VRT200 Transmission Service Manual

VRT200 Transmission Service Manual

FOREWORD This manual briefly introduces disassembling and assembling process of the transmission, and provides maintenance technics and standard requirements of the transmission, which can help the serviceman profoundly understand how to disassemble and assemble the transmission, and also help to lay a solid technical foundation for the serviceman to diagnosis and solve the faults. This manual is organized as follows: Chapter 1

GENERAL

This chapter mainly introduces precautions for maintenance of the transmission, significance of all kinds of symbols used in this manual and tightening torque of common bolts. Chapter 2

TRANSMISSION SYSTEM

This chapter introduces gear shifting principle of the transmission, transmission line of each gear, oil supply line, and operation and maintenance of the transmission. Chapter 3

DISASSEMBLY AND ASSEMBLY OF TRANSMISSION

This chapter tells the serviceman/user how to disassemble and assemble each component step by step correctly, and precautions need to be noted during the process.

ATTENTION The parts and components that mentioned in this manual may change along with product improvements, but we do not promise to inform the changes of products that have been sold, please consult or ask Shandong Lingong Construction Machinery Co. Ltd for the updated details.

I

VTR200 Transmission Service Manual 880×1230 mm

16#

1st Edition in 2014. 10

18pieces 1st Print

SHANDONG LINGONG CONSTRUCTION MACHINERY CO.，LTD Address: Linyi Economic Development Zone Tel: 86-0539-8785688 Fax: 86-0539-8785698 Postal code：276023 Website：www.sdlg.cn Services Tel：8008607999 4006587999 0539-8785800 Services Fax：86-0539-8785671

VRT200 Transmission Service Manual

CONTENTS 1 GENERAL.............................................................................................................. 1 11 Safety Precautions .................................................................................................. 1 12 Marks ...................................................................................................................... 2 13 Tightening Torque of Common Bolts .................................................................... 3 2 TRANSMISSION SYSTEM .................................................................................. 4 21 Adaptable Automobile Modes and Main Parameters ............................................ 4 22 Structure of Transmission ....................................................................................... 5 221 Torque Converter............................................................................................ 6 222 Clutch Box (Transmission Box) ..................................................................... 7 223 Transfer Case ................................................................................................ 18 23 Transmission Principle ......................................................................................... 20 231 Transmission Principle Diagram .................................................................. 20 232 Power Transmission Line of Each Gear ....................................................... 20 24 Oil Supply and Lubricating System of Transmission .......................................... 24 241 Oil Supply Line of Transmission ................................................................. 24 242 Main Components in Transmission Oil Supply System .............................. 26 243 Transmission Oil Supply Principle............................................................... 29 244 Pressure Test of Transmission System ......................................................... 31 25 Electric Control of Transmission.......................................................................... 33 251 Principle ........................................................................................................ 33 252 Functions ...................................................................................................... 34 253 Transmission Controller LGTC-3 ................................................................ 35 254 Gear Selector (Gear Shifting Control Handle) ............................................. 36 255 Solenoid Valve ............................................................................................. 36 256 Fault Detection of Transmission Controller ................................................. 37 3 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ............................. 39 31 Key points for Disassembly and Assembly of Transmission ............................... 39 311 Disassembling Tools and Gauges................................................................. 39

VRT200 Transmission Service Manual

312 Fit Clearance of Transmission Key Points ................................................... 40 32 Steps to Disassemble and Assemble the Transmission ........................................ 41 321 Disassembly of Transfer Case ...................................................................... 41 322 Disassembly of External Parts ...................................................................... 47 323 Disassembly of Torque Converter ................................................................ 50 324 Disassembly of Transmission Box ............................................................... 52 33 Step to Disassemble the Assembly Components.................................................. 55 331 Disassembly of Clutch Shaft Assembly ....................................................... 55 332 Disassembly of Transmission Control Valve ............................................... 58 333 Disassembly of Cushion Valve..................................................................... 59 334 Disassembly of Lubricating Oil Valve ......................................................... 60 34 Step to Assemble the Assembly Components ...................................................... 62 341 Assembly of Lubricating Oil Valve.............................................................. 62 342 Assembly of Cushion Valve ......................................................................... 63 343 Assembly of Transmission Control Valve ................................................... 64 344 Assembly of Clutch Shaft Assembly ............................................................ 65 345 Assembly of Transfer Case........................................................................... 80 35 Steps to Assemble Transmission Box ................................................................ 107

II

VRT200 Transmission Service Manual

1 GENERAL 11 Safety Precautions Important Safety Notes Maintenance and repair is vitally important for safety operation of the machine. This manual mainly expounds techniques about how to correctly disassemble and assemble the transmission assembly. To protect related personnel against injury, this manual uses

as safety label, for

precautions marked with this label, please be careful during the operation and must never on any account be negligent. For operations that possible dangers are involved, firstly pay attention to your own safety and necessary security measures shall be taken.

Safety Tips In the process of assembly and disassembly, wrong operation method may damage the parts or components, shorten the service life and deteriorate the performance of the machine, even brings potential safety hazard. Therefore, before assembling and disassembling each component, please read related content in this manual carefully. 1.

The parameters, graphs and related contents in this manual are applicable to products of standard configuration. As for the updated products, please consult our company or refer to related materials.

2.

In repair workshop, special placing area should be should be designated for the removed parts, components and tools, where the corresponding tools and components should be placed orderly. Meanwhile, be sure to keep the operation area clean and make sure there is no oil dirt or pollutant. Smoking is strictly forbidden during the operation and fire extinguishing devices should be in preparation.

3.

Welding operation should be performed by well trained and experienced personnel. Be sure to wear gloves, baffles, goggles, hats and work clothes during welding operation.

4.

Before disassembling the torque converter-transmission assembly, the external surface of which must been cleared up to avoid polluting the parts in the process of disassembling.

5.

Always wear safety shoes and safety helmet during the operation. Never wear unqualified work clothes, and be sure to button the clothes neatly. When knocking parts/components with copper

VRT200 Transmission Service Manual rod, be sure to wear goggles. 6.

The disassembled parts/components could be cleaned with petrol, gasoline and water-based oil cleaner.

7.

When use the travelling crane or other lifting appliance, firstly check whether the lifting tools are broken. Make sure the lifting appliance has enough lift range. During lifting operation, be sure to use specified lifting positions and operate carefully to prevent bumping against other parts/components. Nobody is allowed to operate or stand under lifting parts/components.

8.

For operation requires two or more people, be sure to come up an operating procedure before the operation to avoid accidents caused by out of step.

9.

All tools must be kept properly, and be familiar with their using methods.

10. When aligning two mounting holes, do not put your hands and fingers into the holes. Pay attention to crushing danger when assembling parts by hand directly. 11. The disassembled parts/components must be inspected. The part with defects that may affect its service performance must be replaced. 12. Make sure there is no interference after assembling each part/component. 13. When assembling the oil seal and the seal ring, if key grooves, screw holes or shoulder are exist in the fitting area, be sure to take protective measures to avoid damaging the seal or seal ring. 14. When assembling the parts/components, all tools you use must be matched with threaded fastener to avoid damaging the screw fasteners. 15. It is not allowed to use pneumatic impact wrench to tighten the joint bodies or screw plugs. Pre-tighten them by hand first, and then tighten them with specified torque wrench to meet related torque requirements. 16. When draining the oil in the transmission, loose the oil drain plug slowly to avoid spurting of oil.

12 Marks In order to emphasize the significance of safety and quality visually, and help the user make best use of this manual, we design the signs in table 1-1 as marks. Table 1-1 Marks

Items

Notes Be careful for the safety during the operation.

Safety

Be quite careful for the safety if there is pressure inside during the operation.

VRT200 Transmission Service Manual Attention

Emphasize the technical requirements to ensure that the operation can meet the requirements of standard during operation. Weight and installation way of parts or device.

Weight Carefully select hanging tools and the operation gesture. Tightening torque

Pay more attention to the tightening torque of assembly parts.

Coating

Carefully note the parts need to be coated with grease or adhesion agent.

Oil, water

Fill a certain amount of water, oil and fuel.

Draining

Be careful for the parts where water and oil need to be drained, and judge their volume.

13 Tightening Torque of Common Bolts Table 1-2 Bolt nominal diameter (mm)

Bolt strength grade

Yield strength (N/mm2)

6

8.8

640

9~12

22~30

10.9

900

13~16

30~36

Bolt strength grade

Yield strength (N/mm2)

16

8.8

640

193~257

264~354

376~502

521~683

651~868

10.9

900

280~330

380~450

540~650

740~880

940~1120

Bolt strength grade

Yield strength (N/mm2)

27

8.8

640

952~1269

1293~1723

1759~2345

2259~3012

2923~3898

10.9

900

1400~1650

1700~2000

2473~3298

2800~3350

4111~5481

8

10

12

14

45~59

78~104

124~165

65~78

110~130

180~210

Tightening torque (Nm)

Bolt nominal diameter (mm) 18

20

22

24

Bolt nominal diameter (mm)

Bolt nominal diameter (mm) 30

33

36

39

Bolt nominal diameter (mm)

VRT200 Transmission Service Manual

2 TRANSMISSION SYSTEM 21 Adaptable Automobile Modes and Main Parameters Table 2-1 Items

Torque converter

Transmission

Parameters/contents Type

Single stage three-component single-turbine hydraulic torque converter

Torque converter inlet oil pressure (MPa)

0.8~1.0

Torque converter outlet oil pressure (MPa)

0.6~0.75

Type

Fixed shaft power shift

Gear shifting

Forward-4-reverse-4

Gearshift pressure (MPa)

1.9~2.3

Adaptable automobile modes

LG956V, LG958N, LG969N, LFT30

LG968V,

LG968N,

VRT200 transmission (also known as A306 transmission) is a new generation product of high performance and high reliability, which is jointly developed by SDLG and VOLVO according to VOLVO standards and development processes. VRT200 transmission is in the leading domestic level, which greatly improved technical merit and market competitiveness of wheel loaders designed by SDLG. VRT200 is electro-hydraulic controlled fixed shaft power shift transmission, and on-off control of hydraulic circuit is realized by pulling-in/out of solenoid valve. Through combined work of the clutches, forward-4-reverse-4 function can be achieved. The transmission is designed with KD (kick down) function (namely forced downshift function), power cutoff and gear interlock function, the shifting process is steady and stable.

VRT200 Transmission Service Manual

22 Structure of Transmission VRT200 transmission is mainly composed of three parts: torque converter, transmission box (clutch box) and transfer case (PTO), as shown in Fig. 2-1. Power from engine is processed by the transmission (slowdown and increase torsion) and outputted via the PTO. By engaging the KR gears in the transmission box, backward driving of the vehicle can be realized.

Transmission box (clutch box)

Transfer case (PTO) Torque converter

Fig. 2-1

Fig. 2-2 1 Lubricating oil valve

2 Oil filler of transmission box

3 Oil filler of transfer case

4 Oil dipstick of transfer case

5 Parking brake

6 Brake disc

7 Oil drain plug of transfer case

8 Oil pan

9 Transmission control valve

10 Power takeoff (PTO)

11 Filter

12 Turbine

VRT200 Transmission Service Manual

221 Torque Converter 1.

Structure of torque converter

Fig. 2-3 1 Elastic plate

2 Front cover

6 Turbine shaft

7 Guide wheel seat

3 Turbine

4 Guide wheel

5 Pump impeller

Torque converter is composed of elastic plate, front cover, pump impeller, guide wheel, turbine and turbine shaft. The guide wheel seat is fixed on torque converter housing, the transfer gear is fixed with front cover and supported on guide wheel seat by needle bearings. Front cover, pump impeller, guide wheel and turbine are all adopt unitary structure, which are connected with guide wheel seat by spline. 2.

Power transmission line of torque converter

Power input: The outer bolts of elastic plate are connected with engine flywheel, while the inner bolts are connected with torque converter front cover and pump impeller, so as to transmit power from engine to the converter. Power output of torque converter is separated into two parts: (1) Output by turbine shaft, one end of turbine shaft is connected with turbine module by spline, the other end is connected with front/rear baffle shaft by spline too. So as to transmit one part of power to the transmission. (2) Output by the transfer gear that secured together with front cover, power from the transfer gear passes through two transition wheels to drive the working pump and steering pump. Fig. 2-4

VRT200 Transmission Service Manual 3.

Oil supply of torque converter

Two oil galleries are processed in/on torque converter guide wheel seat, the outside one is oil inlet of torque converter, while the inner one is oil outlet. An inlet relief valve is installed in the inlet port of torque converter housing (guide wheel seat), which is used to control the inlet oil pressure. While the outlet oil pressure is controlled by counterbalance valve that installed on lubricating oil valve assembly. The contact area between guide wheel seat excircle and the transfer gear, and contact area between turbine shaft and guide wheel seat inner bore are sealed by seal rings that made from polyester material. Refer to Fig. 2-5 for oil supply diagram of torque coveter.

Fig. 2-5

222 Clutch Box (Transmission Box) 1.

Structure of clutch box

Fig. 2-6 1 Torque converter

2 Transition gear for KR gears

4 KF/KR clutch shaft assembly

5 Intermediate shaft

3 K1/K2 clutch shaft assembly 6 K3/K4clutch shaft assembly

VRT200 Transmission Service Manual Clutch box consists of 4 shafts and 6 similarly structured gear clutches. K1 and K2 clutch, K3 and K4 clutch, and KF and KR clutch are respectively installed on three clutch shafts. An intermediate shaft is installed in the middle of the three clutch shafts. By engagement of the intermediate gear and gears that installed on three clutch shafts, forward-4-reverse-4 gear function can be realized. Inner ends of the four shafts are supported by torque converter housing, while the outer ends are supported by transmission box housing. 2.

Power transmission line of clutch box

Power from torque converter passes through turbine shaft to KF/KR clutch shaft in clutch box (by engaging of KF gear and intermediate gear). A transition gear is designed between KR gear and intermediate gear to carry out speed reduction, torque increasing and power transfer direction. And then power passes through gears in clutch box to transfer case. 3.

