differential CHERY TIGGO 2009 Service User Guide

Downloaded from www.Manualslib.com manuals search engine Inspection
1. Place a tin solder sheet (1) (approximate length is10 mm and diameter is 1.6 mm) on the specified
part of the transaxle housing, and then install the
differential outer bearing race.
2. Install the clutch housing, and tighten the bolts to the specified torque.
3. Replace the tin solder sheets with thicker tin solder sheets.
4. With a micrometer, measure the thickness (T) of the flattened tin solder sheet.• Select the thickness of the shim to be installed
according to the following equation.
Thickness of washer: (T + 0.005 mm) - (T +
0.11 mm)
5. Do not clean the release bearing.
6. Clean the sealing surface of all contaminates, remove all old sealant, and clean all bolt holes.
7. Check all parts for damage, replace any damaged parts if necessary.
8. Always align the bearing cap (1) with the shaft opening. Align the bearing collar to the bearing cap
opening (as the two circular rings indicate in the
figure).
MANUAL TRANSAXLE UNIT REPAIR
LTSM080026
LTSM080027
LTSM080131
08–274Chery 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 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.

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 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 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.