Gearbox 16JSD220TA PDF

Transmission (16JSD220TA)
Transmission.....................................31A-1 Transmission upper cover..............31A-46

General..........................................31A-1 Component drawing ....................31A-46
Cautions ........................................31A-2 Removal ......................................31A-48
Structure and principle of transmission31A-6 Installation ...................................31A-51
List of failure symptoms...............31A-18 Main gearbox assembly..................31A-54
Inspection and adjustment ..........31A-20 Component drawing ....................31A-54
Shift mechanism assembly............31A-26 Removal ......................................31A-55
Component drawing ....................31A-26 Installation ...................................31A-57
Removal and installation .............31A-27 Auxiliary gearbox assembly...........31A-59
Transmission assembly..................31A-30 Removal ......................................31A-59
Removal ......................................31A-30 Installation ...................................31A-63
Installation ...................................31A-33 Reverse gear countershaft.............31A-68
Input shaft assembly.......................31A-36 Component drawing ....................31A-68
Component drawing ....................31A-36 Removal ......................................31A-69
Removal ......................................31A-37 Installation ...................................31A-71
Installation ...................................31A-39 Main gearbox countershaft.............31A-72
Output shaft assembly....................31A-41 Component drawing ....................31A-72
Component drawing ....................31A-41 Disassembly and assembly .........31A-73
Removal ......................................31A-42
Installation ...................................31A-43
Transmission (16JSD220TA) - Transmission 31A-1
Transmission
General
The major characteristic of Fast dual-shaft transmission consists in another countershaft
provided in addition to the countershaft equipped in an ordinary transmission, to constitute
the dual-countershaft transmission. With this auxiliary countershaft, the symmetrical trans-
fer of power is obtained, thus realizing the steady transmission and lower noise.
Definition of transmission model:
16 J (D) S 220 (T) A
Gear ratio code
All synchromesh transmission
X10 nominal input torque (N·m)
Double-countershaft structure
Single gearbox
Mechanical
Number of forward gears
31A
Nameplate of transmission:
Model of transmission assembly
16JSD220TA
(Production based on
American technology)
Input power Input torque
User ID Factory No.
Shanxi Fast Gear Co., Ltd

31A-2 Transmission (16JSD220TA) - Transmission
Cautions
I. Cautions for transmission operation
Correct and proper operation of the transmission and providing regular maintenance are
critical for ensuring the safe and reliable driving of the vehicle and prolonging the service
life of the transmission. Please observe the following operation requirements:
1. Before vehicle start, release the parking brake. For vehicles equipped with air
cutoff brake, the vehicle can only be started after the air pressure rises to the
value necessary for releasing the brake.
2. Start the vehicle at 3-speed and 4-speed according to the road conditions.
3. Where the gearshift lever is located in the high-speed range, the neutral gear
is located between 9-speed and 10-speed; where the lever is in the low-speed
range, the neutral gear is located between 3-speed and 4-speed. When the vehi-
cle is stopped, the transmission shall be shifted in the Neutral gear of the low-
speed range; in other words, the change-over switch on the control lever is in
the low position.
4. In the shifting operation, the clutch must be disengaged thoroughly; otherwise
the service life of main transmission synchromesh device will be adversely af-
fected. Furthermore, the gearshift lever shall be engaged in place.
5. To engage the reverse gear, firstly shut down the engine and then engage the
gear to avoid damage to the parts inside the transmission. When shifting into R
31A position, apply strong selecting force to overcome the resistance from the re-
verse lock.
6. To shift from 6-speed to 7-speed (or from 7-speed to 6-speed ), a short pause is
required intentionally to enable the auxiliary transmission to fulfill the change
between high-speed and low-speed ranges. Before disengaging the gear, oper-
ate the control handle to the target zone, and then change between different
speed ranges.
7. When changing from low-speed range to high-speed range (vice versa), do not
skip any gear, otherwise the service life of the auxiliary transmission synchro-
mesh device may be adversely affected.
8. Frequently check the ventilating plug, and if any dirt is found, remove it immedi-
ately.
9. Check the air cleaner screen for running every 2,000 Km and clean the screen
and cleaner inner wall with soap water and dry them with compressed air.
10. When the vehicle goes downhill, avoid the changeover between high-speed and
low-speed ranges as much as possible.
11. If any abnormal symptom, such as abnormal noise or obviously heavy operation
in the transmission, is detected, park the vehicle immediately for troubleshoot-
ing.
12. The operation of power take-off should strictly observe the regulations, other-
wise it may result in fast damage to auxiliary transmission synchromesh device.
13. Transmission within the period of "three guarantees" is not allowed to disas-
semble and install privately.
Warning:
• Gear skipping is forbidden when the transmission is shifted from low speed to
high speed (vise versa).
• Shift between high and low speeds is forbidden when going downhill.
• Never coast at the neutral gear.
• Never tow the vehicle with the driving wheel in contact with the ground.
• If any abnormal symptom, such as abnormal noise or obviously heavy operation
in the transmission, is detected, park the vehicle immediately for check.
Continue driving after troubleshooting.
II. Maintenance issues of transmission
Each time the required interval is expired, it is required to perform all service and mainte-
nance inspection items specified in the service and maintenance regulations.
1. Daily inspection
(a) Inspection on lubricating oil level
Check the transmission lubricating oil level and leakage on a daily basis, and add the oil if
necessary. If any leakage is found, repair the transmission immediately to avoid any failure
resulting from the loss of lubricating oil.
31A
Oil level Oil level Oil level
Incorrect Incorrect Incorrect
(b) Pneumatic system 1-2

• Remove the water in the vehicle pneumatic system on a daily basis.
• Check whether there is air leakage by hearing and carry out repairs if necessary on a
daily basis.
• Confirm whether the air dryer works normally, and carry out repairs if necessary.
Inspect and repair the vehicle air compressor as required to prevent the entry of
lubricating oil into the pneumatic system.
2. Every 2,000-5,000km’s travel of the new transmission
(a) Replacethe lubricating oil;
(b) Check the transmission fastening bolts and fasteners for looseness and loss. Espe-
cially those bolts used to attach the transmission onto the engine.
(c) Lubricate the release bearing;
(d) Lubricate the clutch fork shaft;

(e) Clean the air cleaner element;
(f) Check and clean the transmission vents;
(g) Check the transmission control mechanism for normal operation.
3. Every 10,000 km or two months
(a) Check the transmission fastening bolts and fasteners for looseness and loss, espe-
cially those bolts used to attach the transmission onto the engine.
(b) Lubricate the release bearing;
(c) Lubricate the clutch fork shaft;
(d) Clean the air cleaner element;
(e) Check and clean the transmission vents;
(f) Check the transmission control mechanism for normal operation.
4. Replace oil
(a) The use of correct lubricating oil is critical for the maintenance of the transmission. You
are kindly required to strictly observe the maintenance procedure specified below:
• Purchase lubricating oil from a qualified supplier; the use and maintenance of the rear
axle;
• Employ the lubricating oil with correct type and class; trademark of the lubricating oil:
31A 85W-90 GL-5;
• Replace the oil as per the proper interval;
• Maintain a correct oil level.
(b) The interval for replacement of lubricating oil shall not exceed the time stipulated in the
table below.
Road conditions Off-road conditions Rigorous conditions
One year (at most) or 5,0000 km Every 1,000 h Every 500 h
Note:
Rigorous conditions refer to the circumstances where components are required to
constantly work at high load or in severely contaminated environment or on a steep
slope. Under these circumstances, adopt the replacement interval of lubricating oil
required by the rigorous conditions.
III. Cautions for removal of the transmission
1. Maintenance of the transmission should be carried out in a clean place to avoid
the entry of dust or other foreign matters into the transmission. Prior to the re-
moval operation, carefully clean the external surface of the transmission.
2. To remove various assemblies, place all parts on a clean work bench in the se-
quence of the removal operation. Thus to make the steps of the reinstallation
convenient and minimize the possibility of loss of parts.
3. At removing the input shaft , it is unnecessarily to remove the countershaft, out-
put shaft and input shaft gear.
4. Use the special tool to remove the bearing. Carefully clean the bearing and
check whether there is pit corrosion on the rolling way and whether the roller is
in good conditions.
IV. Cautions for fitting
Before fitting, thoroughly clean all parts for fitting and avoid the entry of dust and foreign
matters into the transmission; otherwise the unnecessary damages may occur.
1. Liner: Use the new liners to refit the transmission.
2. Bolts: To prevent oil leakage, all bolts must be coated with thread sealant and
tightened as per the standard torque.
3. O-ring: Lubricant all the O-rings with the silicon-grease lubricant.
4. Initial lubrication: Coat all thrust washers with the grease for initial lubrication to
avoid scratches or wear during fitting.
5. Tighten the output shaft flange plate nuts, and use the torque of 610-680 N•m to
fasten output shaft nuts; otherwise severe consequences may be aroused.
31A
Structure and principle of transmission