Clutch assembly

Clutch is mainly composed of clutch shaft, isolation carrier (two-way oil cylinder block), piston, drive and driven friction plates, clutch hub, pressure plate, gear assembly (gear, ring gear), return spring and bearings.

Fig. 2-7 1 Clutch shaft

2 Bearing

3 Gear assembly

5 Drive and driven friction plates 6 Isolation shaft 7 Piston

4 Pressure plate

8 Return spring 9 Clutch hub

The pressure oil delivered by transmission control valve, flows into oil cylinder through oil gallery inside the clutch shaft, to push the piston to move and press the friction plate against the pressure plate. And then power outputs via the ring gear (gear assembly) that connected with drive friction plate. (1) KF/KR clutch 1) Installation site of clutch assembly KF/KR clutch assembly is installed in top of transmission box, supported on torque

VRT200 Transmission Service Manual converter and transmission box housing by two tapered roller bearings. The inner one is KR clutch, while the outer one is KF clutch. The shaft end on KR clutch side is connected with torque converter output shaft by spline, so that the power outputted by torque converter can be delivered to transmission box.

Fig. 2-8 2) Structure of KF/KR clutch assembly

Fig. 2-9 1 Lubricating oil gallery

2 KR clutch

3 KR clutch working oil gallery

4 KF clutch

5 KF clutch working oil gallery

6 Oil distributor

3) Oil supply of clutch Oil inlet of KF/KR clutch is designed on top of transmission box housing. An oil distributor is used to allocate oil from transmission control valve to the two clutch oil cylinders. The distributor inner side oil port is KF gear clutch oil inlet, while the outside one is KR gear clutch oil inlet. The staggered oil ports in the middle of oil distributor are inlet of lubricating oil. Lubricating oil directly comes from lubricating oil valve, and then flows through the oil

VRT200 Transmission Service Manual distributor into the two clutches, for cooling and lubricating of bearings and friction plates inside the clutch. 4) Main parts and components of clutch assembly a) Gear assembly 

Ring gears of KF/KR clutch are of the same diameter and height (whose diameter is bigger than that of isolation carrier). Each end is weld fitted with a helical gear (KF gear has three more teeth than KR gear). The KF gear (clutch) is engaged with the KF gear and K2 gear on intermediate shaft. The KR gear (clutch) is indirectly engaged with KR gear and K3 gear on intermediate shaft via an idle gear.



Gear assembly is installed on rear end of clutch shaft. Since two needle roller thrust bearings and two needle bearings are used to support the gear and gear shaft respectively, the gear assembly can rotate smoothly.

b) Isolation carrier 

Isolation carrier of the KF/KR clutch has the minimum diameter and thickness (compared to other carriers). Oil chamber is designed for oil cylinder on both sides, and a radial orifice of 1mm is processed on each end of the isolation carrier leading to outside of the cylinder.



Shrinkage fit is adopted between isolation carrier inner bore and clutch shaft, fixed by retainer ring on both ends.



Isolation carrier inner bore directly contacts with gear piston seal ring, thus, sealed chamber will be formed during working.

c) KF/KR clutch shaft 

KF/KR clutch shaft has the shortest length among the three clutch shafts.



Only lubricating oil port of KF/KR clutch shaft is radially processed on journal.



Gear assembly on both ends of clutch shaft is processed with a retainer ring groove. Besides, there is a blackened free-of-grinding area on the journal at the top of each retainer ring. The size of blackened area that close to spline end (KR gear end) is 2.5 times of the other blackened area, about 25mm, while the other end is about 10mm.

d) Drive and driven friction plates 

KF gear clutch and KR gear clutch has the same number of friction plates, 9 drive plates and 9 driven plates respectively (among the 9 plates, three of them have

VRT200 Transmission Service Manual thickness of 1.9mm, while the other 6 have thickness of 2.1mm). 

Assembly sequence of friction plates: The fiction plates on piston side are driven plates, while the plates on pressure plate side are drive ones.



After assembling of friction plates and pressure plate are finished, be sure to measure the clearance between the last drive friction plate and pressure plate with feeler gauge, the measured value should be within 2.65~3.35mm.

e) Piston, seal ring 

Isolation carrier of KF/KR clutch has different structure than other carriers, number of pistons are different too. The annual groove on piston is installed with an outer piston ring, which directly contacts with cylinder block inner wall for sealing.



Piston ring is made from soft material (polyester). When installing the piston ring to piston annual groove or clutch shaft seal groove, you can bend the ring inwardly to smaller its diameter, and then nest it into the ring groove, so as to avoid damaging sealing surface of the ring.

f)

Clutch hub, return spring 

Clutch hub is connected with clutch shaft by spline, and two semicircular thrust plates that installed in the locating grooves (chamfer end of the thrust plate faces upward) on clutch shaft are used to fix the hub axially. Internal teeth of clutch driven friction plates are connected with the hub external teeth, while external teeth of the drive friction plates are connected with internal teeth of gear assembly. During working, the drive and driven friction plates can move along their tooth grooves axially.



Return spring pocket is installed in inner bore on clutch hub, one end contacts with piston end face, and the other end contacts with hub end. When the cylinder stops supplying oil, the piston can return to its original position under action of return spring force.



Specification of clutch hub and return spring: Clutch hub is divided into three types: Hub of KF/KR/K1 clutch has the longest length, hub of K3 clutch comes second, and hub of K2/K4 is shortest type. Return spring is divided into two types: Return spring of KF/KR/K1/K3 clutch is longer than that of K2/K4 clutch.

g) Pressure plate, circlip

VRT200 Transmission Service Manual 

After assembling the friction plates orderly, nest the pressure plate onto clutch hub (spline connection), and then snap an outside circlip into the groove on hub end, snap a double-layer inside circlip into the groove on pressure plate, inner surface of the double-layer inside circlip should contact with outer surface of the outside circlip after assembling. Purpose: The outside circlip is used to fix the pressure plate. The double-layer inside circlip can prevent the outside circlip from getting loose or broken and falling off, the inside circlip can also keep the pressure plate stable under stress.

(2) K1/K2 clutch 1) Installation site of the clutch assembly K1/K2 clutch assembly is installed in left-bottom side of transmission box (towards engine flywheel), supported on torque converter and transmission box housing by two tapered roller bearings. The inner one is K1 clutch, while the outer one is K2 clutch. The shaft end on K2 clutch side is connected with K1/K2 shaft inside the transfer case by spline (the skeleton oil seal on transmission box side is used to seal K1/K2 shaft journal), so that the K1/K2 power can be transmitted to the transfer case.

Fig. 2-10

2) Structure of K1/K2 clutch assembly

Fig. 2-11 1 Lubricating oil gallery

2 K1 clutch working oil gallery

4 K2 clutch working oil gallery

5 K2 clutch

3 K1 clutch

VRT200 Transmission Service Manual 3) Oil supply of clutch Oil inlet of K1/K2 clutch is designed on inner side of torque converter housing. An oil distributor is used to allocate pressure oil from transmission control valve to the two clutch oil cylinders through oil gallery inside the torque converter housing. The distributor inner side oil port is K2 clutch oil inlet, while the outside one is K1 clutch oil inlet. Lubricating oil inlet is designed on the distributor end. 4) Main parts and components of clutch assembly a) Gear assembly 

Ring gears of K1/K2 clutch are of the same diameter (whose diameter is bigger than that of isolation carrier) but different height/thickness. Ring gear of K1 clutch is significantly thicker than that of K2 clutch (about 10mm).



End of ring gear: Ring gear of K1 clutch is weld fitted with a spur gear (K1 gear), diameter of the gear is significantly greater than that of K1 gear. Ring gear of K2 clutch is weld fitted with a helical gear. K1 gear meshes with the smallest spur gear on intermediate shaft. K2 gear meshes with the KF gear and K2 gear on intermediate shaft.

b) Isolation carrier 

Isolation carrier of the K1/K2 clutch has the maximum diameter and thickness (compared to other carriers). Shrinkage fit is adopted between isolation carrier inner bore and clutch shaft, fixed by retainer ring on both ends. Isolation carrier inner bore directly contacts with gear piston seal ring, thus, sealed chamber will be formed during working.

c) K1/K2 clutch shaft 

K1/K2 clutch shaft has neither the shortest nor the longest length among the three clutch shafts.



Lubricating oil port of K1/K2 clutch shaft is radially processed on the end of journal.



There is only one retainer ring groove processed on clutch shaft end gear assembly.



Lubricating oil gallery is processed in the middle of clutch shaft. In the area nearby spline, there is a orifice with diameter of about 2mm goes through center of clutch shaft to lubricate the spline and bearing.

d) Drive and driven friction plates

VRT200 Transmission Service Manual 

K1 clutch has 10 drive plates and 10 driven plates respectively (among the 10 plates, eight of them have thickness of 1.9mm, while the other two have thickness of 2.1mm).



K2 clutch has 6 drive plates and 6 driven plates respectively (among the 6 plates, two of them have thickness of 1.9mm, while the other four have thickness of 2.1mm).



Assembly sequence of friction plates: The fiction plates on piston side are driven plates, while the plates on pressure plate side are drive ones.



After assembling of friction plates and pressure plate are finished, be sure to measure the clearance between the last drive friction plate and pressure plate with feeler gauge, the measured value should be within 2.85-3.35mm for K1 clutch and 1.75-2.25mm for K2 clutch.

e) Piston, seal ring 

Since each end of the isolation carrier are designed with both inside oil gallery and outside oil gallery, there are two sealing surfaces in the contact area between piston and isolation carrier. The annual groove on piston is installed with an outer piston ring, which directly contacts with cylinder block inner wall for sealing. The inner piston ring directly contacts with the sealing ring installed on clutch shaft for sealing.



Material and installation method of the seal ring are the same as those of KF/KR clutch seal ring.

(3) K3/K4 clutch (K1/K2) 1) Installation site of the clutch assembly K3/K4 clutch assembly is installed in right-up side of transmission box, supported on torque converter and transmission box housing by two tapered roller bearings. The inner one is K3 clutch, while the outer one is K4 clutch. The shaft end on K4 clutch side is connected with K3/K4 shaft inside the transfer case by spline (the skeleton oil seal on transmission box side is used to seal K3/K4 shaft journal), so that the K3/K4 power can be transmitted to the transfer case.

Fig. 2-12

VRT200 Transmission Service Manual 2) Structure of K3/K4 clutch assembly

Fig. 2-13 1 Lubricating oil gallery

2 K3 clutch working oil gallery

4 K4 clutch working oil gallery

5 K4 clutch

3 K3 clutch

3) Oil supply of clutch Oil inlet of K3/K4 clutch is also designed on inner side of torque converter housing. An oil distributor is used to allocate pressure oil from transmission control valve to the two clutch oil cylinders through oil gallery inside the torque converter housing. The distributor inner side oil port is K3 clutch oil inlet, while the outside one is K4 clutch oil inlet. Lubricating oil inlet is designed on the distributor end. 4) Main parts and components of clutch assembly a) Gear assembly 

Ring gears of K3/K4 clutch are of the same diameter (whose diameter is smaller than that of isolation carrier) but different height/thickness. Ring gear of K3 clutch is significantly thicker than that of K4 clutch (about 5mm).



End of ring gear: Ring gear of K3/K4 clutch is weld fitted with a helical gear, diameter of K3 gear is significantly greater than that of K2 gear. K3 gear meshes with the K3 gear and KR gear on intermediate shaft. K4 gear meshes with the K4 gear (the biggest one) on intermediate shaft.

b) Isolation carrier 

Isolation carrier of the K3/K4 clutch has the medium diameter and thickness (compared to other carriers). Shrinkage fit is adopted between isolation carrier inner bore and clutch shaft, fixed by retainer ring on both ends. Isolation carrier inner bore directly contacts with gear piston seal ring, thus, sealed chamber will be formed during working.

c) K3/K4 clutch shaft

VRT200 Transmission Service Manual 

K3/K4 clutch shaft has the longest length among the three clutch shafts.



Lubricating oil port of K3/K4 clutch shaft is also processed on the end of journal.



The oil inlet end of clutch shaft (top of gear assembly) is processed with a retainer ring groove.



Lubricating oil gallery is processed in the middle of clutch shaft. In the area nearby spline, there is a orifice with diameter of about 2mm goes through center of clutch shaft to lubricate the spline and bearing.

d) Drive and driven friction plates 

K1 clutch has 9 drive plates and 9 driven plates respectively (among the 9 plates, eight of them have thickness of 1.9mm, while the other one has thickness of 2.1mm).



K2 clutch has 6 drive plates and 6 driven plates respectively (among the 6 plates, four of them have thickness of 1.9mm, while the other two have thickness of 2.1mm).



Assembly sequence of friction plates: The fiction plates on piston side are driven plates, while the plates on pressure plate side are drive ones.



After assembling of friction plates and pressure plate are finished, be sure to measure the clearance between the last drive friction plate and pressure plate with feeler gauge, the measured value should be within 2.65-3.35mm for K3 clutch and 1.75-2.25mm for K4 clutch.

e) Piston, seal ring 

Structure and installation method of the piston and seal ring of K3/K4 clutch are the same as those of K1/K2 clutch.

(4) Intermediate shaft assembly 1) Installation site of intermediate shaft assembly Intermediate shaft assembly is installed between the

three

clutch

assemblies

inside

the

transmission box, supported on torque converter and transmission box housing by two tapered roller bearings. 2) Function of intermediate shaft assembly The gears on forward/reverse clutch assembly mesh with gears on intermediate shaft, or gears

Fig. 2-14

VRT200 Transmission Service Manual on intermediate shaft mesh gear I/II/III/IV gear to transmit power (torque) to transfer case. 3) Structure of K3/K4 clutch assembly Intermediate shaft assembly is composed of one shaft and four gears, including a naturally processed helical gear (reverse, gear III). The smallest gear (spur gear, gear I) is shrinkage fitted on the shaft against the naturally processed helical gear. On the other end of the shaft, two gears are installed: the inner one is helical gear (forward, gear II) with relatively large diameter; while the outer one is helical gear (gear IV) with the biggest diameter.

Fig. 2-15 1 Spur gear 4.

