1
50 M-1702141 Balanced block 2
51 M-1703126 hex bolts 2
52 Q340B10 hex nut 3
54 Q40310 Spring washer. 3
55 B-1702131-00-00 Shift balance arm 1
56 B-1702120-10-02 Shift shaft assembly 1
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57 M-1702191-A4 dual-head cap screw 2
58 Q34008 Nuts 5
59 Q40308 Spring washer. 5
27
61 Q72120 patch 3
62 M-1702122 direct pin 1
63 M-1702181 air outlet valve 1
64 M-1702111-A5 upper cover 1
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65 B-1702187-00-01 reverse lamp retaining ring 1
Chapter 6 disassembly and assembly of transmission

Remove of transmission assembly
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1, drain the oil. oil drain

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Note: Using a wrench to remove the drain plug and drain oil through oil drain plug.
Do not allow drain oil through the other parts.
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Remove front cover of shaft 1
18
Remove clutch housing assembly
28
Note: clutch housing surface with glue, remove it using a brass rod percussion, but the force shall be
27
evenly to prevent damage clutch housing.
4, remove the top cover assembly.

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20
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5, remove shaft 2 nut and shaft 2 flange.

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19
6 remove odometer guide bushings and the teeth.
28
27
7 remove the back cover assembly.
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20
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8, take the odometer drive gear.

JA
20
9, Remove rear bearing retaining ring of shaft 2 and intermediate shaft.
28
27
10.Remove rear bearing of shaft 2
12
20
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11, Remove the bearing ring of shaft 1 and the retaining ring.
JA
21
12 Remove composition of shaft 1
28
27
13, Remove the roller bearing of shift 1 and sync tooth ring of shift 5.
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20
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14. Remove shaft 2 assembly

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22
15, shaft 2 assembly disassembly processes.

(1) Remove the reverse gear and needle roller bearings.
28
27
(2) Remove reverse gear teeth snap ring and reverse gear teeth candy set.
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20
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(3) Remove shift 1gear assembly of 2nd shaft and needle bearings.
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(4) Remove 1/2 sync ring and 1/2 synchronizer assembly.
23
28
(5) Remove dual-cone ring assembly
27
12
20
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(6) Remove shift 2 gear assemblies of 2nd shaft and needle bearings.
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(7) Remove 5/6 synchronizer assembly and snap ring.
24
28
(8) Remove synchronization gear hub of shift 6
27
12
20
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(9) Remove the 6 teeth assembly and needle roller bearings.

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(10) Remove the main 4-tooth ring, adjust shims and steel balls.
25
28
(11) Remove the 6 teeth assembly and needle roller bearings.
27
12
20
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(12) Remove 3/4 synchronizer assembly and snap ring of shift 4.

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26
(13) Remove 3/4 synchronizer assembly and snap ring of shift 3.
28
27
(14) Remove the main 3- teeth assembly and needle roller bearings.
12
20
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16 Remove the side cover of PTO.

JA
27
17 Remove reverse locking tabs and reverse gear shaft.
28
27
18, Remove intermediate shaft front and rear bearings.
12
20
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Note: Because the middle shaft assembly removal and installation needs pressure bed
with great pressure, therefore, the intermediate shaft assembly is no need to
disassembly.
19 remove reverse gear and reverse gear spacer ring.

JA
28
Completely remove the process

(2) Transmission assembly process
Precautions:
1, when assembled, must be careful to follow the correct assembly sequence. Assembly
site should be clean to prevent the mud or other debris entering into the box when
fitting.
2, pre-assembly, scrape mating surface of the sealant (Note that do not damage the
surface), with the appropriate cleaning solution
28
Clean the mating surface to remove oil to prevent oil leakage.
3, Return for Repair, it is required to ensure that all parts are clean, meets the
requirements (all the parts must be clean before assembly.The component does not exist
27
any oil, burrs, dings, etc.).
4, The bolt tightening torque must be in strict compliance with the Norms when
assembling.
12
5, all sync tooth ring and needle bearings should be greased with clean oil to lubricate.
6, The easy-broken parts should be replaced in the process of returning for repair and
disassembly, please refers to easy-broken list.
20
Assemble Step-by-step
1、 The main 3- teeth assembly and needle roller bearings.
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JA
Note: inner surface of needle bearing and taper shal apply rust preventive oil, note gear mounting
orientation, and whether rotating the gear is smooth.
2、Assemble sync ring of shift 3 and synchronizer assembly of shift 3/4.
29
Note: The synchronization loop shall assemble with greasing oil.

3、Assemble 3/4 synchronizer assembly snap ring and synchronizer ring of shift 4.
28
27
12
Note: Select the appropriate ring, guarantee axial clearance is less than 0.05 MM, sync ring assembly
required with the lubricant.
20
4、assemble needle roller bearings of main four-teeth and main four-teeth

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JA
Note: inner surface of needle bearing and taper shall apply rust preventive oil, note gear mounting
orientation, and whether rotating the gear is smooth.
5、Assembly steel ball.
30
6、Assemble the 4four-tooth adjustment shims and snap ring.
28
27
12
Note: Adjust the shim and let the side with the sump toward the main 4 -teeth, and select the appropriate
card ring to guarantee axial clearance at 0.15 - 0.39 mm.
7、assemble needle roller bearings of main six-teeth and main six-teeth

20
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JA
Note: needle bearing and taper shall apply lubricating oil, note gear mounting orientation, and whether
rotating the gear is smooth after assembled.
8、Assembly synchronization rings of 6 shifts.
31
Note: gear tapers and sync ring tapers are required with the lubricant.
9、Assemble synchronizer assembly of shift 5/6 and snap ring.
28
27
12
Note: Adjust the shim and let the side with the sump toward the main 6 -teeth, and select the appropriate
card ring to guarantee axial clearance not more than 0.15mm.
20
10、assemble needle roller bearings of main two-teeth and main two-teeth

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JA
Note: needle bearing and taper shall apply rust preventive oil, note gear mounting orientation, and
whether rotating the gear is smooth after assembled.
11、 Assembly synchronization rings of shift 2.
32
Note: every tapers of sync ring are required with the lubricant.
12、Assemble synchronizer assembly of shift 1/2 and snap ring.
28
27
12
Note: The synchronization without level side toward the main 2 -teeth.
13、needle roller bearings of main one-teeth and one gear

20
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JA
Note: needle bearing and taper shall apply rust preventive oil, gear side with oil toward
synchronization assembly ,and check whether rotating the gear is smooth after assembled.
14、Assembly reverse gear tooth candy, tooth set.
33
Note: candy teeth closer to the side toward the main one tooth, teeth set with a high-level toward reverse
gear.
15、Assembly reverse gear hub ring
28
27
12
Note: select the appropriate snap ring to guarantee axial clearance not more than 0.05mm.
20
16、Assembly reverse gear needle bearings and reverse gear.

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JA
Note: needle bearing and taper shall apply lubricating oil, and whether rotating the gear is smooth after
assembled.
17, Assembly reverse gear shaft, reverse ring gear spacer ring, reverse gear teeth and needle roller
bearings.
34
28
Note: needle bearing assembly required with the lubricant oil, reverse gear shaft with slot is facing up .
18, Assembly reverse locking tabs.
27
12
20
19, load the intermediate shaft assembly, and hit it into front and rear bearings of the intermediate shaft,
and equipped the snap ring.
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JA
20, load the assembly of 2nd shaft.
35
28
21、Equip rear bearing of the 2nd shaft and load the snap ring.
27
12
20
22, equip the 1st shaft composition, 2nd axis head of needle bearings, synchronization rings of shift 5
and the 1st shaft bearings, and equip the snap ring
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JA
Note: now put the 2-axis head needle bearing on the 2-axis head, with one hand inside the case to put
synchronization ring of shift 5 on the sync server, and then put the 1st shaft composition into it .
23, equip the odometer drive gear, noting non-threaded end toward the inside
36
24、Install the rear cover, and then tighten the bolt in order
28
Note: The back cover mounting surface with sealing, tdo not damage the oil seal lip when put the back
cover into it
25、equip the odometer shaft sleeve and a passive gear and install the lock screw
27
12
26、Install flange and lock 2nd shaft nut
20
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JA
Note: first load the O" seal, and install lock nut
27、equip the transmission side cover, and then install the retaining screw in order
37
Note: The side cover mounting surface shall be with sealing
28、Install the locating pin (2) and pad
28
29、equip the cover assembly, and then install the retaining screw in order
27
12
Note: To ensure that 2-axis synchronization teeth set is in the middle position, and align the fork to let
the cover assembly into it, and whether switch gear is normal after bolt locked.
20
30、equip the clutch housing assembly, and then install the retaining screw in order
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JA
Note: The equipped surface of clutch housing shall be with sealing, do not damage the oil seal lip when
put the clutch housing into it
31、 Install the shaft front cover and install the mounting bolts
38
32、Install the oil filler plug and drain plug
28
33、 complete transmission assembly process
27
12
20
(3), important parts check.

(1), check the 1st shaft assembly
1) Check whether the 1st shaft gear is with broken teeth, the pitting,
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tooth-wear and surface of the teeth is glued, and if

There are any of the above phenomenon, you must replace the shaft
2) Check the 1st shaft splines whether there is excessive wear and damage,
and if there is, you must replace the shaft.
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3) Use your hand to "feel" whether bearings are flexible; there is no

hysteresis, if bearings are not flexible or sticky now, you need to replace
bearings.
(2) check the 2nd shaft assembly: Check whether the gear rotates flexible
(the remaining steps as above.)
(3), check the intermediate shaft assembly (Check process is the same as 2nd
Shaft Assembly Check)
(4), check the synchronization loop
1) Check whether there is injury or damage in the synchronous ring teeth
surface.
2) Inspect whether there is damage or wear in tapers and damage pressure of
39
thread.
Note: The dedicated tool of our company is not available to supply

separately, only supply the combination:
Chapter 7 Transmission maintenance

1, Repair and Maintenance Considerations:
1.1, our products in addition to the full requirement for maintenance,
transmission assembly shall replace the gear oil every 6000 ~ 10,000 Km, the
28
gear oil filled by our company is 75W/90 GL-4 ; we recommend
to use GL - 4 gear oil. Do not replace the gear oil in time, or do not add
the real gear oil, that is, the oil with low quality, which makes that the
27
gear case rotation couldn't form the effective protective film, and
accelerate gear shaft and bearing wear.
12
1.2, overload: transmission load safety index is small, the overload ability
is poor, our company made some technical improvements and strengthened to
transmission key gear, and we hope that our users do not overload or
20
appropriately overload.
1.3, overdrive (6 shifts) is economic shift, which is used when no-load or
light-load to make full use of engine power, high-speed, convenience, and
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safety factor close to 1. So, it couldn't be used when in the overload or

poor road conditions, and vehicle speed is less than 50 km/h, otherwise this
JA
will cause the overload teeth broken.

