CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 14. Install the vehicle speed sensor.
15. Install the gear shifting arm assembly. Apply lubri-cating fluid on the contact surface of the gear shift-
ing drive slider and the gear shifting arm assembly.
(The specified lubricating fluid: Mobilux Ep2)
STATUS OF SWITCH CIRCUIT
Pressed Off
Released On
16. Inspect the backup lamp switch. Inspect the switch for broken terminal or an open circuit.
Input Shaft
Specifications
Clearance Specifications
SYNCHRONIZER RING VALUE OF A (mm)WEARING LIMIT
1st-2nd Gear 1.10 - 1.170.05 mm
3rd-4th Gear 1.35 - 1.900.05 mm
5th Gear 1.10 - 1.170.05 mm
MANUAL TRANSAXLE UNIT REPAIR
LTSM080035
LTSM080036
08–278Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Disassemble
1 - Input Shaft
2 - Input Shaft Front Bearing
3 - Snap Ring
4 - Needle Bearing-3rd Gear
5 - 3rd Driving Gear Assembly
6 - Synchronizer Ring-3rd-4th Gear
7 - Gear Hub-3rd-4th Gear
8 - Guide Block
9 - Spring-3rd-4th Gear Synchronizer
10 - Hub Sleeve-3rd-4th Gear11 - Gear Bushing-4th Gear
12 - Needle Bearing-2nd-4th Gear
13 - 4th Driving Gear Assembly
14 - 5th Driving Gear
15 - Thrust Ring-5th Driving Gear
16 - Clip-5th Driving Gear Thrust Plate
17 - Input Shaft Rear Bearing
18 - Snap Ring-Input Shaft Rear Bearing
19 - Seal-Input Shaft Fluid-Collecting Hole
MANUAL TRANSAXLE UNIT REPAIR
LTSM080037
08
08–279Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NOTE :
The following special tools are required to perform the repair procedure:
•MB-998801 - Bearings Remover
• MB-998812 - Installer Cap
• MB-998813 - Installer (100 mm)
• MB-998816 - Installer Connector (30 mm)
• MB-998825 - Installer Connector (52 mm)
• MB-998824 - Installer Connector (50 mm)
1. Using special tool MB-998801 (1), disassemble the input shaft rear bearing.
2. Using special tool MB-998801 (1), disassemble the 5th driving gear.
3. Disassemble the sleeve-4th gear. Mount special tool MB-998801 (1) on the 3rd driv-
ing gear to disassemble the sleeve-4th gear.
MANUAL TRANSAXLE UNIT REPAIR
LTSM080038
LTSM080039
LTSM080040
08–280Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 4. Using special tool MB-998801 (1), disassemble theinput shaft front bearing.
Assemble
1. Install the input shaft seal.Press the seal in until the dimension shown in the
figure is obtained.
2. Using special tools MB-998801 (4), MB-998812 (1), MB-998813 (2) and MB-998816 (3), install the
input shaft front bearing.
3. Install the input shaft front shaft snap ring. Select a snap ring to maintain the axial clearance
standard.
(The standard value: 0.01 mm - 0.12 mm)
MANUAL TRANSAXLE UNIT REPAIR
LTSM080041
LTSM080042
LTSM080043
LTSM080044
08
08–281Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 4. Install the synchronizer spring.Install the synchronizer spring in the specified posi-
tion of the synchronizer ring, shown in the figure.
5. Install the gear hub-3rd-4th gear. Install the gear hub-3rd-4th gear in the direction
shown in the figure.
CAUTION:
Ensure that the synchronizer ring is not locked when installing the gear hub.
6. Using special tools MB-998801 (4), MB-998812 (1),MB-998813 (2) and MB-998825 (3), install the gear
bushing-3rd-4th gear.
7. Install the hub sleeve in the direction shown in the figure.
MANUAL TRANSAXLE UNIT REPAIR
LTSM080045
LTSM080046
LTSM080047
LTSM080048
08–282Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 8. Ensure that these two deep tooth spaces of gearhub (1) & (2) are correctly aligned with the two
high racks of the gear hub during the installation of
gear bushing.
9. Using special tools MD-998801 (4), MD-998812 (1), MD-998813 (2), and MD-998824 (3), install the
sleeve-4th gear.