2 Intermediate transmission shaft

3 Helical gear

4 Helical gear

Power takeoff (PTO) assembly 1) Installation site of PTO There are two PTO assembly installed on top of the torque converter housing, the left one is for working pump, and the right one is for steering pump. 2) Function of PTO Power supplied by engine can be transmitted to the two gear pumps by engagement of drive gear in the PTO and driven gear in torque converter. 3) Structure of PTO PTO gear is installed on PTO shaft, supported by

Fig. 2-16

two ball bearings in PTO case. An orifice plug and bowl shape plug are installed in the middle of PTO end cover, as shown in Fig. 2-17.

VRT200 Transmission Service Manual

Fig. 2-17 1 Orifice plug

2 Bowl-shape plug

3 PTO shaft

4 PTO gear

4) Function of bowl-shape plug and orifice plug a) Bowl-shape plug is used to prevent backflow of lubricating oil, make sure there is enough lubricating oil during working and avoid all oil returning back to oil pan. b) Orifice plug is used to build up lubricating oil pressure. Besides, the injected oil can go through clearance between spline teeth to lubricate the bearings.

223 Transfer Case 1.

Function of transfer case The transfer case can further reduce output speed and increase torque, and keep the output shaft in a suitable position. Besides, parking brake is designed on the transfer case for realization of parking brake.

Fig. 2-18 1 Speed sensor

2 Transfer case oil filler

3 Transfer case oil dipstick

5 Parking brake

6 Vent pipe

7 Oil drain plug

4 Brake disc

8 Rear output flange

VRT200 Transmission Service Manual 2.

Structure of transfer case Transfer case is composed of K1/K2 gear, K3/K4 gear, intermediate gear, output gear and casing. Its main function is to further reduce speed and increase torque of power from transmission box and output.

Fig. 2-19 1 K3/K4 gear

2 K1/K2 gear

3 Intermediate gear

4 Output gear

VRT200 Transmission Service Manual

23 Transmission Principle 231 Transmission Principle Diagram

Fig. 2-20

232 Power Transmission Line of Each Gear KF gear I power transmission line: Torque converter output shaft → KF → ZF → ZI3 → ZI1 → Z1 → K1 → Z12 → ZI → Zoutput

Fig. 2-21

VRT200 Transmission Service Manual KF gear II power transmission line: Torque converter output shaft → KF → ZF → ZI3 → Z2 → K2 → Z12 → ZI → Zoutput

Fig. 2-22

KF gear III power transmission line: Torque converter output shaft → KF → ZF → ZI3 → ZI2 → Z3 → K3 → Z34 → ZI → Zoutput

Fig. 2-23

VRT200 Transmission Service Manual KF gear IV power transmission line: Torque converter output shaft → KF → ZF → ZI3 → ZI4 → Z4 → K4 → Z34 → ZI → Zoutput

Fig. 2-24

KR gear I power transmission line: Converter output shaft → KR → ZR → Zm → ZI2 → ZI1 → Z1 → K1 → Z12 → ZI → Zoutput

Fig. 2-25

VRT200 Transmission Service Manual KR gear II power transmission line:

KR gear III power transmission line:

Converter output shaft → KR → ZR → Zm → Converter output shaft → KR → ZR → Zm → ZI2 → ZI3 → Z2 → K2 → Z12 → ZI → Zoutput

ZI2 → Z3 → K3 → Z34 → ZI → Zoutput

Fig. 2-26

KR gear IV power transmission line: Converter output shaft → KR → ZR → Zm → ZI2 → ZI4 → Z4 → K4 → Z34 → ZI → Zoutput

Fig. 2-27

VRT200 Transmission Service Manual

24 Oil Supply and Lubricating System of Transmission 241 Oil Supply Line of Transmission Rotating torque converter pump impeller (driven by engine) → Transfer gear on pump impeller, PTO → Transmission pump is driven to absorb oil from oil pan → Pumped pressure oil → Oil filter (when oil filter element is clogged, bypass valve will open to discharge oil) → Transmission control valve Transmission pump

Fig. 2-28

Fig. 2-29

After flowing through the pressure valve (with set pressure of 1.9~2.2MPa), pressure oil will be divided into two paths: (1) Working oil line 1) Cushion valve → KF/KR gear oil distributor → KF/KR gear clutch 2) Transmission control valve → Interior of transmission box → K2, K3, K4 oil distributor →K2, K3, K4 clutch

Fig. 2-30

Fig. 2-31

VRT200 Transmission Service Manual Pressure oil in the other path goes into the working chamber of torque converter (2) Lubricating oil line 1) Oil in torque converter → One part of the oil circulates between first-second-stage turbine and guide wheel → The other part of oil goes through clearance between gears in the converter → Oil outlet groove on guide wheel seat → Oil outlet of lubricating oil valve → Radiator → Oil return port of lubricating oil valve

Fig. 2-32

Fig. 2-33

1 Lubricates the two PTOs 2) Cooling oil from the radiator

2 Flows through the KF/KR gear oil distributor to lubricate the clutch 3 Flows through the K1/K2 and K3/K4 oil distributor to lubricate the clutch 4 Redundant oil goes back to transmission box

Fig. 2-34

Fig. 2-35

VRT200 Transmission Service Manual

242 Main Components in Transmission Oil Supply System (1) Filter The filter is installed on right side of torque converter casing (next to the transmission control valve). Transmission oil flows into the filter through the inlet port conjoined by the filter and torque converter casing. Oil inlet port of the filter is connected to oil inlet port of transmission control valve by an oil pipe. A bypass valve is designed inside the filter, which is used to allow oil through when the filter element is clogged. A sensor is installed on the end of the filter, which is able to send warning signal to the instrument panel once the filter element is clogged (the filter element must be replaced if alarm indicator on instrument panel is on).

Fig. 2-36 1 Bypass valve

2 Transmission oil filter switch

3 Filter element

(2) Transmission control valve The transmission control valve adopts electro-hydraulic drive mode. When a gear is selected, one or more solenoid valves on the transmission control valve will be activated, in this case, transmission oil will flow into the corresponding clutches to realize gear shifting. Transmission control valve consists of 6 valve rods and 5 solenoid valves. Among the 6 valve rods, one is different from the rest five, which is used to control main pressure of the transmission. A cushion valve is designed on the of transmission control valve for realization of steady gear shifting process. Main pressure of transmission system is controlled by pressure regulating valve inside the transmission control valve. The five same valve rods can move to open or close oil galleries inside to realize traveling of the vehicle.

VRT200 Transmission Service Manual

Fig. 2-37 1 Transmission oil pressure switch port

2 Main pressure measuring joint

4 Pressure regulating valve

5 Gear selector valve



3 Cushion valve

Solenoid valve (Gear selector valve): A set of solenoid valves (From top to bottom the valves are S4, S3, S1, S2, S5) are integrated on transmission control valve body. The solenoid valves are connected with gear selector by wires. Once the solenoid valve is electrified, the orifice on one end of the valve will open, and then the valve rod will move under the action of pressure oil to open the oil galleries inside. Once solenoid valve is out of power, the orifice will be blocked by valve rod, and the valve rod will return to its original position to close the oil galleries under action of spring force. Refer to table 2-2 for working condition of the five solenoid valves in each gear. Table 2-2 Gear

Solenoid valve S1

S2

S3

S4 ●

S5

Activated clutch

Neutral Forward II

●

●

Forward II

●

●

Forward III

●

Forward IV

●

Reverse I

●

●

●

Reverse II

●

●

●

Reverse III

●

●

Reverse IV

●

●

KF, K1 KF, K2 KF, K3 ●

●

KF, K4 KR, K1 KR, K2 KR, K3

●

KR, K4

VRT200 Transmission Service Manual The mark “●” means that the solenoid valve is electrified 

Cushion valve: There are two cushion valves installed on transmission control valve body, the one on torque converter side is used to control F (forward) gears, the one on transfer case side is used to control R (reverse) gears. For each cushion valve, an oil outlet pipe is connected to the oil port on bottom of the valve, while the other end of the pipe is connected to KF/KR gear oil distributor. In the moment of gear shifting, the valve can cushion the engagement of clutches to realize steady gear shifting process. The cushion function is realized by structure of the oil cylinder block and oil supply time difference of the orifice.

Fig. 2-38 (3) Lubricating oil valve The valve assembly is installed on right side of torque converter casing, including a lubricating oil valve and a torque converter outlet oil counterbalance valve. The upper one is used to control lubricating oil pressure: 0.12~0.3MPa, while the bottom one is used to control torque converter outlet oil pressure: 0.6~0.75MPa. When the oil pressure exceeds the set value, the valve rod will move to open the pressure relief opening and the redundant oil will return back to transmission through the opening.

Fig. 2-39 1 Torque converter outlet oil counterbalance valve

2 Torque converter oil outlet port

VRT200 Transmission Service Manual 3 Relief valve

4 Relief valve oil return port

5 Lubricating oil port for K1/22, K3/K4 clutch assembly (4) Oil distributor In transmission system, the pressure oil and lubricating oil is allocated to each clutch assembly by the oil distributors and inlet oil ring grooves on clutch shaft, to realize engagement of different gears and lubricating function. There are three oil ports on the distributor, two of them are for pressure oil, and the third one is for lubricating oil. K1/K2, K3/K4 oil distributor and KR/KF oil distributor are not the same. The middle oil port on KR/KF oil distributor is lubricating oil port, while for K1/K2 and K3/K4 oil distributor, the lubricating oil port is on the end of the distributor.

Fig. 2-40 1 KR/KF oil distributor

2 K3/K4 oil distributor

3 K1/K2 oil distributor

243 Transmission Oil Supply Principle (1) After starting the vehicle, the oil pumped by transmission pump will flow into transmission control valve through the filter first, after being regulated by the pressure valve, the pressure oil will be divided into two paths: One part of oil will flow into transmission box to engage the clutches; the other part of oil will flow into torque converter to drive the turbine module. Outlet transmission oil from torque converter will flow through the radiator for cooling and then enter into the transmission to cool and lubricate the parts and components inside. (2) Function of transmission control valves 

U is pressure valve, which is used to control the system main pressure and supply oil to transmission box and torque converter, while the redundant oil will return back to oil pan through the oil return port.

VRT200 Transmission Service Manual 

S1 is stop valve, only when the valve is electrified can the oil line to each clutch be connected, normally the oil lines are disconnected.



S2 is F/R switching valve, when the valve is electrified, an R gear must be engaged. Normally, transmission is supplied for F gears.



S3 is high/low speed switching valve, when the valve is electrified, oil will be supplied to engaged gear I/II. Normally, transmission oil is supplied to engage gear III/IV.



S4 is gear I/II switching valve, when the valve is electrified, oil will be supplied to engage gear I. Normally, transmission oil is supplied to engage gear II.



S5 is gear III/IV switching valve, when the valve is electrified, oil will be supplied to engage gear IV. Normally, transmission oil is supplied to engage gear III.

Fig. 2-41

VRT200 Transmission Service Manual

244 Pressure Test of Transmission System

Fig. 2-42 Table 2-3 Code of pressure measuring port T1 T2 T3

Name of pressure measuring port

Pressure range

Torque converter outlet oil pressure and temperature measuring port

0.6~0.75MPa

Transmission system main pressure measuring port Torque converter inlet oil pressure and temperature measuring port

1.9~2.3MPa 0.8~1.0MPa

T4

KR pressure measuring port

1.8~2.2MPa

T5

KF pressure measuring port

1.8~2.2MPa

T6

I, II, III, IV gear pressure measuring port (from top to bottom)

1.8~2.2MPa

T7

Lubricating oil pressure measuring port

0.12~0.35MPa

(1) Main pressure of transmission system is controlled by pressure regulating valve inside the transmission control valve. Measuring port T2 is on top of transmission control valve body. (2) Torque converter inlet oil pressure valve is installed in torque converter casing. Measuring port T3 is on right-up side of transmission control valve (inlet oil temperature can also be measured here). (3) Torque converter inlet oil pressure valve is a part of lubricating oil valve assembly. Lubricating valve assembly consists of two valve rods: The upper one is used to control lubricating oil pressure: while the bottom one is used to control torque converter outlet oil pressure.

VRT200 Transmission Service Manual Lubricating oil pressure measuring port T7 is designed on torque converter casing (nearby the transmission control valve) (4) On torque converter casing between transmission control valve and the filter, there are five oil measuring ports. From top to bottom the oil ports are: I, II, III, IV gear pressure measuring port and lubricating oil pressure measuring port. (5) KF/KR pressure measuring port is designed on the oil distributor. The inner one is KF pressure measuring port, and the outside one is KR pressure measuring port.

VRT200 Transmission Service Manual

25 Electric Control of Transmission 251 Principle VRT200 transmission electric control principle diagram (here we take LG956V for example):

Gear selector Controller

Transmission control valve Speed sensor

(Power cutoff) (Reverse/backup)

(Start interlock)

Fig. 2-43 

Power 48#



Ground wire 0#

VRT200 Transmission Service Manual 

Power cutoff signal input 57#: The power will be cut off if the input is high-level signal.



Reverse output signal 58#: Output high-level signal when an R gear is engaged.



Start interlock output 59#: Output high-level signal when neutral gear is engaged.

252 Functions (1) Gear shifting function The gear shifting control handle must be able to control the solenoid valves correctly according to Table 2-2. Adjust the shifting time and clutch engaging time, and prevent impact when jump shifting. (2) Neutral start interlock function The engine can be started only when gear shifting control handle is neutral position. Before engine is started, there is only AD2 signal when gear shifting control handle is neutral position. In this case, CPU is able to send signal to the external starting relay to close the relay, and then the engine can be started. When gear shifting control handle is in other positions, CPU is not able to send signal to the external starting relay. (3) Reverse signal output function When a KR gear is selected, the gear shifting control handle will send AD5 signal to CPU. And then the CPU reverse signal output port will output signal. (4) Forced Kick-Down function (KD function) There is KD button on the gear shifting control handle, press this button (there will be AD7 and AD3 signal) when the handle is in forward II or reverse II position, a lower gear will be switched to automatically. One of the following ways can be used to deactivate the KD function. 1) Press the KD button again. 2) Turn the gear shifting handle to select a different gear. 3) Engage the neutral gear. (5) Power cutoff function When engaging foot brake or emergency brake during driving, an external positive electrical signal can be used to cut off the pressure oil of gear I/II. In this case, power from engine will not be outputted by the transmission. When the gear shifting handle is in gear I or II position, the power will be cut off once the foot brake is engaged, while in other gears, the power cutoff function is not activated. (6) Anti-interference and anti-disorder of gears

VRT200 Transmission Service Manual When the electrical system is influenced by external radiation, the system will not malfunction. The solenoid valves will not interfered by each other and mis-operate. (7) Gear interlock function The solenoid valves have interlock function, only the required solenoid valves will be activated when a gear is selected, the others will be locked.