2, lubrication and sealing
Lubricants and
Item Quantity
sealant.
transmission gear oil 75W/90 GL-4 5.6±0.1L
Transmission oil seal: grease modest
40
The transmission
cover, clutch housing,
the rear cover, Side Flat sealant. modest
Cover-to-Housing
contacts
Chapter 8 Easy-to-wear Directory
28
No. Code Name Quantity
1 X-1601310-13-07 oil seal of shaft 1 1
2 M-1703407 oil seal of odometer shaft sleeve 1
27
3 M-1703406 Rear Oil Seal 1
12
Chapter 9 Special Instructions
1、This maintenance service manual of transmission LC6T55 is only for
20
reference, the different models of LC6T55 products shall be dispatched based

on the factual situation.
2、Different model of LC6T55 products are with different parts and components,
when repair and required parts could be ordered according to BOM or directly
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contact with our company for purchasing.

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41
Chapter Ⅳ Drive shaft

第四章传动轴
I Overview
Drive shaft is an important component that transmits power in the automotive driveline. It functions
with gearbox and drive axle to transmit the power of engine to the wheels, making the vehicle generates
driving force.
传动轴是汽车传动系中传递动力的重要部件，它的作用是与变速箱、驱动桥一起将发动机的动
28
力传递给车轮，使汽车产生驱动力。
The movable or rotatable circular parts that are connected or assembled to the drive shaft are usually
made of alloy-steeltube which is light and with good torsional resistance. For the front-engine rear-wheel
27
drive vehicle, drive shaft transfers the rotation of the transmission to the final drive shaft, which can be
made up of several sections and connected by universal joints. It is a rotating body with high rotating
12
speed and less support, which means the dynamic balance is of great importance. Generally, dynamic
balance test of drive shaft should be carried out before drive shaft leaves the factory, and adjustment of
drive shaft should be performed on the balance machine.
20
传动轴连接或装配各项配件，而又可移动或转动的圆形物体配件，一般均使用轻而抗扭性佳的
合金钢管制成。对前置引擎后轮驱动的车来说是把变速器的转动传到主减速器的轴，它可以是好几
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节由万向节连接。它是一个高转速、少支承的旋转体，因此它的动平衡是至关重要的。一般传动轴
在出厂前都要进行动平衡试验，并在平衡机上进行了调整。
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II Location plan and exploded view 位置图及爆炸图
1、 Location plan 位置图
28
27
12
2、 Exploded view 爆炸图
20
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JA
01 Drive shaft assembly 传动轴总成
02 Bracket on the drive shaft protection 传动轴保护上支架
03 Drive shaft protection under the bracket 传动轴保护下支架
04 Rear axle drive shaft bolt 后桥传动轴螺栓
05 spring washer 弹垫
06 I type hex nuts
28
Ⅰ型六角螺母
27
09 hexagon flangen bolts 六角法兰面螺栓
10
12
Hex head bolt, spring washer and plain washer assemblies 六角头螺栓、弹簧垫圈和平垫圈组合件
11 Drive shaft assembly 传动轴总成

20
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JA
III Removal and Adjustment 拆装与调整
□ Protection should be taken in the process of removing and installing parts to avoid scratches
拆卸和安装部件过程中，应做好防护，以免出现划伤。
□ Check if there is poor lubrication of the parts when removing them, if necessary smear "Grease."
拆装某些部件时，检查部件是否润滑不良，如果有必要，进行润滑。
□ Multi-man cooperation is required in the removing process because of the complexity of auto
28
parts.
由于汽车部件结构的复杂性，拆卸过程可能需多人配合进行。
27
□ Do not use excessive force when removing which may cause deformation of parts
拆卸时请勿用力过大，因此可能导致零部件变形过大。
12
2、 Driveshaft Removal 传动轴拆装
20
□ When disassembling the drive shaft assembly, the

disassembly order is differential end nut, middle
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hanging, transmission end nut, drive shaft assembly.
拆解传动轴总成，拆解顺序为差速端螺母、中间吊挂、
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变速器端螺母、传动轴总成
□ Make the vehicle in a steady state to prevent it from

slipping before removal and installation. Flat cart
should be put at the bottom of vehicle to prevent the
falling damage of drive shaft.
拆装前，使车辆处于平衡稳定状态，防止溜车。拆解
前须将平板推车放入车底部，防止传动轴跌落损伤
□ Disassemble drive shaft and differential side coupling

nut.
拆解传动轴与差速器端连接螺母，拆解时需在螺母上
做好标记
□ Disassemble the middle hanging mounting nut
拆解中间吊挂固定螺母
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27 □ Disassemble drive shaft and transmission side coupling
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nut.
拆解传动轴与变速器端连接螺母，拆解时需在螺母上
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做好标记
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□ Remove the drive shaft, and disassemble the coupling

nut of front and rear axle.
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取下传动轴总成，拆解前轴与后轴连接螺母
Installation: Please note the following procedures and install in the reverse order of removal:
装配：按照拆解相反步骤开展,但是需注意一下事项
□ Caution: Make an assembling mark on the universal

joint when disassembling, because the drive shaft
requires a good balance performance.
注意：因为传动轴要求有良好的平衡性能,所以在拆
卸时，应在万向节上作好装配记号
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3、 Universal joint tear open outfit 万向节拆装
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□ When disassembling the universal joint, the disassembly
order is grease nipple of universal-joint pin, bearing
retainer of universal joint, needle roller bearings,
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universal-joint pin, and flange yoke.
拆解万向节，拆解顺序为十字轴滑脂嘴、万向节轴承
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挡圈、滚针轴承、十字轴、突缘叉
□ Gently knock on the universal-joint pin, and then

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disassemble the needle roller bearings. Disassemble

other bearings with the same method.
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轻轻敲击十字轴，拆下滚针轴承。用同样的方法将其
他轴承拆解
装配：按照拆解相反步骤开展，但是需要注意以下事项：
□ The flange yoke of drive shaft must be installed as the

picture shows: spline shaft and spline should be
assembled in alignment as the arrow shows.
传动轴的突缘叉必须如图所示安装，花键轴与花键叉
如箭所示对齐装配
□ Smear grease on the oil seal and needle roller bearings.

Assemble the needle roller bearings into flange yoke
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with the universal joint pin as a guider. During assembly,
please use a soft faced hammer to knock.
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把油封和滚针轴承涂上油脂。用十字轴做导向将滚针
轴承装进突缘叉中。装时用软面锤敲击
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□ Install grease nipple to universal joint pin by a specified
angle. Make sure that the grease nipple is upwards.
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安装润滑脂油嘴至十字轴规定角度。必须保证滑脂嘴
朝上
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4、 Removal of Center Bearing 中心轴承拆装
□ When disassembling the center bearing, the disasse mbly

order is intermediate rubber, center bearing, dustproof
cover, connecting fork, washers, and nuts.
拆解中心轴承，拆解顺序为中间橡胶、中心轴承、防
尘罩、连接叉、垫圈、螺母
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□ The seal lip and the center bearing should be coated with
12 bearing grease when in re-installation.
复装时把油封唇和中心轴承涂上轴承油脂
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□ After the middle nut is tightened up, make a mark on the

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nut and make two symmetric piling in the

circumferential direction.
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中间螺母上紧后在螺母上打标桩。在圆周方向对称打
两个
□ Check the diameter of universal joint pin, and replace it

if there is any abnormal wear.
检查十字轴销直径，如果异常磨损想要进行更换
□ Check spline backlash, and replace it if there is any

abnormal wear.
检查花键侧隙，如果异常磨损想要进行更换
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IV Trouble Diagnosis and Troubleshooting 故障诊断与处理
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Chapter Ⅴ Suspension
第五章悬架
I Interview 概述
The suspension system is the general term for all power transmission and connecting devices that
connected between the frame and axles or wheels. Its function is to transmit force and moment that
function between the wheels and the frame, cushion the impact coming from the uneven road and
attenuate the vibration resulted from the impact, in order to ensure smooth running. Functions that
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suspension system should have are to support the body and improve the driving feeling, for different
suspension settings make drivers get different driving experience. Deceptively simple as it looks, the
suspension system integrates a variety of forces and determines the stability, comfort and safety of the
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vehicle, becoming one of the crucial components of modern automobiles.
悬架系统是汽车的车架与车桥或车轮之间的一切传力连接装置的总称，其功能是传递作用在车
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轮和车架之间的力和力矩，并且缓冲由不平路面传给车架或车身的冲击力，并衰减由此引起的震动，
以保证汽车平顺行驶。悬挂系统应有的功能是支持车身，改善乘坐的感觉，不同的悬挂设置会使驾
驶者有不同的驾驶感受。外表看似简单的悬挂系统综合多种作用力，决定着汽车的稳定性、舒适性
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和安全性，是现代汽车十分关键的部件之一。
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Front suspension 前悬
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Rear suspension 后悬
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Front suspension 前悬

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01 nut 螺母
02 Front leaf spring pin assembly 前板簧销总成

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03 Front leaf spring bushing 前板簧衬套
04 Front left leaf spring assembly 前左钢板弹簧总成
05 Front right leaf spring assembly 前右钢板弹簧总成
06 Before the horse bolts 前骑马螺栓
07 Buffer block assembly 前缓冲块总成
08 iron mat 前板簧垫铁
09 nut 前骑马螺栓螺母
10 Front leaf springs hanging ear plate assembly 前板簧吊耳板总成
12 left upper bracket,front shock absorber 前减震器左上支架
13 right upper bracket,front shock absorber 前减震器右上支架
14 front shock absorber 前减震器总成
15 Front shock absorber rubber sleeve gasket (outer) 前减震器橡胶套垫圈（外）
Front shock absorber rubber sleeve gasket

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前减震器橡胶套垫圈（内）
(within)
17 down pin ,front shock absorber 前减震器下销
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19 I type hex nuts Ⅰ型六角螺母
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spring washer 弹垫
21 Hexagon head bolts - fine tooth 六角头螺栓-细牙

