Page 489 - Foton Workshop Manual - Auman EST-M

Diagnosis - Mechanical fault diagnosis DI - 435

Failure phenomenon Possible reason Failure elimination IN

1. The parts in the clutch are broken or the Check the clutch moving parts. Repalce the
tightening parts are loose broken or loose fixing parts DI
Check the drive shaft and universal joint.
2. The cardan joint is worn seriously or the
Replace the broken parts or adjust the
drive shaft has too much clearance EG
coordination clearance
3. Lubricant not sufficient or gear oil Check the oil level. Fill in to the specified level
deteriorates or replace gear oil TR
Check and replace the broken parts. Recover
4. Bearing or gear broken and/or worn
the worn parts
AX
5. Vent plug leaking Replace the vent plug
Transmission noise
6. The fork of shift fork shaft is worn
abnormal Replace the shift fork shaft or fork
seriously FR
7. Fixing parts loose or relvant moving parts Check if the fixing parts are loose and replace
broken the broken ones
ST
8. The gear is found with burr, bruise,
breakage or ineligible tooth shape or tooth Repair the gear or replace it
BR
direction.
9. Synchronizer worn which causes noise in
Replace the synchronizer
shifting BW
Clean the transmission and replace with the
10. Mixture of different oil
lubricant meeting the specification
EL
1. Loose air holes and/or cracks on the cover
Replace or repair
or screw holes punched through
2. Fixing parts loose Check if the fixing parts are loose
3. The sealing component is defective or
Replace the failed or broken parts
damaged (oil seal, sealing gasket, gasket).
The transmission leaks
4. Seal fails because of vent blocked Replace and clean
5. Gear oil too much Reduce the gear oil properly
6. Housing cracked Replace the housing
7. Oil filler plug and oil discharge plug bolts Tighten relevant parts and add sealant if
loose necessary
Check the clutch clearance and adjust the drive
1. The clutch is not separated thoroughly
shaft or reduce the gear oil properly
Check and adjust the lever system or replace
2. Gear oil viscosity too high, too much oil
the damaged part.
3. The control lever system (drag link,
electing and shifting rocker, connecting plate, Check and replace the broken parts. Recover
Difficult to shift
supporting rod) is improperly adjusted the worn parts
or worn.
4. The parts of synchronizer or joint sleeve are Check and replace the broken parts. Recover
broken the worn parts
Check if the reverse slid rail and reverse switch
5. Difficult to shift to the reverse gear
are stuck

DI-435