253 Transmission Controller LGTC-3 (1) Structure

Fig. 2-44 1 SCM

2 35-core connector

3 Power module

4 Power output module

5 Program downloading pins CPU is the core part of the whole system, it hardware interface is composed of two parts: 1) Input interference 

The gear shifting control handle is designed with 8 signal input interferences: AD1~AD7 and a power interference (refer to the logic diagram for details).



Power interference, which must feature wide-voltage-range function (DC9V~DC36V).



Speed sensor input signal interference.



Power cutoff input signal interference.

2) Output interference 

5 solenoid valve signal interferences (required current for each interference is 1.5A).



1 reverse output signal interference (required current for the interference is 1A).

VRT200 Transmission Service Manual 

1 neutral start interlock signal interference (for starting protection, the required current is 1A).



A set of diagnostic output interferences (preinstalled).

(2) Control interference Logic diagram of transmission controller: On the electrical systematic drawing, the solenoid valve M6 and M7 represents real valve S3 and S4 respectively.

254 Gear Selector (Gear Shifting Control Handle) (1) Function introduction 1) KD (Kick-Down) function, i.e., forced down-shift function. 2) Gear I/II power cutoff function. 3) Neutral start interlock function make the vehicle safer. (2) Gear shifting control handle output logic diagram Gear selector Forward (F) Control Gear Wire wire Terminal selector 1 2 3 4 color 270 7 AD1 B1 ● ● 280 8 AD2 B2 ● ● 290 9 AD3 B3 ● ● ● ● 240 4 AD4 V ● ● ● ● 58 6 AD5 R 59 5 AD6 AS 210 10 AD7 220 2 ED1

Reverse (R) 1

2

Neutral gear

3

4

1

● ● ●

●

●

● ●

●

● ●

●

●

●

2

KD

3

4 ● ● ●

●

●

●

● ●

●

●

●

● (+)

255 Solenoid Valve The solenoid valves are arranged for realization of progressive control, from top to bottom the valves are S4, S3, S1, S2, S5. Specification of each valve is about 26Ω-20w, the resistance may increase as temperature rises during working. 

S1 is F gear control solenoid valve.



S2 is R gear control solenoid valve.



S3 is high/low gear control solenoid valve.



S4 is gear I control solenoid valve.



S5 is gear IV control solenoid valve.

VRT200 Transmission Service Manual

Fig. 2-46

256 Fault Detection of Transmission Controller The ECU (electric control unit) is able to monitor all input signals from gear selector and output signals from solenoid valve and speed sensor (refer to the electric system principle diagram). When an abnormal signal combination occurs (such as abnormal signal caused by worn cable), the ECU will act to switch to neutral state immediately and lock all output signals. The system will act in the same way if the power exceeds specified range or there is open circuit. Turn the gear shifting handle to neutral gear at this point, the ECU will reset to normal state. Thus, when the ECU plug or transmission control valve plug is not firmly connected, the solenoid valve coil will be open-circuit and result in no gears of the vehicle. So make sure the circuit is in normal connection and restart after troubleshooting the solenoid valves. (1) Method to measure resistance of the solenoid valve: Pull out the transmission control valve plug(s), loosen the wire terminals of the solenoid valve. Connect the red probe of the multimeter (V/Ω) to one end of the solenoid valve, and connect the black probe to the other terminal to measure the resistance, which should be about 26Ω. The valve is faulty and must be replaced if the measured resistance is not in the specified range. If the resistance is 0, then there must short circuit in the solenoid valve. If the resistance is infinitely great, then there must be open circuit. Considering that ambient temperature may have some influence on the resistance of the valve, there may be a gap (a few ohms) between the measured value and the specified range, but the solenoid valve can still work normally. (2) Use multimeter to check whether each gear and function is normal Method to check whether the KD button on gear shifting handle is normal: Connect one probe of the multimeter to the red wire, and the other probe to the purple wire. When measuring, turn the shifting handle to Forward gear II, press the KD button do not release it, at this point, if the measured resistance is 0, then it indicates that the circuit is in good connection. Release the KD button, and the resistance should be infinitely great.

VRT200 Transmission Service Manual Yellow

Blue

Purple

Red/Black

Grey Green

Pink

Black

Fig. 2-47 Method to check whether the wiring of each gear is in good condition: Connect the multimeter to the handle 2# wire and each terminal marked with ● in the logic diagram.

VRT200 Transmission Service Manual

3 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION 31

Key points for Disassembly and Assembly of Transmission

311 Disassembling Tools and Gauges Common tools Table 3-1 Name

Specification

Qty.

Application

Pneumatic wrench

MI-16, MI-17HE, MR-2410B

1 set

Choose according to the size of the to be assembled bolt

Socket

10, 13, 16, 18, 22, 24, 27

1 set

Choose according to the size of the to be assembled bolt

1 for each

Used to knock gently to disassemble some tight parts

Adz-eye hammer, rubber hammer Hexagon socket head wrench

6, 12

1 for each

T-shape socket

5, 6, 8, 12

1 for each

Dull-head wrench

24, 26, 27

1 for each

Ratchet wrench

10, 13, 16, 18

1 for each

Slotted screwdriver

6.0×150, 3.0×75

1 for each

Stud socket

M12

Socket extension

300mm, square head 10, 12.5

1 for each

Retainer plier

For shaft/hole, 300mm, straight head

1 for each

Puller

Double-claw puller, width 90, depth 135

1

Puller

Double-claw puller, width 250, depth 200

1

Puller

Double-claw puller, width 310, depth 300

1

Chuck puller

Double-claw puller, width 310, depth 300

1

1

VRT200 Transmission Service Manual Special tools Table 3-2 S/N

Name

Specification

Qty.

1

6390300030

Mount support for transmission box

1

2

6390300075

1

3

6386900027

4

6386900028

Mount support for transfer case Torque converter side shaft end runout measuring tool Shaft end runout measuring tool

5

6392200431

Dam-board

1

6

6392201258

KR gear bearing outer ring press-fitting tool

1

7

6900002607

Oil seal pressing sleeve K1/K2

1

8

6900002613

Oil seal pressing sleeve K3/K4

1

9

6392201372

6210 bearing outer ring press-fitting tool

1

10

6392201373

6210 bearing outer ring press-fitting tool

1

11

6392202063

PTO bearing press-fitting sleeve (inside)

1

12

6392201365

PTO bearing tooling (outside)

1

13

6392201297

PTO transition gear bearing outer ring tooling

1

14

6392201215

Output shaft gear tooling

1

15

6392201214

Output shaft front end oil seal tooling

1

16

6900002617

1

17

6392201225

18

6392201222

19

6392201248

20

6392201244

21

6392201197

Output shaft rear end oil seal pressing sleeve Transfer case intermediate shaft bearing outer ring tooling Transfer case intermediate shaft bearing inner ring tooling Transfer case gear I/II bearing outer ring press-fitting tool Transfer case gear I/II bearing inner ring press-fitting tool Transfer case gear III/IV bearing tooling

22

6392201887

Transfer case gear III/IV assembly lifting appliance

1

1 1

1 1 1 1 1

312 Fit Clearance of Transmission Key Points Table 3-3 S/.N

Fit point

Fit clearance

1

KR gear shaft and intermediate shaft bearing clearance

0.25~0.5mm

2

Clutch piston stroke

4.5~6mm

VRT200 Transmission Service Manual

32

Steps to Disassemble and Assemble the Transmission 321 Disassembly of Transfer Case 1.

Fix the transmission box on the support, and then connect the lifting appliance to the transfer case and lift it up a bit. Remove the connecting bolts between transfer case and transmission box.

Fig. 3-1 1

2.

Fix the transfer case on the support, screw off the parking brake connecting bolts and take down the parking brake.

Fig. 3-2 1 Bolt 3.

Remove the brake disc fixing bolts and gaskets, take down the pressing plate.

1 Fig. 3-3 1 Pressing plate

2 2 Brake disc

VRT200 Transmission Service Manual 4.

Remove the connecting bolts and gaskets between the fixed plate and transfer case, take down the fixed plate.

1 Fig. 3-4 1 Fixed plate 5.

Remove the connecting bolts and gaskets of rear output flange, take down the pressing plate and rear output flange.

ATTENTION Knock the flange gently with copper rod, so as to remove the flange easily.

1 Fig. 3-5 1 Rear output flange 6.

Remove the connecting bolts between K3/K4 assembly bearing retainer and transfer case body. Push the K3/K4 assembly out with jackscrews, take down the sealing gasket and put the K3/K4 assembly aside. Jackscrew: M8

ATTENTION 1 Fig. 3-6 1 Jackscrew hole

Make sure the sealing gasket is intact.

VRT200 Transmission Service Manual 7.

Remove the fixing bolts of K3/K4 assembly end cover.

1 Fig. 3-7 1 End cover 8.

Take down the end cover and O-ring. Remove the snap ring on the bearing with snap ring plier

Fig. 3-8

9.

Knock the K3/K4 assembly bearing out with copper rod

1 Fig. 3-9 1 Bearing

VRT200 Transmission Service Manual 10. Disassemble the end cover of K1/K2 assembly, take down sealing gasket.

ATTENTION Knock the end cover gently with crowbar, to remove it. Make sure the sealing gasket is intact.

1 Fig. 3-10 1 End cover 11. Knock the K1/K2 assembly out slowly with copper rod from the rear side

ATTENTION Knock the assembly gently to avoid safety accident caused by the falling of the assembly.

Fig. 3-11 12. Remove the fixing bolts and gaskets, take down the locking plate, bearing retainer and bearing.

1 Fig. 3-12 1 Locking plate 2 Bearing retainer

2

VRT200 Transmission Service Manual 13. Remove

the

connecting

bolts

between

intermediate shaft assembly bearing retainer and transfer case, use two jackscrews to push the bearing retainer out. Jackscrew: M10

1 Fig. 3-13 1 Bearing retainer 1

14. Take down the bearing retainer and adjusting gasket.

Fig. 3-14 1 Adjusting gasket 15. Screw two M10 bolts into the bolt holes on transfer case body through the bearing retainer, plus a nut and screw a M22×1.5 bolt into the intermediate shaft. Tighten the two M10 bolts evenly to pull the intermediate shaft out.

1 2 3 Fig. 3-15 1 Bolt M10 2 Bolt M22×1.5 3 Bearing retainer

VRT200 Transmission Service Manual 16. Take out the intermediate gear.

1 Fig. 3-16 1 Gear 17. Remove the connecting bolts of bearing retainer on rear output shaft assembly. Push the bearing retainer out with two jackscrews. Jackscrew: M10

1 Fig. 3-17 1 Bearing retainer 18. Take down the bearing retainer, adjusting gasket and O-ring.

1 2 Fig. 3-18 1 Adjusting gasket

2 O-ring

VRT200 Transmission Service Manual 19. Take out the output shaft assembly.

1 Fig. 3-19 1 Output shaft assembly 20. Remove the connecting bolts between transfer case oil dipstick and transfer case body, take down the oil dipstick and paper gasket.

ATTENTION Make sure the paper (sealing) gasket is intact.

1 Fig. 3-20 1 Paper gasket

2 2 Oil dipstick

322 Disassembly of External Parts 1.

Remove the fixing bolts and copper gaskets of lubricating oil pipes on PTO and lubricating oil valve, take down the lubricating oil pipes.

ATTENTION Take

protective

measures

to

ensure

cleanliness of the exposed oil ports and pipe joints.

Fig. 3-21 1 PTO lubricating oil pipe 2 Fixing bolt

VRT200 Transmission Service Manual 2.

Disassemble the KF and KR clutch oil pipe.

ATTENTION Take

protective

measures

to

ensure

cleanliness of the exposed oil ports and pipe joints.

1 2

Fig. 3-22 1 KR clutch oil pipe 1 KF clutch oil pipe 3.

Disassemble the filter to transmission control valve oil pipe.

ATTENTION Take

protective

measures

to

ensure

cleanliness of the exposed oil ports and pipe joints.

1 Fig. 3-23 1 Oil pipe 4.

Remove the filter and O-ring.

ATTENTION Take

protective

measures

to

ensure

cleanliness of the exposed oil ports and pipe joints.

1 Fig. 3-24 1 Filter

VRT200 Transmission Service Manual 5.

Remove the guard plate of transmission control valve, take down the cushion valve and sealing gasket.

ATTENTION Make sure the sealing gasket is intact. Take protective measures to ensure cleanliness of the exposed oil ports and pipe joints.

1 Fig. 3-25 1 Guard plate 6.

Screw off the fixing bolts of transmission control valve, take down the valve and sealing gasket.

ATTENTION Make sure the sealing gasket is intact. Take protective measures to ensure cleanliness of the exposed oil ports and pipe joints. 1 Fig. 3-26 1 Transmission control valve 7.

Remove

the

connecting

bolts

between

lubricating oil valve and torque converter, take down the valve and sealing gasket.

ATTENTION Make sure the sealing gasket is intact. Take protective measures to ensure cleanliness of the exposed oil ports and pipe joints. 1 Fig. 3-27 1 Lubricating oil valve

VRT200 Transmission Service Manual 8.

Remove the two PTOs.

ATTENTION Knock gently with rubber rod, so as to remove the PTO easily.

1 Fig. 3-28 1 PTO

323 Disassembly of Torque Converter 1.

Keep the torque converter upward, lift the torque converter out with lifting appliance.

ATTENTION Keep the lifting process slowly, and turn the converter to detach the internal spline connection in the same time.

1 Fig. 3-29 1 Torque converter 2.

Remove the fixing bolts of the two PTOs, take down the screws, pressing plate, transfer gear and bearing orderly.

