Changan SC1010 - Transmission Maintenance; Reverse Gears and Idle Gear Check; Input Shaft Check; Combination of Gear and Synchronizer Ring

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Table of Contents1
General Information2
Specifications3
Locations of Engine Number and Body Number6
Standard Shop Practices6
Special Tools8
Troubleshooting11
Engine Troubles12
Carburetor Troubleshooting19
Exhaust and Muffler Troubleshooting19
Clutch Troubleshooting19
Transmission Troubleshooting20
Differential Troubleshooting21
Propeller Shaft Troubleshooting22
Brakes Troubleshooting22
Front Suspension and Steering System Troubleshooting24
Starting Motor Troubleshooting25
Alternator Troubleshooting26
Wiper Motor Troubleshooting27
Fuel Meter Troubleshooting27
Turn Signal Lights Troubleshooting28
Speedometer Troubleshooting29
Water Temperature Meter Troubleshooting29
Oil Pressure Warning Light Troubleshooting29
Charge Warning Light Troubleshooting30
Horn Troubleshooting30
Engine31
Engine Description32
Blowby Gas Recycling System35
Engine Services Not Requiring Engine Removal36
Dismounting the Engine37
Engine Disassembly38
Engine Maintenance Service Notes46
Cylinder Head Maintenance47
Rocker-Arm Shaft and Rocker Arms Maintenance48
Valve Guide Replacement50
Valves Maintenance51
Valve Seat Repair53
Valve Springs Maintenance54
Camshaft Maintenance55
Journal Wear56
Cylinder Block Maintenance57
Piston and Piston Rings Maintenance57
Flatness of Gasketed Surface57
Cylinder Bore57
Ring Clearance in the Groove58
Piston Ring End Gap58
Connecting Rods Maintenance59
Connecting Rod Big End Bearings Maintenance60
Crankshaft Maintenance61
Crankshaft Thrust Play61
Crankshaft Journal Bearing62
Flyweel Maintenance63
Timing Belt and Timing Pulleys Maintenance63
Engine Reassembly64
Engine Inspection and Adjustment76
Engine Lubrication80
Oil Pump Disassembly81
Oil Pump Reassembly82
Oil Filter Servicing83
Checking the Oil Pressure83
Carburetor85
Slow Speed Mixture87
High Speed Mixture87
Accelerator Power System87
Carburetor System Diagram88
Carburetor Inspection and Adjustment89
Needle Valve90
Choke Valve90
Accelerator and Choke Cables90
Fuel Hose91
Fuel Tank Cap91
Idle Speed and Idle Mixture Adjustment91
Air Cleaner, Cyclone, Fuel Pump and Fuel Filter93
Air Cleaner94
Use of the Selector Lever94
Cyclone System95
Fuel Pump96
Fuel Filter97
Engine Cooling System99
Engine Cooling System Description100
Cooling Water Circuit100
Coolant Draining Removal101
Cooling Water Hoses Removal102
Radiator Removal102
Cooling Fan Removal102
Water Pump Removal102
Water Reservoir Tank103
Thermostat103
Radiator Filler Cap103
Water Pump Description104
Requirements on Coolant104
Cooling System Services105
Water Temperature Gauge105
Thermostat Servicing105
Anti-Freeze Proportioning Chart105
Fan Belt106
Radiator107
Coolant Level107
Water Hoses107
Filling up the Cooling System108
Cooling Fan Installation108
Car Heater109
Electrical Circuit (Heater)111
Heater Services112
Fan Resistor112
Fan Switch112
Heater Valve112
Ignition System115
Ignition System Components Description117
Distributor117
Ignition Coil117
Timing Advancer118
Vacuum Advancer118
Ignition System Maintenance Services119
Distributor Cap Maintenance119
Spark Plugs119
Distributor Driven Gear120
Contact Point Faces120
Checking the Primary Circuit for Fault120
Condenser121
Ignition System - Reminders for Reassembly and Installation122
Distributor Installation122
Ignition Timing Specifications123
Ignition Timing Checks123
High-Tension Cords123
Ignition Timing Adjustment124
Replacement of Distributor Drive Gear125
Checking the Timing Advancer Action125
Centrifugal Advance125
Vacuum Advance125
Starter Motor127
Starter Motor Specifications129
Cranking Action129
Starting up the Motor129
Pinion Meshing with the Ring Gear130
Engine Cranking130
Starter Motor Removal131
Starter Motor Disassembly131
Terminating Cranking Operation131
Starter Motor Maintenance Services132
Checking the Field Coils132
Checking the Armature132
Servicing the Commutator133
Testing the Magnetic Switch134
Servicing the Brushes134
Servicing the Brush Holders134