I. Dual countershaft floating structure
1 Main shaft 3 Input shaft gear
2 Input shaft 4 Auxiliary gearbox driving gear
As to the 16-speed transmission, the main and auxiliary transmissions adopt two coun-
tershafts, of which structure are completely the same. The power with interval of 180° is
31A
transferred to the input shaft, then shunt to two countershafts. At last, the power is output
from the main shaft. So does the auxiliary transmission.
Theoretically, each countershaft only transfer 1/2 torque. Therefore, the double counter-
shafts could reduce the center distance of transmission, thin the thickness of gear, shorten
the axial dimension and decrease the mass. After the adoption of double countershaft,
each-speed gear on the main shaft should simultaneously engage the gears of two coun-
tershafts.
To fulfill the correct engagement and distribute the load as uniformly as possible, the main
shaft gear floats in a radial direction on the main shaft which is provided with a hinged
floating structure. The main shaft journal is inserted into a hole on the input shaft. An oil-
bearing guide sleeve is accommodated in this hole, with a sufficient radial clearance be-
tween the main shaft journal and the guide sleeve. The rear end of the main shaft is insert-
ed into the auxiliary driving gear hole via an involute spline, and the auxiliary transmission
driving gear journal is supported on the ball bearing.
As all gears on the main shaft float along the main shaft, the conventional needle bearing
is thus canceled to simplify the structure of the main shaft assembly. In the operation, both
countershaft gears exert the same radial force on the main shaft gear in opposite direc-
tions to offset each other; in such a way, the main shaft will only bear torque, but no bend-
ing moment, which has largely relieved the load on both the main shaft and the bearing,
and has also significantly improved the transmission’s reliability and durability.
II. Power transfer line
Understanding the specific gear positions of the transmission for the engine power drive
route can help the technicians to overhaul and maintain the transmission. The 16 JS series
transmission is an insert transmission with 16 forwarding gears and 2 rear gears composed
by a main transmission consisting of 4 forwarding gears and 1 reverse gear, an auxiliary
transmission consisting of high and low gears and a front auxiliary transmission consisting
of half-high gear and half-low gear. For the main transmission, the front auxiliary transmis-
sion of half gear and the rear auxiliary are both dual countershafts structure.
1-speed
2-speed
3-speed 31A
4-speed
5-speed
6-speed
7-speed
8-speed
9-speed
10-speed
11-speed
12-speed
13-speed
14-speed
15-speed
16-speed
R1-speed
R2-speed
Note:
This transmission is the type of normally engagement. In the working process, all
the gears are rotated although only some of the gears are used to transmit power.
31A
The figure above shows the Fast double shaft transmission power transfer. It can be visu-
ally seen that: the power is divided into two and then two parts are combined in the main
gearbox. The power that is transmitted to the auxiliary gearbox is also divided into two and
then two parts are combined together.
III. Tooth alignment and tooth alignment procedure
To ensure the correct engagement between the countershaft gear and main shaft gear, the
tooth alignment must be conducted.
(1) At first, mark two adjacent teeth of the input shaft gear, and then mark the other side
symmetrical to it. (The teeth number of both groups of marks shall be equal.)
(2) Mark the tooth on each countershaft driven gear opposite to the gear key groove.
(3) During installation, engage the marked teeth on both countershaft driven gears into
both marked teeth on left and right sides of the input shaft gear separately.
(4) At installing the auxiliary transmission, select the reducer gear for tooth alignment with
auxiliary transmission countershaft pinion.
Tooth alignment procedure:
1 2 3
1 Left countershaft gear 3 Right countershaft gear
2 Input shaft gear
Tooth alignment of main gearbox

• At first, mark any two adjacent teeth with paint on the input shaft gear, and then mark
another two adjacent teeth on the other side in the corresponding 180° direction. The
31A
two groups of teeth shall be of equal numbers.
• Apply marking paint on the external teeth top opposite to the hole keyways of the
constant mesh gears of two countershafts, and such mark is unique.
• During installation, insert the marked teeth separately into the marked grooves of input
shaft gear.
• If installed correctly, the input shaft rotates flexibly; if the input shaft can not rotate or
rotates inflexibly, check if the teeth alignment marks are correct.
Teeth alignment for auxiliary gearbox
• At first, mark any two adjacent teeth with paint auxiliary reducer gear, and then mark
another two adjacent teeth on the other side in the corresponding 180° direction. The
two groups of teeth shall be of equal numbers.
• Separately paint the tooth crown top marked with “O” on the auxiliary transmission
countershaft gear , and such a mark shall be exclusive.
• During installation, insert the marked teeth of both auxiliary gearbox countershaft
gear into the marked tooth groove on the auxiliary gearbox reducer gear. Before the
installation of the auxiliary transmission assembly onto the main gearbox, carefully
check the tooth alignment marks. Perform the installation after confirming that there is
no error.
• Before the installation of the main gearbox, carefully check the tooth alignment marks.
Perform the installation after confirming that there is no error.
Note:
16 JS series is designed with serration. Furthermore, the difference of the speed ra-
tio between the adjacent gears is small. So special attention should be paid during
"alignment" installation; Before installation, mark the "alignment teeth" and install
in strictly accordance with the alignment marks. Alignment error is prone to oc-
cur without carefulness. The installation can be finished without correct alignment
sometimes and after the installation, the input shaft can rotate for several circles.
However, after the installation of such a transmission on the complete vehicle, as
long as the engine starts, severe damage will occur. During installation of the main
transmission countershaft, if the countershaft is heavy to move to align with the
bearing inner hole, it indicates that there is something wrong with "alignment" in-
stallation and careful check is thus required. After the installation of the transmis-
sion, it is a must to check whether it runs freely.
31A
IV. Structure and working principle of main geabox synchronizer
1 6
2 7
5
8
3
1 Synchronizer gear sleeve 5 Synchronizer outer cone
2 Locating block 6 Synchronizer double cone 31A
3 Spring 7 Synchronizer engaging gear
4 Synchronizer gear hub 8 Synchronizer inner cone
The transmission synchronizer enable the easy and rapid gearshift without causing impact
or noise, so as to prolong the gear’s useful life, and improve the vehicle’s accelerating per-
formance and save fuel. Therefore, except for the reverse gear, the transmission can be
applied at all gears. A large torque range, stable performance and endurance is required.
The inertia synchronizer can ensure the gearshift with the synchronizer engaged, being
stable and reliable. It is divided into the inertia lock type and inertia servo type, and those
of the most widespread use is inertia lock synchronizers, such as the locking ring type,
locking pin type etc.
The lock ring synchronizer is widely used at present due to its compact structure, good per-
formance, reliable use and low cost. Its defect lies in that the synchronizer friction torque is
too small. Double-cone lock ring synchronizer is a new synchronizer device developed and
designed on the base of the similar working principle and structural arrangement to the
lock ring synchronizer. It inherits the merits of the lock ring synchronizer as well as covers
the shortage by improving the friction torque of the synchronizer.
The figure above shows the 5-6 speed synchronizer, in which both the 5-speed-speed and
6-speed are provided with a double cone, with the synchronizer gear sleeve, gear hub,
sliding block, spring etc. shared by them. In addition, three conical members (5, 6, 8) are
provided for these two speeds. For the synchronizer outer cone (5), 6 single keys are con-
nected with these 6 key grooves on the inner cone (8); therefore, the outer cone (5) and
inner cone (8) can rotate synchronously with the transmission output shaft, while these 6
lugs on the synchronizing cone (6) are engaged with these 6 holes on the combining ring
(7), so the cone (6) rotates with 5-speed. As a result, when the gear is shifted from 4-speed
to 5-speed or from 6-speed to 5-speed, a relative angular speed difference is produced be-
tween the 5-speed and the output shaft; at this moment, two pairs of sliding friction cones
will start to work in the 5-speed synchronizer cone structure. Consequently, the synchro-
nous frictional torque produced on the friction cone due to the axial thrust exerted on the
synchronizer gear sleeve is equal to the sum of friction torques between these two pairs of
cones, provided that the overall sizes are the same, that’s to say, the synchronous friction-
al torque produced at the shift to 5-speed is about 2 times of that of a single-cone synchro-
nizer, thus deducting the gear shifting force by approximately 50%.
Working precess: To start the gearshift, the engagement sleeve will bring the sliding block,
to push the outer cone to move. Next, the synchronizer tooth sleeve, by overcoming the
spring force, will be separated from the sliding block to continue to move forward, thus to
enable the inclined face of the locking corner at the tooth sleeve tooth end to press against
the inclined face of the locking corner at the synchronizing ring tooth end. When the friction
torque on the cone overcomes the inertia torque of the jointed part, the speed difference
and friction torque disappear. The ring pulling force aligns the external cone, the locking
slope is disengaged, and the meshing sleeve overcomes the spring force of the sliding
block and crosses the locking ring to synchronously joint with the gear joint teeth, so as to
guarantee shock-free shift.
V. 16-speed transmission gearshift operation device
31A
High-speed
Low-speed
Black Red
Compressed air inlet
7-8bar (from air reservoir)
Black Red
Provided by manufac-
ture of main machine
1 Double H shift valve 4 Clutch switch