12 3 Fig. 3-30 1 Screw 2 Pressing plate 3 Transfer gear

VRT200 Transmission Service Manual

3.

Disassemble the guide wheel seat, take down the sealing gasket.

ATTENTION Make sure the sealing gasket is intact.

1 Fig. 3-31 1 Guide wheel seat 4.

Dismantle the K1/K2 and K3/K4 lubricating oil pipe.

ATTENTION Take

protective

measures

to

ensure

cleanliness of the exposed oil ports and pipe joints. 1 Fig. 3-32 1 Lubricating oil pipe 5.

Remove the auto emptying valve (oil drain valve) seat and steel ball.

1 2 Fig. 3-33 1 K1/K2 oil distributor 2 K3K4 oil distributor

VRT200 Transmission Service Manual

324 Disassembly of Transmission Box 1 2 3

4

1.

Turn over the transmission to keep the torque converter downward. Remove the K1/K2 bearing retainer, take down the adjusting gasket and O-ring. Remove the fixing bolts and gaskets of intermediate shaft assembly, take down the adjusting gasket and spacer bush. Remove the KFR oil distributor, take down the adjusting gasket and O-ring. Remove

5 Fig. 3-34 1 K1/K2 bearing retainer 2 Adjusting gasket 3 Spacer bush 4 KFR oil distributor 5 K3K4 bearing retainer

the K3/K4 bearing retainer, take down the adjusting gasket and O-ring.

ATTENTION Take

protective

cleanliness

of

measures the

to

ensure

disassembled

oil

distributor. 2.

Remove

the

connecting

bolts

between

transmission box and torque converter, lift the transmission box up with lifting appliance and put it aside.

ATTENTION Keep the lifting process slowly. 1 Fig. 3-35 1 Transmission box 3.

Remove the oil pan, take down the sealing gasket.

ATTENTION Make sure the sealing gasket is intact.

1 Fig. 3-36 1 Oil pan

VRT200 Transmission Service Manual 4.

Remove the coarse filter.

ATTENTION Take

protective

measures

to

ensure

cleanliness of the disassembled oil filter.

1 Fig. 3-37 1 Coarse filter 1

2

3

5.

Take down the K1/K2 assembly, intermediate shaft assembly, KFR assembly and K3/K4 assembly orderly.

ATTENTION Take down each assembly slowly to avoid safety accidents caused by falling parts. Take

protective

measures

to

ensure

cleanliness of the disassembled assemblies. 1 Fig. 3-38 1 K1/K2 assembly 2 Intermediate shaft assembly 3 KF/KR assembly 4 K3/K4 assembly 6.

Remove the fixing bolts of reverse transition gear assembly, take down the pressing plate, gear, bearing inner ring and spacer bush.

1 Fig. 3-39 1 Reverse transition gear assembly

VRT200 Transmission Service Manual 7.

Dismantle the reverse transition gear shaft.

8.

Remove the oil absorption pipe and torque

1 Fig. 3-40 1 Shaft

converter inlet safety valve.

1 Fig. 3-41 1 Oil absorption pipe 2 Safety valve

2

VRT200 Transmission Service Manual

33

Step to Disassemble the Assembly Components 331 Disassembly

of

Clutch

Shaft

Assembly ATTENTION The three clutch assemblies are of similar structure, here we take K3/K4 clutch assembly for example. 1.

Use puller to remove the two bearings.

2.

Take down the locating ring, bearing and

1 Fig. 3-42 1 Bearing

thrust washer orderly.

1 2 3 Fig. 3-43 1 Locating ring 3 Thrust washer

2 Bearing

VRT200 Transmission Service Manual 3.

Take down the K4 gear, the two bearings and spacer bush.

1 Fig. 3-44 1 K4 gear 3 Bearing

2

3

2 Spacer bush

1 2 Fig. 3-45 1 Bearing

4.

Take down the bearing and thrust washer.

5.

Take down the outer snap ring and inner snap

2 Thrust washer

ring orderly.

1 Fig. 3-46 1 Snap ring

2 2 Snap ring

VRT200 Transmission Service Manual 6.

Take down the pressure plate, drive and driven friction plates.

1 2 Fig. 3-47 1 Friction plate 2 Friction plate

3

3 Pressure plate

7.

Compress the K4 clutch hub with clutch spring disassembling tooling, take down the isolating rings. Remove the tooling, take down the clutch hub and spring.

1 2 Fig. 3-48 1 Clutch spring

2 Clutch hub 8.

Take out the K4 clutch, detach the inner and outer piston ring.

ATTENTION Take

protective

measures

to

ensure

cleanliness of the disassembled parts and components.

1 2 Fig. 3-49 1 K4 clutch piston 2 Inner piston ring 3 Outer piston ring

3

VRT200 Transmission Service Manual

332 Disassembly

of

Transmission

Control Valve 1.

Remove the five solenoid valves.

ATTENTION Use marking pen to mark each solenoid valve properly.

1 Fig. 3-50 1 Solenoid valve 2.

Take down the solenoid valve seats and the two O-rings on each valve seat.

ATTENTION Take

protective

measures

to

ensure

cleanliness of the disassembled parts and components.

1 2 Fig. 3-51 1 Solenoid valve seat

2 O-ring 3.

Dismantle the transmission control valve plate.

ATTENTION Safety accident may occur if the valve plate is popped up by the spring during disassembling, so please process with great caution.

1 Fig. 3-52 1 Valve plate

VRT200 Transmission Service Manual 4.

Take down the valve plate and sealing gasket.

ATTENTION Make sure the sealing gasket is intact.

1 Fig. 3-53 1 Sealing gasket 1

2

3

5.

Take out the valve spring and valve rod of the pressure regulating valve and each gear control valve.

ATTENTION Take

protective

measures

to

ensure

cleanliness of the disassembled parts and components. 4 5 6 Fig. 3-54 1, 2, 4, 5, 6 Gear control valve rod 3 Pressure regulating valve rod

333 Disassembly of Cushion Valve 1.

1 Fig. 3-55 1 Cushion valve bottom cover plate

Remove the cushion valve bottom cover plate.

VRT200 Transmission Service Manual 2.

Take down the O-rings, and then take out the valve rods and springs.

ATTENTION Take

protective

measures

to

ensure

cleanliness of the disassembled parts and components.

1 2 Fig. 3-56 1 Valve body 3 O-ring

3

4

2 Spring 4 Valve rod

334 Disassembly of Lubricating Oil Valve 1.

Remove the valve cover of counterbalance valve in the oil outlet port of lubricating oil valve.

ATTENTION Safety accident may occur if the valve cover is popped up by the spring during disassembling, so please process with great caution. Fig. 3-57 2.

Take out the valve rod and spring of the counterbalance valve.

1 Fig. 3-58 1 Valve rod

2 2 Spring

VRT200 Transmission Service Manual 3.

Remove the plug of safety valve in the oil return port of lubricating oil valve.

ATTENTION Safety accident may occur if the valve plug is popped up by the spring during disassembling, so please process with great caution.

1 Fig. 3-59 1 Valve plug

4.

Take out the valve rod and spring of the safety valve.

1 Fig. 3-60 1 Valve rod 3 O-ring

2 2 Spring

3

VRT200 Transmission Service Manual

34

Step to Assemble the Assembly Components ATTENTION Rinse the parts and components before assembling.

341 Assembly

of

Lubricating

Oil

Valve 1.

Put the valve rod and spring of the safety valve into the mounting hole, add an O-ring and tighten the valve plug.

1 Fig. 3-61 1 Valve rod 3 O-ring

2

34

2 Spring 4 Valve plug

2.

Put the valve rod and spring of the counterbalance valve into the mounting hole, and tighten the valve cover.

1 Fig. 3-62 1 Valve rod 3 Valve cover

2 2 Spring

VRT200 Transmission Service Manual

342 Assembly of Cushion Valve 1.

Put the valve rods and springs of the cushion valve into the mounting holes, and place the O-rings.

1 2 Fig. 3-63 1 Spring 3 Valve rod

3

4

2 O-ring 2.

Tighten the fixing bolts of the cushion valve bottom cover plate.

1 Fig. 3-64 1 Cushion valve bottom cover plate

VRT200 Transmission Service Manual

343 Assembly

of

Transmission

Control Valve 1

2 1.

Put the valve spring and valve rod of the pressure regulating valve and each gear control valve into the corresponding mounting hole.

3 4 Fig. 3-65 1 Gear control valve spring 2 Pressure regulating valve spring 3 Gear control valve rod 4 Pressure regulating valve rod 2.

Add a sealing gasket and install the valve plate.

ATTENTION Check and replace the sealing gasket with a new one.

1 Fig. 3-66 1 Sealing gasket 3.

Tighten the transmission control valve plate connecting bolts.

ATTENTION Take several steps to tighten the connecting bolts diagonally.

1 Fig. 3-67 1 Valve plate

VRT200 Transmission Service Manual 4.

1

Place two O-rings on each valve body and tighten the solenoid valves orderly.

ATTENTION Make sure the solenoid valves are correctly installed to the original positions.

2 Fig. 3-68 1 Solenoid valve

2 O-ring

344 Assembly

of

Clutch

Shaft

Assembly ATTENTION The three clutch assemblies are of similar structure, here we take K3/K4 clutch assembly for example. 1.

Nest the snap ring onto the transition bush (snap ring assembling tool). Turn the transition bush (assembled with snap ring) over and place it on the pedestal (snap ring assembling tool).

1 2 Fig. 3-69 1 Transition bush

2 Pedestal

VRT200 Transmission Service Manual 1

2.

Install

the

mounting

socket

(snap

ring

assembling tool) on the transition bush. Push down the snap ring and use it to clamp the mounting socket.

Fig. 3-70 1 Mounting socket 3.

Nest the K3/K4 shaft into the special tools. Push down the snap ring to fit it into the snap ring groove on K3 end of the shaft (with the spline end upward, the snap ring should be fitted into the bottom snap ring groove).

ATTENTION Do not damage the shaft external surface. Fig. 3-71

4.

Heat the isolation carrier to about 180oC and keep it at this temperature for about 2 hours. Nest the isolation carrier onto the shaft and let it fall down to the right position smoothly. The spline end of shaft should be upward, do not fit the isolation carrier fiercely and be sure to continue to heat it for assembling if necessary.

1 Fig. 3-72 1 Isolation carrier

ATTENTION Wear heat insulating gloves during the operation to prevent scalding.

VRT200 Transmission Service Manual 5.

Use snap ring assembling tools to fit the other snap ring into the grove on the shaft above the isolation carrier. Let the assembly cool down.

ATTENTION Be sure to fit the snap ring in place.

Fig. 3-73

6.

Apply a small amount of lubricating grease on the opening area of each piston ring, stick the piston ring to the tool by grease and fit them to the piston ring grooves orderly.

ATTENTION Check cleanliness of piston surface first.

1 2 Fig. 3-74 1 Inner piston ring 2 Outer piston ring 7.

Keep the spline end of the K3/K4 shaft upward, and

install

the

shaft

assembly to

the

workbench.

ATTENTION Adjust the workbench to keep the clearance between shaft bottom shoulder and upper plane of the nylon protecting cover no less than 2mm. 1 Fig. 3-75 1 Workbench

VRT200 Transmission Service Manual 8.

Apply a small amount of lubricating grease on the opening area of the piston ring, fit the piston ring into the piston ring groove on the shaft.

ATTENTION Check cleanliness of the shaft and isolation carrier first, especially the oil hole. It is forbidden to install the piston ring when the

1

shaft is not fully cooled.

Fig. 3-76 1 Piston ring

9.

Nest the piston assembly onto the shaft, push slowly to fit it into the isolation carrier.

ATTENTION Big end of the piston should be downward. It is prohibited to fit the piston fiercely, do not squeeze and damage the piston ring.

1 Fig. 3-77 1 Piston 10. Install the guide sleeve and spring. Place the

1

clutch hub on the spring.

ATTENTION For clutch hub, the end processed with snap ring groove should be upward. Check

the

machining

cleanliness of each part first.

2 3 Fig. 3-78 1 Clutch hub 3 Spring

2 Guide sleeve

quality

and

VRT200 Transmission Service Manual

11. Clamp the bottom edge of the hub press-fitting tool to the hub.

ATTENTION Keep the press-fitting tool upright.

1 Fig. 3-79 1 Press-fitting tool 12. Move the shaft together with the workbench to the press machine, start to press the spring until the isolating rings can be easily assembled.

Fig. 3-80

13. Install the isolating rings.

ATTENTION The end with big chamfer should face downward, isolating rings must be mounted in pair. Make sure the isolating rings can rotate smoothly, replace them otherwise. 1 Fig. 3-81 1 Isolating ring

VRT200 Transmission Service Manual

14. After correctly installed the isolating rings, unload the press machine slowly and take out the press-fitting tool.

ATTENTION Protect your eyes and hands.

Fig. 3-82

15. Alternatively install the driven and drive friction plates, 6 pairs, 12 plates in total.

ATTENTION Check the cleanliness and flatness of each friction plate. Comply with the “first driven plate, then drive plate” order. 1 2 Fig. 3-83 1 Driven friction plate 2 Drive friction plate 16. Install the pressure plate and snap ring.

ATTENTION The big end of pressure plate should face downward. Stir the snap ring with screwdriver to make sure it can rotate freely. Be careful not to scratch your fingers. 1 Fig. 3-84 1 Pressure plate

2 2 Snap ring

VRT200 Transmission Service Manual

17. Measure the clearance between the friction plate and pressure plate with feeler gauge, adjust the clearance to specified range.

ATTENTION Required clearance range: 1.75~2.25mm. Record the measured values.

1 Fig. 3-85 1 Feeler gauge 18. Firstly fit one end of the snap ring into the groove on pressure plate, and then rotate slowly to fit the whole ring into the groove gradually.

ATTENTION Be careful not to scratch your fingers.

Fig. 3-86

19. Install the thrust washer and bearing.

1 2 Fig. 3-87 1 Thrust washer

2 Bearing

VRT200 Transmission Service Manual

20. Install the K4 gear to the shaft, rotate the gear assembly left and right until the assembly is fitted in place

ATTENTION Check

the

machining

quality

and

cleanliness of each part first.

