GEELY FC 2008 Workshop Manual

Third gear Put input shaft assembly into position with pressure machine
liking that shown in figure, at the same time, hold the lower
end of input shaft to disassemble gear cover, gear hub and
five gear.
Check the axial clearance of forth gear, its standard value is:
0.1—0.55mm.
Take down clip spring used by shaft with clip spring wrench.
Take out fixing ball with magnetic stick, and take down the
gear and third-and-forth synchronous gear loop.
Transmission—Disassemble assembly
 170 

Take down clip spring with clip spring wrench.
Note: do not hurt its surface.
Take down synchronizer assembly, synchronous loop and third
gear with pressure machine liking that shown in figure.
Note: hold lower end of shaft with hand to make it stand.
Take down radial ball bearing with pressure machine, and
hold lower end of shaft with hand to make it stand.
Disassemble synchronizer assembly liking that shown in
figure.
Transmission—Disassemble assembly
 171 

Take our elastic cylindrical pin from shift swing lever with pin
taker and hand hammer liking that shown in figure.
Note: do not hurt its surface.
Take down clip spring liking that shown in figure.
Disassemble interlocking bracket, shift swing lever, spring and
A gasket liking that shown in figure.
Disassemble shift swing lever and connecting bolt.
Disassemble clip spring liking that shown in figure, and dis-
connect it.
Transmission—Disassemble assembly
 172 

Disassemble shift guide shaft and dust-proof cover from shift
cover, and take down gasket liking that shown in figure.
Take out the shift cover oil seal with wrench liking that shown
in figure
Take out the other oil seal on shift cover with same method.
Transmission—Disassemble assembly
 173 

Take down tapered bearing on differential shell liking that
shown in figure.
Note: put column end surface in bearing into position
reliably.
Take down cylindrical bearing of speedmeter driving wheel
side liking that shown in figure.
Take down driving gear of speedmeter
Disassemble by sequence the fastening bolts of differential.
Take out elastic cylindrical pin with pin taker, and take out
second planetary gears and gaskets, two axle shaft gears
and gaskets and planetary gear shaft by sequence.
Transmission—Disassemble assembly
 174 

Check the radial run-out of input shaft liking that shown in
figure, maximal diameter is 0.03mm.
Check the distance from back surface of synchronous loop to
gear end surface with clearance gauge, the minimal value
should be 0.8mm, if the minimal distance could not reach this
value, it is necessary to change synchronous loop.
Check the distance between gear cover and shift fork with
clearance gauge, its maximal value is 0.35mm, or it is neces-
sary to change gear cover or shift fork.
Measure the minimal diameter of abrasion surface A of input
shaft with micrometer, its value is 33.985mm, and the mini-
mal diameter of surface B is 30.985mm, if the value exceeds
this scope, it is necessary to change input shaft.
Transmission—Disassemble assembly
 175 

Measure axial clearance of 1 gear and 2 gear with thickness
gauge,
1 gear: 0.1—0.35mm
2 gear: 0.1—0.35mm
Measureradial clearance of 1 gear and 2 gear liking that shown
in figure, the maximal flop value is 0.056mm.
Take down tapered bearing liking that shown in figure
Note:
1. Hold the lower end of shaft to prevent it falling.
2. Clamp inner ring of bearing to make it reliable.
Disassemble tapered bearing on the other end with same
method.1 gear 2 gear
Transmission—Disassemble assembly
 176 

Disassemble spring clamp loop on output shaft liking that
shown in figure.
Take down forth and fifth gear wheel with pressure machine.
Note: hold the lower end of shaft to prevent it falling.
Move first and second gear to first gear.
Disassemble third gear with pressure machine, and hold the
lower end of shaft to prevent it falling, at this time, disassemble
roller bearing, synchronous loop and second gear.
Disassemble clip spring with clamp spring pliers, and do not
hurt bearing surface of shaft.
Transmission—Disassemble assembly
 177 

Measure the round flop liking that shown in figure, its maxi-
mal allowed flop value is 0.03, if exceeding this value, it is
necessary to change the output shaft.
Check the axial clearance between the back surface of syn-
chronous loop and end surface of gear splines with clear-
ance gauge, its minimal value is 0.8mm, if the clearance is
less than this value, it is necessary to change the synchro-
nous loop.
Check the clearance between gear cover fork slot and fork
with clearance gauge, its maximal value is 0.35mm, if exceed-
ing this value, it is necessary to change fork.
Check the abrasion and damaged situation of output shaft,
and measure the exterior diameter of bearing platform with
micrometer, its minimal value is 33.985mm, if measured re-
sult is less than this value, it is necessary to change the out-
put shaft.
Assemble first gear and synchronous loop liking that shown
in figure.
Transmission—Disassemble assembly
 178 

Press first and second gear synchronizer assembly in input
shaft with pressure machine, its direction likes that shown in
figure.
Use new clip spring used for shaft to replace that one which
has been stretched.
Note: do not hurt the shaft surface.
Assemble synchronous ring, roller bearing and second gear.
Press third gear in output shaft with pressure machine liking
that shown in figure, its direction likes that shown in figure.
Use pressure machine to press forth and fifth gear in output
shaft with the method in figure, its direction likes that shown
in figure.
Transmission—Disassemble assembly
 179