2 Auxiliary gearbox gear shift cylinder 5 Clutch pedal
3 Air filter regulator 6 Front auxiliary gearbox shift valve
16 JS series transmission gearshift operation system is composed by two sets of devices.

The figure fhwx310009 shows the pneumatic system of two sets of devices. One device
is to shift gears of the main and auxiliary gearboxes and adopts single-lever or double-
pole remote double H shift device. This device has no difference from the shift device of
RT11509C, 8JS transmission. The shift lever controls the shift shaft of the gearbox with
the link to make the shift lever swing, later, the shift lever stirs double H shift guide block,
thus, the shift lever can directly change the speed of the main transmission gearbox. When
the shift lever moves around, it can shift gears and can control double H shift valve 1 (as
shown in fhwx310009) to change between high and low speeds through the auxiliary
gearbox shift cylinder 2. The control pressure for this set of device is 0.67-0.71 Mpa. The
other device is to shift half gears of front auxiliary gearbox with the gear selector switch.
This device consists of the preselection valve, front auxiliary gearbox shift valve 6, clutch
switch valve 4 and front auxiliary gearbox shift cylinder, as shown in fhwx310009. Figure
ifhwx310061 shows the working principle of shift valve of the front auxiliary gearbox.
The air filter pressure regulating valve reduces the control pressure to be 0.28-0.32 Mpa
and the pressure is transmitted to the shift valve 6 of the front auxiliary gearbox through
the clutch switch valve 4. The shift valve 6 is controlled by the preselection valve of the
control lever. Two output pipelines of the shift valve 6 are connected with the shift cylinder
of the front auxiliary gearbox. 31A
When the driver depresses the clutch pedal 5, the clutch switch valve 4 is opened and
the compressed air is transmitted to the shift valve 6. At the same time, the compressed
air flows into the shift valve 6 and preselection valve. If the preselection valve is turned
upward to “even speed” position, the preselection valve is closed, as shown in Figure
fhwx310061, and the shift valve element is pushed on the right by the compressed air to
the position in Figure fhwx310061 (b). At this moment, the compressed air is connected
with the high-speed pipe 3 through the shift valve. Push the front shift cylinder 8 piston to
move on the right, input shaft synchronizer engagement sleeve and high half speed gear
are engaged, and then the vehicle drives at variable speed in the range of the high half
gear. When the clutch pedal is stepped on and the preselection valve switch is turned
downward to “odd speed” position, as shown in Figure fhwx310061, the preselection valve
is turned on. The compressed air flows into the shift valve “P” joint through the “P pipe 2”,
as shown in Figure fhwx310061 (c). The shift valve element is pushed on the left to the
limiting position because of the action of the pressure difference. At this moment, the valve
element will make the compressed air flow into the pipe 4 of the low speed but the com-
pressed air in the pipe 3 in the high speed is emptied through the shift valve. The piston of
the shift cylinder is pushed off forward (left). Input shaft synchronizer and the low half gear
are engaged and the gearbox will run at variable speed in the range of low half speed.
When the clutch pedal is stepped on and the clutch is thoroughly disengaged, the clutch
switch valve is to shift the gears in the front auxiliary gearbox. Thus, it can avoid driver’s
false operation and the gearbox can change speeds under full load to cause fault and
damage.
Figure fhwx310008 shows the gear position of 16JS series of gearbox lever.
Null Null
Figure fhwx310008 shows that when the preselection valve switch is turned upward to
“1” position, the gearbox will appear “2-4-6-8-10-12-14-16” even speed range. When the
preselection valve switch is turned downward to “2” position, the gearbox will appear “1-3-
5-7-9-11-13-15” odd speed range. Under general conditions, either a vehicle drives in the
31A even speed range or drives in the odd speed range. At the same time, the driver can oper-
ate the preselection valve switch at any speed according to the load change to change be-
tween the odd and even speeds. In other words, the odd and even speeds can be changed
at any speed. Therefore, 16JS series of transmission, main gearbox and rear auxiliary
gearbox are designed into a range-speed transmission but the front gearbox is designed
into insert-type speed transmission.
Note:
• When the main gearbox and rear auxiliary gearbox double H mechanism for
16JS series of transmission change the speeds, the clutch must be thoroughly
disengaged, or else the synchronizer will be worn early. This is a common
knowledge.
• When the preselection valve of the front auxiliary gearbox changes the speeds
and the clutch is not stepped on thoroughly, the clutch cannot be disengaged
thoroughly to cause early fault of the synchronizer. At the same time, as the
clutch switch valve is not turned on, the preselection valve cannot change the
speeds. Obviously, if the front auxiliary gearbox cannot change speeds, please
check the preselection valve and shift valve first and especially check the clutch
switch valve.
The even gears
The odd gears
Low-speed air pipe
High-speed air pipe
31A
Low-speed air pipe
High-speed air pipe
fhwx310061
1 Preselection valve 5 Intake pipe

