lock CHERY TIGGO 2009 Service Repair Manual

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 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 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.

Downloaded from www.Manualslib.com manuals search engine 5. Install the gear hub-1st-2nd gear.Install the gear hub-1st-2nd gear in the position (1)
shown in the figure.
CAUTION:
Using special tools MD-998814 (1), MD-998815
(2) and MD-998825 (3), install the synchronizer
ring (4). Ensure that the synchronizer ring is
not locked when installing the gear hub.
6. Install the gear hub sleeve-1st-2nd gear synchro-nizer.• Install the gear bushing on the position (1)
shown in the figure.
• Ensure that the two deep tooth spaces of the
gear hub (1) are correctly aligned with the two
high racks of the gear hub during the installa-
tion of gear bushing.
MANUAL TRANSAXLE UNIT REPAIR
LTSM080079
LTSM080071
LTSM080048
LTSM080049
08
08–291Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 11. Using special tools MB-998812 (1), MB-998813 (2)and MB-998819 (3), install the 4th driven gear (4).
12. Using special tools MB-998812 (1), MB-998813 (2) and MB-998819 (3), install the sleeve-5th gear (4).
13. Install the gear hub-5th-reverse gear. Install the gear hub-5th-reverse gear in the position
(1) shown in the figure.
CAUTION:
Using special tools MD-998812 (1), MD-998813
(2) and MD-998819 (3), install the synchronizer
ring (4). Ensure that the synchronizer ring is
not locked when installing the gear hub-5th-re-
verse gear.
MANUAL TRANSAXLE UNIT REPAIR
LTSM080077
LTSM080078
LTSM080079
LTSM080080
08
08–293Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 17. Install the gear bushing 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.
CAUTION: The gear bushing or gear hub of
the synchronizer are replaced as a com-
plete set.
18. Install the transaxle 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
08–295Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 5th-Reverse Gear Shift Fork
Disassemble
1. Separate the 5th-Reverse shift fork from the shiftfork assembly.
2. Use a suitable tool to remove the shift fork spring pin from the shift fork and the shift fork shaft.
3. Remove the spring pins (3) from the 5th shift fork shaft (1).
4. Separate the 5th shift fork (2) and the reverse fork rack (4) from the 5th shift fork shaft (1).
5. Separate the backup lamp switch driving block (5) from the 5th shift fork shaft (1).
1 - 5th Shift Fork Shaft
2 - 5th Shift Fork
3 - Spring Pin for Fork Shaft4 - Reverse Fork Rack
5 - Driving Block - Backup Light Switch
6 - 5th-Reverse Shift Fork Shaft Assembly
MANUAL TRANSAXLE UNIT REPAIR
LTSM080192 VISM020015
LTSM080136
08
08–297Chery Automobile Co., Ltd.

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 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.