Genuine SINOTRUK HOWO Countershaft Assembly Kit AZ2203030210 + AZ2203030209 – Heavy Duty Transmission Spare Parts

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‌Pre-Installation Requirements‌

1. ‌Essential Tools‌

   • 200-400Nm digital torque wrench (calibrated within 3 months)
   • Bearing puller set (50-150mm range)
   • Dial indicator with 0.001mm resolution

2. ‌Consumables‌

   • LOCTITE 574 flange sealant (100ml tube)
   • Mobil SHC Gear 85W-140 lubricant

‌Installation Process‌

‌Step 1: Component Removal‌

• Drain transmission oil through 28mm hexagonal drain plug (minimum 15min drainage)
• Mark original shim positions with alignment punches (every 45°)
• Remove retaining rings using JIS V-32 circlip pliers

‌Step 2: Surface Preparation‌

1. Clean mating surfaces with non-chlorinated brake cleaner
2. Apply sealant in spiral pattern:
   • 3mm continuous bead around bolt holes
   • 5mm offset from oil channels

‌Step 3: Assembly Installation‌

• Verify gear backlash: 0.10-0.15mm (measure at 3 positions 120° apart)

‌Post-Installation Verification‌

1. ‌Leak Testing‌

   • Conduct 30min pressure test at 400kPa (max allowable drop: 25kPa)

2. ‌Functional Check‌

   • Run through all gear ranges 50x at 1500rpm
   • Monitor temperature rise: ≤65°C after 15min operation

‌Critical Warnings‌

• Replace all circlips (mandatory for warranty validation)
• Maintain ambient temperature between 15-35°C during installation
• Initial oil replacement required after 300km break-in period