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Rear suspension 后悬
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01 nut 螺母
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02 Front leaf spring pin assembly 前板簧销总成
03 Front leaf spring bushing 前板簧衬套

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04 Front left leaf spring assembly 前左钢板弹簧总成
05 Front right leaf spring assembly 前右钢板弹簧总成
06 Before the horse bolts 前骑马螺栓
07 Buffer block assembly 前缓冲块总成
08 iron mat 前板簧垫铁
09 nut 前骑马螺栓螺母
10 Front leaf springs hanging ear plate assembly 前板簧吊耳板总成
12 left upper bracket,front shock absorber 前减震器左上支架
13 right upper bracket,front shock absorber 前减震器右上支架
14 front shock absorber 前减震器总成

15 前减震器橡胶套垫圈（外）
(outer)
16 前减震器橡胶套垫圈（内）
(within)
17 down pin ,front shock absorber
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前减震器下销
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19 I type hex nuts Ⅰ型六角螺母
20 spring washer 弹垫
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Hexagon head bolts - fine tooth 六角头螺栓-细牙
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1、 Front suspension removal 前悬拆装
□ When disassembling the front suspension, the

disassembly order is front shock absorber、U-bolt、 lug
pin、steady pin、leaf spring
拆解前悬，拆解顺序为前减振器、U 型螺栓、吊耳销、
固定销、钢板弹簧
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□ Preparations: fix rear –wheel, and jack the vehicle, then
jack front axle with lift equipment.
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准备工作：先抵住后轮，顶起汽车，然后再用举升装
置顶起前轴
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□ Removal of U-bolt
拆解 U 形螺栓：
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 Loosen(not removing) U-bolt and nut
松开(不要拆下来)U 型螺栓和螺母
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 Raise the vehicle ,and support it with the chassis holder
将车辆升起并将它支承在底盘支架上
 Removal U-bolt and nut
拆下 U 型螺栓和螺母
□ Removal of front shock absorber
拆解前减震器
 Remove front shock absorber upper bracket and front

axle hold-down nut
拆解前减震器上支架与前轴固定螺母
 Remove front shock absorber lower bracket and front

axle hold-down nut
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拆解前减震器下支架固定螺母
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□ Remove of front axle assembly
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拆解前桥总成
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 Removal of front leaf spring

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拆解前板簧
 Remove front leaf spring hold-down nut
拆解前板簧固定螺母
 Remove front leaf spring lug pin
拆解前板簧吊耳销
 Take down front leaf spring assembly
取下前板簧总成
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Installation: Please note the following procedure and install in the reverse order of removal:
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□ Make a assembling mark on the leaf spring intersecting

surface before removal leaf spring
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拆卸钢板弹簧之前，要在钢板弹簧横面上做安装标记
□ Smear lubricating grease on two sides of leaf spring
在每个钢板弹簧两面上涂润滑脂。
□ Removed center bolt cannot be reused and should be

replaced with new one.
拆下的中心螺栓不要再使用，应更换新的中心螺
□ Use leaf spring with same sagitta ,when changing leaf

spring
更换钢板弹簧时，使用相同弧高的钢板弹簧
□ Check the clearance between leaf spring bushing and

leaf spring pin. If the clearance is too big, leaf spring
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bushing or leaf spring pin should be replaced.
查看板簧衬套与板簧销的间隙。如果间隙过大，应更
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换板簧衬套或板簧销
□ Pay attention to filling lubricating oil (until the oil oozes

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a little) when assemble lug pin.
装配吊耳销时应注意加注润滑油，至有少许渗出为止
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□ Check the absorber leakage, and a little leakage is

acceptable.
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检查减振器的泄露，允许有少量渗漏。
□ Check the temperature of shock absorber rises or not,

after driving for some distance, if the temperature does
not rise, it indicates that the shock absorber is not
working and should be replaced.
车辆行使一段行程后，检查减振器的温度是否升高，
如果温度没有升高，说明减振器不工作，应予更换。
□ Stretch shock absorber, if there is no heavy resistance, it
indicates the absorber does not work and should be
replaced
拉伸减振器，如果感觉不到有较大阻力，说明减振器
不工作，应予更换。
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2、后悬拆装 Removal rear suspension
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□ When disassembling the rear suspension, the
disassembly order is front shock absorber、U-bolt、lug
pin、steady pin、leaf spring
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拆解后悬，拆解顺序为后减振器、U 形螺栓、吊耳、
板簧销、钢板弹簧
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□ Fix rear –wheel, and jack automobile, then jack front

axle with lift equipment.
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先抵住前轮，顶起汽车，然后再用举升装置顶起后桥
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□ Removal U-bolt 拆解 U 形螺栓
 Loosen(not dismantle) U-bolt and nut
松开(不要拆下来)U 型螺栓和螺母
 Raise the vehicle ,and let it supports on the chassis

holder
将车辆升起并将它支承在底盘支架上
 Remove U-bolt and nut
拆下 U 型螺栓和螺母
□ Remove rear shock absorber
拆解后减震器
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 Remove rear shock absorber upper bracket and front
axle hold-down nut
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拆解后减震器上支架与前轴固定螺母
 Remove front shock absorber lower bracket and front

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axle hold-down nut
拆解前减震器下支架固定螺母
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□ Remove rear axle assembly
拆解后桥总成
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□ Remove rear leaf spring
拆解后板簧
 Remove rear leaf spring hold-down nut
拆解后板簧固定螺母
 Remove front leaf spring lug pin, and take down front
leaf spring assembly.
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拆卸前板簧吊耳销，取下前板簧总成
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□ Make a assembling mark on the leaf spring surface,

before removal leaf spring
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拆卸钢板弹簧之前，要在钢板弹簧横面上做安装标记
□ Smear lubricating grease on two sides of leaf spring
在每个钢板弹簧两面上涂润滑脂。
□ Remove center bolt can’t be reused ,should use new one
拆下的中心螺栓不要再使用，应更换新的中心螺栓
□ Use the leaf spring with same sagitta , when changing

leaf spring.
更换钢板弹簧时，使用相同弧高的钢板弹簧
□ Check the clearance between leaf spring bushing and

leaf spring pin. If the clearance is too big, leaf spring
bushing or leaf spring pin should be replaced.
查看板簧衬套与板簧销的间隙。如果间隙过大，应更
换板簧衬套或板簧销
□ Pay attention to fill lubricating oil(until the oil oozes a
28
little),when assembling lug pin.
装配吊耳销时应注意加注润滑油，至有少许渗出为止
27
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□ Check the absorber leakage, and a little leakage is
acceptable.
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检查减振器的泄露，允许有少量渗漏。
□ Check the temperature of shock absorber rises or not,

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after driving for some distance, if the temperature does

not rise, it indicates that the shock absorber is not
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working and should be replaced.
车辆行使一段行程后，检查减振器的温度是否升高，
如果温度没有升高，说明减振器不工作，应予更换。
□ Stretch shock absorber, if feel no heavy resistance, it

indicates the absorber does not work and should be
replaced.
拉伸减振器，如果感觉不到有较大阻力，说明减振器
不工作，应予更换。
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Chapter Ⅵ Steering
第六章转向
I Description 概述
A series of devices used to change or keep the vehicle running or reversing are called automotive
steering systems .The function of steering system is to control of the driving direction in accordance with
the driver's will. Automobile steering system is critical to the driving safety, so auto steering system parts
are called security pieces. Automotive steering systems and braking systems are two important systems in
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auto safety that must be paid attention to.
用来改变或保持汽车行驶或倒退方向的一系列装置称为汽车转向系统。汽车转向系统的功能就
是按照驾驶员的意愿控制汽车的行驶方向。汽车转向系统对汽车的行驶安全至关重要，因此汽车转
27
向系统的零件都称为保安件。汽车转向系统和制动系统都是汽车安全必须要重视的两个系统。
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Steering important parameters
转向系统重要参数
For maximum front axle load

2000kg～3500kg
适用最大前轴负荷
Theory of maximum output torque

1965N.m
最大理论输出力矩
Turning laps
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≥5.1
转向圈数
Output Angle
44.5°-47.5°
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输出角
Input spline (diameter x number of teeth)

Φ17.805×36
输入花键(外径×齿数)
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Output spline (big end diameter x number of teeth)
Φ35×36
输出花键（大端外径×齿数）
Oil pressure
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10.3Mpa
工作油压
Appropriate working temperature

-40℃～120℃
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适用工作温度
Oil pump rated flow

(9～11)L/min
油泵额定流量
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01 steering wheel 转向盘总成
02 dustproof cover
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防尘罩
03 steering gear adjust rack unit 转向可调支架总成

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04 steering column cover unit 转向柱护罩总成
05 steering shaft and driving universal joint 转向轴及传动万向节总成
06 steering gear assembly 转向器总成
07 nut, hexagon flange 六角法兰面螺母
08 Hexagon-headed bolt 六角法兰面螺栓
09 Hex bolt 六角法兰面螺栓
10 cross slotted screw and flat washer 十字槽盘头螺钉和平垫圈组合件
11 steering cover button 转向护罩卡扣
Hex head bolt spring washer and plain washer

12 六角头螺栓弹簧垫圈和平垫圈组合件
assemblies
13 Hex nut and taper washer 六角螺母和锥形弹性垫圈
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01 power steering oil outlet pipe assembly 动力转向进油钢管总成
02 power steering oil inlet pipe assembly 动力转向出油钢管总成
03 hose clamp (φ10) 平管夹（φ10）
05 power steering hose assy 动力转向软管总成
06 oil pump outlet perforation bolt 油泵出油穿孔螺栓
07 combined seal washer 组合式密封垫圈
08 power steering pump assy 动力转向泵总成
09 Compressor bracket tightening bolt Ⅱ 压缩机支架紧固螺栓Ⅱ
11 pipe clip 管夹
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12 Worm drive type hose clamp B 型蜗杆传动式软管环箍
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13 clip 卡箍
14 hose clip 软管夹
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12
hexagon flange bolts 六角法兰面螺栓
16 power steering return pipe 动力转向回油软管

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17 pump inlet hose 油泵进油软管
18 oil tank bracket 油罐支架总成

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19 power steering oil tank 动力转向油罐总成
20 steering oil reservoir cover 动转油罐盖