1 Fig. 3-88 1 K4 gear

21. Install the spacer bush and the two bearings, pat the gear assembly gently to fit the bearings and spacer bush in place.

ATTENTION It is forbidden to press the bearings into the bush fiercely. Installation order: Bearing— Spacer bush— Bearing. 1 2 Fig. 3-89 1 Spacer bush

2 Bearing

22. Install the thrust washer, bearing and locating ring orderly.

1 Fig. 3-90 1 Locating ring 3 Thrust washer

2

3

2 Bearing

VRT200 Transmission Service Manual

23. Install the bearing inner ring, place the bearing inner ring tooling on the ring. Use the press machine to fit the bearing in place.

ATTENTION After the press fitting, do not raise the pressure machine too high, ensure that the bearing ring and locating ring are in close contact. 1 2 Fig. 3-91 1 Bearing inner ring tooling 2 Bearing

24. Turn the K3/K4 clutch assembly upside down, lock the handle. Rotate the turning wheel to adjust the clearance between bottom end of the clutch assembly and the upper plane of the support to 2~3mm.

ATTENTION The end with spline should face downward. Fig. 3-92 25. Place the shield sleeve and the steel ball pressing sleeve. Use the press machine to fit the two steel balls into the holes.

ATTENTION The steel balls should be fitted in place, no protrusion to the shaft end face. Be careful not to squeeze your hand. 1 2 Fig. 3-93 1 Shield sleeve 2 Steel ball pressing sleeve

VRT200 Transmission Service Manual

26. Apply some grease on the piston ring and install it to the shaft ring groove.

ATTENTION Check the cleanliness of piston surface first.

1 Fig. 3-94 1 Piston ring 27. Apply a small amount of lubricating grease on the opening area of each piston ring, stick the piston ring to the tool by grease and fit them to the piston ring grooves orderly.

1 2 Fig. 3-95 1 Outer piston ring 2 Outer piston ring

28. Nest the piston assembly onto the shaft, push slowly to fit it into the isolation carrier.

ATTENTION Big end of the piston should be downward. It is prohibited to fit the piston fiercely, do not squeeze and damage the piston ring.

1 Fig. 3-96 1 Piston

VRT200 Transmission Service Manual

1

29. Install the guide sleeve and spring. Place the clutch hub on the spring.

ATTENTION For clutch hub, the end processed with snap ring groove should be upward. Check

the

machining

quality

and

cleanliness of each part first.

2 3 Fig. 3-97 1 Clutch hub 3 Spring

2 Guide sleeve

30. Clamp the bottom edge of the hub press-fitting tool to the hub. Use the press machine to compress the spring until the isolating rings can be easily assembled.

ATTENTION Keep the press-fitting tool upright.

1 Fig. 3-98 1 Press-fitting tool 31. Install the isolating rings.

ATTENTION The end with big chamfer should face upward, isolating rings must be mounted in pair. Make sure the isolating rings can rotate smoothly, replace them otherwise. 1 Fig. 3-99 1 Isolating ring

Protect your eyes and hands.

VRT200 Transmission Service Manual

32. Alternatively install the driven and drive friction plates, 9 pairs, 18 plates in total.

ATTENTION Check the cleanliness and flatness of each friction plate. Comply with the “first driven plate, then drive plate” order. 1 2 Fig. 3-100 1 Drive friction plate 2 Driven friction plate

33. Install the pressure plate.

ATTENTION The big end of pressure plate should face downward.

1 Fig. 3-101 1 Pressure plate

34. Install the snap ring.

ATTENTION Stir the snap ring with screwdriver to make sure it can rotate freely. Be careful not to scratch your fingers.

Fig. 3-102

VRT200 Transmission Service Manual

1

35. Measure the clearance between the friction plate and pressure plate with feeler gauge, adjust the clearance to specified range.

ATTENTION Required clearance range: 2.65~3.35mm. Record the measured values.

Fig. 3-103 1 Feeler gauge 36. Firstly fit one end of the snap ring into the groove on pressure plate, and then rotate slowly to fit the whole ring into the groove gradually.

ATTENTION Be careful not to scratch your fingers.

1 Fig. 3-104 1 Snap ring 1

Fig. 3-105 1 Thrust washer

2

37. Install the thrust washer and bearing.

2 Bearing

VRT200 Transmission Service Manual

38. Install the K3 gear to the shaft, rotate the gear assembly left and right until the assembly is fitted in place

ATTENTION Check

the

machining

quality

and

cleanliness of each part first.

1 Fig. 3-106 1 K3 gear 1 2 39. Install the spacer bush and the two bearings.

ATTENTION Pat the gear assembly gently to fit the bearings and spacer bush in place. It is forbidden to press the bearings into the bush fiercely. Installation order: Bearing— Spacer bush— Bearing. Fig. 3-107 1 Bearing

2 Spacer bush 40. Install the thrust washer and bearing.

1 2 Fig. 3-108 1 Thrust washer 2 Bearing

VRT200 Transmission Service Manual

41. Heat the thrust block to 130~140oC.

ATTENTION Let the block fall in place. Prevent getting scaled by the hot part.

Fig. 3-109 42. Install the retainer ring.

ATTENTION The two ends of the retainer ring are not the same, the end with smaller hole should face upward.

Fig. 3-110 43. Install the bearing inner ring, apply some grease on the bearing and bearing inner ring. Place the bearing inner ring tooling on the ring, use the press machine to fit the bearing in place.

ATTENTION Big end of the bearing should face downward. 1 Fig. 3-111 1 Bearing inner ring tooling

After the press fitting, do not raise the pressure machine too high, ensure that the bearing ring and locating ring are in close contact. 44. Turn the K3/K4 clutch assembly upside down, and lift the assembly with lifting appliance.

ATTENTION Put the K3/K4 shaft assembly on special

VRT200 Transmission Service Manual bracket.

345 Assembly of Transfer Case 1.

Lift and place the transfer case housing on the assembling bracket, turn housing to the state as shown in the left figure.

Fig. 3-112

2.

Apply some grease on the external surface of output shaft bearing outer ring, press-fit the bearing outer ring with special press-fitting tool.

Fig. 3-113

3.

Place the output shaft upright with the small end (with small spline) down. Apply some grease on the external surface of bearing inner ring, press-fit the bearing inner ring with special press-fitting tool.

Fig. 3-114

VRT200 Transmission Service Manual

4.

Turn over the output shaft, install the gear R61. The end with higher gear face should face downward. You can heat the gear to 50~70oC for assembling, and then use fit it with press-fitting tool.

Fig. 3-115

5.

Install the other end bearing inner ring, apply some grease on the external surface of bearing inner ring, press-fit the bearing inner ring with special press-fitting tool.

Fig. 3-116

6.

Install the output shaft assembly to the transfer case housing, the end with longer shaft should face downward.

Fig. 3-117

VRT200 Transmission Service Manual

7.

Apply some lubricating grease on the inner bore of bearing retainer and external surface of the bearing. Place the bearing outer ring into the sleeve and fit it with press-fitting tool.

Fig. 3-118

8.

Install the TBS dial gauges to the bearing retainer.

Fig. 3-119

9.

Place the bearing retainer on zero setting disc to perform zero setting.

ATTENTION Make sure there is no burr and impurity on the contact surfaces of the bearing retainer and zero setting disc.

Fig. 3-120

VRT200 Transmission Service Manual

10. Rotate the bearing retainer after the zero setting, the reading on the dial gauge should always be zero.

Fig. 3-121

11. Install

the

bearing

retainer

to

the

corresponding mounting hole on transfer case housing,

and

place

the

output

shaft

press-fitting sleeve.

ATTENTION The fit between bearing retainer and the mounting hole should not be too tight. Fig. 3-122

12. Install the output shaft TBS tooling.

ATTENTION Do not touch the dial gauge module during the operation.

Fig. 3-123

VRT200 Transmission Service Manual

13. Turn the TBS hydraulic power unit switch to high-pressure position (1100±100psi) to exert force on the bearing retainer, rotate the output shaft. Turn the switch to low-pressure position (110±100psi) to reduce the force, rotate the output shaft again.

ATTENTION Fig. 3-124

When the hydraulic power unit switch is in high-pressure position and low-pressure position, be sure to rotate the output shaft for at least 5 circles respectively.

14. Observe the dial gauges during the rotating, the reading difference between the two dial meters should not exceed 0.05. Otherwise, find out the cause and adjust it. Maintain the 110±100psi pressure, record the readings of the two dial meters and calculate the average value.

15. Total thick of the required adjusting gaskets= The previously calculated average value (at 110±100psi)+ Bearing clearance (0.06~1.12). Three types of adjusting gaskets are available: T=1.00, 0.35, and 0.1. Install the adjusting gaskets and fix the bearing retainer on the housing. Fig. 3-125

VRT200 Transmission Service Manual

16. Install the four bolts (with washers) nearby the two dial gauges, tighten the bolts. Record the readings of the two dial gauges, and calculate the average value. 48±3Nm 17. Calculate and verify the bearing clearance. Bearing clearance= The calculated average Fig. 3-126

value (after tightening the 4 bolts)- The previously

calculated

average

value

(at

110±100psi).

ATTENTION If the bearing clearance is not in the required range 0.06~0.12, then the adjusting gaskets are must be re-selected. 18. Screw off the 4 fixing bolts, remove the two dial gauges and take down the bearing retainer. Apply some lubricating grease on the oil seal fitting area of the bearing retainer.

ATTENTION The lubricating grease should be evenly distributed and no particle impurity is Fig. 3-127

allowed.

19. Install the oil seal to the output oil seal press-fitting tool and press-fit it in place.

ATTENTION Apply some grease on the oil seal lip, the lip end should face outward. No distortion and squeeze damage to seal is allowed. Fig. 3-128

VRT200 Transmission Service Manual

20. Place the O-ring into the corresponding ring groove.

ATTENTION Apply some grease on the O-ring. No distortion and squeeze damage to ring is allowed.

Fig. 3-129

21. Install the O-ring to the output shaft.

ATTENTION Apply some grease on the O-ring. No distortion and squeeze damage to ring is allowed.

Fig. 3-130

22. Install the bearing retainer (with pre-assembled O-ring and oil seal) to the transfer case housing.

Fig. 3-131

VRT200 Transmission Service Manual

23. Install the 7 bolts and gaskets, tighten the bolts. 48±3Nm

Fig. 3-132

24. Turn the transfer case upside down and fix it. Apply some grease on the oil seal lip, the lip end should face outward. Install the oil seal to the oil seal to the front end of output shaft.

ATTENTION Apply some grease on the oil seal lip, the lip end should face outward. No distortion and Fig. 3-133

squeeze damage to seal is allowed.

25. Apply some lubricating grease on the bearing hole and bearing external surface, install the intermediate shaft bearing outer ring.

Fig. 3-134

VRT200 Transmission Service Manual

26. Press-fit the bearing outer ring.

Fig. 3-135

27. Apply some lubricating grease on the bearing inner bore and mounting shaft. Install the bearing inner ring to the shaft spline-free end, install the guide tooling first, and then press-fit the inner ring.

Fig. 3-136

28. Heat the bearing inner ring to 50~70oC, and install it to the transfer case.

ATTENTION Perform the next step as soon as possible while the bearing is hot. Be careful not to get scalded by the hot bearing.

Fig. 3-137

VRT200 Transmission Service Manual

29. Install the gear R51 to the transfer case.

ATTENTION The end with chamfer on the boss should face downward.

Fig. 3-138

30. Installed the intermediate shaft(pre-assembled with bearing) to the transfer case, and press-fit it.

Fig. 3-139

31. Apply some lubricating grease on the inner bore of bearing retainer and external surface of the bearing. Place the bearing outer ring into the sleeve and fit it with press-fitting tool.

Fig. 3-140

VRT200 Transmission Service Manual

32. Install the TBS dial gauges to the bearing retainer.

Fig. 3-141

33. Place the bearing retainer on zero setting disc to perform zero setting.

ATTENTION Make sure there is no burr and impurity on the contact surfaces of the bearing retainer and zero setting disc. Rotate the bearing retainer after the zero Fig. 3-142

setting, the reading on the dial gauge should always be zero

34. Install

the

bearing

retainer

to

the

corresponding mounting hole on transfer case housing, and place the intermediate shaft press-fitting sleeve. Install the intermediate shaft TBS tooling.

ATTENTION Do not touch the dial gauge module during Fig. 3-143

the operation.

VRT200 Transmission Service Manual

35. Turn the TBS hydraulic power unit switch to high-pressure position (1100±100psi) to exert force on the bearing retainer, rotate the intermediate

shaft.

Turn

the

switch

to

low-pressure position (110±100psi) to reduce the force, rotate the intermediate shaft again.

ATTENTION Fig. 3-144

When the hydraulic power unit switch is in high-pressure position and low-pressure position, be sure to rotate the intermediate shaft for at least 5 circles respectively. 36. Maintain the 110±100psi pressure, record the readings of the two dial meters and calculate the average value. Total thick of the required adjusting gaskets= The previously calculated average value (at 110±100psi)+ Bearing clearance (0.06~1.12). 37. Install the adjusting gaskets and fix the bearing

Fig. 3-145

retainer on the housing. Three types of adjusting gaskets are available: T=1.00, 0.35, and 0.1. 38. Install the four bolts (with washers) nearby the two dial gauges, tighten the bolts. Record the readings of the two dial gauges, and calculate the average value. Bearing clearance= The calculated average value (after tightening the 4 bolts)- The previously calculated average value (at 110±100psi).

Fig. 3-146

23±3Nm

ATTENTION If the bearing clearance is not in the required range 0.06~0.12, then the adjusting gaskets are must be re-selected.

VRT200 Transmission Service Manual

39. Screw off the 4 fixing bolts, remove the two dial gauges and take down the bearing retainer. Install the O-ring to the bearing retainer.

