CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The differential includes the differential side gears and the shaft mounted differential pinion gears. Direct contact
between the gears and the differential case is prevented by the differential side gear thrust washers installed under
the gears. The differential pinion shaft is held in position by a differential pinion shaft lock pin that extends through
the end of the differential pinion shaft and the differential case.
The differential transaxle assembly consists of the following components:
•Differential case (part of the final drive carrier)
• 2 pinion gears supported by a pinion shaft
• 2 side gears supported by the differential case and half-shafts
08–308Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
LTSM080109
08
08–309Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Operation
The differential operates through the gear mesh with the ring gear bolted to the differential case. The engine power
is transmitted to the axle shafts through the pinion mate and side gears. The side gears are connected to the axle
shafts.
Specifications
Clearance Specifications
Clearance Between Side Gear And Planetary Gear0.028 - 0.150 mm
Adjusting Washer 0.93 - 1.00 mm
Special Tools
Installer Connector (40 mm)
MD-998819
Installer CapMD-998812
1 - Front/Rear Bearing Of Differential
2 - Adjustment Gasket-Axle Shaft Gear
3 - Axle Shaft Gear
4 - Planetary Gear Shaft
5 - Thrust Washer
6 - Spherical Washer-Planetary Gear7 - Anchor Pin-Planetary Gear Shaft
8 - The Driving Gear-Speedometer
9 - Differential Housing
10 - The Driven Gear Of Main Reducing Gear
11 - Bolt-The Driven Gear Of Main Reducing Gear And The
Differential Housing
GENERAL INFORMATION
LTSM080109
08–310Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Bearing RemoverMD-998801
Fluid InstallerMD-998325
GENERAL INFORMATION
08
08–311Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIFFERENTIAL UNIT REPAIR
Differential Carrier
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
•MD-998801 - Bearing Remover
1. Remove the transaxle input shaft assembly, transaxle output shaft assembly, 1st-2nd shift fork, 3rd-4th shift fork and 5th-reverse fork shaft together as a unit (See Transaxle Assembly Unit Repair in Section 08 Transaxle).
2. Remove the transaxle differential assembly.
3. Mount the differential in a vice.
4. Remove the drive gear bolts (1).
5. Using special tool MD-998801 (1), disassemble the differential-front/rear shaft bearing.
6. Tap the drive gear off the differential case assembly using a suitable tool.
7. Remove the pinion mate shaft use a suitable tool.
LTSM080117
LTSM080110
LTSM080112
08–312Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 8. Turn the pinion mate gear, then remove the pinion mate gear, pinion mate thrust washer, side gear and side gearthrust washer from the differential case.
Inspection
1. Clean all components.
2. Inspect the following components for wear: •Ring gear
• Adjusting washers
• Side gears
• Spherical washers
• Planetary gears
• Planetary gear shaft
Assembly
1. Install the adjustment shim-axle shaft gear/axle shaft gear/spherical washer-planetary gear/planetary gear/plan-
etary gear shaft.
2. Assemble the spherical washer on the back of axle shaft gear, and then install the axle shaft gear on
the differential.
NOTE :
The adjustment shim with intermediate thickness (0.93 to 1.00 mm) shall be assembled when a new axle shaft gear
is installed. 3. Place the spherical washer on the back of any planetary gear to make two planetary gears engage simulta- neously with the axle shaft gear. Turn these gears, and at the same time, install them in their proper positions.
4. Insert and install the planetary gear shaft.
5. Measure the gear clearance between the axle shaft gear and the planetary gear.
(Standard value: 0.08 to 0.15 mm)
6. If the measured gear clearance doesn’t conform to the standard value, select and install the adjust-
ment shim, and then measure the gear clearance
again.
NOTE :
Adjust the gear clearance until the gear clearance of
both sides is the same as each other.
DIFFERENTIAL UNIT REPAIR
LTSM080111
LTSM080113
08
08–313Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 7. Install the lock pin (2).
8. Install the lock pin in the position shown in the fig-ure.
CAUTION:
After the lock pin is taped in, the axle shaft
gear and the planetary gear should operate
normally.
9. Using special tools MD-998812 (1) and MB-998819(2), install the differential front/rear bearing (3).
10. Install the driven gear of main reducing gear.
11. Apply thread sealant to the threads of all bolts.
1 - Differential Housing
2 - Lock Pin
3 - Pinion Shaft
DIFFERENTIAL UNIT REPAIR
LTSM080114
LTSM080115
LTSM080116
08–314Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 12. Tighten the ring gear bolts (1) in the sequenceshown in the figure.
(Tighten: Ring gear bolts to 132 N·m)
DIFFERENTIAL UNIT REPAIR
LTSM080117
08
08–315Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CLUTCH SYSTEM
GENERAL INFORMATION08-317
Description 08-317
Operation 08-317
Specifications 08-317
Special Tools 08-318
CLUTCH ASSEMBLY SERVICE08-319
Clutch and Pressure Plate 08-319
Removal & Installation 08-319
Clutch Pedal Height 08-321Clutch Pedal Free Travel
08-321
Clutch Master Cylinder 08-322
Description 08-322
Operation 08-322
Removal & Installation 08-322
Clutch Slave Cylinder 08-324
Removal & Installation 08-324
Bleeding Hydraulic Clutch 08-325
Operation 08-325
08–316Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The hydraulic clutch system consists of a clutch master
cylinder (2), slave cylinder (3), and an interconnecting
hydraulic fluid line. Hydraulic fluid is supplied by the
clutch system from the clutch master cylinder reservoir
(1).
Operation
The hydraulic clutch system is responsible for engaging and disengaging the clutch. Depressing the clutch pedal
develops fluid pressure in the clutch master cylinder. This pressure is transmitted to the integral release bearing
which is in contact with the pressure plate diaphragm spring. As additional force is applied, the bearing depresses the
diaphragm spring fingers inward on the fulcrums. The action moves the pressure plate rearward, relieving clamping
force on the clutch disc.
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Transaxle Mounting Bolts 6.9
Clutch Housing Mounting Bolts 44
Clutch Release Bearing Seat Retainer Mounting Bolts 9.8
Gear Shift Mechanism Assembly Mounting Bolts 18
Shift Gear Control Cable Bracket Mounting Bolts 18
Speedometer Gear Mounting Bolts 3.9
Final Drive Driven Gear Mounting Bolts 132
Back Up Lamp Switch 32
Idler Gear Assembly Mounting Bolt 48
Clutch Slave Cylinder Mounting Bolts 11 ± 1
LTSM080194
08
08–317Chery Automobile Co., Ltd.