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□ In the process of disassembly and installation parts should be protection, lest appear scratches
拆卸和安装部件过程中，应做好防护，以免出现划伤。
□ Check if there is poor lubrication of the parts when removing them, if necessary smear "Grease."
拆装某些部件时，检查部件是否润滑不良，如果有必要，需进行润滑
□ Multi-man cooperation is required in the removing process because of the complexity of auto parts
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由于汽车部件结构的复杂性，拆卸过程可能需多人配合进行。
□ Do not use excessive force when removing, because it may cause deformation of parts
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拆卸时请勿用力过大，因为可能导致零件变形。
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2、 Steering System Removal 转向系统拆装
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□ When disassembling the steering system, the

disassembly order is steering wheel, combination switch,
steering column, steering shaft, power steering gear,
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dynamic steering oiler, steering lines
拆解转向系统，拆解顺序为方向盘、组合开关、转向
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管柱、转向轴、动力转向器、动转油壶、转向管路
□ Preparations: Make the vehicle in a steady state to

prevent it from slipping; The oil in the dynamic steering
oiler should be dumped before disassembling.
准备工作：使车辆处于平衡稳定状态，防止溜车。拆
解前需将动力转向油壶中的动转油放尽.
□ Turn the cab over and remove the coupling nut between
steering shaft and power steering gear. Pre-mark on the
steering shaft and mounting bolts of the power steering
gear to ensure the corresponding installation.
翻转驾驶室，拆解转向轴与动力转向器连接螺母拆卸
前预先在转向轴与动力转向器固定螺栓上做标记，安
装时确保标记对应
□ Removal of steering wheel
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拆解方向盘
□ Remove the steering wheel cover with both hands, and
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remove the retaining nut that fixing the steering wheel
with sleeve.
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双手扣下方向盘上盖，并用套筒拆解下方向盘固定螺
母
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□ Unscrewed the retaining nut, and disassemble the upper

cover of the steering column.
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拧下固定螺母，拆解转向管柱上护罩
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□ Remove the retaining nut, and unplug the connectors,

then disassemble combination switch assembly.
拆下固定螺母，拔下接插件，拆解组合开关总成
□ Remove the lower cover assembly of steering column.
取下转向管柱下护罩总成
□ Remove the instrument panel (consult the cab

disassembling section).Disassemble the adjustable
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steering bracket and steering column assembly
拆解仪表台（参见拆装驾驶室章节）。拆解转向可调
27
支架与转向管柱总成
□ Disconnect steering fluid pipe and steering gear coupling

12
nut
断开转向液钢管与转向器连接螺母
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□ Remove the coupling nut between steering gear and

steering drag link.
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拆解转向器与转向直拉杆连接螺母
□ Remove the retaining nut between steering gear and

frame and remove steering gear assembly.
拆解转向器与车架固定螺母，拆下转向器总成
□ Remove the connection clamps between power steering

oil tank and oil in-and-back software
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拆解动力转向油罐与进回油软件连接卡箍
27 □ Disassemble the coupling nut that connect the power

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steering oil tank and the frame, then remove the tank.
Remove the power steering pump and power steering
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hose steel pipe
拆解动力转向油罐与车架连接螺母，拆下油罐。拆解
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动力转向泵及动力转向钢管软管
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□ Power steering oil refueling 动力转向油的加注
Refueling process: First fill up the tank, then start the engine and make the drive pump running in
low speed to fill the hydraulic system. During engine operation, the oil in the tank will continue to decline,
refueling must be continued so as to avoid air inflow. Meanwhile turn the steering wheel to the both ends
of the limit position of the left and right respectively, and repeat it several times until the oil in the tank no
longer decreases.
加油过程：先将油罐加满，起动发动机，低速运行驱动油泵，使油液充满液压系统。在发动机
运转过程中，油罐的油面会不断下降，必须不断加油，以免油泵吸入空气。同时分别向左右打方向
盘至两端极限位置,反复几次,至油罐中油液不再下降为止.
Oil change process: Jack up the front axle, and open the tank cover and fuel returning port of
steering gear. Then start the engine in less than 15 seconds, and turn the steering wheel in both directions
consecutively to each extreme position to drain the oil .Then refuel according to the refueling procedures.
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换油过程：顶起前轴，打开油罐盖，将转向器回油口打开，短时间起动发动机，不超过 15 秒，
连续两个方向转动方向盘至两极限位置，将油液全部排出。然后再按加油程序进行加油。
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Exhaust process: Jack up the front axle (or remove drag link) and make the engine idling, turn the
steering wheel to the limit position of the left and right respectively, repeat it several times so as to
exhaust air and vaporized fluid. With the bubble discharging, the oil in the tank will fall. At this time oil
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should be added continuously until the oil surface keep placid, which completes the exhaust process.
排气过程：顶起前轴（也可卸去直拉杆）发动机怠速，左、右转动方向盘至极限位置，反复转
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动数次，让空气和汽化的油液排出。随着汽泡的排出，油罐油面将下降，这时要不断补充油液，直
到油面稳定，这就完成了排气过程。
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Precautions 注意事项：
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 Oil with inconsistent model is forbidden to mix.
禁止型号不一致的油液混用。
 Filter screen that on the oil tank must be used when filling the oil.
加注油液时必须经过转向系统油罐上的过滤网过滤。
 The volume of oil filling must be between two scale marks specified by the tank gauge (Keep the
engine start in 3min-5mins after oil filling, check if the oil filling volume is between the scale marks.
If too much oil, oil spilling is tend to occur after the engine is started；If too less oil, Ablation of vane
pump of the steering system is tend to occur.
油量加注必须在油罐标尺规定的两刻线之间（油量加注后启动发动机 3min-5min,检查补加油量
至规定标尺刻度线间。过多，发动机启动后易造成油液溢出；过少，易造成转向叶片泵烧蚀）。
 When regularly change the oil, the tank and the tank filter should be cleaned at the same time, not
allowing any debris mixed with the oil. Pay special attention to that do not use cotton fiber materials
(such as cotton yarn, emery cloth, etc.) to clean parts, which is to avoid their entry into the system
and causing malfunction.
定期换油时，应同时清洗油罐和油罐中的滤芯，不允许有任何杂物混入油内。特别注意不能用
棉织纤维物品（如棉纱、砂布等）擦试零件，以免带入系统内，造成故障。
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□ When assemble the new steering gear, make sure that
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there is no foreign material or damage in the steering
12 gear and steering column joint.
装配新转向器时要确保转向器与转向管柱接头处无
异物，无损伤
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□ The steel pipe of power steering fluid and steering gear

should be coated with leak-proof glue when assembling.
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Specific brands and smear standard, please consult

"Overview and maintenance manual "
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装配动力转向液钢管与转向器是需要涂防漏胶。具体
品牌与涂抹标准请参见《概述与保养分册》
□ When reinstallation is carried out, make sure that the

steering wheel is in the middle position under the
condition of straight driving, or start from the steering
wheel when removal or installation.
复装必须保证车辆处于直线行驶状态下方向盘处于
中间位置进行，或在拆装钱预先在方向盘
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Chapter Ⅶ
第七章制动系统
I Interview 概述
Brake system mainly consists of brakes, air reservoir, brake pipe, brake pedal and other components,
which is a series of specialized devices used to enable outside object (mainly the road) to apply a certain
force to some automotive parts (mainly the wheels), so that it can apply constraint braking force to the
vehicle. The function of Braking system role to make the running vehicle slow down or even stop
mandatory in accordance with the willing of the driver; ensure the parking vehicle be stably parked under
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various road conditions (including the ramp); make the downhill running vehicle remain a stable speed.
The vehicle braking action can only come from the apposite direction external force while the magnitude
of these external forces are random, uncontrollable, so a series special devices need to be installed on the
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vehicle to achieve the above functions.
制动系统主要包含制动器、储气筒、制动管路、制动踏板等零部件，是汽车上用以使外界（主
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要是路面）在汽车某些部分（主要是车轮）施加一定的力，从而对其进行一定程度的强制制动的一
系列专门装置。制动系统作用是：使行驶中的汽车按照驾驶员的要求进行强制减速甚至停车；使已
停驶的汽车在各种道路条件下（包括在坡道上）稳定驻车；使下坡行驶的汽车速度保持稳定。对汽
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车起制动作用的只能是作用在汽车上且方向与汽车行驶方向相反的外力，而这些外力的大小都是随
机的、不可控制的，因此汽车上必须装设一系列专门装置以实现上述功能。
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II Location drawing and exploded view 位置图及爆炸图
1、 Schematic Diagram 原理图
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□ Front Brake 前制动器
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00 Return spring-brake shoe 回位弹簧-制动蹄
01 Assembly of brake shoe with friction plate (lower) 制动蹄带摩擦片总成

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02 Assembly of front brake shoe with friction plate (upper) 前制动蹄带摩擦片总成
03 Assembly of front brake bottom board(R) 前制动器底板总成
04 Shaft of front brake shoe 前制动蹄片轴

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05 Front brake cam(R) 前制动凸轮
06 Hex nut 六角螺母
07 Assembly of front brake chamber assembly(R) 前制动器室支架总成
08 Assembly of front brake chamber assembly(R) 前制动气室总成
09 Front brake adjustable arm assembly 前制动间隙调整臂
10 Hex nut 六角螺栓
11 Dust proof cover of front brake 前制动器防尘罩
□ Rear Brake 后制动器
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00 Dust proof cover 防尘罩
01 Assembly of brake shoe with friction plate (lower) 制动蹄带摩擦片总成（下）
02 Return spring-brake shoe 回位弹簧-制动蹄

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03 Assembly of brake shoe with friction plate (upper) 制动蹄带摩擦片总成（上）
04 Assembly of left brake bottom board(R) 左制动器底板

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05 Shoe pin 蹄销
06 Rear left brake cam 后左制动凸轮

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□ Brake Pipe 制动管路
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00 brake valve push rod 制动阀推杆
01 transmission fork 传力叉

