Dongfeng LoongGine Gearbox Sub box synchronizer assembly 1701540-TV202

Engineered for exceptional shifting performance, this synchronizer assembly features a multi-cone design (typically 2-3 cones) that significantly enhances friction contact area and synchronization speed. The cones are made of high-carbon alloy steel (SCM440) with a precision-ground surface (roughness Ra ≤0.8 μm), ensuring uniform friction during gear engagement and reducing shift force by 25-30% compared to single-cone synchronizers. Rigorous testing shows it can synchronize gear speeds (ranging from 500 to 2000 rpm) in ≤0.3 seconds, eliminating gear grinding and enabling smooth, quiet shifting—even under heavy loads (e.g., climbing slopes with full cargo). The synchronizer’s blocker ring, treated with a molybdenum disulfide coating, further reduces friction and wear, ensuring consistent shifting performance throughout the assembly’s service life

The 1701540-TV202 synchronizer assembly is built to withstand the high torque and mechanical stress of heavy-duty gearbox operations. Key components—including the synchronizer hub, slider, and cones—are crafted from high-strength alloy steel (20CrMnTiH) that undergoes carburizing heat treatment (surface hardness HRC 58-62, core hardness HRC 30-35). This treatment enhances surface wear resistance while maintaining core toughness, preventing cracking or deformation under extreme torque (up to 2000 N·m, compatible with LoongGine gearbox ratings). The assembly’s spring pins and return springs are made of stainless steel (304) for corrosion resistance, ensuring reliable component movement even in gearboxes with minor fluid contamination

Designed to handle the harsh operating conditions of heavy-duty gearboxes, this synchronizer assembly exhibits excellent thermal stability and vibration resistance. The alloy steel components have a low coefficient of thermal expansion (11.5 × 10⁻⁶/°C), ensuring dimensional stability even when gearbox temperatures reach 120-150°C (common during prolonged high-load operation). This prevents component seizing or binding that could disrupt shifting. Additionally, the synchronizer’s slider and hub feature a floating design with precise clearance (0.05-0.1 mm) that absorbs gearbox vibration, reducing stress on friction surfaces and extending component life. The assembly’s friction cones are also engineered to dissipate heat quickly, preventing thermal degradation of the friction material and maintaining consistent synchronization performance over time

The 1701540-TV202 synchronizer assembly is designed for straightforward installation and minimal maintenance, optimizing repair efficiency for fleet workshops. It comes pre-assembled with all critical components (hub, slider, cones, springs, pins), eliminating the need for tedious individual part alignment during installation. The assembly’s spline interfaces and mounting points are marked with alignment notches, ensuring quick, accurate positioning within the gearbox sub-box—reducing installation time by 40% compared to disassembled synchronizer kits. For maintenance, the assembly’s modular design allows easy inspection of friction cones (via gearbox inspection ports) without full disassembly; worn cones can be replaced individually, lowering repair costs. The part is also laser-marked with the part number, material grade, and manufacturing date for easy identification and traceability, simplifying inventory management and ensuring compliance with Dongfeng LoongGine maintenance standards