Page 931 - Workshop Manual - Aumark (BJ1051)

31B-11
Transmission 6g120 - transmission assy

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 while filling transmission oil, the oil shall be filled into 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 the 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). Clean all the parts, unclog the lubricating orifices of each part and blow off with compressed air
before assembling. 31B
(d). 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.
(e). The paper washers and sealant remained on each faying surfaces must be cleaned.
(f). Notice the positions and directions of the gear, thrust pad and pad.
(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 gaskets 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 931