lock CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Operating Components Condition
•Related Operating Components
RELATED OPERATING COMPONENT
GEARSHIFT LEVER
POSITION GEAR
RATIO ENGINE
START PARKING
MECHANISM DRIVE
LOCK
LOW
SPEED
CLUTCH (UD) REVERSE
GEAR
CLUTCH (REV) OVERSPEED
CLUTCH(OD) LOW
GEAR/
REVERSE GEAR
BRAKE (L/R) GEAR
2ND
BRAKE (2ND) ONE-
WAY
CLUTCH (OWC)
P Parking - Enabled -- - --
R Reverse
Gear 2.480 -
-- ---
N Neutral
Gear - Enabled -
-- ---
D Gear 1 2.842 -
--- *-
Gear 2 1.529 - ---- -
Gear 3 1.000 - --  ---
Gear 4 0.712 - --  - -
3 Gear 1 2.842 -
--- *-
Gear 2 1.529 - ---- -
Gear 3 1.000 - --  ---
2 Gear 1 2.842 -
--- *- 
Gear 21.529

- ---- -
L Gear 1 2.842 - --- --
* Low gear/reverse gear is applied when vehicle speed is lower than 10 km/h. Operating components
On Board Diagnostic Logic
•Self-diagnosis detection logic.
DTC NO. DTC DEFINITION DTC DETECTION
CONDITION DTC SET
CONDITION POSSIBLE CAUSES
46 Reverse gear, ratio
out of limits Vehicle is driving •
The Transaxle
Control Module
(TCM) will set this
DTC when the TCM
detected that
reverse Gear Ratio
Error is already
present. The output
shaft speed signal is
increased.
• If the DTC was
set 4 times, then the
A/T will be locked in
3rd gear (D gear). •
Input shaft speed
sensor
• Output shaft speed
sensor
• The retainer of
deceleration clutch
• Transfer case
driven and drive gear
• Reverse gear
clutch system
• low gear/reverse
gear brake (L/R)
system
• Noise interference
DTC Confirmation Procedure:
Before performing the following procedure, confirm that battery voltage is more than 12 V.
• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.
DIAGNOSIS & TESTING
08
08–231Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine On Board Diagnostic Logic
•Self-diagnosis detection logic.
DTC NO. DTC DEFINITION DTC DETECTION
CONDITION DTC SET
CONDITION POSSIBLE CAUSES
54 Electrical relay open
circuit Ignition switch on •
The Transaxle
Control Module
(TCM) will set this
DTC when the TCM
detected that the
A/T control voltage
is below 7 V.
• If the DTC was
set, then the A/T will
be locked in 3rd
gear (D gear) or
shifted to low gear
when in sports
mode. •
A/T control relay
• Harness or
connectors (The
sensor circuit is open
or shorted)
• TCM
DTC Confirmation Procedure:
Before performing the following procedure, confirm that battery voltage is more than 12 V.
• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.
• After connection, press POWER key to start X-431.
• Turn the ignition switch on.
• With the scan tool, view and erase stored DTCs in the TCM.
• Start engine and warm it to normal operating temperature.
• With the scan tool, select view DTC and data stream.
• If the DTC is detected, the DTC condition is current. Go to Diagnostic Procedure - Step 1.
• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-
bleshooting in Section 08 Transaxle & Transfer Case for more information).
NOTE :
While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit
and component information.
Diagnostic Procedure
1.CHECK GROUND CONNECTION
• Turn ignition switch off.
• Loosen and retighten ground screws on the body (See Ground Inspection in Section 12 Brakes).
• Inspect the ground connection C-201 mounting position (See Vehicle Wiring Harness Layout - Main Harness in
Section 16 Wiring).
Are the ground connections OK?
Ye s>>Go to the next step.
No
>>Repair or replace the ground connections.
DIAGNOSIS & TESTING
08
08–237Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 1. Disconnect the negative battery cable.
2. Remove the air cleaner housing assembly.
3. Remove the two shift cables (1) from the transaxle.
4. Remove the shift cable clamp (1) from the shiftcable bracket.
5. Raise and support the vehicle.
1 - Backup Lamp Switch Assembly
2 - Limit Stop Screw-Interlocking Plate
3 - Plain Washer-Interlocking Plate Limit Stop Screw
4 - Bearing-Gear Shift Mechanism
5 - Lower Lining - Selector Lever
6 - Selector Lever Assembly
7 - Washer
8 - Bolt
9 - Upper Dust Boot - Selector Lever
10 - Nut
11 - Plain Washer-Gear Selecting Arm Nu
12 - Gear Shifting Arm Assembly
13 - Gear Shifting Drive Slider
14 - Dust Cap-Gear Shifting Shaft Fluid Seal
15 - Lower Dust Cap-Gear Selecting Arm
16 - Lower Bushing-Gear Selecting Arm17 - Gear Selecting Arm Assembly
18 - Upper Bushing-Gear Selecting Arm
19 - Baffle-Rear Neutral Position Return Spring
20 - Rear Neutral Retracting Spring
21 - Reverse Gear Lock Assembly
22 - Reverse Gear Lock Assembly Pin
23 - Selector Finger Pin
24 - Selector Finger
25 - Interlock Plate Assembly
26 - Front Neutral Retracting Spring Assembly
27 - Gearshift Shaft
28 - Retainer-Reverse Gear Lock
29 - Gear Shift Mechanism Housing
30 - Air Duct
31 - Air Duct Cap
32 - Bolt
ON-VEHICLE SERVICE
LTSM080087
BESM080051 VISM080026
08
08–265Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 12. Remove the selector cable clamps (1) and bracketretaining bolts (2).
13. Remove the gear selector & shifter assembly.
14. Installation is in the reverse order of removal.
NOTE :
Selector cable can be adjusted with the adjusting bolt (1). Adjust bolts as needed to obtain proper cable adjustment.
Disassembly
1. Drive out the locking selector finger (1) pin follow- ing the direction as shown in the diagram.
2. Drive out the locking pin (2) reverse gear lock assembly pin.
3. Remove all of the components from shaft.
4. Thoroughly clean and check all parts, replace any worn parts as necessary.
ON-VEHICLE SERVICE
VISM080006
LTSM080180
LTSM080094
08
08–267Chery Automobile Co., Ltd.

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
LTSM080138
LTSM080139
LTSM080140
08–268Chery Automobile Co., Ltd.

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
LTSM080094
LTSM080128
LTSM080134
LTSM080135
08
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)
LTSM020229
LTSM080119
08–270Chery Automobile Co., Ltd.

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
LTSM080120
LTSM080121
LTSM080122
LTSM080123
08
08–271Chery Automobile Co., Ltd.

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
LTSM080132
LTSM080133
LTSM080028
08
08–275Chery Automobile Co., Ltd.

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
LTSM080029
LTSM080024
LTSM080030
LTSM080031
08–276Chery Automobile Co., Ltd.