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02 Air outlet hose unit I on the upper chamber of brake valve 制动阀上腔出气尼龙管总成Ⅰ
03 air inlet hose unit II on the upper chamber of brake valve 制动阀上腔进气尼龙管总成Ⅱ
04 air inlet hose unit II on the lower chamber of brake valve 制动阀下腔进气尼龙管总成Ⅱ
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05 connecting hose unit 连接软管总成
06 air outlet hose unit on the upper chamber of brake valve 制动阀上腔出气尼龙管总成Ⅱ
07 air outlet hose unit on the lower chamber of brake valve 制动阀下腔出气尼龙管总成
08 seal board unit of air outlet hose,brake valve 制动阀出气密封板总成
09 air inlet hose unit of front quick-release valve 前快放阀进气软管总成
10 brake pedal and driving gear assembly 制动踏板及传动机构总成
11 air inlet hose unit I on the upper chamber of brake valve 制动阀上腔进气尼龙管总成Ⅰ
12 bracket of brake pipe 制动管支架
13 air inlet hose unit I on the lower chamber of brake valve 制动阀下腔进气尼龙管总成Ⅰ
14 seal board unit of air inlet hose,brake valve 制动阀进气密封板总成
15 brake valve assembly 制动阀总成
16 exhaust hose of brake valve 制动阀排气管
17 inlet hose unit of front brake chamber 前气室进气软管总成
18 hex nut 六角薄螺母
19 Serrated lock washer 外锯齿锁紧垫圈
20 inlet hose of front brake chamber（R) 前气室进气尼龙管总成（右）
21 front quick-release valve and bracket assembly 前快放阀带支架总成
22 inlet hose of front brake chamber(L) 前气室进气尼龙管总成（左）
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23 hose joint 管接头
25 brake pipe unit 制动尼龙管总成
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26 seal washer 密封垫圈
27 hex nut 12 六角薄螺母
28 air pump outlet elbow 打气泵出气弯头
29 air compressor outlet steel pipe unit 空压机出气钢管总成

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31 air compressor outlet hose unit 压缩机出气软管总成
32 bracket 支架
33 hex flange bolts 六角法兰面螺栓

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34 hex nut 六角薄螺母
35 washer 垫圈
36 hex flange nuts 六角法兰面螺母

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00 Air compressor outlet steel pipe unit(Ⅱ) 压缩机出气钢管总成(Ⅱ)

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01 Air compressor outlet pipe bracket unit (Ⅱ) 压缩机出气钢管支架(Ⅱ)
03 rubber pipe clip 橡胶管夹

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05 clip(Ф4-Ф12) 管夹(Ф4-Ф12)

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07 air compressor outlet pipe bracket unit (Ⅲ) 压缩机出气钢管支架(Ⅲ)
09 air reservoir model 储气筒模块
10 inlet hose unit of air reservoir(Ⅱ) 储气筒进气尼龙管总成(Ⅱ)
11 inlet hose unit of air reservoir(Ⅰ) 储气筒进气尼龙管总成(Ⅰ)
12 inlet hose unit of air reservoir(Ⅲ) 储气筒进气尼龙管总成(Ⅲ)
13 inlet hose of unit air reservoir(Ⅳ) 储气筒进气尼龙管总成(Ⅳ)
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00 pipe clip 带保护管卡

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02 pipe bracket 尼龙管支架

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06 air inlet hose unit of rear brake chamber 后气室进气软管总成

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07 relay valve with quick-release valve assembly 后继动阀带快放阀总成
08 air inlet hose unit of rear brake chamber 后气室进气软管总成
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00 Manual control valve bracket 制动阀推杆
01 hex flange nuts 传力叉

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02 manual control valve assembly 手控阀支架
03 spring washer 六角法兰面螺母
04 cross recessed screws 手控阀总成

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05 hand brake valve outlet hose assembly I 弹簧垫圈
06 hand brake valve inlet hose assembly II 十字槽盘头螺钉

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07 card 手制动阀出气尼龙管总成 I
08 connecting hose unit 手制动阀进气尼龙管总成 II
09 hand brake valve inlet hose assembly 卡片

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10 hand brake valve outlet hose assembly II 连接软管总成
11 air inlet hose unit of front quick-release valve 手制动阀进气尼龙管总成
12 hex flange bolts 手制动阀出气尼龙管总成 II
13 air inlet hose unit of front quick-release valve 前快放阀进气软管总成
14 quick-release valve assembly 六角法兰面螺栓
15 hex flange nuts 前快放阀进气软管总成
Remarks: The above pictures are typical component pictures, there is subtle difference between
some models and we didn’t mark them here
1、 Cautions 注意事项
□ Good protection should be conducted to avoid scratches in removing and installing components
process
拆卸和安装部件过程中，应做好防护，以免出现划伤；
□ When remove and install some parts, check the lubrication of parts. If necessary, smear "Grease";
拆装某些部件时，检查部件是否润滑不良，如果有必要，涂抹“润滑脂”；
□ Several persons may be required to cooperate in removing and installing because of the complexity
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of the structure of vehicle parts.
由于汽车部件结构的复杂性，拆卸过程可能需多人配合进行；
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□ Do not use excessive force when removing, because it may cause deformation of parts.
拆卸时请勿用力过大，因为可能导致零件变形。 12
2、 Removal and Installation of air reservoir 储气筒拆装
□ Remove air reservoir, removal order: brake pipe,

dual-circuit protection valve, air reservoir fixing bolts;
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拆解储气筒，拆解顺序为：制动管路、双回路保护阀、
储气筒固定螺栓
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□ Preparation: pull the clip ring of air release hole of air

reservoir until the air is released clearly.
准备工作：用手拉住储气筒放气孔卡环，直至空气放
完为止
□ Remove the connecting nuts between brake pipe and air
reservoir.
拆解制动管路与储气筒链接螺母
□ Remove the connecting nuts between dual-circuit

protection valve and air reservoir.
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拆解双回路保护阀与储气筒链接螺母
27□ Remove the fixing nuts between air reservoir and

12 ground.
拆解储气筒与地盘固定螺母
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Installation: Install according to the opposite order of removal and please be noted with the
following items:
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□ Please smear leakage-proof glue when installing the

connecting bolts of brake pipe, dual-circuit protection
valve and air reservoir.
装配制动管路、双回路保护阀与储气筒链接螺栓时需
要涂防漏胶。
3、 Removal and Installation of brake pipe 制动管路拆装
□ Remove brake pipe: remove the brake pipe one by one

along with pipe alignment.
拆解制动管路，沿着制动管路走向逐一拆解各段制动
管路
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准备工作：用手拉住储气筒放水孔卡环，直至空气放
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完为止
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装配：按照拆解相反步骤开展。
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Installation: Install according to the opposite order of removal
4、Removal and Installation of brakes 制动器拆装

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□ Remove brakes, removal order: brake chamber, brake

chamber bracket, brake shoe with friction plate
assembly.(Please refer to Front axle and Rear axle for
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the removal of brakes assembly from front and rear

axle )
拆解制动器，拆解顺序为：制动器室、制动器室支架、
制动蹄带蹄片总成（制动器总成从前轴、后桥拆解
下的步骤请参见《前桥》、《后桥》章节）
□ Remove the connecting bolts between brake chamber
and brake chamber bracket, take off brake chamber
拆解制动器室与前制动器室支架链接螺栓，取下制动
器室
□ Remove the fixing bolts between brake chamber and

dust-proof cover, take off brake chamber bracket.
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拆解制动器室支架与防尘罩固定螺栓，拆下制动器室
支架
27□ Remove the fixing bolts of brake shoe shaft, take off
12 brake shoe shaft and return spring and take off brake
shoe
拆解制动蹄片轴固定螺栓，取下制动蹄片轴与回位弹
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簧，拆下制动蹄片
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□ Remove brake camshaft
拆解制动凸轮轴
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following items:
□ Adjust brake clearance
调整制动间隙
□ It’s required to adjust brake clearance when re-installing:

first press down the lock of brake adjustment arm, then
rotate adjustment bolts to adjust brake clearance. Rotate
clockwise to narrow the clearance. Rotate anti-clockwise
to increase the clearance.
复装时必须调整制动间隙：先压下制动调整臂上的锁
止套，然后旋转调整螺栓调整制动间隙。顺时针旋转
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减少间隙。逆时针旋转增加间隙。
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5、Brake lever removal of parking brake 驻车制动制动手柄拆装
□ Remove the fixing nuts, take off brake lever.

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拆解固定螺母，拆下驻车手柄
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following items
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准备工作：用手拉住储气筒放水孔卡环，直至空气放
完为止
6、制动踏板拆装
□ Removal the bolts and replace the brake pedal
拆解制动踏板固定螺母，取下制动踏板
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following items:
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IV Diagnosis and treatment 故障诊断与处理
1、 Brake block
制动不灵
□ Fault phenomenon: when the car brake, driving people feel inadequate deceleration; When the car
emergency braking, braking distance is too long.
故障现象：汽车制动时，驾驶人感到减速度不足；汽车紧急制动时，制动距离太长。
□ The cause of the problem
故障原因：
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 The poor work of air compressor results in the low-pressure or no air within air reservoir. The reasons
may be the loose or broken of air compressor belt, leakage of exhaust valve, the spring of exhaust
valve being too soft or broken, leakage of piston or piston ring.
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空气压缩机工作不良，而使贮气筒内气压低或无气。可能是空气压缩机皮带过松或折断，空气
压缩机排气阀漏气，空气压缩机排气阀弹簧过软或折断，活塞或活塞环漏气。
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 Pipe cracks or connections loosen
气管破裂或接头松动。
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 Brake diaphragm or brake chamber diaphragm cracks
制动阀膜或制动气室膜片破裂。
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 The stroke of brake pedal is too large
制动踏板自由行程过大。
 Improperly adjustment of brake arm worm makes the brake chamber push rod outstretch too long
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制动臂蜗杆调整不当，使制动气室推杆伸出过多。
 The clearance between friction plate and brake drum is too big or there is oil spill on the friction plate
摩擦片与制动鼓间隙过大或摩擦片有油污。
□ Diagnosis and Trouble clearing
诊断与排除：
 If the barometer indicates the number "0", please depress the brake pedal, if there is a sound of
deflating when lift the pedal, it means the barometer is broken and please replace it. If there is no
sound of deflating, please check the air compressor belt and the pipes between air compressor and air
reservoir.
如压表指示数为“0”可踏下制动踏板，松起时如有放气声，即说明气压表有故障，应更换气压
表。如无放气声，则检查空气压缩机皮带和由空气压缩机至贮气筒一段气管的情况。
 After the above inspection, if the barometer indicates a low pressure level, it means there are faults
within air compressor. Please check the exhaust valve and inner cylinder and clear the trouble.
经上述检查，情况良好，如气压表指示数很低，则故障在空气压缩机，应检查排气阀或汽缸内
部技术状况，予以修复。
 If barometer indicates a normal pressure level, then depress the brake pedal and check whether there
is leakage among brake valve and each wheel. If there is no leakage, please check the stroke of brake
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pedal and adjust the clearance between brake friction plate and brake drum
如气压表指示压力数值合乎标准，可踏下踏板，检查由制动阀至各车轮间有无漏气之处。如无
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漏气处，则检查踏板自由行程和调整制动蹄摩擦片与制动鼓的间隙。
Made brake bite 12