ATTENTION Apply some grease on the O-ring. No distortion and squeeze damage to ring is allowed. Fig. 3-147

40. Install the bearing retainer (with pre-assembled O-ring and oil seal) to the transfer case housing. Install the 6 bolts and gaskets, tighten the bolts. 23±3Nm

Fig. 3-148

41. Apply some grease on O-ring, and install the O-ring to the screw plug. Install the screw plug to the bearing shell, tighten the plug.

Fig. 3-149

VRT200 Transmission Service Manual

42. Apply some grease on O-ring, and install the O-ring to the plug.

Fig. 3-150

43. Press-fit the plug (with O-ring) to gear R33.

Fig. 3-151

44. Turn over the gear R33 assembly, install the bearing inner ring to the spline-free end of K1/K2

shaft.

Apply

some

lubricating

oil/grease on the shaft and bearing inner ring first, and then press-fit the ring.

Fig. 3-152

VRT200 Transmission Service Manual

45. Install the retainer ring.

Fig. 3-153

46. Apply some lubricating oil/grease on the bearing mounting hole and external surface of the bearing.

Fig. 3-154

47. Press-fit the bearing outer ring.

Fig. 3-155

VRT200 Transmission Service Manual

48. Place the K1/K2 shaft (pre-assembled with bearing inner ring) into the transfer case from the bottom side of the case.

Fig. 3-156

49. Apply some thread locking agent on the two bolts, install the locking plate with the bolts and gaskets. Place the bearing ring on the bearing first in this step.

Fig. 3-157

50. Tighten the bolts. 90±15Nm

Fig. 3-158

VRT200 Transmission Service Manual

51. Place the sealing gasket and cover, fix them with 5 bolts and gaskets.

ATTENTION Clean the fitting surface thoroughly and pay attention to the mounting position.

Fig. 3-159

52. Tighten the bolts. 23±3Nm

Fig. 3-160

53. Apply some lubricating oil/grease on the bearing mounting hole and external surface of the bearing, press-fit the bearing.

Fig. 3-161

VRT200 Transmission Service Manual

54. Install the retainer to fix the bearing.

Fig. 3-162

55. Apply some lubricating oil/grease on the shaft and bearing inner bore, and then install the R43 gear to the bearing retainer.

Fig. 3-163

56. Turn over the K3/K4 gear assembly, install the retainer to fix the bearing.

Fig. 3-164

VRT200 Transmission Service Manual

57. Install the sealing gasket and align the holes. Install the K3/K4 gear assembly to the transfer case.

Fig. 3-165

58. Install the 8 bolts and gaskets, tighten the bolts. 23±3Nm

Fig. 3-166

59. Apply some lubricating oil/grease on the O-ring, and install the O-ring to the bearing retainer.

Fig. 3-167

VRT200 Transmission Service Manual

60. Install the cover, fix it with two bolts and gaskets, and tighten the bolts. 75±5Nm

Fig. 3-168

61. Wind some thread seal tape on the thread of vent pipe, and apply some thread locking agent on the vent pipe thread.

ATTENTION The winding direction should be opposite to screwing-in direction of the thread.

Fig. 3-169

62. Install the vent pipe to the K3/K4 bearing retainer. Adjust the direction of the vent pipe, which should be 45o to the horizontal line.

Fig. 3-170

VRT200 Transmission Service Manual

63. Align the bolts holes, install the fixed plate and fix it with 9 bolts and gaskets.

Fig. 3-171

64. Tighten the bolts. 75±5Nm

Fig. 3-172

65. Place the brake disc and flange on the assembling tooling, align the bolt holes and fix the front flange with 12 bolts and gaskets, the bolts should be applied with thread locking agent in advance.

Fig. 3-173

VRT200 Transmission Service Manual

66. Tighten the bolts. 75±5Nm

Fig. 3-174

67. Install the brake disc and flange assembly to transfer case output port, the flange end should face downward.

Fig. 3-175

68. Install the brake with bolts. Apply some thread locking agent on the bolts in advance and tighten the bolts. 180±20Nm

Fig. 3-176

VRT200 Transmission Service Manual

69. Install the locking plate and align the bolts holes. Apply some thread locking agent on the 2 bolts, and use the bolts and gaskets to fix the locking plate.

Fig. 3-177

70. Clamp the brake disc with tooling, and then tighten the locking plate fixing bolts. 90±15Nm

Fig. 3-178

71. Turn over the transfer case to install the rear output flange.

Fig. 3-179

VRT200 Transmission Service Manual

72. Apply some thread locking agent on the 2 bolts, and use the bolts and gaskets to fix the locking plate on the output shaft.

Fig. 3-180

73. Tighten the locking plate fixing bolts. 90±15Nm

Fig. 3-181

74. Apply some grease on the O-ring, and install the O-ring to the plug.

Fig. 3-182

VRT200 Transmission Service Manual

75. Install the plug to the transfer case and tighten it by hand.

76. Screw the studs (the end with shorter thread length) into the flange. Tighten the studs.

Fig. 3-184

77. Check the fitting surface and make sure there is no impurity. Install the sealing gasket and fix the oil dipstick on the seat with 4 bolts and gaskets.

Fig. 3-185

VRT200 Transmission Service Manual

78. Tighten the bolts. 12±3Nm

Fig. 3-186

79. Apply some grease on the O-ring, and install the O-ring to the oil dipstick. And then install the oil dipstick.

Fig. 3-187

80. Apply some grease on the O-ring, and install the O-ring to the straight joint. Install the straight joint to transfer case and tighten it by hand.

Fig. 3-188

VRT200 Transmission Service Manual

81. Install the screw plug (with gasket) to the transfer case, tighten the plug. 73±10Nm

ATTENTION Do not leave out the gasket.

Fig. 3-189

VRT200 Transmission Service Manual

35

Steps to Assemble Transmission Box 1.

Lift and place the torque converter housing on the assembling bracket, turn the housing to the state as shown in the left figure.

Fig. 3-190

2.

Install the 4 locating pins and knock them to the bottom with hammer.

Fig. 3-191

3.

Turn the housing to suitable position, install the pipe joint and pre-tighten it by hand.

Fig. 3-192

VRT200 Transmission Service Manual 4.

Tighten the pipe joint with “Click” wrench. 55±5.5Nm

Fig. 3-193

5.

Install the guide wheel seat locating pin(s) and knock it/them to the bottom with hammer. The flat side surface of the locating pin should face the center of the guide ring seat.

ATTENTION Knock gently to fit the entire cylindrical part of the pin into the seat. Fig. 3-194

6.

Turn the housing to the state as shown in the left figure. Install the cylindrical locating pin(s).

Fig. 3-195

VRT200 Transmission Service Manual 7.

Knock the flat-head locating pins into the through-holes. The flat side surface of the locating pin should be perpendicular to the connecting line of the two locating pins.

ATTENTION Knock gently to fit the entire cylindrical part of the pin into the housing. Fig. 3-196

8.

Install the two sealing pins into the pin holes. Knock until there is be no protrusion to the torque converter housing.

Fig. 3-197

9.

Apply some grease on the O-ring, and install the O-ring to the screw plug. Install the plug to the torque converter housing and pre-tighten it by hand.

Fig. 3-198

VRT200 Transmission Service Manual 10. Tighten the plug with “Click” wrench. 60±6Nm

Fig. 3-199

11. Thoroughly press-fit the 4 bearing outer rings to the corresponding mounting holes with rebound-free hammer and special tools.

Fig. 3-200

12. Install the oil return pipe. Adjust the position of the pipe and install a tube expander to the pipe, connect the tube expander machine to the expander and expand the pipe.

ATTENTION After expanding the pipe, check and make sure there is protrusion to the housing external surface. Fig. 3-201

VRT200 Transmission Service Manual 13. Apply some lubricating oil on the transition gear bearing mounting hole. Press-fit the bearing with special press-fitting tool.

Fig. 3-202

14. Press-fit the other end bearing.

Fig. 3-203

15. Install the transition gear shaft.

ATTENTION Ensure that the line of centers of the two bolt holes is perpendicular to the line of the shaft center and KF/KR bearing hole center. As shown in the left figure.

Fig. 3-204

VRT200 Transmission Service Manual 16. Use special socket to fit the transition gear shaft to place.

Fig. 3-205

17. Install the bolts and gaskets. Pre-tighten them by hand first, then tighten them with “Click” wrench. 23±3Nm

Fig. 3-206

18. Install the bearing inner ring to the shaft with a spacer bush.

Fig. 3-207

VRT200 Transmission Service Manual 19. Install the transition gear assembly, with the gear end upward.

Fig. 3-208

20. Install the gasket and align the two thread holes, and the flat end of the gasket should face KF/KR bearing hole. Apply some thread locking agent on the two bolts, and use the bolts (gaskets) to fix the gasket.

Fig. 3-209

21. Tighten the bolts. 23±3Nm

Fig. 3-210

VRT200 Transmission Service Manual 22. Apply some thread locking agent on the safety valve thread end.

Fig. 3-211

23. Tighten the safety valve with “Click” wrench.

ATTENTION Check whether the cotter pin is too long or loose, the cotter pin should be fixed reliably. And make sure no part of the cotter pin is higher than the safety valve. 70±10Nm Fig. 3-212

24. Lift the K1/K2 clutch assembly and install it to the corresponding mounting hole on torque converter housing (with spline end upward).

Fig. 3-213

VRT200 Transmission Service Manual 25. Install the intermediate shaft assembly to the corresponding

mounting

hole

on

torque

converter housing, the end with the biggest gear should be on the top. Fit the intermediate shaft assembly with K1/K2 shaft assembly.

Fig. 3-214

26. Install the KF/KR clutch assembly (with spline end downward).

Fig. 3-215

27. Install the K3/K4 clutch assembly (with spline end upward).

Fig. 3-216

VRT200 Transmission Service Manual 28. Apply some grease on the O-ring and install it to the torque converter housing.

ATTENTION Do not scratch the O-ring.

Fig. 3-217

29. Apply sealant on torque converter housing for one circle, width of sealant lace should be about 2~3mm, and 1~2m for the O-ring area.

Fig. 3-218

30. Screw the studs (the end with shorter thread length) into the transmission box. Tighten the studs. 8±3Nm

Fig. 3-219

VRT200 Transmission Service Manual 31. Install the transmission box to torque converter housing,

avoid

bumping

and

align

the

mounting holes, especially align the studs.

Fig. 3-220

32. Install the connecting bolts and gaskets.

Fig. 3-221

33. Pre-tighten the bottom bolts, pre-tighten the bolts on both sides of the locating pin first.

Fig. 3-222

VRT200 Transmission Service Manual 34. Pre-tighten the upper bolts, pre-tighten the bolts on both sides of the locating pin first.

Fig. 3-223

35. Tighten all pre-tightened bolts. 75±5Nm

Fig. 3-224

36. Apply some lubricating oil on the inner bore of bearing fitting holes, and then install the 4 bearing outer rings.

Fig. 3-225

VRT200 Transmission Service Manual 37. Install the TBS dial gauges to the K1/K2 bearing retainer. Place the bearing retainer on zero setting disc to perform zero setting.

ATTENTION Make sure there is no burr and impurity on the contact surfaces of the bearing retainer Fig. 3-226

and zero setting disc. Rotate the bearing retainer after the zero setting, the reading on the dial gauge should always be zero. 38. Install

the

bearing

retainer

to

the

corresponding mounting hole on transmission box, and place the K1/K2 shaft press-fitting sleeve.

ATTENTION The fit between K1/K2 bearing retainer and the mounting hole should not be too tight. Fig. 3-227

39. Install the K1/K2 shaft TBS tooling.

ATTENTION Do not touch the dial gauge module during the operation.

Fig. 3-228

VRT200 Transmission Service Manual

40. Turn the TBS hydraulic power unit switch to high-pressure position (1100±100psi) to exert force on the bearing retainer, rotate the K1/K2 shaft. Turn the switch to low-pressure position (110±100psi) to reduce the force, rotate the K1/K2shaft again.

ATTENTION Fig. 3-229

When the hydraulic power unit switch is in high-pressure position and low-pressure position, be sure to rotate the K1/K2 shaft for at least 5 circles respectively.

41. Maintain the 110±100psi pressure, record the readings of the two dial meters and calculate the average value. Total thick of the required adjusting gaskets= The previously calculated average value (at 110±100psi)+ Bearing clearance (0.15~0.22). Three types of adjusting gaskets are available: Fig. 3-230

T=1.00, 0.35, and 0.1. Install the adjusting gaskets and fix the bearing retainer on the transmission box.

ATTENTION Observe the dial gauges during the rotating, the reading difference between the two dial meters should not exceed 0.05. Otherwise, find out the cause and adjust it.

VRT200 Transmission Service Manual

42. Install the four bolts (with washers) nearby the two dial gauges, tighten the bolts. Record the readings of the two dial gauges, and calculate the average value. Calculate and verify the bearing clearance. Bearing clearance= The calculated average value (after tightening the 4 bolts)- The previously calculated average value (at 110±100psi). Fig. 3-231

23±3Nm

ATTENTION If the bearing clearance is not in the required range 0.06~0.12, then the adjusting gaskets are must be re-selected. 43. Screw off the 4 fixing bolts, remove the two dial gauges and take down the bearing retainer. Apply some lubricating grease on the oil seal fitting area of the bearing retainer. Install the oil seal to the K1/K2 oil seal press-fitting tool.

ATTENTION Apply some grease on the oil seal lip, the lip Fig. 3-232

end should face upward.

44. Press-fit the oil seal in place.

Fig. 3-233

VRT200 Transmission Service Manual

45. Place the O-ring into the corresponding ring groove.

ATTENTION Apply some grease on the O-ring lip. No distortion and squeeze damage to ring is allowed.

Fig. 3-234

46. Install the bearing retainer (with pre-assembled O-ring and oil seal) to the transmission box and fix it with 6 bolts and gaskets.

Fig. 3-235

47. Tighten the bolts. 23±3Nm

Fig. 3-236

VRT200 Transmission Service Manual

48. Use the same TBS measuring method to determine required specification and quantity of adjusting gaskets for K3/K4 bearing retainer.

Fig. 3-237

49. Apply some lubricating oil on the 3 seal rings and install them to the KF/KR clutch shaft.

Fig. 3-238

50. Apply some lubricating grease on the O-ring and install it to the plug. Install the plug to oil distributor and tighten it. Install and tighten the other plug in the same way.