2 P air pipe 6 S air pipe
3 High-speed air pipe 7 Front auxiliary gearbox shift valve
4 Low-speed air pipe 8 Front auxiliary gearbox shift cylinder
Note:
• The air circuit control valve is switched on only in the neutral gear. The air
circuit is cut off in the air circuit control valve when engaging a shift. That is, the
high-low speed switching can be realized only in neutral gear.
• There is air in the outlet pipe of control air circuit (preselection valve) at low
speed and there is no air in the control air circuit at high speed.
VI. Working principle of parking PTO
In order to meet the demand for some special vehicles, PTO can be installed below trans-
mission and between the clutch housing and transmission. Power taken off from the ex-
tended countershaft of auxiliary gearbox at the right bottom of transmission rear end is
called “rear power take-off”. This way of taking off the power is widely applied at present.
Power taken off from the clutch housing and transmission is called “front power take-off” or
“full power take-off”.
When “rear power take-off” is adopted, the rear auxiliary gearbox synchronizer must be set
in the Neutral gear to realize power take-off power on stop. In order to solve this problem,
you just need to remove the transmission range cylinder head and to add one neutral gear
cylinder.
The orifices A and B are separately connected with low-speed pipe and high-speed pipe
of transmission and further connected with single H valve of transmission. The pressure is
0.57-0.6 Mpa. The orifice C is the inlet of compressed air when the transmission is set in
the N (neutral) position and the pressure is 0.7-0.8 Mpa. During power taking-off on stop,
31A disengage the clutch and set the shift lever in the Neutral gear of low-speed range to tightly
press the range cylinder piston 15 on the positioning ring. Then, operate the Neutral gear
cylinder control valve and make 0.7-0.8 Mpa compressed air flow into the Neutral gear
cylinder 7. As the cylinder has pressurization function, the Neutral gear cylinder pistons 10
and 13 move towards the left and will stop until reaching the locating ring. As a result, the
transmission range cylinder piston 15 is set in the Neutral gear. At the moment, shift the
main gearbox into the appropriate speed, connect the air circuit of PTO, engage the clutch,
and then PTO can realize power taking-off on stop.
A 4 5 B 6 7
3
8
2
7
1
15 14 13 12 11 10 9
31A
1 Range gear shift fork shaft 9 Cylinder head
2 Range gear cylinder 10 Middle-position cylinder piston
3 Rear cover housing 11 O-ring
4 O-ring 12 Hollow shaft
5 Hexagon nylon locking nut 13 Middle-position cylinder piston
6 Air vent plug 14 Bolt
7 Middle-position cylinder 15 Range gear cylinder piston
8 Shaft snap ring

List of failure symptoms

The following list will help you to locate the fault. Serial number means the sort of possible
reason. Check each section according to that sequence, and replace if necessary.
Failure symptom Suspected part Refer to

Replace with the lubricating oil
1. Poor quality of lubricating oil 85W-90 GL5 specified by the
manufacturer.
2. Improper lubricating oil level Add lubricating oil
3. The tooth surface of the gear
Chapter 31 Transmission (16JS-
is damaged or worn exces-
D220TA) – Transmission, Testing
sively to generate large back-
and Adjustment
lash.
4. Bearing is damaged or has
Abnormal sound or noise cracks
and Adjustment
5. The jointing position of fork D220TA) – Transmission Control
and gear is improper. Mechanism, Testing and Adjust-
ment
6. Synchronizer wear or dam-
age
and Adjustment
31A
7. Gear damage D220TA) – Transmission, Testing
and Adjustment
1. Bearing wear or damage D220TA) – Main Gearbox, Disas-
sembly and Assembly
2. The shift fork and shaft bend D220TA) – Transmission Upper
or have burrs. Cover, Disassembly and Assem-
bly
The shift of the main gearbox is
3. The check screws of fork are D220TA) – Transmission Upper
difficult or fails.
loose. Cover, Disassembly and Assem-
bly
Replace with the lubricating oil
4. The viscosity of lubricating oil
85W-90 GL5 specified by the
is too high.
manufacturer.
5. Main shaft twist D220TA) – Main Shaft Assembly,
Disassembly and Assembly
Failure symptom Suspected part Refer to

1. Defective pressure regulator
Replace the regulator valve
valve
D220TA) – Double H Control
2. Failure of air pipe or joint
Mechanism, Removal and Instal-
Off-gear of the high-speed and lation
low-speed sections of the auxil-
iary gearbox 3. The shaft is distorted, and the Chapter 31 Transmission (16JS-
gear leaves the teeth align- D220TA) – Transmission, Testing
ment position. and Adjustment
4. The engaging teeth or gear
sleeve back taper fails.
and Adjustment
1. The interlock steel ball or
D220TA) – Transmission Upper
The gears are in disorder. interlock pin is not installed or
Cover, Disassembly and Assem-
worn.
bly
Adjust the lubricating oil level to
1. Too much lubricating oil
the specified value
2. The seals are damaged or
failed.
and Adjustment
Oil or air leakage
3. Fasteners are loose. Fasten the loose components
31A
Clean or replace the air vent
4. The air vent plug is clogged.
plug.
5. The bolt is not coated with Coat with sealant, and re-install
sealant. the bolt.
Inspection and adjustment

1. Testing of the axial clearance of the main
shaft gears
(a) Place the output shaft vertically, install the re-
verse gear snap ring, and install the auxiliary
gearbox drive gear assembly and snap ring.
(b) Check the clearance between the reverse
gear and drive gear by a feeler gauge.
Standard clearance: 0.3-0.9 mm
(c) Check the axial clearance between the low-
speed and reverse gear and between the
2-speed and 3-speed gears of the output
shaft.
Standard clearance: 0.13-0.3 mm
2. Testing of double H air valve

4 (a) Appearance testing: The housing shall be free
31A 2 from defects, and the plunger shall move flex-
1 ibly and have no heavy wear.
3 (b) Channel testing: When the pin is in the origi-
nal position, the compressed air introduced in
shall flow out from the outlet 4 only; when the
fhwx310162 pin backs to the lowest position due to force
carrying, the compressed air introduced in
shall flow out from the outlet 2 only.
Note:
Replace the air valve if any of the fault phe-
nomena appears.
3. Testing of air filter regulator

(a) Appearance testing: The part shall be free
from defects and leakage.
(b) Pressure testing: When the air pressure of the
vehicle reaches 0.7-0.8 Mpa, the barometer is
installed at the outlet, and the pressure valve
displayed by the barometer shall be 0.41-0.44
Air outlet
Mpa.
Air inlet
Note:
Replace the air filter regulator if the reading
doesn't meet the requirement.
4. Testing of neutral gear switch

(a) Appearance testing: The part shall be free
from defects and leakage.
31A
(b) Resistance testing: Measure the resistance
between the two wiring terminals of the switch
by a multimeter.
.
fhwx310164
Gear position Contact resistance (Ω)
Neutral gear <1
Other positions ∞
5. Testing of range gear switch

(a) Appearance testing: Free from defects such
as deformation, damage or contact looseness.
by a multimeter.
fhwx310165 Resistance range Contact resistance (Ω)
Low range 1
High range ∞
6. Testing of reverse gear switch

(a) Appearance testing: Free from defects such
as deformation, damage or contact looseness.
by a multimeter.
fhwx310166 Gear position Contact resistance (Ω)
Low range 1
Other positions ∞
7. Testing of auxiliary shift cylinder

(a) Test whether the O-ring or other seals are
damaged, deformed, lubricated poorly or in-
stalled not ineutral gear.
31A
8. Inspection of high low speed synchronizer