制动发咬
□ Phenomenon: when lifting the brake pedal, the exhaust brake valve exhausts slow or does not exhaust,
resulting in no release of brake immediately; Or the exhaust valve exhausts normally, but there is still
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a left braking effect that causes the car running hard or weakness. Original car:
现象：抬起制动踏板后，制动阀排气缓慢或不排气，不能立即解除制动，或排气虽快，但仍有
制动作用，致使汽车起步困难或行车无力。原车：
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 No free stroke of brake pedal

制动踏板无自由行程
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 Brake exhaust valve adjustment pads is too thin, the return spring is too soft or broken or Rubber seat
is aging
制动阀的排气阀调整垫片过薄，其回位弹簧过软、折断或橡胶阀座老化发胀。
 Brake valve lever rusts

制动阀挺杆锈蚀
 The transmission parts between the brake pedal and brake valve arm get stuck
制动踏板至制动阀位臂之间传动件发卡。
 Brake camshaft and brackets bushings rust and get stuck
制动凸轮轴与支架衬套锈蚀发卡
 The clearance between brake drum and brake friction plate is too small
制动鼓与摩擦蹄片间隙过小
 Brake shoe pins rust or the return spring is too soft or broken.
制动蹄支销锈污或回位弹簧过软、折断
 The match section between axle tube and its rear axle housing or wheel bearings wear, resulting in
loosening
半轴套管与其后桥壳或轮毂轴承配合处磨损造成松动
 Brake chamber diaphragm is deformed and aged, single-layer film ruptured or a brake hose is aged,
the air flow is not smooth.
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制动气室膜片老化变形，单层胶膜破裂鼓起或制动软管老化，气流不畅
□ Diagnosis
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诊断
 The exhaust brake valve exhausts slow or does not exhaust when lifting the brake pedal, it is the
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brake valve fault in most cases and the symptom is that all the brake drums get hot.
抬起制动踏板时制动阀排气缓慢或不排气，多属制动阀故障，表现为各轮制动鼓均发热。若排
气声怯或继续排气而制动发咬，一般为个别轮制动发咬，摸试各轮制动鼓温度高者即为有故障
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之轮。
 If it’s confirmed that its fault of brake valve, please the free stroke of brake pedal first. If the free
stroke is too small, please adjust it. If the free stroke is normal, please loosen the exhaust valve to test.
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If the situation gets better, then the fault is the exhaust valve adjustment pads is too thin. If the
situation remains bad, please check whether the exhaust valve return spring and film are fine, if yes,
please check the whether the brake lever rusts or not and brake passing rod is flexible or not.
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若确定制动阀有故障，应先检查制动踏板自由行程。若自由行程太小或没有，应予以调整。若
自由行程正常，可旋松排气阀试验。如有好转，则为排气阀调整垫片过薄。仍无好转，可检查
排气阀回位弹簧及胶座以上均正常，则应检查制动挺杆是否锈污及制动传递杆件是否活动灵
活。
 Individual gears bite. Please observe the brake chamber push rod returning situation when lifting the
brake pedal. If it returns slowly or does not return, please check whether there is no lubrication
between the brake camshaft and its bracket cover or too large angle of different axles that causes
stuck. If the clearance is found normal when lifting the wheel, but the clearance changes when
putting down the wheel, then it means the wheel bearing loosens or the match of axle tube and its rear
axle housing loosens. If the clearance remains normal, please check whether there are problems with
brake chamber diaphragm and return spring.
个别轮发咬，可在抬起制动踏板时，观察制动气室推杆回位情况。若其回位缓慢或不回位，应
检查制动凸轮轴与其支架套是否失去润滑或不同轴度过大而发卡。若架起车轮检查该间隙正
常，而落下车轮后间隙在变化，则系轮毂轴承松旷或半轴套管与后桥壳配合松动。若间隙正常，
可检查制动气室膜片及回位弹簧是否有问题。
3、 Brake deviation (unilateral)

制动跑偏(单边)
□ Phenomenon: Two wheels can not brake concertedly when brake, the vehicle cannot stop along with
straight direction while deviate to one side
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现象：制动时，同轴两车轮不能同时制动，汽车不能沿立脚点直行方向停车而偏向一侧。
□ Causes
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原因
 The clearance of friction plate and brake drum of left and right side is different.
左右车轮摩擦片与制动鼓的间隙大小不均
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 There are oil spill, hardening or rivet head exposed of some friction plate.
个别车轮摩擦片有油污、硬化或铆钉头露出
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The friction plate material of left and right side is inconsistent or poor contact.
 左右车轮摩擦片材料不一致或接触不良
 Camshaft stuck or brake chamber fault of some wheels

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个别车轮凸轮轴发卡或制动气室有问题
 The brake drum of some wheels goes out of roundness or the surface of the drum gets grooves of
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some wheels
 个别轮制动鼓失圆度过大或鼓壁磨出沟槽
 Two front leaf springs elastic is unequal

两前轮钢板弹簧的弹力不等
 Uneven front beam

有负前束
 Horizontal connecting rod pin loosens or vertical arm loosens.

横、直接杆球头销或垂臂松旷
□ Diagnosis
诊断
 First, please conduct road test. If the vehicle deviates to left side when braking, it means that the right
brake is not effective. If the vehicle deviates to right side it means the left brake is not effective. After
parking, please check the grinding crack of left and right wheels on the ground. The brake of the side
is not effective if its grinding crack is short and light. Referring to the exclusion of the above reasons,
if it’s the problem of friction plate, please repair, replace, adjust, tighten and so on. There are many
similarities of brake deviation of air brake and hydraulic brake, please refer to each other.
首先进行路试。制动时，汽车向左偏斜即为右边车轮制动不灵，向右边偏斜好为左边车轮制动
不灵。停车后察看左右两边车轮在地面上的拖痕，拖痕短而轻的一边车轮制动不灵。参照上述
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原因进行排除，如是摩擦片有问题，可进行修复、更换、调整、紧固等。气压制动跑偏与液压
制动跑偏有许多相同之处，可以互相参考
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Chapter Ⅷ Rear axle
第八章后桥
I Overview 概述
This series drive axle is for two-wheel drive, rear suspension is not single suspension construct. it
comprises reducer、bevel gear differential and drive axle housing and some of other parts. It is the last
stage reducing speed mechanism in automotive driving system.
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Final reduction can enlarge torque and reduce rev, at the same time change the direction.It is
composed of driving gear and driven gear. Driving gear, in which side there is spine, connects with
coupling assembly of driving axle by driving gear’s flange. It is sustained by two cone bearings, which is
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reverse assembled, in its middle for supporting axial force and radial force. The axle neck on small end of
driving gear, bearing radial force, is assembled columnar bearing. Driven gear is fastened to left housing
of differential of some bolts.
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Differential, which can make the right and left wheel’s rev different, consists of the housing of
differential, spider, four spider gears, and two side gears and some of other parts.
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Drive axle’s half-shaft is connected with half-shaft gear by spine in one side, and with hub by some
bolts in flange in another side.
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该系列后桥是两轮驱动汽车驱动桥，后悬挂是非独立悬挂结构。由主减速器、差速器及桥壳等
部分组成，是汽车传动系中末级减速传动机构。主减速器即能改变传动方向，又能降低转速、增大
扭矩。它由主动齿轮和从动齿轮组成，主动齿轮有花键的一端通过主齿凸缘与传动轴万向节总成联
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接，中间支撑在两个安装方向相反的圆锥轴承上，以承受轴向力和切向力。主动齿轮小端面颈则安
装在圆柱滚子轴承上，仅承受径向力。从动齿轮用螺栓紧固在差速器左壳上。
差速器是使左、右车轮可产生不同转速，它由差速器左右壳、十字轴、二/四个行星齿轮、两
个半轴齿轮等零件组成。
后桥半轴的一端用花键与半轴齿轮联接，另一端凸缘用螺栓与轮毂带制动鼓总成联接。
Rear axle important parameters
后桥重要参数
后桥型号
2400000LE410A
Rear axle model
Gear oil model

（GL-4)85W / 90
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齿轮油型号
Gear oil filling quantity

5.5L
齿轮油加注量
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The main reduction ratio
4.875
主减速比
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1、 Location Map 位置图
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2、 Exploded diagrams 爆炸图
□ Rear axle assembly 后桥总成
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00 Rear axle with brake assembly 后桥带制动器总成

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01 hex bolt 六角头螺栓
03 bolt 六角头螺栓
04 spring washer 重型弹簧垫圈
05 shaft 半轴
06 oil seal 半轴油封
07 lock washer 锁止垫圈
08 nut 轴承螺母
09 bolt 制动底板螺栓
10 hexagon nut 六角螺母
12 hex fine bolt 六角头细牙螺栓（预涂胶）
13 stud bolt 双头螺栓（桥壳）
螺母
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14 nut
15 plug coke 六角头磁性螺塞
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16 plug coke 放油塞密封垫圈
17 VENTILATE PLUG 通气塞
18 plug cock
12 加油塞
19 plug coke 加油塞密封垫圈

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20 Rear wheel hub with brake drum assembly (left) 后轮毂带制动鼓总成（左）
21 Rear wheel hub with brake drum assembly (right) 后轮毂带制动鼓总成（右）

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22 Rear brake assembly (left) 后制动器总成（左）
23 Rear brake assembly (right) 后制动器总成（右）

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24 Rear axle housing assembly 后桥壳总成
25 Main reducer assembly 主减速器总成
□ Drum assembly 轮毂总成
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00 Rear drum oil seal 后轮鼓内油封

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01 Rear brake drum 后制动鼓
02 inner bearing 后轮毂内轴承

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03 rear hub 后轮毂
04 outer bearing 后轮毂外轴承

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05 Tire bolt assembly (right) 轮胎螺栓组件（右）
06 gear ring 齿圈
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□ Main reducer assembly 主减速器总成
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00 Drive gear assembly 主动齿轮总成
01 oil seal O 形圈-主动齿轮轴承座

