Page 857 - Workshop Manual - Aumark (BJ1051)

31A-11
Transmission (646b/651b)-transmission assembly

Transmission assembly

Notes
1. Notes for the use of transmission
(a). Inspect the level of transmission oil regularly and add some transmission oil if it is not enough.
Hint:
Park the vehicle on the level road when filling transmission oil, the oil shall be filled to the lower edge of the oil filling
opening.
(b). Change the transmission oil for the new transmission every 5,000 kilometers, and change it every 24,000
kilometers or once a year after the breaking-in period.
Notice:
• 80W/90 (GL-5) oil shall be used for the transmission
• Different brands of transmission oil can’t be used together.
(c). Maintain the breather plug regularly to ensure its cleanness and smoothness.
(d). Start with the first gear or the second gear according to the road conditions and the load of vehicles.
(e). Neutral sliding is not permitted for the transmission, especially when the engine is at flameout state so as to avoid
burning out the synchronizers and various kinds of bearings.
(f). The clutch must be separated completely during the gearshift to avoid half linkage state and damage of
synchronizers and other parts; park the vehicle first and then shift the gear so as to avoid damaging the backward
gear and the gear ring of the synchronizer.
(g). When the vehicle needs to be dragged for malfunction, disconnect the transmission axle or drag it above the
ground, avoid the driving wheels roll and turn the output axis of transmission to rotate so as to burn out the
bearings and other components.
2. Notes for the disassembly and assembly of transmission
(a). The vehicle must be parted on the level and safe place before removing the transmission from the complete vehicle,
shut off and turn off the power supply, fasten the front and rear wheels with tools to ensure the safety of the
complete vehicle.
(b). Clean the outside of the transmission before disassembling it, avoid the dust and impurities entering into the
transmission during the disassembly of the transmission.
(c). Don’t knock with a hammer directly while disassembling or assembling the axles, bearings and oil seals and
fastening the gears, copper hammers or copper rods must be used while knocking to avoid damaging the parts.
Various special tools shall be used for the disassembly. 31A
(d). The paper washers and sealant remained on each faying surfaces must be cleaned.
(e). Clean all the parts in the transmission, unclog the lubricating orifices of each part, and blow off with compressed
air before assembling.
(f). Notice the positions and directions of the gear, thrust pad and pad during the assembly.
(g). Apply clean lubricating oil on all the thrust washers, needle bearings and synchronizer conical surfaces during the
assembly so as to avoid the damage caused by the dry friction.
(h). New sealing washer must be used during the assembly; omitted installation of sealing gaskets is not permitted.
(i). Inspect whether each oil seal lip is damaged, replace with new parts if oil leakage is found.
(j). Apply sealant uniformly on each gasket to avoid oil leakage, 5699 or 5702 silicone sealant is suggested to be used,
apply uniformly to avoid breaking. 262 screw-thread retaining compound is suggested to be used during the
assembly of through-hole bolts.
(k). Check the important matching parts, especially the interference fit parts and check them carefully before the
assembly so as to avoid rework.

Page 857