(a) Check the fit state between the synchronizer
and auxiliary gearbox output shaft.
(b) Check whether the synchronizer keyway and

lock pin are worn.
fhwx310169
(c) Check whether there are cracks, deformation,

etc. on the synchronizer ring gear.
fhwx310170
9. Bearing inspection
(a) Place all bearings in clean solution and wash
them. Check whether the steel balls, rollers
and ball track have pits or fall off. 31A
(b) Measure the bearing inner diameter.
(c) Replace the bearing if the measured value ex-
ceeds the limit value.
10. Measurement of reverse shaft diameter

(a) Measure the diameter of the reverse shaft by
a micrometer.
(b) Replace the reverse shaft if the measured
value exceeds the limit value.
fhwx310172
11. Adjustment of transmission shift control

mechanism
(a) The technician A in the cab holds the shift le-
ver in the center.
(b) The technician B releases the adjusting nut of
the expansion link assembly or shift lever as-
sembly, and adjusts the gears to the best posi-
tion.
(c) Tighten the nut.
12. Measure the fit clearance between the ring

gear and fork.
(a) Measure the size of the ring gear with a mi-
31A crometer.
(b) Measure the size of the shift fork with a mi-
crometer.
Note:
Replace the corresponding ring gear and fork
if the fit clearance exceeds the limit value.
13. Gear inspection

(a) Check whether there is pitting on the tooth surface of the gears, and replace the gears
if any.
(b) Check all mesh gears, replace the gears which are worn into a cone or have a de-
creased mesh length due to impact.
(c) Check the axial clearance of gears, and check whether the gear split ring, washer, ad-
justing gasket and gear flange are worn excessively if detecting the part with excessive
clearance. The axial gap of forward gear of main shaft should be kept between 0.13
and 0.30 mm. The axial clearance of reverse gear: 0.30-0.90 mm.
14. Spline inspection
(a) Check the wear degree of splines on all shafts, and replace if the sliding gear sleeve
and output flange incline to one side of the spline due to wear.
15. Inspection of thrust washer
(a) Check the surface condition of all thrust washers. Replace the washers with scratches
or thinned depth.
16. Inspection of gray cast iron parts
(a) Check whether there are cracks or damages on all gray cast iron parts. Fusion weld-
ing or braze welding can be conducted for large castings, but the heat generated shall
not extend to the bearing hole or bolt connecting surface.
17. Inspection of bearing cover
(a) Check the seam for wear.
(b) Check the oil seal in input shaft bearing cap and the oil seal in the odometer housing,
replace if the sealing function of the lip fails.
18. Inspection of sliding sleeve
(a) Check whether all forks and fork grooves on the sliding sleeves are overworn or dis-
colored due to overheating.
(b) Check whether the contact area of the engaging teeth of the sliding sleeve deflects. 31A
19. O-ring inspection
(a) Check all O-rings for cracking and deformation conditions. Replace the O-rings which
are worn and aged.
31A-26 Transmission (16JSD220TA) - Shift mechanism assembly
Shift mechanism assembly

Component drawing
9
31
32 20
30 28
34 33 22
35 29
3 17
19
10 8
1
5
13
15
18
16
27
25
26
24
14
16 2
4 7
6
23 11
31A
12 21
1 Air vent plug 18 Dust cover

2 Air pipe assembly 19 End cover lining
3 Shift mechanism housing 20 Spring seat
4 Gear shift shaft 21 Low and reverse gear cam
5 Slide block 22 Bolt
6 Air circuit bend 23 Bolt
7 Air line control valve 24 Cheese head screw
8 Stop collar 25 Nut, style 1
9 Compression spring 26 Spring washer
10 Cylindrical pin 27 Spring washer
11 Air pipe tee joint 28 Shaft elastic snap ring
12 Elastic cylindrical pin 29 Bowl-shaped plug
13 Shift shaft bushing 30 Neutral gear switch
14 Control valve gasket 31 Travel top pin
15 Oil seal 32 Washer
16 Shift crank 33 Reverse lamp switch
17 End cover
Transmission (16JSD220TA) - Shift mechanism assembly 31A-27
Removal and installation

1. If the oil seal is removed, put the shift
mechanism assembly vertically, and install
the oil seal.
fhwx310134
2. Install the transverse shift shaft and as-

semble the elastic cylindrical pin of the
reverse control block with the small end
facing up.
fhwx310135
3. Install the cylindrical pin of the shift guide

block, and bind with wires.
31A
fhwx310136
4. Install the spring, spring seat and snap

ring
fhwx310137
31A-28 Transmission (16JSD220TA) - Shift mechanism assembly
5. Install the limiting sleeve and the side pan-

el.
fhwx310138
6. Install the reversing lamp switch and neu-

tral switch.
fhwx310139
7. Install dust cover and shift rocker to guar-

antee the rocker and block are in the same
straight line.
31A
fhwx310140
8. Install the shift mechanism on the upper

cover.
fhwx310141
9. Fasten the four bolts
fhwx310142
Transmission (16JSD220TA) - Shift mechanism assembly 31A-29
10. Install the air circuit reversing valve, air

circuit control valve and air pipeline.
fhwx310143
31A
31A-30 Transmission (16JSD220TA) - Transmission assembly
Transmission assembly
Removal
1. Lift the rear gearbox
2. Disconnect the negative cable of battery
3. Unscrew the oil drain plug at the bottom of
the transmission, drain transmission oil,
and tighten the oil drain bolt.
Torque: 54.5±7 N•m
fhwx310077
4. Remove the intermediate drive shaft. Refer to Chapter 33 Drive shaft – Interme-
diate Drive Shaft, Overhaul.
5. Remove the drive shaft of the power take-off. Refer to Chapter 34 Power Take-off
– QH50 Power Take-off, Removal and Installation.
6. Remove the transmission accessory
31A (a) Remove the air pipe assembly of the air filter
regulator.
fhwx310063
(b) Remove the grounding cable of the transmis-

sion.
fhwx310064
Transmission (16JSD220TA) - Transmission assembly 31A-31
(c) Remove the air inlet of PTO.
fhwx310065
(d) Disconnect the combined plug of the transmis-

sion.
fhwx310066
7. Remove transmission shift control mechanism assembly

8. Remove the cover plate of the clutch ob-
servation hole.
31A
(a) Remove four bolts and take down the cover
plate.
fhwx310067
9. Pick off the spring clamping wire hook of

the clutch release bearing.
10. Remove the clutch slave cylinder. Refer to
Chapter 32 Clutch – Clutch Slave Cylinder,
Overhaul.
fhwx310068
11. Disconnect the connection of transmission

and engine
(a) Remove the lower connecting bolts of the
transmission and engine.
fhwx310069
fmwx010001
(b) Remove the upper connecting bolts of the

transmission and engine.
fhwx310070
12. Remove the subframe

13. Remove the transmission assembly
(a) Jack up the transmission assembly by a trans-
31A mission hydraulic jack.
fhwx310071
(b) Remove the connecting nut of the transmis-

sion mounting, and take down the lower spring
beam.
fhwx310072
(c) Separate the transmission from the engine by

a flat crowbar.
(d) Remove the transmission assembly.
fhwx310073
Installation
1. Install the transmission assembly
(a) Connect the transmission assembly with the
engine assembly.
fhwx310074
2. Tighten the connecting bolts of the trans-

mission and engine.
(a) Tighten the upper connecting bolts of the
transmission.
fhwx310075
(b) Tighten the lower connecting bolts of the

transmission.
31A
fhwx310069
fmwx010001
3. Install the spring beam of the transmis-

sion, and tighten the connecting nut of the
mounting.
Torque: 240 N•m
4. Install the transmission shift control mech-
anism assembly.
fhwx310072
5. Install the transmission accessory