10. Using special tools MD-998801 (4), MD-998812 (1), MD-998813 (2), and MD-998824 (3), install the
5th driving gear.
11. Installation of transaxle housing assembly. Select the thickness of the thrust plate (1) 5th driv-
ing gear to maintain the proper axial clearance of
input shaft 5th driving gear shaft.
(The Standard Value: 0.01 mm to 0.09 mm)
MANUAL TRANSAXLE UNIT REPAIR
LTSM080049
LTSM080050
LTSM080051
LTSM080052
08
08–283Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 12. Install the clip-5th driving gear thrust plate (1).Ensure that the thrust plate doesn’t tilt when install-
ing the clip.
13. Using special tools MD-998801 (3), MD-998812 (1) and MD-998818 (2), install the input shaft rear
bearing.
14. Install the snap ring. Select the thickness of snap ring (1) to maintain
the proper axial clearance of input shaft rear bear-
ing.
(Standard Value: 0.01 mm to 0.12 mm)
MANUAL TRANSAXLE UNIT REPAIR
LTSM080053
LTSM080054
LTSM080055
08–284Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Inspection
1. Input Shaft•Inspect the external surface of the input shaft
and needle bearings (1) for any damage or
excessive wear.
• Inspect the input shaft spline for any damage
or excessive wear.
2. Needle Bearing Inspect the input shaft and gears for smooth operation.
3. Synchronizer Ring •Inspect the synchronizer rings for any damage
or signs of breakage in the surface of synchro-
nizer rings.
• Press synchronizer ring (1) 3rd-4th gear (2),
and then examine the clearance “A”. If the “A”
is less than the limit value, the synchronizer
ring and 3rd-4th gear should be replaced.(Limit
Value: 0.5 mm)
1 - Synchronizer Ring
2 - Gear
MANUAL TRANSAXLE UNIT REPAIR
LTSM080056
LTSM080057
LTSM080058
08
08–285Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 4. Gear Hub and Hub of Synchronizer•Assemble the gear bushing together with the
gear hub of synchronizer, and then inspect for
smooth operation without lockup.
• Inspect the front/rear of the interior surface of
the gear bushing for any damage.
• Inspect the synchronizer springs for any weak
springs or damage.
NOTE: If it is necessary to replace the gear
bushing and gear hub of the synchronizer,
they are only serviced as a complete set.
5. 3rd-4th Driven Gear •Inspect the gear surface of the skew gear and
clutch gear (1) for any damage.
• Inspect the conical surface of the synchronizer
(2) for thickening, damage or wear.
• Inspect the internal diameter of the front/rear
surface of the gear.
MANUAL TRANSAXLE UNIT REPAIR
LTSM080059
LTSM080085
08–286Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Output Shaft
Disassemble
1 - Outer Ring-1st-2nd Synchronization Ring
2 - Gear Hub Sleeve-1st-2nd Synchronizer
3 - Guide Block
4 - Spring-1st-2nd Gear And 5th-Reverse Gear Synchronizer
5 - Gear Hub-1st-2nd Gear
6 - Steel Ring-1st-2nd Synchronization Ring
7 - Inner Ring-1st-2nd Synchronization Ring
8 - 4th Driven Gear
9 - Gear Bushing-5th Gear
10 - Needle Bearing-Reverse Gear
11 - 5th Driven Gear Assembly
12 - Reverse Driven Gear Assembly
13 - Sleeve-Reverse Gear
14 - Synchronization Ring-3rd-4th Gear And 5th-Reverse
Gear
15 - Gear Hub Sleeve-5th-Reverse Gear16 - Gear Hub-5th-Reverse Gear
17 - Snap Ring-3rd Driven Gear
18 - 3rd Driven Gear
19 - 2nd Driven Gear Assembly
20 - Needle Bearing-2nd Gear
21 - Sleeve-2nd Gear
22 - 1st Driven Gear Assembly
23 - Needle Bearing-1st Gear
24 - Sleeve-1st Gear
25 - Snap Ring-Output Shaft Front Bearing
26 - Output Shaft Front Bearing
27 - Output Shaft
28 - Output Shaft Rear Bearing
29 - Snap Ring-Output Shaft Rear Bearing
MANUAL TRANSAXLE UNIT REPAIR
LTSM080060
08
08–287Chery Automobile Co., Ltd.