CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Assembly
1. Carefully press and fit two gear shift mechanism(1) & (2) bearings to the corresponding position on
the gear shift mechanism housing. The bearing (1)
should be pressed to the end, both end faces of
the bearing should align with the hole end faces of
the housing bearing. The side of the bearing with
letters should be placed outwards.
2. Press the air duct into the housing orifice to ensure the air duct is in the proper position.
3. Press and fit the fluid seal of the gearshift shaft into the fluid seal hole of the housing, ensure the fluid seal is pressed and fitted in position.
NOTE :
Apply transaxle fluid to the fluid lip seal. 4. Install the gearshift shaft through the fluid seal and into the housing of gear shift mechanism.
5. Following the direction of the arrow, install the rear neutral return spring stop, rear neutral return
spring, reverse gear lock assembly, selector finger
and interlock plate assembly, front neutral return
spring assembly onto the gearshift shaft (as shown
in the figure). Check the turn-down rims of rear
neutral return spring stop, and ensure they have
entered into corresponding vent groove of the
housing. One end of main body of reverse gear
lock with blind hole shall face rear neutral return
spring stop. And the small end face of front neutral
return spring assembly shall face towards selector
finger.
6. Insert the gearshift shaft into the bearing.
7. Install the reverse gear limiter lock mechanism (1) (as shown in the figure).
(Tighten: Reverse gear limiter bolt to 22 N·m)
8. Install the gearshift fluid seal dust boot to the gearshift shaft fluid seal.
9. Install the gearshift lever assembly to the gearshift shaft, then press it in the pin hole of gearshift lever assembly, finally install the pin.
NOTE :
Neither end of the pin is allowed to protrude beyond the two end surfaces of the pin holes.
ON-VEHICLE SERVICE
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Downloaded from www.Manualslib.com manuals search engine 10. Align the selector finger (1) and fork shaft springpin (2), install the spring pin of selector finger (as
shown by the arrow in the figure).
11. Tighten the interlock plate limit bolt (1) together with the shim to the housing (as shown in the fig-
ure). The tightening torque of the bolt is 30 N·m.
Check front end circular cylinder of the bolt to
ensure it is in the corresponding groove of selector
finger.
12. Check the gearshift shaft to ensure it is able to rotate and perform axial movement freely.
13. Install air duct (1) and air duct cap (2). Apply seal- ant to the surface of the inserted part of air duct.
14. Install the backup light switch assembly (1). (Tighten: Backup light switch to 32 N·m)
ON-VEHICLE SERVICE
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08–269Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine MANUAL TRANSAXLE UNIT REPAIR
Transaxle
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Gear Shift Mechanism Housing Bolt 18
Gear Positions Self-Locking Bolt 35
Reverse Gear Bolt 20
Reverse Gear Cap Bolt 20
Rear Transaxle Bearing End-Plate Bolt 6.9
Transaxle To Clutch Housing Bolt 44
Bearing Input Shaft Bolt 18
Disassembly
1. Place the transaxle on a workbench.
2. Remove the clutch fork (2) and remove the release
bearing (1).
NOTE: The release bearing (1) is not serviceable.
3. Set the transaxle gear in the neutral position. Remove the gear shift mechanism housing retain-
ing bolts (1), and remove the gear shift mechanism
housing.
(Tighten: Gear shift mechanism housing bolts to
18 N·m)
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Downloaded from www.Manualslib.com manuals search engine 4. Remove the three gear positions self-locking bolts(1).
(Tighten: Three gear positions self-locking bolts to
35 N·m)
5. Remove the reverse gear bolt (1). (Tighten: Reverse gear bolt to 20 N·m)
6. Remove the 6 reverse gear cap bolts (1), and remove the cap.
(Tighten: Reverse gear cap bolts to 20 N·m)
7. Gently pry the idler gear downward using a screw- driver, and then remove the idler gear assembly.
MANUAL TRANSAXLE UNIT REPAIR
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08–271Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 8. Remove the 10 rear transaxle bearing end-platebolts (1), and then remove the bearing cap.