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02 shim 主齿轴承座调整垫片
03 nut 六角螺母
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05 spring sprag 导向轴承弹簧挡圈
06 guided bering 主动齿轮导向轴承
07 stopping plate assy 导向轴承挡板总成
08 Final drive housing assembly 主减速器壳总成
09 differential unit 差速器总成
10 bolt 螺栓-从动齿轮
11 bolt 轴承座螺栓
□ Differential assembly 差速器总成
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00 bearing 差速器轴承
01 Differential case 差速器壳总成

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02 thrust plate 半轴齿轮止推垫片
03 side gear combination 侧卫齿组件

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04 spinder 行星齿轮轴
longer remark.
1、 Matters needing attention 注意事项
□ Check the parts with special inspection implement or tool
应使用专门的测量仪器或工具来检查零件。
Decide whether one part can reuse or not according to maintenance standard table. Broke part must
be repaired or replaced. If one of partner parts wore, leading to B/L out of set standard, we must
change the partner parts whole.
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根据指定维修标准表来断定零件是否能继续使用。损坏零件按要求进行修理和更换。如果在
配对零件中有一个被磨损，使间隙超出了规定的间隙，按有关要求更换此零件以及其他配件
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□ Some repairing parts which still in limited tolerance must be change according to pre-maintenance
opinion.
从预防保养的观点出发，某些仍在修理或磨损极限内的零件，在超出极限之前就应更换。
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□ All rubber parts, such as O loop, oil seal, shim etc., can not be reused after disassembly.
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所有的橡胶件，如O形圈、油封、垫片等在拆下之后应抛弃，不准在使用。
□ When there have noise or shake in transmission system, check the total B/L of rear axle firstly then
decide whether to disassembly differential carrier assy’.
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传动系统产生异响或震动时，先测量后桥的总游隙，决定是否需要拆卸主减速器总成。
□ Stop the truck on flat ground, push the transmission or transfer into empty speed position, rise the
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truck after braking with hand brake rod, turn the flange clockwise to bottom, mark matching sign on
dust cover & carrier, then turn the flange counterclockwise to bottom, measure the mark moving
distance. The limit windage is 6mm，if measured date is bigger then the limit, we must disassembly
rear axle and adjust it.
将车辆放在水平地面上，将变速器及分动箱置于空档位置，拉上驻车制动杆后将车辆顶起。顺
时针方向旋转凸缘到底，并在凸缘防尘罩和减壳上做匹配标记，再反时针方向将凸缘旋转到底，
测量两匹配标记所移动的距离，极限游隙为6mm，游隙大于极限，说明后桥的齿轮间隙过大，
必须拆卸后加以调整。
□ Abnormal noise, which belong to noise, such as clash or harshness etc. abnormal sound under
different condition, some can die away after normal wear, some change much bigger, and the main
reason is adjustment N/G, we can solve them through adjusting the assembly B/L if all parts are
good.
异响属噪音的一种，主要表现为在不同的使用条件下（如车速、路况）会产生撞击声或刺耳的
尖叫声等非正常声响，有些声响会通过磨合逐渐消失，有些声响会不断加大；主要是因为装配
调整不当造成的，在零件合格的前提下，其解决方法大多可通过调整零件装配间隙解决。
2、 Remove rear axle assembly 后桥总成拆卸
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□ Before Remove and Install, make sure front and rear
wheels with a mask to prevent it from rolling
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□ Lift the vehicle to safety height with jack
用千斤顶将车辆举升至安全高度
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□ Remove the tyre retaining bolt and remove the rear

wheel vehicles
拆卸轮胎固定螺栓，拆下车辆后轮
□ Disassembly the link between transmission shaft and

differential carrier assembly.
分解传动轴与主减速器的连接
□ Remove the front saddle bolts. Remove the front
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bumper blocks
拆卸前骑马螺栓，拆下前缓冲块
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□ Remove the Rear brake and vehicle Connect pneumatic
tubing and remove the front axle assembly
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拆卸后制动器与车辆连接液力制动管路并取下前桥
总成。
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3、 Decomposition rear axle assembly 后桥总成分解
□ Disassembly shaft
拆卸半轴
 Loose shaft nuts
松开半轴螺母
 Disassembly shaft. if difficult, strike the shaft slightly

with copper hammer until it loose
拆下半轴。如果半轴卸不下，用铜锤轻轻的敲击半轴
法兰，直到半轴松动。
□ Disassembly hub
分解轮毂
 Disassembly the lock plate
拆下锁止垫圈
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□ Disassembly the lock nut hub B/R
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卸下轮毂轴承锁紧螺母
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□ Disassembly the hub assembly
拆下轮毂总成
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□ Disassembly oil seal bush and inner B/R loop
同内轴承内圈一起，拆下油封衬套
□ Disassembly the brake drum
拆除制动鼓
□ Disassembly differential carrier assembly
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分解主减速器总成
 Check and record the B/L of pinion & ring gear before
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disassembly
12 在分解之前，测量和记录主被动齿轮的齿侧间隙；
 Note: check the mesh condition of gears after adjust
注意：调整后，检查齿轮啮合情况
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□ Disassembly lock plate
拆除锁片
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□ Mark matching sign on the B/R cover & carrier
在轴承盖和壳体上，做上装配标记
□ loose bolt of B/R cover, then disassembly adjust nut

with differential wrench
拧松轴承盖的固定螺栓，利用差速器扳手，拆下调整
螺母；
□ Disassembly B/R cover & bolt
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拆下轴承盖和螺栓；
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□ Disassembly the differential case assembly
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拆下差速器总成
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□ Disassembly the pinion gear assembly with special

disassembly implement, and disassembly the shim
利用拆卸器拆下主动齿轮总成，同时拆下调整垫片
□ Disassembly differential case assembly
分解差速器总成
 Disassembly right case
拆下差速器右壳
□ Disassembly shaft gear & shim
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拆下半轴齿轮和支承垫圈
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□ Inspection and record the backlash of planet gear
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测量和记录行星齿轮的齿侧间隙
 Note: locking the cross shaft when check backlash

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注意：测量齿侧间隙时，要压住行星齿轮十字轴
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□ Disassembly the cross shaft & planet gear assembly

then take out the planet gear and washer
拆除行星齿轮十字轴总成，再从十字轴上拆下行星齿
轮和支承垫圈；
□ Take out shaft gear and shim
拿出半轴齿轮和半轴齿轮的止推垫圈
 Remove the ring gear
拆下从动齿轮
□ Disassembly differential case B/R
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从差速器壳上拆下差速器轴承
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□ Disassembly of pinion gear
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主动齿轮的拆卸
 Disassembly the nut of pinion gear flange

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拆除主齿凸缘螺母
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□ Disassembly spring loop and take out the roller B/R
拆除轴用弹性挡圈和取下主动齿轮导向轴承
□ push out the pinion gear
从轴承座上压出主动齿轮
□ Disassembly adjust shim and distance washer
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拆除调整垫圈和轴承隔套
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□ Disassembly B/R from pinion gear
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从主动齿轮上拆下轴承
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4、 Rear axle assembly and adjustment 后桥装配及调整
□ The assembly of differential carrier assembly is reverse with disassembly.All parts need to be cleaned
before assembly, no oil, iron and other impurities, which are coated with oil lubrication assembly, the
10th and adjusted according to the requirements of the following
主减速器总成装配按以上拆卸逆过程装配，装配前所有零件许保持清洁，无油污、铁屑等杂物
存在，涂以 10 号机油润滑装配，并按以下要求进行调整：
 Preload of pinion fear inner & outer B/R
主动齿轮内外轴承预紧
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The taper B/R must preload when assembly differential carrier assy’, that is on the basis of removing
B/L of B/R, press somewhat preload more, the aim is to decrease pinion gear axis movement in
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transmission. But the preload can not press too much, or the B/R will be worn rapidly.
装配主减速器时，圆锥滚子轴承应有一定的装配预紧度，即在消除轴承间隙的基础上，再给予
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一定的预紧力。其目的是为了减少在锥齿轮传动过程中产生的轴向力引起的轴向位移，以提高
轴的支承刚度，保证锥齿轮副的正常啮合。但也不能过紧，若过紧则传动效率低，且加速轴承
磨损。
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 Adjustment of pinion gear preload: after tight pinion nut, assembly pinion oil seal and adjust the
preload(without ring gear) through remove or add shim between inner and outer B/R. adding shim,
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preload also add and remove shim, it will be decrease.
主动齿轮轴承预紧力调整：在主齿凸缘螺母拧紧力矩的条件下，装上主齿油封，主动齿轮未与
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从动齿轮啮合，保证主齿轴承预紧力矩。预紧度的调整在主齿内外轴承之间增加或减少主齿轴
承调整垫圈。调整垫片减少，预紧力矩增加；调整垫片增多，则预紧力矩减少。
□ Adjustment of differential case B/R preload.
□ 差速器轴承预紧调整
 Adjust of differential B/R : differential B/R should have suitable preload, make two side
over0.01-0.02mm. the B/R start torque is 0.686-1.586 N.m when lubricating the B/R with gear oil
under pinion & ring gear non-match condition. It can get through tight side nut. Tight cover bolt,
then adjust preload. After adjustment, the lock slot should align to lock plate and ring gear have no
axis movement.
差速器轴承的调整：差速器轴承应调整使其具有预紧力，使其两侧得到 0.01-0.02 的过盈,在主
从动齿轮未啮合条件下在轴承转动部分加注齿轮油,起动摩擦力矩为 0.686-1.586N.m。差速器轴
承预紧力调整是借拧紧差速器轴承螺母调整来进行的，调整时应先将轴盖自由地盖上，待调整
环拧动自如时，再将轴承盖螺栓拧紧，然后再调整预紧力。调整后的调整螺母上的锁槽应对准
锁片位置。调整后被动齿轮应无轴向窜动。
 Adjust B/L of differential case gear
差速器齿轮间隙调整
Measuring planet gear B/L with gauge. Note: check more then 3 point, standard:0-0.15mm;
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用百分表在行星齿轮上测量差速器齿轮啮合间隙。注意：测量三个以上点，标准值：0～0.15mm；
极限值：0.3mm。
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□ Adjust of pinion & ring gear B/L and pattern
主被动齿轮齿侧间隙、啮和印迹的调整
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 Adjust B/L
齿侧间隙的调整
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The standard B/L and vary (according to table 5), should check it along ring gear edge 4 points, and
the gauge head should be perpendicularity to check point
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主、从动齿轮正常啮合间隙及侧隙变动量见表 5，调整齿侧间隙时，应在从动齿轮沿圆周大致
均布的四个位置上进行测量，所用千分表的测量头应垂直与被测点表面。
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 Adjust pattern
主被动齿轮啮印迹调整
Applying red paint on the ring gear tooth, turning the ring gear come-and-go, then checking the print
of tooth’s both side. If the print lie in medium and near to small side, total to 60% of whole tooth
surface, we can decide the pattern is good(according to attached picture1). We can get the pattern
through adjusting the pinion gear housing shim(table 6) and adjusting differential case B/R nut.
先在主动齿轮轮齿上涂红丹粉，然后用手使主从动齿轮反复转动，于是从动齿轮的两侧工作面
上出现红色印迹，若从动齿轮正转和反转工作面上的印迹位于齿高的中间偏于小端，并占齿面
的 60%以上，为正确啮合。见附图。正确啮合的印迹位置通过主齿轴承座调整垫片及差速器轴
承调整螺母来调整的。
One B/R nut out circle should equal to another side nut in circle, thus the preload of side B/R will not
change. Recheck B/L and lock the lock plate.
为保持已调整好的差速器轴承预紧度不变，一端调整螺母拧入的圈数应等于另一端螺母拧出的
圈数。再确认间隙后，锁紧锁片。
□ The rear wheel hub with brake drum assembly according to remove the inverse process of assembly,
assembly time adjustment is as follows
后轮毂带制动鼓总成装配按拆卸逆过程装配，装配时调整如下：
28
 The rear wheel hub bearing clearance adjustment
 后轮毂轴承游隙调整
27
Tighten bearing nut to brake drum is not moving or rotating heavy, slightly loose bearing nut 1/6-1/8,
and then turn the brake drum, without any contact with the brake drum brake friction disc, should be
12
able to rotate freely.
将轴承螺母拧紧至制动鼓不动或转动沉重，然后稍松轴承螺母 1/6-1/8 圈，转动制动鼓，制动