(a) Connect the combination plug of the transmis-
sion.
fhwx310066
(b) Install the intake pipe of the power take-off.
fhwx310065
(c) Install the grounding cable of the transmission,

and tighten the bolts.
Torque: 54.5±7 N•m
31A
fhwx310064
(d) Install the air pipe assembly of the air filter

regulator.
fhwx310063
6. Install the clutch slave cylinder, refer to Chapter 32 Clutch - Clutch Slave Cylin-
der, Overhaul
Note:
Before installing the clutch slave cylinder, tie the end of the release bearing crank
by a rope through the window of the clutch slave cylinder, and strongly pull the
crank outward to force the release bearing into the release ring and make it jammed
by spring clamping wire, which shows that the release bearing is installed ineutral
gear.
7. Install the cover plate of the clutch obser-

vation hole
(a) Install the cover plate of the clutch observation
hole, and tighten the four bolts.
fhwx310067
8. Remove the drive shaft of the power take-off. Refer to Chapter 34 Power Take-off
– QH50 Power Take-off, Removal and Installation.
9. Install the intermediate drive shaft. Refer to Chapter 33 Drive Shaft – Intermedi-
ate Drive Shaft, Overhaul.
10. Install the negative cable of the battery.
11. Unscrew the oil filler plug in the middle
of the transmission, fill transmission oil
85W/90GL-5, and tighten the oil filler bolt.
Note:
Run the transmission for several minutes after
filling oil, and then check the transmission oil
31A
level again.
fhwx310076
12. Put down the rear gearbox

13. Transmission running-in specification and test
(a) The environment is that the speed is about 1,500 r/min; the oil temperature is not
lower than 15℃ ; with no load, the transmission is running at Neutral gear for not less
than 15min, and at other gears for not less than 20 min.
(b) Check whether the shift is flexible, the gears are meshed fully, and there is a gear im-
pact sound during shift.
(c) The shift lever of the transmission shall be free from obvious vibration.
(d) There shall be no abnormal friction sound or impact sound during testing of the trans-
mission.
(e) The transmission shall have no oil-leakage.
(f) After running-in, drain transmission oil for running-in, clean the transmission inside
completely, and fill transmission oil as specified.
31A-36 Transmission (16JSD220TA) - Input shaft assembly
Input shaft assembly

Component drawing
10 9
31A
1 2 3 4 5 6 5 5 7 8 7 5
1 Input shaft nut 6 Front auxiliary gearbox synchronizer
2 Input shaft bearing 7 Input shaft gear spline cushion
3 Spacer ring 8 1-speed high splitter group gear
4 Primary shaft low splitter group 9 Guide bush, output shaft
5 Snap ring 10 Input shaft

Transmission (16JSD220TA) - Input shaft assembly 31A-37
Removal
1. Remove the transmission input shaft gear
assembly.
fhwx310010
2. Remove the snap ring in the internal hole

of input shaft gear.
fhwx310011
3. Remove input shaft gear and spline gasket

of both sides
31A
fhwx310012
4. Remove the snap spring in front of the

synchronizer meshed gears
fhwx310013
5. Remove components at the one side of the

odd/even speed synchronizer.
fhwx310014
6. Direction of sliding block and cone ring on

synchronizer. Remove the snap ring at one
side of synchronizer.
Note:
Cone rings on both sides and normally meshed
gears 16-speed odd-even speed synchronizer
cannot be changed mutually.
fhwx310015
31A
Transmission (16JSD220TA) - Input shaft assembly 31A-39
Installation
1. Put input shaft vertically, install input shaft
high splitter group gear, and assemble
input shaft gear spacer with the concave
side down.
fhwx310026
2. Install input shaft bearing
fhwx310027
3. Put the input shaft levelly, install com-

ponents at one side of the odd and even
speed synchronizer and install one snap 31A
ring
fhwx310028
4. Install the gear hub of synchronizer and in-

stall one snap ring
fhwx310029
5. Install the components on the other side of

synchronizer and a snap ring
fhwx310030
6. Install the spline gasket on the input shaft
fhwx310031
7. Assemble the input shaft low splitter group

gear and spline gasket, and install one
snap ring.
31A
fhwx310042
8. Apply anaerobic adhesive on the threads

of the input shaft nut, and assemble the
input shaft nut and rivet it. Make the teeth
alignment marks on two groups of teeth
that are selected freely and are 180° adja-
cent on input shaft gear.
fhwx310043
Transmission (16JSD220TA) - Output shaft assembly 31A-41
Output shaft assembly

Component drawing
8
7
3
3
6 1
5 1 9
3
3
4
3
2 1 10
1 11
12
31A
1 Snap ring 7 1-speed gear, output shaft

3-speed/4-speed synchronizer assem- 8 1-speed/reverse mesh sliding sleeve
2
bly
9 Reverse gear, output shaft
3 Output shaft gear spacer
10 Output shaft
4 3-speed gear, output shaft
11 Output shaft hexagon long key
5 2-speed gear, output shaft
12 Elastic cylindrical pin
6 1-speed/2-speed synchronizer
31A-42 Transmission (16JSD220TA) - Output shaft assembly
Removal
1. Remove the baffle at the front end of out-
put shaft assembly, input shaft gear and
components on one side of 5/6-speeds
synchronizer
fhwx310175
2. Remove the snap ring on the main shaft

fixing 5/6-speeds synchronizer, and take
down the 5/6-speeds synchronizer.
fhwx310176
3. Remove the spring pin on the main shaft,

pull out the long key and then remove
31A gears and gaskets in order
fhwx310177
Installation
1. Put the output shaft vertically on the work-
bench, install the output shaft reverse gear
gasket and insert the long key after turning
a tooth pitch.
fhwx310044
2. Install the reverse gear of the output shaft

into the reverse sliding sleeve with the en-
gaging teeth down, and the tooth space
groove faces the output shaft keyway with
hole.
fhwx310046
3. Install the gear spacer of the output shaft,

and insert the long key upward after turn-
ing a tooth pitch. 31A
fhwx310032
4. Install the engaging teeth of the output

shaft 1-speed gear downward in the out-
put shaft, put the output shaft gear spacer
in, and insert the long key after turning a
tooth pitch.
fhwx310033
31A-44 Transmission (16JSD220TA) - Output shaft assembly
5. Install the components at one side of the

1/2-speeds synchronizer, and install one
snap ring
fhwx310034
6. Install the gear hub of the 1/2-speeds syn-

chronizer, and install a snap ring
fhwx310035
7. Install the components at the other side of

the 1/2-speeds synchronizer, and install
the spline gasket of the output shaft with
the convex side facing down, and insert
31A the long key after turning a tooth pitch.
fhwx310036

shaft 2-speed gear downward in the main
shaft, install the output shaft gear spacer,
and insert the long key after turning a tooth
pitch.
fhwx310037

shaft 3-speed gear downward in the main
shaft, install the output shaft gear spacer,
and insert the long key after turning a tooth
pitch.
fhwx310038
10. Assemble the spring pin on the output

shaft.
fhwx310039
11. Install the components on one side of the

3/4-speeds synchronizer and install a snap
ring.
Note:
The opening of the snap ring towards the out-
put shaft groove with hole.
fhwx310040
12. Install the gear hub of the 3/4-speeds syn-

chronizer, and install one snap ring
Note:
The opening of the snap ring avoids the output 31A
shaft groove with hole.
fhwx310041
13. Install the components at the other side of

the 3/4-speeds synchronizer.
fhwx310046
31A-46 Transmission (16JSD220TA) - Transmission upper cover
Transmission upper cover