(Tighten: Rear transaxle bearing end-plate bolts to
6.9 N·m)
9. Remove shaft clip (3) and shaft clip (1) from the shafts, and then remove bearing collar (2).
10. Remove the transaxle to clutch housing bolts (1), and then use a pry bar to remove the transaxle
housing.
(Tighten: Transaxle to clutch housing bolts to
44 N·m)
11. Perform the following steps to remove the transaxle housing (1).
MANUAL TRANSAXLE UNIT REPAIR
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Downloaded from www.Manualslib.com manuals search engine 12. Tap the transaxle housing and use a suitable toolto remove the transaxle housing.
13. Remove the 3 front bearing input shaft bolts (1). (Tighten: Bearing input shaft bolts to 18 N·m)
14. Grasp the input shaft assembly, output shaft assembly, 1st-2nd shift fork, 3rd-4th shift fork and 5th-reverse fork shaft together and remove.
15. Remove the differential assembly (1) upward (as shown in the figure).
NOTE: Pre-tighten the shim of the differential cone
bearing.
16. Remove the magnet (1) and wipe the magnet clean.
MANUAL TRANSAXLE UNIT REPAIR
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08–273Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Inspection
1. Place a tin solder sheet (1) (approximate length is10 mm and diameter is 1.6 mm) on the specified
part of the transaxle housing, and then install the
differential outer bearing race.
2. Install the clutch housing, and tighten the bolts to the specified torque.
3. Replace the tin solder sheets with thicker tin solder sheets.
4. With a micrometer, measure the thickness (T) of the flattened tin solder sheet.• Select the thickness of the shim to be installed
according to the following equation.
Thickness of washer: (T + 0.005 mm) - (T +
0.11 mm)
5. Do not clean the release bearing.
6. Clean the sealing surface of all contaminates, remove all old sealant, and clean all bolt holes.
7. Check all parts for damage, replace any damaged parts if necessary.
8. Always align the bearing cap (1) with the shaft opening. Align the bearing collar to the bearing cap
opening (as the two circular rings indicate in the
figure).
MANUAL TRANSAXLE UNIT REPAIR
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Downloaded from www.Manualslib.com manuals search engine 9. Place the transaxle in the neutral position wheninstalling the self-locking bolts for the gear posi-
tions. The notches (1) of the shift fork guide block
should align in the same line.
10. Place the transaxle in the neutral position (1) when the gear shift mechanism housing assemble is in
the position of the selector finger in the gear shift
mechanism housing assembly shown in the figure.
11. Alternate tightening each bolt to the specified torque.
Assembly
1. Install the input shaft together with the output shaft.
2. Install the 5th-reverse gear shifting fork/fork stalk-5th-reverse gear fork/3rd-4th gear shifting fork/fork stalk–3rd- 4th fork.
3. Move the gear bushing-3rd-4th gear (1) and the gear bushing-5th-reverse gear (2) in the direction
shown in the figure.
MANUAL TRANSAXLE UNIT REPAIR
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Downloaded from www.Manualslib.com manuals search engine 4. Install the 3rd-4th gear shifting fork (2) and its forkstalk (1) and the 5th-reverse gear shifting fork (3)
and its stalk (4).
5. Install all gear shifting forks into the gear hub, and at the same time, move the fork stalks (1) & (2) in
the direction shown in the figure.
6. Install the locking pin.
7. Using special tools MB-990938 (1) and MB-990935 (2), install the outer bearing race.
MANUAL TRANSAXLE UNIT REPAIR
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Downloaded from www.Manualslib.com manuals search engine 8. Install the transaxle housing.
9. Applya1mmto1.2mmdiameter of sealant onthe specified position of the transaxle housing.
CAUTION:
The sealant line applied should be uniform and
continuous and without breaks.
10. Tighten the transaxle housing bolts to the specified torque.
11. Install the bottom transaxle cover.
12. Applya1mmto1.2mmdiameter of sealant on the specified position of the transaxle housing.
CAUTION:
The sealant line applied should be uniform and
continuous and without breaks.
13. Apply transaxle fluid to the O-ring of speed sensor.(Transaxle fluid: 75W-90)
MANUAL TRANSAXLE UNIT REPAIR
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08–277Chery Automobile Co., Ltd.