20
摩擦片不与制动鼓接触情况下，应能转动自如。
□ The rear brake clearance adjustment

C-
后制动器制动间隙调整
 Bidirectional balance brake according to the direction arrow on bottom plate adjustment hole, first
JA
pump adjustment tooth pulled move two points respectively, brake drum and the friction plate die,
and then adjust the cylinder gear, respectively, and virtually back to 5 ~ 9 after the tooth, the brake
drum to flexible rotation.
双向平衡式制动器按底板调整孔处的箭头方向，先分别拔动两个分泵调整齿，使制动鼓与摩擦
片贴死，然后将分泵调整齿分别跋回 5~9 齿后，使制动鼓能灵活转动。
□ Adjustment of backlash
齿轮啮合间隙调整方法图
28
A、gear contact zone adjustment
Adjustment ways:
Passive work gear tooth surface contact Reason B、gear side clearance adjustment
27
1、Driven gear moves away from
12 main gear
Main gear is too far 2、Main moves to the driven
from the driven gear gear to get the right clearance

Partial gear top
20
(Add gasket）
C-
1 、 Driven gear moves to main
gear
JA
2、 Main moves away from the
driven gear to get the right

Partial gear roof Main gear is too near
clearance
from the driven gear
(Reduce gasket）
1、Driven gear moves away from
main gear
The driven gear is too 2 、 Main moves away from the
near from Main gear driven gear to get the right

Partial gear little side
clearance
(Reduce gasket）
1 、 Driven gear moves to main
28
gear
The driven gear is too 2、Main moves to the driven gear
27
far from Main gear to get the right clearance
Partial gear big side
(Add gasket）
12
20
C-
JA
Gear depth
Gear length
28
27
12
20
C-
JA
Failures 故障 Causes 原因 Action 措施
preload is big adjust preload
轮毂轴承预紧力大调整预紧力
Problem of wheel hub

lack lubrication or misusing add lubrication or change
bearing
轴承缺乏润滑或润滑脂不正确加注或更换润滑脂
轮毂轴承滞涩
28
bearing is contaminated with dust clean and add lubrication
轴承沾灰尘清洗并加注润滑脂
27
camshaft may not be well lubricated or adjusting add lubrication or rectify failure part
arm can not get back to the original position

12 加润滑脂或校正有故障部件
problem of wheel
凸轮轴润滑不良或调整臂不回位
车轮发涩
20
brake shoe or spring is broken or fatigued exchange the failure part
制动蹄或气室回位弹簧折断或疲劳更换有故障部件
C-
the gap of differential gear is not right exchange washer or gear
差速器齿轮间隙不当更换垫片或齿轮
JA
preload of drive gear bearing is too small adjust preload diff pinion
abnormal noise 主动齿轮轴承预紧力过小调整预紧力
传动非正常声音
lack lubrication add enough lubrication
油平面过低加足润滑油
problem of oil seal Replace the oil seal
油封磨损、松动或损伤更换油封
The main reduction fastening bolt loose or

Tighten bolts or recoat sealant
sealant damage
拧紧螺栓或重涂密封胶
主减紧固螺栓松或密封胶损坏
In accordance with the provisions,

The bolt bearing loose.
28
torque screw down the bolt
轴承座紧固螺栓松
lubrication leak 按规定力矩拧紧螺栓
27
润滑油泄漏 Tighten the screw or replace the
Oil drain screw loose or pad damage
gasket
放油螺塞松或衬垫有损伤
12 拧紧螺塞或更换衬垫
Correction or replacement of the

Due to the overload bridge shell deformation
20
bridge shell
由于超载使桥壳变形
校正或更换桥壳
C-
Air plug stuck or damage Clean or replace vent plug
通气塞被堵或损伤清洁或更换通气塞
JA
malfunction of camshaft check camshaft
凸轮轴旋转不灵检查凸轮轴工作情况
problem of brake
制动力不足 the stroke of pushing rod is not well adjusted adjust stroke
制动气室推杆行程调整不当调整行程
the problem of brake shoe lining exchange the brake shoe lining
摩擦片过热或变质更换摩擦片
the position of brake shoe lining is incorrect rectify the position
摩擦片贴合不当校正摩擦片贴合位置
problem of brake
water get into brake drum press pedal and drain the water
制动力不足
制动鼓进水行驶中轻踩踏板，排干水
28
the contacting face of brake shoe lining or brake clear up the brake shoe lining or
drum has grease exchange
27
摩擦片或制动鼓接触面上有油脂清除油脂或更换摩擦片
12
20
C-
JA
28
27
12
20
C-
JA
ANHUI JIANGHUAI AUTOMOBILE CO., LTD
Compiling 编制 King.wang 汪国君

Audit 审核 Youwang.zhang 张有旺
Approve 批准

Í EN&CNí+3 ChassisÁÎ+ ÀÍ ß-LE410

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WORKSHOP MANUAL

in design, addition or improvement for the product.

Pressure plate static torque

Moment of inertia of the clutch assembly

Maximum separation form

The clutch pedal free stroke

The clutch pedal work Angle

1、 Location map 位置图

□ Clutch assembly 离合器总成

S/N 序号 Spare parts name description 备件名称

01 brake oil pipe perforation bolt 变速器总成

02 braking oil pipe joint washer 离合器从动盘

03 hexagon flange bolts 分离套筒

04 oil storage boat 分离拨叉

05 hexagon nuts with flange 导向轴承

S/N 序号 Spare parts name description 备件名称

01 brake oil pipe perforation bolt 制动油管穿孔螺栓

02 braking oil pipe joint washer 制动油管接头垫圈

03 hexagon flange bolts 六角法兰面螺栓

04 oil storage boat 储油壶总成

05 hexagon nuts with flange 六角法兰面螺母

06 hexagon flange bolts 六角法兰面螺栓

07 clutch master cylinder inlet pipe assembly 离合器总泵进油管总成

08 double steel wire ring hoop 双钢丝环箍

10 clutch master cylinder tubing assembly 离合器总泵出油管总成

11 clutch hose assembly 离合软管总成

12 hexagon flange bolts 六角法兰面螺栓

13 clutch tube bracket 离合器管固定支架

14 hexagon flange bolts 六角法兰面螺栓

16 hexagon flange nuts 六角法兰面螺母

17 clutch tube assembly 离合器管总成

20 hexagon flange nuts 六角法兰面螺母

22 clutch tube bracket 离合器管支架

23 clutch tube bracket (I) 离合器管支架(I)

24 clutch booster oil inlet pipe assembly 离合助力器进油管总成

25 brake oil pipe perforation joint 制动油管穿孔接头

26 cylinder booster assembly 离合助力器总成

27 cylinder booster bracket assembly 离合助力器支架总成

28 clutch pedal and bracket assembly 离合踏板支架总成

29 clutch master cylinder 离合器总泵总成

S/N 序号 Spare parts name description 备件名称

01 connecting bracket 连接支架

04 flat washer 平垫圈

05 spring washer 弹簧垫圈

S/N 序号 Spare parts name description 备件名称

01 Clutch pressure plate assembly 离合器压盘总成

03 Hexagonal bolt and spring washer Combination 六角螺栓和弹簧垫圈组合件

□ Before disassembling, vehicle front and rear wheels need

mask wood will cover, to prevent the slide

□ Before disassembling, vehicle front and rear wheels need

□ Disassemble clutch control assembly and disassembly

□ The disassemble oil spout mounting bolts and Lines Link

□ Disassemble the clutch pedal and bracket nuts, remove

□ Assembling the clutch pedal attaching bolts is critical

□ Disassemble clutch circuit, disassemble order: clutch

□ Disassemble the clutch and remove order:

□ Disassemble transmission and engine, frame, the

□ Disassemble clutch driven plate retaining bolts and

□ Disassemble the socket assembly together with the

□ Visually check the clutch cover for wear, cracks and

□ Pilot shaft goes through splined hub. Pilot shaft must be

measured value exceeds limits, should be replaced

1、 Clutch drag (gear with gear grinding teeth) 离合器拖滞（换挡时伴随齿轮磨齿声）

装左、右转向节、止推轴承、O 型密封圈及调整垫片，保证转向节与前轴端面单侧间隙不大

要求：制动鼓能够自由转动，检查其轴向负荷为 10～25N,但不允许有明显的轴向窜动和摆动

内，制动鼓总成能够自由匀速转动为合格，小于 10N 转动为过松，大于 25N 才转动为过紧。检