Amt Jh1 Times

AUTOMATED MANUAL
TRANSMISSION
JH 1 - OVERHAUL
GENERAL SPECIFICATION
JH1 019 GEARBOX SPECIFICATIONS
DRY WEIGHT
GEARBOX RATIOS:
: 42.5 Kg
1 : 11/37
2 : 22/41
3 : 28/37
4 : 34/35
5 : 39/32
R: 11/39
Final drive : 14/59
GEARBOX OIL:
OIL TYPE
APPROVED GEARBOX OILS
GEARBOX OIL CAPACITY
REPLACEMENT INTERVAL
LEVEL CHECKING
: 75 W 80
: ELF XT4447 TEXACO ETL8681
: 3.5 l
: 40 000Km
: TOP-UP (NO DIPSTICK)
TRANSMISSION FEATURES
* Transverse mount
* 5 Forward speed and 1 Reverse speed
* Shiftronic type
* Transmission output torque : 125 Nm
Fitted with BORG WARNER synchronizers
Reverse gear control reverse gear brake.
TRANSMISSION MODEL CODE
Engrave on the transmission

A
C
J H 1 997
C X14766
B
D
E
A = Gearbox type.
B = Gearbox suffix
C = Manufacturing factory ( C = Clon)
D = Production number
E = Letter preceding production numbers greater than 999
999.
TRANSMISSION OIL CAPACITY

& LUBRICANTS
Oil filler plug made of

plastic base material
Trans ELF TRJ 75W/80

3.4 Liters
MAINTENANCE
Transmission oil change :

Every 40,000km
CLUTCH SYSTEM
* Single dry plate

* Mechanical operating mechanism
( cable linkage clutch )
SST~Clutch disc
center guide
SPECIAL TOOLS
Tool
Tool
Number
Name/Use
B.Vi 945
Mandrel for fitting the

sun wheel seal
Number
Name/Use
B.Vi 31-01
Set of 3 pins for fitting

the 5mm diameter roll
pins
SPECIAL TOOLS
Tool
Number
B.Vi 946
Tool
Name/Use
Mandrel for fitting the
snap ring on the sun
wheel
Number
Name/Use
B.Vi 949
Fork roll pins fitting

and removal tool
SPECIAL TOOLS
Tool
Number
B.Vi 1000
Tool
Name/Use
Extractor for the 5th
fixed gear on the
output shaft,use with
B.Vi 22-01
Number
Name/Use
B.Vi 1059
Ring for fitting

differential bearing
SPECIAL TOOLS
Tool
Tool
Number
Name/Use
B.Vi 1170
Extractor for the 5th

gear hub on the input
shaft
Number
Name/Use
B.Vi 1576
Mandrel for fitting

bearings in the
mechanism housing
SPECIAL TOOLS
Tool
Number
Name/Use
B.Vi 1570
Tool for fitting ball

indentation
TORQUE SPECIFICATION
DISASSEMBLY PROCEDURE
Note: Part must be removed and handled on a work bench with cove
which protects against impact ( rubber or thick plastic )
1st Step : Remove the rear housing. This must be remove in horizontal
centerline of the transmission as it has a lubricating nozzle
located in the input shaft. ( 3 bolts size 13mm)
2nd Step : Engage 1st gear with the gear lever and 5th gear by sliding
the 5th gear fork on the shaft.
Downward
Forward
Pull
1st gear with the gear lever
5th gear fork on the shaft
3rd Step : Remove the input

shaft nut 27mm
and loosen the
output shaft bolt.
27mm
E14
Wood
4th Step :Using the B.Vi.31-01 remove the 5th gear fork pin
placing a piece of wood behind the shaft to support it.
5th Step :Remove the 5th gear fork and sliding gear.
Note: Place the transmission in neutral again.
6th Step :Extract the 5th gear synchronizer hub using tool
B.Vi. 1170.
Note: Fit the special tool onto the 5

Grooves and the hub grooves oppos
each other.
7th Step :Remove the 5th gear assembly
5th gear hub
Bottom
Washer
5th gear spacer
Washer
Nut
Top
5th gear
5th gear ring
Synchronizer ring
5th gear sliding gear hub & fork
8th Step :Remove the 5th gear bolt at output shaft.
9th Step :Extract the 5th gear at output shaft.
Note: Using tools B.Vi.22-01 an

B.Vi 1000 remove the ou
shaft gear.
10th Step :Remove the reverse gear plunger lock.
11st Step : Remove the
primary shaft
speed sensor ( B )
12nd. Step :Remove the mechanism housing bolts.
( 16pcs bolts size E12 )
Note: Before pull out the mechanism h

it is advisable to fit two magne
or to close the opening in orde
retrieve the 1/2 and 3/4 shaft lo
ball and springs.
13rd Step : Turn the 5th and Rev. gear

selector shaft to clockwise
direction.
Gap
14th Step : Press the control shaft and turn downward.
Selector shaft 1/2
15th Step : Unpin the 3/4 fork

using B.Vi 949.
Selector shaft 3/4
Note: Place the 1/2 shaft and the
gear in neutral.
Reverse gear
16th Step : Remove the 3/4 shaft from the housing bore sliding
in it fork and remove the shaft fork assembly.
17th Step : Raise and separate the input
and output shaft and remove
the reverse gear shaft .
18th Step : Simultaneously pull the

two shaft (input & output)
and assembled 1/2 fork
shaft and remove the
assembly.
NOTE : For assemble, reverse the procedure.
Note: Retrieve the interlock plunger located in the housing
PARTS MUST BE REPLACE