Component drawing
24
23
25 21
20
27
6
1
30
29
28
9
31A 13
2
5 8
14
10
4
22
5 5
11 5
16
18
15
17 12
17
19
3
26
Transmission (16JSD220TA) - Transmission upper cover 31A-47
1 Steel ball 16 3/4-speeds shift shaft
2 Steel ball 17 Y-shaped seal ring
3 O-ring 18 Y-shaped seal ring
4 Fork shaft interlock pin 19 End cover
5 Fork lock pin screw 20 Compression spring
6 Stud bolt 21 Compression spring
7 Upper cover 22 3/4-speeds, 7/8-speeds guide block
8 Reverse gear guide block 23 Thin nut
9 Reverse gear shift fork 24 Z-nut
10 1/2-speeds shift fork 25 Spring washer
11 3/4-speeds fork 26 Snap ring for hole
12 Front auxiliary gearbox fork 27 Nut
13 Reverse gear shift fork shaft 28 Reverse pin plunger
14 1/2-speeds shift shaft 29 Reverse pin spring
15 Front auxiliary gearbox fork piston rod 30 Reverse pin plug screw
31A
Removal
1. Remove the slave valve and pipe of odd-
even speed cylinder.
fhwx310016
2. Remove the upper cover bolt.
fhwx310017
3. Push the upper cover out with bolts and

remove the upper cover assembly.
31A
fhwx310018
4. Take out three locating springs and steel

balls from the housing hole.
fhwx310019
5. Remove the reverse fork shaft, guide block

and reverse fork.
fhwx310020
6. Remove 1/2-speeds fork shaft and fork,

and take out interlock steel ball from the
housing.
Note:
The 1/2-speeds fork shaft hole has interlock
pin.
fhwx310021
7. Remove 3/4-speeds fork shaft, guide block

and fork, and take out interlock steel ball
from the housing.
31A
fhwx310022
8. Remove the snap spring of odd-even

speed shifting cylinder on the upper cover
housing.
fhwx310023
9. Knock the piston and fork shaft, take out

the spring and steel ball from the housing,
and remove the piston and fork shaft.
fhwx310024
10. Remove the Y-ring on the piston form shaft

and O-ring on the side cover.
fhwx310025
31A
Installation
1. Y-ring in the bore of odd/even gear shift
cylinder on upper cover housing
fhwx310048
2. Apply a layer of grease on the Y-ring of

piston shaft, and install the shaft into the
odd/even speed gear cylinder on the upper
cover housing.
Note:
Direction of Y-ring.
fhwx310049
3. Install the locating steel ball in the bore of

odd/even gear shift cylinder.
31A
Note:
Spring upside, steel ball downside
fhwx310050
4. Install side cover with the plane facing out-

ward
fhwx310051
5. Install the snap ring of shift cylinder
fhwx310052
6. Assemble bolts on the fork of odd/even

speed shift cylinder, and fasten with iron
wire.
fhwx310053
7. Install the 3/4-speeds fork shaft, guide

block and fork, fastening bolts, and install
one interlock steel ball.
31A
fhwx310053
8. Install the 1/2-speeds fork shaft, interlock

pin.
fhwx310055
9. Fasten bolts on the 1/2-speeds fork and

guide block, bind with iron wire and install
one interlock steel ball.
fhwx310056
10. Install the reverse fork shaft, guide block

and reverse fork, and fastening bolts.
fhwx310057
11. Install the upper cover assembly
fhwx310058
12. Assemble three locating steel balls and

spring in the upper cover holes
Note:
The spring in the hole of the 3/4-speeds fork 31A
shaft is thicker.
fhwx310059
13. Screw up bolts on the upper cover, and

connect the air pipes of shift device and
upper cover.
fhwx310060
31A-54 Transmission (16JSD220TA) - Main gearbox assembly
Main gearbox assembly

Component drawing
16 13
9
2
12
31A 5
4
3
14
6 10 8 1 17 11
15
7
Hexagon head bolt and spring washer

1 Side power take off window lining 10
assembly
Pregluing hexagon head bolt and spring
2 Round magnet 11
washer assembly
3 Bottom power take-off window cover 12 Slotted lock screw with flat end
4 Bottom power take-off window gasket 13 Hexagon nut, type-1
5 Transmission housing 14 Flat washer
6 Stud bolt 15 Flat washer
7 Hexagon nylon locking thin nut 16 Spring washer
8 Power take-off window cap 17 Slotted cone screw plug
9 Stud bolt
Transmission (16JSD220TA) - Main gearbox assembly 31A-55
Removal
1. Remove the snap ring on the back of the
main gearbox countershaft.
fhwx310121
2. Install the driven gear bearing to locate the

output shaft rear end.
fhwx310122
3. Remove the countershaft rear bearing with

the soft rod.
31A
fhwx310123
4. Knock the countershaft backward by ap-

proximately 10 mm with the copper rod
and remove the two countershaft front
bearings with special tools.
fhwx310124
5. Remove the driven gear bearing for one

more time.
fhwx310125
6. Take the output shaft assembly out from

the main gearbox.
fhwx310126
7. Take the countershaft assembly and the

reverse idle gear from the main gearbox
housing.
31A
fhwx310127
Transmission (16JSD220TA) - Main gearbox assembly 31A-57
Installation
1. Put the two countershafts of main gearbox
into the main gearbox housing.
fhwx310128
2. After making the teeth aligning marks on a

pair of teeth which are 180° adjacent on in-
put shaft gear, put the output shaft assem-
bly into the main gearbox, and install the
drive gear bearing to locate the rear end of
the output shaft.
fhwx310126
3. Insert the marked teeth on the lower side

countershaft into the two marked teeth on
input shaft gear, and install the lower side 31A
countershaft rear bearing.
fhwx310130
4. Assemble the front bearing of lower side

countershaft.
fhwx310132
5. Align and assemble the rear and front

bearing of upper side countershaft with the
same method.
fhwx310133
31A
Transmission (16JSD220TA) - Auxiliary gearbox assembly 31A-59
Auxiliary gearbox assembly

Removal
1. Enable the two synchronizers in the main
gearbox to engage with the gear separate-
ly.
fhwx310082
2. Use the special force-saving spanner to

loose the output shaft flange nut.
fhwx310083
3. Remove the three air pipes on the auxiliary 31A

gearbox cylinder and the two bolts on the
air filter.
fhwx310084
4. Remove the connecting bolt of rear cover

and main gearbox.
fhwx310085
31A-60 Transmission (16JSD220TA) - Auxiliary gearbox assembly
5. Push the auxiliary gearbox backward for

approximately 10 mm with three bolts.
fhwx310086
6. Take the auxiliary gearbox assembly off

with the auxiliary gearbox hanger.
fhwx310087
7. Remove the flange nut and the flange.
31A
fhwx310088
8. Remove the two output bearing cover and

the snap ring on the auxiliary gearbox
shaft with the snap ring plier.
fhwx310089
9. Knock the output shaft backward to sepa-

rate it from the bearing and take down the
countershaft bearing.
fhwx310090
10. The two countershaft and bearing of the

auxiliary gearbox.
fhwx310091
11. Remove the connecting bolt of auxiliary

gearbox gearshift cylinder and the auxil-
iary gearbox gearshift fork.
fhwx310092
12. Remove the four bolts on the auxiliary

gearbox gearshift cylinder and take the
cylinder assembly down.
31A
fhwx310093
13. Take the cynchronizer assembly down

form the output shaft.
fhwx310094
14. Knock the output shaft backward until it is

off the bearing hole.
fhwx310095
15. Block up the output shaft assembly and

knock off the bearing.
fhwx310096
16. Each part of the output shaft assembly.
fhwx310097
17. Remove the bolt of the output bearing cov-

er and and take down the bearing cover.
Remove the odometer connector and the
master and slave gear of odometer.
31A
fhwx310098
18. Take the combined bearing outer ring out

from the rear cover hole.
fhwx310099
Installation
1. Put the low speed ring of synchronizer
flat and put it into the synchronizer sliding
sleeve.
fhwx310100
2. Put the synchronizer high-speed ring, and