Important Reminders for Starter Motor Reassembly135
Charging System137
Charging Operation138
Alternator Description140
Alternator Data and Specifications141
Alternator Removal141
Alternator Disassembly142
Alternator Maintenance Services143
Alternator Regulator145
Guide on Regulator Diagnosis147
Battery Specifications148
Care of the Battery148
Voltage Regulator148
Clutch151
Clutch Removal153
Clutch Maintenance Services153
Clutch Disc Facing Surface Condition153
Clutch Facing Wear153
Backlash in Disc Serration Fit154
Clutch Cover154
Release Bearing154
Input Shaft Bearing and Oil Seal154
Clutch Installation155
Clutch Cable Lubrication155
Clutch Pedal Play155
Clutch Disc Center Guide156
Input Shaft Bearing156
Clutch Release Bearing Retainer156
Clutch Release Arm156
Gear Shifting Control157
Gear Shifting Control Maintenance Services162
Gear Shifting Control Installation163
Transmission165
Flow of Drive through Transmission168
Transmission Gear Ratio172
Transmission Dismounting172
Transmission Disassembly172
Removing the Countershaft173
Removing the Main Shaft and Input Shaft174
Removing the Shifter Fork Shafts and Forks175
Transmission Maintenance176
Reverse Gears and Idle Gear Check176
Input Shaft Check176
Combination of Gear and Synchronizer Ring176
Chamfered Tooth Ends of Ring (External Teeth) and Sleeve177
Synchronizer Rings Check177
Fork Shaft Locating Springs178
Extension Case Bush178
Transmission Installation179
Reverse Gears and Idle Gear181
Input Shaft and Main Shaft Installation181
Putting Together Upper and Lower Cases181
Extension Case Oil Seal182
Transmission Oil182
Propeller Shaft183
Propeller Shaft Removal184
Propeller Shaft Maintenance185
Propeller Shaft Installation185
Universal Joint Noise185
Differential187
Differential Removal189
Differential Disassembly189
Differential Maintenance190
Side Gear Backlash190
Determination of Shim Thickness for Bevel Pinion191
Bevel Pinion Bearing Preload Adjustment192
Bevel Gear Backlash Adjustment193
Pinion-To-Gear Tooth Contact Pattern Check and Adjustment195
Differential Reassembly196
Drive Bevel Gear Bolts196
Bevel Pinion Bearings196
Differential Side Bearings197
Differential Gear Oil197
Differential - Important Steps in Installation and Tightening Torque198
Suspension199
Front Suspension Diagram201
Rear Suspension Diagram201
Front Suspension Strut202
Ball Joint202
Front Coil Spring202
Installation and Tightening Torque (Front Suspention)204
Leaf Spring Inspection206
Shock Absorber Inspection206
Rear Suspension Installation and Tightening Torque207
Steering System209
Steering System Specifications and Data210
Steering Gear Box Construction and Operation210
Steering Shafts Removal212
Steering System Maintenance212
Gear Box Removal212
Steering Handwheel Play212
Steering Gear Box213
Steering Rubber Joint213
Wheel and Wheel Nuts214
Tires214
Tire Pressure Specification214
Steering System Reassembly215
Steering Center Lever215
Steps in Installation and Tightening Torque (Steering System)216
Wheel Alignment219
Steering Handwheel219
Steering Angle220
Brakes223
Tandem Master Cylinder226
Front Brake Construction227
Rear Brake Construction228
Parking Brake Construction228
Wheel Cylinder Construction228
Brake Maintenance229
Master Cylinder Checks229
Brake Drum Check229
Brake Shoes Check229
Master Cylinder and Wheel Cylinders Check230
Brake Pipes Check230
Air Purging230
Brake Fluid231
Brake Shoe Clearance Adjustment231
Brake Pedal Check231
Parking Brake Lever232
Parking Brake Cable232
Brake Hoses and Pipes233
Brake Light Switch Installation233
Brake Tightening Torque236
Body Electrical Equipment237
Head Light Wiring Circuit238
Heal Light Beam Setting238
Turn Signal Light and Hazard Warning Light240
Windshield Wiper Motor241
Fuel Gauge242
Service Data and Maintenance Schedules245
Tightening Torque Table246
Service Data249
Periodical Inspection Schedule256

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Changan SC1010 - Transmission Maintenance; Reverse Gears and Idle Gear Check; Input Shaft Check; Combination of Gear and Synchronizer Ring

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