CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Assemble
Assemble in the reverse order of disassembly.
NOTE :
•Check and ensure the shift fork is properly installed to the fork shaft, there should be NO axial or radial motion in
the fork shaft.
• Check and ensure the fork rack is properly installed to the fork shaft, there should be NO axial or radial motion in
the fork shaft.
• Check and ensure backup light driving block is properly installed to the fork shaft, there should be NO axial or
radial motion in the fork shaft.
• Check the fork shaft surface for any damage.
• Check the position of the three spring pins, ensure the pins are in proper alignment. The extension of both ends
of the three spring pins should not exceed 3 mm.
3rd-4th Gear Shift Fork
Disassemble
1. Separate the 3rd-4th shift fork from the shift fork
assembly.
2. Use a suitable tool to remove the shift fork spring pin from the shift fork and the shift fork shaft.
MANUAL TRANSAXLE UNIT REPAIR
LTSM080193
VISM020015
08–298Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 3. Remove the spring pins (3) from the 3rd-4th shift fork shaft (1).
4. Separate the 5th shift fork (4) and the fork rack (2) from the 3rd-4th shift fork shaft (1).
Assemble
Assemble in the reverse order of disassembly.
NOTE :
•Check and ensure the shift fork is properly installed to the fork shaft, there should be NO axial or radial motion in
the fork shaft.
• Check and ensure the fork rack is properly installed to the fork shaft, there should be NO axial or radial motion in
the fork shaft.
• Check the fork shaft surface for any damage.
• Check the position of the three spring pins, ensure the pins are in proper alignment. The extension of both ends
of the three spring pins should not exceed 3 mm.
1st-2nd Gear Shift Fork
Disassemble
1. Separate the 1st-2nd shift fork from the shift fork
assembly.
1 - 3rd-4th Shift Fork Shaft
2 - Fork Rack - 3rd-4th Gear Shift Fork
3 - Spring Pin for Fork Shaft4 - 3rd-4th Shift Fork
5 - 3rd-4th Shift Fork Shaft Assembly
MANUAL TRANSAXLE UNIT REPAIR
LTSM080137
VISM020016
08
08–299Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2. Use a suitable tool to remove the shift fork springpin from the shift fork and the shift fork shaft.
3. Remove the spring pins (3) from the 1st-2nd shift fork shaft (1).
4. Separate the 1st-2nd shift fork (4) and the fork rack (2) from the 1st-2nd shift fork shaft (1).
Assembly
Assemble in the reverse order of disassembly.
NOTE :
• Check and ensure the shift fork is properly installed to the fork shaft, there should be NO axial or radial motion in
the fork shaft.
• Check and ensure the fork rack is properly installed to the fork shaft, there should be NO axial or radial motion in
the fork shaft.
• Check the fork shaft surface for any damage.
• Check the position of the three spring pins, ensure the pins are in proper alignment. The extension of both ends
of the three spring pins should not exceed 3 mm.
1 - 1st-2nd Shift Fork Shaft
2 - Fork Rack - 1st-2nd Gear Shift Fork
3 - Spring Pin for Fork Shaft4 - 1st-2nd Shift Fork
5 - 1st-2nd Shift Fork Shaft Assembly
MANUAL TRANSAXLE UNIT REPAIR
VISM020015
LTSM080141
08–300Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Transaxle Clutch Housing Assembly
Disassemble
MANUAL TRANSAXLE UNIT REPAIR
LTSM080095
08
08–301Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NOTE :
The following special tools are required to perform the repair procedure:
•MB-998772 - Valve Spring Compressor
• MB-999566 - Hook
• MB-990938 - Handle
• MB-990935 - Installer Connector
• MB-990934 - Installer Connector
• MB-998325 - Fluid Seal Installer
• MB-990926 - Installer Connector
1. Using special tools MB-999566 (1), MB-996772 (3), and MD-998348 (4), disassemble the outer race of
the front/rear bearing (2) of the differential.
1 - Clutch Housing
2 - Pin GB119 A10×20
3 - Fluid Seal-Input Shaft
4 - Bushing-Gear Shifting Mechanism
5 - Output Shaft Front Bearing
6 - Bearing-Gear Shifting Mechanism
7 - Magnetic Assembly8 - Front/Rear Bearing Of Differential
9 - Fluid Seal-Differential
10 - Speedometer Banking Cover
11 - Bolt GB5787 M6×12
12 - Release Bearing Race
13 - Buttonhead-Seat Release Fork
MANUAL TRANSAXLE UNIT REPAIR
LTSM080095
LTSM080096
08–302Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Assembly
1. Install the bushing.Press the bushing (1) into position (2) as shown in
the figure.
2. Using special tools MB-990938 (2) and MB-990934 (3), install the outer race-output shaft bearing (1).
Install the outer race with the stamped side in the
position shown in the figure.
MANUAL TRANSAXLE UNIT REPAIR
LTSM080098
LTSM080100
08
08–303Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 3. Using special tools MB - 990938 (1), and MB - 990935(2), install the race-differential bearing.
4. Using special tools MB-998325 (1),
install the fluid
seal-differential.
Apply transaxle fluid
on the fluid seal lip.
(Specified fluid: 75W-90)
5. Using special tool MB-990938 (1) and MB-990926 (2), install the input shaft fluid seal.
Apply the lubricating grease on the fluid seal lip.
(Specified lubricating grease: Mobilux Ep2 or
equivalents)
MANUAL TRANSAXLE UNIT REPAIR
LTSM080102
LTSM080103
LTSM080105
08–304Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Transaxle Main Housing Assembly
Assembly
NOTE :
The following special tools are required to perform the repair procedure:
•MD-998325 - Fluid Installer
1 - Transaxle Housing
2 - Bearing-Gear Shifting Mechanism
3 - Pin GB119
4 - Outer Race Of Front/Rear Bearing Of Differential
5 - Adjustment Gasket-Differential Rear Bearing
6 - Fluid Seal-Differential7 - Fluid Baffle
8 - Fluid Draining Screw Plug
9 - Plain Washer-Fluid Draining Screw Plug
10 - Plain Washer-Fluid Limiting Screw Plug
11 - Fluid Limiting Screw Plug
MANUAL TRANSAXLE UNIT REPAIR
LTSM080106
08
08–305Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 1. Install the bearing-gear shifting mechanism (1).Press the bearing in until it is flush with the surface
of housing.
2. Install the differential fluid seal. Inspect the fluid seal for damage. Apply lubricating
grease on the external diameter and inner lip of the
fluid seal, and then use special tool MD-998325 (1)
to install the seal into position.
(Lubricating grease: Mobilux Ep2)
MANUAL TRANSAXLE UNIT REPAIR
LTSM080107
LTSM080108
08–306Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine FRONT DIFFERENTIAL
GENERAL INFORMATION08-308
Description 08-308
Operation 08-310
Specifications 08-310
Special Tools 08-310DIFFERENTIAL UNIT REPAIR08-312
Differential Carrier 08-312
Removal & Installation 08-312
Inspection 08-313
Assembly 08-313
08
08–307Chery Automobile Co., Ltd.