add one rotating force to assemble the
high-speed ring ineutral gear in place.
fhwx310101
3. Put the low-speed ring of the synchronizer

up on a wood block 50 mm high, and insert
the output shaft. 31A
fhwx310102
4. Install the gasket of the auxiliary gearbox

main shaft, with the rabbet facing down.
fhwx310103
5. Nest the auxiliary gearbox reduction gear

into the output shaft with the plane facing
upward, and put the pressure plate of the
auxiliary gearbox main shaft gear.
Note:
Apply the lubricating grease on the pressure
plate of auxiliary gearbox main shaft gear
6. Put the one side of the combination bear-

ing into the output shaft, and make the
teeth aligning mark in the 180° direction of
the auxiliary gearbox reduction gear.
7. If the bearing inner rings of auxiliary gear-

box has been removed, install the bearing
inner rings into two countershafts.
31A
fhwx310106
8. Make teeth alignment mark on the marked

tooth top of countershaft of auxiliary gear-
box.
fhwx310107
9. Put the marked teeth of the two counter-

shafts into the marked grooves of the re-
duction gear.
fhwx310108
10. Put down the rear cover housing

Note:
Install the extended countershaft of power
take-off on the lower right of rear cover hous-
ing.
fhwx310109
11. Install two countershaft bearings and out-

put shaft outer bearing on the rear cover.
fhwx310110
12. Install the snap ring on the countershaft

bearing of auxiliary gearbox.
31A
fhwx310111
13. Install two countershaft end caps.
fhwx310112
14. Install the output shaft bearing cap, and

put the odometer drive and driven gears
and joint in.
fhwx310113
15. Insert the shift fork of the auxiliary gearbox

into the synchronizer sliding sleeve, with
the plane facing outward, install the con-
necting bolt of the fork and fork shaft, and
lock with iron wires.
fhwx310114
16. Assemble shift cylinder of auxiliary gear-

box
fhwx310115
17. Tighten the flange nut with a special sock-

et.
31A
fhwx310116
18. Place the auxiliary gearbox synchronizer in

the low-speed range.
fhwx310117
19. Apply grease evenly on the front bearing

inner holes of two countershafts at the rear
end of main gearbox (this step is very im-
portant).
fhwx310118
20. Assemble the auxiliary gearbox assembly

with lifting appliance.
fhwx310119
21. Tighten the connecting bolt of the rear cov-

er and main gearbox housing.
fhwx310120
31A
31A-68 Transmission (16JSD220TA) - Reverse gear countershaft
Reverse gear countershaft

Component drawing
5
1
31A 1 Cupped reverse gear washer 4 Reverse gear countershaft
2 Reverse countershaft gear 5 Slotted lock screw with flat end
3 Needle bearing
Transmission (16JSD220TA) - Reverse gear countershaft 31A-69
Removal
1. Remove the snap ring in the output shaft
reverse gear.
fhwx310147
2. Take out the output shaft gear washer in

the main shaft reverse gear.
fhwx310148
3. Remove the countershaft front bearing of

auxiliary gearbox by a special tool.
31A
fhwx310149
4. Remove the screw plug in the reverse idle

gear shaft with the screwdriver.
fhwx310150
31A-70 Transmission (16JSD220TA) - Reverse gear countershaft
5. Loosen the self-locking nut on the reverse

idle gear shaft.
fhwx310151
6. Remove the reverse idle gear shaft by a

special shaft puller.
fhwx310152
7. All components of reverse idle wheel as-

sembly
31A
fhwx310153
Transmission (16JSD220TA) - Reverse gear countershaft 31A-71
Installation
1. Fit the reverse idle gear with the convex
surface facing forward.
fhwx310145
2. Fit the reverse idle shaft and tighten the

self-locking nut.
fhwx310146
31A
31A-72 Transmission (16JSD220TA) - Main gearbox countershaft
Main gearbox countershaft

Component drawing
9 8 7 6 5 3 4 3 2 1
31A 1 Countershaft snap ring 6 Countershaft square key
2 Countershaft differential gear 7 Elastic cylindrical pin
3 Spacer sleeve 8 Woodruff key
4 Countershaft drive gear 9 Countershaft
5 3-speed gear, countershaft

Transmission (16JSD220TA) - Main gearbox countershaft 31A-73
Disassembly and assembly

Note:
Do not remove the countershaft gear, except for severe wear or tooth collision.
1. Disassemble the left countershaft
(a) Remove the left countershaft snap ring.
31A
(b) Remove the countershaft differential gear,

spacer sleeve, countershaft driven gear, coun-
tershaft 3-speed gear, countershaft square
key and woodruff key in order.
31A-74 Transmission (16JSD220TA) - Main gearbox countershaft
2. Assemble the left countershaft.

(a) Fit the woodruff key, countershaft square
key, countershaft 3-speed gear, countershaft
driven gear,countershaft differential gear and
spacer sleeve in order.
(b) Install the countershaft snap ring.
31A
Note:
As for the disassembly and assembly of the left countershaft, refer to the disassem-
bly and assembly of the right one.

Gearbox 16JSD220TA PDF

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Transmission (16JSD220TA)

Transmission.....................................31A-1 Transmission upper cover..............31A-46

16 J (D) S 220 (T) A

Gear ratio code

All synchromesh transmission

X10 nominal input torque (N·m)

Number of forward gears

Model of transmission assembly

Input power Input torque

User ID Factory No.

Shanxi Fast Gear Co., Ltd

Oil level Oil level Oil level

Incorrect Incorrect Incorrect

(b) Pneumatic system 1-2

(d) Lubricate the clutch fork shaft;

Road conditions Off-road conditions Rigorous conditions

One year (at most) or 5,0000 km Every 1,000 h Every 500 h

Structure and principle of transmission

1 Main shaft 3 Input shaft gear

2 Input shaft 4 Auxiliary gearbox driving gear

Tooth alignment procedure:

1 Left countershaft gear 3 Right countershaft gear

2 Input shaft gear

Tooth alignment of main gearbox

IV. Structure and working principle of main geabox synchronizer

1 Synchronizer gear sleeve 5 Synchronizer outer cone

2 Locating block 6 Synchronizer double cone 31A

3 Spring 7 Synchronizer engaging gear

4 Synchronizer gear hub 8 Synchronizer inner cone

1 Double H shift valve 4 Clutch switch

16 JS series transmission gearshift operation system is composed by two sets of devices.

The even gears

The odd gears

Low-speed air pipe

High-speed air pipe

Low-speed air pipe

High-speed air pipe

1 Preselection valve 5 Intake pipe

1 Range gear shift fork shaft 9 Cylinder head

2 Range gear cylinder 10 Middle-position cylinder piston

3 Rear cover housing 11 O-ring

4 O-ring 12 Hollow shaft

5 Hexagon nylon locking nut 13 Middle-position cylinder piston

6 Air vent plug 14 Bolt

7 Middle-position cylinder 15 Range gear cylinder piston

8 Shaft snap ring

List of failure symptoms

Failure symptom Suspected part Refer to

Failure symptom Suspected part Refer to

Inspection and adjustment

2. Testing of double H air valve

3. Testing of air filter regulator

4. Testing of neutral gear switch

Neutral gear <1

5. Testing of range gear switch

fhwx310165 Resistance range Contact resistance (Ω)

6. Testing of reverse gear switch

fhwx310166 Gear position Contact resistance (Ω)

7. Testing of auxiliary shift cylinder

8. Inspection of high low speed synchronizer

(b) Check whether the synchronizer keyway and

(c) Check whether there are cracks, deformation,

10. Measurement of reverse shaft diameter