Fig. 3-239

VRT200 Transmission Service Manual

51. Use the same TBS measuring method to determine required specification and quantity of adjusting gaskets. Adjust the bearing clearance to 0.15~0.22.

Fig. 3-240

52. Apply some lubricating grease on the O-ring, and install the O-ring to the oil distributor.

Fig. 3-241

53. Install and fix the oil distributor with bolts and gaskets.

Fig. 3-242

VRT200 Transmission Service Manual

54. Tighten the bolts. 23±3Nm

Fig. 3-243

55. Apply some lubricating grease on the O-ring, and install the O-ring to the straight joint. Install the straight joint to the oil distributor and tighten it. 55±5.5Nm

Fig. 3-244

56. Install and tighten the other straight joint in the same way. 80±8Nm

Fig. 3-245

VRT200 Transmission Service Manual

57. Apply some lubricating grease on the O-ring, and install the O-ring to the straight joint. Install the straight joint to the oil distributor and tighten it. 80±8Nm

Fig. 3-246

58. Install the intermediate shaft locking plate.

Fig. 3-247

59. Apply some thread locking agent on the two bolts, and use them to fix the locking plate. Tighten the bolts. 23±3Nm

Fig. 3-248

VRT200 Transmission Service Manual

60. Install the spacer bush.

Fig. 3-249

61. Use the same TBS measuring method to determine required specification and quantity of adjusting gaskets. Adjust the bearing clearance to 0.15~0.22.

Fig. 3-250

62. Apply some thread locking agent on the two bolts, install the bolts and gaskets. Tighten the bolts. 23±3Nm

Fig. 3-251

VRT200 Transmission Service Manual

63. Install the oil filter assembly with two sealing gaskets. Installation order: Sealing gasket— Oil filter assembly— Sealing gasket.

Fig. 3-252

64. Fix the oil pan and filter assembly on transmission box with bolts and gaskets. Pre-tighten the bolts first, and then tighten them to 23±3Nm. 23±3Nm

ATTENTION Pay attention to position of the two holes on Fig. 3-253

oil pan.

65. Apply some lubricating grease on the O-ring, and install the O-ring to the straight joint. Install the straight joint to the oil pan and tighten it. 310±31Nm

Fig. 3-254

VRT200 Transmission Service Manual

66. Apply some lubricating grease on the O-ring, and install the O-ring to the plug. Install the plug to the oil pan and tighten it by hand.

Fig. 3-255

67. Apply some thread locking agent on the two plugs, install them to the split-flow block. Tighten the plugs. 28±4Nm

Fig. 3-256

68. Apply some lubricating grease on the O-rings, and install the O-rings to the split-flow block.

Fig. 3-257

VRT200 Transmission Service Manual

69. Apply some thread locking agent on the two plugs, install them to the oil distributor. Tighten the plugs. 28±4Nm

Fig. 3-258

70. Apply some lubricating grease on the O-rings, and install the 3 O-rings.

Fig. 3-259

71. Apply some lubricating grease on the 6 piston rings, and install the piston rings to K1/K2 shaft and K3/K4 shaft.

ATTENTION Make sure the piston ring is free of scratch and keep it clean. Fig. 3-260

VRT200 Transmission Service Manual

72. Install the split-flow block and oil distributor. Fix them with bolts and gaskets, pre-tighten the bolts.

ATTENTION Do not scratch the pre-installed O-rings and piston rings.

Fig. 3-261

73. Tighten the bolts. 23±3Nm

Fig. 3-262

74. Apply some lubricating oil on the guide wheel bearing fitting surface, install the bearing inner ring to the guide ring wheel, and press-fit with special tool.

Fig. 3-263

VRT200 Transmission Service Manual

75. Install the retainer ring.

Fig. 3-264

76. Apply some lubricating grease on the big seal ring, and install it.

Fig. 3-265

77. Apply some lubricating oil on the turbine shaft bearing fitting surface, and press-fit the bearing to the turbine shaft.

Fig. 3-266

VRT200 Transmission Service Manual

78. Install the retainer ring.

Fig. 3-267

79. Apply some lubricating grease on the small seal ring, and install it.

Fig. 3-268

80. Install the turbine shaft assembly (pre-installed with bearing) to guide wheel seat.

Fig. 3-269

VRT200 Transmission Service Manual

81. Install the lubricating oil pipe, fix it with two bolts and gaskets, tighten the bolts. 12±3Nm

Fig. 3-270

82. Expand upper end of the pipe with expander. After expanding the pipe, check and make sure there is protrusion to the housing external surface.

Fig. 3-271

83. Apply some lubricating grease on the O-ring, and install the O-ring to the straight joint. Install the straight joint to the end of lubricating oil pipe and tighten it. 55±5.5Nm

Fig. 3-272

VRT200 Transmission Service Manual

84. Fix the lubricating oil pipe on split-flow block with two bolts and gaskets, tighten the bolts.

ATTENTION Pay attention not to damage and leave out the O-ring. 12±3Nm

Fig. 3-273

85. Tighten the joint.

ATTENTION Pay attention not to damage and leave out the O-ring. 65±10Nm

Fig. 3-274

86. Apply thread locking agent on the oil pipe joint. Install the pipe joint to transmission box and tighten it. 70±10Nm

Fig. 3-275

VRT200 Transmission Service Manual

87. Install the sealing gasket.

ATTENTION Pay attention to installing direction of sealing gasket and align the oil holes.

Fig. 3-276

88. Install the guide wheel seat. Apply thread locking agent on the 5 bolts, use the bolts and gaskets to fix the guide wheel seat on torque converter housing.

Fig. 3-277

89. Tighten the joint. 48±3Nm

Fig. 3-278

VRT200 Transmission Service Manual

90. Install the retainer ring to the gear inner groove.

Fig. 3-279

91. Apply some lubricating oil on the gear mounting hole and bearing outer ring. Press-fit the bearing into the mounting hole.

ATTENTION Big end of bearing inner ring should face upward.

Fig. 3-280

92. Turn the gear upside down and install the stop ring.

Fig. 3-281

VRT200 Transmission Service Manual

93. Install and press-fit the other bearing.

ATTENTION Big end of bearing inner ring should face upward.

Fig. 3-282

94. Install the two PTO transition gear shaft to torque converter housing. Fix each shaft with 3 bolts and tighten the bolts. 23±3Nm

Fig. 3-283

95. Install the two PTO transition gears.

ATTENTION The end with shoulder should face outward.

Fig. 3-284

VRT200 Transmission Service Manual

96. Fix each shaft locking plate with two bolts and gaskets. The bolts should be applied with thread locking agent in advance.

Fig. 3-285

97. Tighten the bolts. 52±7Nm

Fig. 3-286

98. Clean the fitting surfaces of PTO and torque converter with cleaning agent. Apply sealant on the torque converter for one circle, width of sealant lace should be about 2~3mm.

Fig. 3-287

VRT200 Transmission Service Manual

99. Install the working pump PTO (the left one) and steering pump PTO (the right one), fix each PTO with 4 bolts and gaskets.

ATTENTION Do not mix the two PTOs.

Fig. 3-288

100.Tighten the bolts. 48±3Nm

Fig. 3-289

101.Turn the transmission to the state as shown in Fig. 3-290.

Fig. 3-290

VRT200 Transmission Service Manual

102.Lift and install the turbine module.

ATTENTION Pay attention to the seal ring on guide wheel seat.

Fig. 3-291

103.Install the guard plates and elastic plate. Installation order: The thicker guard plate— Elastic plate— The thinner guard plate. For elastic plate, the side with “crescent moon” mark should face upward.

Fig. 3-292

104.Apply thread locking agent on the bolts, and use the bolts to fix the elastic plate, tighten the bolts. 65±4.5Nm

Fig. 3-293

VRT200 Transmission Service Manual

105.Lift up the transmission box and remove the overturning bracket fixing bolts.

Fig. 3-294

106.Lift away the transmission box and place it on the special bracket..

Fig. 3-295

107.Remove fixing bolts of the bracket, take down the bracket.

Fig. 3-296

VRT200 Transmission Service Manual

108.Clean the fitting surface and ensure the cleanliness. Apply sealant on the transfer case fitting surface along the route illustrated in the left figure, width of sealant lace should be about 2~3mm.

Fig. 3-297

109.Apply some lubricating grease on the K1/K2 and K3/K4 shaft spline, and then connect the transfer case assembly to transmission box assembly.

Fig. 3-298

110.Install the 11 bolts and gaskets, tighten the bolts. 75±5Nm

Fig. 3-299

VRT200 Transmission Service Manual

111.Install the bottom 4 bolts and gaskets. Use a nut to connect the middle stud. Tighten the bolts and nut. 75±5Nm

Fig. 3-300

112.Clean the fitting surfaces of transmission control valve assembly and transmission box with cleaning agent. Install the gasket.

ATTENTION Pay attention to installing direction of the gasket, align the holes and make sure the gasket is free of remnant corner and Fig. 3-301

material.

113.Connect

the

transmission

control

valve

assembly to the transmission box, and fix it with the build-in bolts. Tighten the upper two bolts by hand first, and then screw-in the other bolts for 2~3 pitches. Tighten the bolts. 23±3Nm Fig. 3-302

VRT200 Transmission Service Manual

114.Apply some lubricating grease on the O-ring, and install the O-ring to the joint. Install the joint to the bottom of transmission control valve and tighten it. Install and tighten the other joint in the same way. 80±8Nm

Fig. 3-303

115.Fix the guard plate on the cover with two rivets.

ATTENTION Pay attention to cleanliness of fitting surfaces.

Fig. 3-304

116.Fix the cover plate on transmission with 8 bolts and gaskets. Tighten the upper two bolts by hand first, and then screw-in the other bolts for 2~3 pitches. Tighten the bolts.

ATTENTION The side with concave edge should face upward. 23±3Nm Fig. 3-305

VRT200 Transmission Service Manual

117.Wind some thread seal tape on the thread of vent pipe, and apply some thread locking agent on the vent pipe thread.

ATTENTION The winding direction should be opposite to screwing-in direction of the thread.

Fig. 3-306

118.Install the vent pipe to the cover plate.

ATTENTION Make sure the vent pipe is upright or in horizontal position.

Fig. 3-307

119.Install the nut and gasket, pre-tighten it. Tighten the nut. 75±5Nm

Fig. 3-308

VRT200 Transmission Service Manual

120.Install the oil nozzle with gasket. Tighten it by hand.

Fig. 3-309

121.Install the sealing gasket on the fitting surface. Fix the cover plate on transmission with 8 bolts and gaskets. Tighten the upper two bolts by hand first, and then screw-in the other bolts for 2~3 pitches. Tighten the bolts.

Fig. 3-310

122.Apply some lubricating grease on the O-ring, and install the O-ring to the plug. Install the plug to the torque converter housing and tighten it. 110±10Nm

Fig. 3-311

VRT200 Transmission Service Manual

123.Apply some lubricating grease on the O-ring, and install the O-ring to the plug. Install the plug to the torque converter housing and tighten it by hand. Install and tighten the other 4 plugs in the same way.

Fig. 3-312

124.Fix the filter on torque converter housing with 4 bolts and gaskets, tighten the bolts. 48±3Nm

Fig. 3-313

125.Apply some lubricating grease on the O-ring, and install the O-ring to the straight joint. Install the straight joint to the filter oil inlet port (the right one). Tighten the straight joint. 310±31Nm

Fig. 3-314

VRT200 Transmission Service Manual

126.Apply some lubricating grease on the O-ring, and install the O-ring to the straight joint. Install the straight joint to the filter oil port (the left one). Tighten the straight joint. 170±17Nm

Fig. 3-315

127.Apply some lubricating grease on the O-ring, and install the O-ring to the joint. Install the joint to the transmission control valve. Tighten the joint. 170±17Nm

Fig. 3-316

128.Apply some lubricating grease on the two O-rings, and install the O-rings to the oil pipe assembly. Use the pipe assembly to connect the filter and transmission control valve. Tighten the two nuts. 145±15Nm

Fig. 3-317

VRT200 Transmission Service Manual

129.Clean the fitting surfaces of lubricating oil valve and torque converter housing with cleaning agent. Install the gasket.

Fig. 3-318

130.Fix the lubricating oil valve on torque converter housing with 4 bolts and gaskets. Tighten the upper two bolts by hand first, and then screw-in the other bolts for 2~3 pitches. Tighten the bolts. 23±3Nm

Fig. 3-319

131.Apply some lubricating grease on the O-ring, and install the O-ring to the rubber hose joint. Use a bolt and two gaskets to connect the hose to lubricating oil valve.

Fig. 3-320

VRT200 Transmission Service Manual

132.Tighten the bolts. 70±10Nm

Fig. 3-321

133.Connect the other end of rubber hose to KF/KR oil distributor. Tighten the bolt. 70±10Nm

Fig. 3-322

134.Insert a bolt (with two gaskets, one for each side of the pipe hole) into the pipe hole. Screw the bolt into steering pump PTO housing. Insert a bolt (with 3 gaskets installed between the two pipe joints) into the pipe hole. Screw the bolt into working pump PTO housing. Insert a bolt (with two gaskets, one for each side of the pipe hole) into the third pipe hole. Fig. 3-323

Tighten the three bolts.

ATTENTION Adjust and straighten out the rubber hoses, make sure there is no distortion and

VRT200 Transmission Service Manual interference. 35±3.5Nm 135.Apply some lubricating grease on the O-ring, and install the O-ring to the joint of F/R rubber hose assembly. Use the F/R rubber hose assembly to connect KR/KR oil distributor and transmission control valve, tighten the two nuts. Install, connect and tighten the other F/R rubber hose assembly in the same way. Fig. 3-324

ATTENTION Do not connect the rubber hose inversely. Adjust and straighten out the rubber hoses, make sure there is no distortion and interference. 65±10Nm

136.Apply some thread locking agent on the bolts, fix the connecting base on the transfer case with 4 bolts and gaskets, pre-tighten and tighten the bolts. Install and tighten the other connecting base in the same way. 180±20Nm

Fig. 3-325

VRT200 Transmission Service Manual