When they have been removed.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Lip seals.
O-Rings.
Stop ring.
Thrust pad guide tube.
Differential ball bearing.
Speedometer shaft and gear.
Roll pins.
Output shaft and differential nuts.
Ring under the gear.
Input and output shaft bearing circlips.
REPLACEMENT
PROCEDURE
REPLACEMENT
PROCEDURE
1. Removal and installation the bearings in the mechanism housing.
1st Step : Separate the circlips with circlip pliers and drive the
bearing inside the housing using tool B.Vi.1576
REPLACEMENT PROCEDURE
2nd Step : Place the new circlips in their respective housing
3rd Step : Fit the bearing using tool

B.Vi.1576 and knock the
tool with the bearing
using small hammer.
2. Removal and installation the bearings on the clutch housing.
1st Step : Cut the base of the plastic
hollow needle located
at the centre of the bearing.
2nd Step : Use the special tool to extract the bearing.
3rd Step : Fit the deflector and the bearing on the press flush
with inner side of the housing..
4th Step : Set the bearing with a mortise chisel.
5th Step : Refit the bearing guide using tool B. Vi. 1601.
3. Thrust Pad Guide Tube.
4. Differential Ball Bearing.
5. Removal and installation the speedometer gear.
Note: The gear and the shaft must be changed whenever they are rem
Removed the shaft by pull out

using the long nose plier
6. Removal and installation the Control shaft.
INSPECTION
PRIMARY SHAFT ( INPUT SHAFT).
1st
2nd
4th
3rd
(B)
Rev
(A)
5th gear lubrication hole
Note: 1. The primary shaft cannot be repaired.

2. There no adjustment to be carried out.
3. On the shaft which have a jet (B), this cannot be remove.
4. Clean the 5th gear lubrication hole.
5. Check the condition of the mating surface (A) . If there are any
scratches or faults in appearance, change the primary shaft.
INSPECTION
SECONDARY SHAFT ( OUTPUT SHAFT).
Note: 1. The gear teeth and the clows should not be chipped or excessively w
2. Also ensure that there are no signs of grating or abnormal wear on t
surfaces of the shafts or the inner walls of the gear.
3. It is advisable to mark the position of the sliding shafts in relation to
INSPECTION
Secondary Shaft ( Output Shaft) Assembly.
TOP
Rev
1st
2nd 3rd
4th
5th
BOTTOM
INSPECTION
Output Shaft
Groove facing 2nd gear
Circlip
2nd gear
1st gear
1st gear
Continue
Grooved Washer
Synchronizer ring
1/2 sliding gear assy.
Big cutting shape
No Groove facing 1st gear..
INSPECTION
Grooved Washer
2nd gear
Synchronizer ring
Continue
Circlip
3rd gear
Synchronizer ring
INSPECTION
Small cutting shape
3/4 sliding gear assy
Grooved Washer
4th gear
4th gear
3rd gear
Circlip
Synchronizer ring
Continue
Groove facing 3rd gear
INSPECTION
Washer
Continue
5th gear
Retaining bolt
DIFFERENTIAL
Disassembly and Assembly .
Note: This operation is carried out
after separating the housing.
1st Step : Remove the O-Ring
2nd Step : Strike the lip seal,

using the pin extractor
and small hammer
in order to tilt it.
3rd Step : Remove the seal, taking
care not to damage the splines on the sun gear.
DIFFERENTIAL
4th Step : Using the circlip pliers to
free the circlip and extract it.
Press
5th Step : The differential is extracted by pushing on the

shouldered sun wheel using a press..
DIFFERENTIAL
6th Step : Remove the snap ring

and the shim.
DIFFERENTIAL
7th Step : Extract the tripod sun gear.
DIFFERENTIAL
8th Step : Place the differential
unit and press the housing.
DIFFERENTIAL
Circlip
DIFFERENTIAL
Coated with oil
INSPECTION
Checking The Pre-Load
1st Step : Turn the differential
through several revolutions.
2nd Step : Wind the string around

the crown wheel.
3rd Step : Pull the string using
a spring balance.
4th Step : The differential should turn under a load of between:
Used bearing = 0 to 2 daN ( 0 ~ 204 gf )
New bearing = 1.6 to 3.2 daN ( 163 ~ 326 gf )

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AUTOMATED MANUAL

TRANSMISSION MODEL CODE

Engrave on the transmission

TRANSMISSION OIL CAPACITY

Oil filler plug made of

Trans ELF TRJ 75W/80

Transmission oil change :

* Single dry plate

Mandrel for fitting the

Set of 3 pins for fitting

Fork roll pins fitting

Ring for fitting

Extractor for the 5th

Mandrel for fitting

Tool for fitting ball

1st gear with the gear lever

5th gear fork on the shaft

3rd Step : Remove the input

Note: Place the transmission in neutral again.

Note: Fit the special tool onto the 5

5th gear ring

5th gear sliding gear hub & fork

Note: Using tools B.Vi.22-01 an

Note: Before pull out the mechanism h

13rd Step : Turn the 5th and Rev. gear

15th Step : Unpin the 3/4 fork

18th Step : Simultaneously pull the

Note: Retrieve the interlock plunger located in the housing

PARTS MUST BE REPLACE

3rd Step : Fit the bearing using tool

2nd Step : Use the special tool to extract the bearing.

Removed the shaft by pull out

5th gear lubrication hole

Note: 1. The primary shaft cannot be repaired.

Groove facing 2nd gear

No Groove facing 1st gear..

Groove facing 3rd gear

1st Step : Remove the O-Ring

2nd Step : Strike the lip seal,

5th Step : The differential is extracted by pushing on the

6th Step : Remove the snap ring

7th Step : Extract the tripod sun gear.

Coated with oil

2nd Step : Wind the string around

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