transmission GEELY FC 2008 User Guide

Engine mechanism - Crankshaft rear oil seal assemblyReplacement1. Remove transmission assembly.
2. Remove clutch assembly and flywheel components.Fix crankshaft with special tool, remove clutch assembly at
first, and then remove flywheel components.3. Remove crankshaft rear oil seal.(a) Cut oil seal mouth with blade.
(b) Prize out oil seal with flathead screwdriver whose sharp
end is winded with tape.
Note: check crankshaft is damaged after removing oil
seal, and repair with abrasive paper (#400) if it is
damaged.4. Install crankshaft rear oil seal [4G18-1002130].(a) Coat a little MP grease on new oil seal lip.
Note: do not let oil seal lip contact with foreign
matters.
(b) Gently knock new oil seal in with special tool and hammer
until the seal surface is parallel and level with the end sur-
face edge of mounting hole.
Note: wipe off redundant grease on crankshaft.5. Install flywheel components and clutch assembly.(a) Fix crankshaft with special tool.
(b) Clean bolts and bolt holes.
(c) Coat bolts with adhesive.
Adhesive: thread locking adhesive 1234 (Kesaixin 1234)
(d) Install flywheel components.
As sequences shown in the diagram, tighten bolts at sev-
eral times.
Torque: (e) Install clutch assembly.6. Install transmission assembly.Special
tool
Cut
positionSpecial
tool62Crankshaft rear oil seal assembly

(e) Make mark on transmission shaft and triangle joint.
Note: do not use the punch to make mark.
(f) Use copper stick and hammer to disassemble triangle joint.
Note: do not knock the stator position.
(g) Disassemble No.2 fixing clamp of inner joint dustproof cover
and fixing clamp of inner joint dustproof cover.15. Disassemble the absorber of drive shaft (right trans-
mission shaft).(a) Single-contact fixing clamp type:
Liking that shown in figure, use screw driver to disassemble
fixing clamp.
(b) Mesh clamp type.
Liking that shown in figure, use pliers to disassemble fixing
clamp.
(c) Disassemble dynamic absorber of drive shaft.16. Disassemble No.2 fixing clamp of exterior joint
dustproof cover of left front drive shaft.(a) Use screw driver to disassemble No.2 fixing clamp of exte-
rior joint dustproof cover.17. Disassemble fixing clamp of exterior joint dustproof
cover of left front drive shaft.(a) Use screw driver to disassemble fixing clamp of exterior
joint dustproof cover.18. Disassemble fixing clamp of exterior joint dustproof
cover (B type and C type).(a) Disassemble dustproof cover of exterior joint.
(b) Remove old lubricating grease of exterior joint.Drive shaft--Front drive shaftAlign the markCopper stick
Single-contact fixing
clamp type
Mesh clamp type116

Driveshaft--Front drive shaftTransmission shaft Left mm Right mm
A type 570.2 ± 5 842.7 ± 5
B type 570.2 ± 5 847.3 ± 5
C type 570.2 ± 5 844.7 ± 5(b) Mesh clamp type:
Liking that shown in figure, use pliers to assemble No.2
fixing clamp of inner joint dust-proof cover.32. Check front drive shaft.(a) Check whether there is any obvious clearance on exterior
joint.
(b) Check whether inner joint could slide smoothly in pushing
direction.
(c) Check whether there is any obvious clearance of inner joint
in radial direction.
(d) Check whether the dustproof cover is damaged.
Note: drive shaft assembly should keep moving on hori-
zontal position.33. Assemble left front drive shaft assembly [64000082](a) Spread ATF on gear slot of inner joint shaft assembly.
(b) Put gear slot of drive shaft in integrated transmission, then
use copper stick and hammer to knock drive shaft to its
position.
Note:zmake the placket of clasp face the downside to
assemble.zBe careful not to damage the seal oil
Hint: Whether the drive shaft contacts with gear shaft
could be felt by the sound or feeling in running process.
(c) Assemble seal board of left front swing board.34. Assemble left front shaft hub assembly.Assemble left front drive shaft assembly to left front hub assembly.
Note:zDo not damage exterior joint dustproof cover.zDo not damage the stator of speed sensor. Hint: A size, please referring to following table.Pliers
clamp121

Drive shaft--Left front shaft hub assembly5. Disassemble left front brake assembly [64000134]
6. Disassemble left transversal lever assembly(a) Disassemble cotter pin and nuts.
(b) Use special tool to disassemble transversal lever assembly
from steering knuckle.7. Disassemble left lower control arm assembly
[64000091]Disassemble the bolt and two nuts, then disassemble lower
control arm from lower ball joint.8. Disassemble left front shaft hub assembly.(a) Use plastic hammer to disassemble transmission shaft from
shaft hub.
Note: do not damage the dustproof cover and the sta-
tor of ABS speed sensor.
(b) Disassemble two bolts and nuts, then disassemble steer-
ing knuckle with shaft hub.9. Disassemble left front lower control arm ball head
assembly [64000093](a) Disassemble cotter pin and nut.
(b) Use special tool to disassemble ball head.10. Disassemble the clasp in left front shaft hub hole.Use clasp pliers to disassemble the clasp.124Special
toolSpecial tool

18. Assemble left front lower control arm ball head as-
sembly [64000093](a) Assemble lower ball head and locking nut.
Torque: 103
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m
(b) Assemble new cotter pin.
If hole position of cotter pin could not make a line, lock the
screw cap for 60again.19. Assemble left front shaft hub assembly(a) Assemble two bolts and nuts, and assemble shaft hub as-
sembly on absorber.
Torque: 153
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m
Note: when the bolts and nuts should be used again,
spread engine oil on the thread of nuts.
(b) Push the front shaft hub assembly to the outside of
automobile, then assemble transmission shaft assembly
in the gear slot of front shaft hub assembly.
Note:
Front shaft assembly could not be pushed to outside
too much.zDo not damage the exterior joint dustproof cover of
drive shaft.zDo not damage the stator of speed sensor.20. Assemble left lower control arm assembly
[64000091]Assemble lower control arm and ball head with two nuts and
bolts.
Torque: 142
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m21. Assemble left transversal lever assembly(a) Connect transversal lever to steering knuckle.
(b) Assemble screw cap and new cotter pin.
Torque: 49
± ±± ±
± 5 N
⋅ ⋅⋅ ⋅
⋅m22. Assemble left front brake assembly [64000134]
23. Assemble front brake caliper assembly(a) Assemble brake caliper assemble on steering knuckle with
two bolts.
Torque: 106
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m24. Assemble fixing nuts of left front drive shaft
[64000083]Use torque wrench (30mm) to assemble new fixing nuts.25. Disassemble left front brake branch pump assembly
26. Disassemble left front brake assembly [64000134]
27. Check the axial clearance of bearingDrive shaft--Left front shaft hub assembly126

Firstly, loosen the connecting bolt of cover, and take out cover and stop disc spring of output shaft
bearing, secondly, put special wrench whose surface has four cylindrical column heaves in four holes
of support cover of rear shaft of output shaft and screw it out; lastly, loosen fastening bolt of shift cover,
take out shift cover assembly, and loosen connecting bolt of transmission to take out transmission
shell.
Transmission—Disassemble assembly
Transmission
Disassemble assembly
 165 
Connecting bolt of cover
Cover
Fastening bolt of shift coverStop disc spring of output shaft bearing
Support cover of rear shaft of output shaft
Connecting bolt

Transmission—Disassemble assembly
Take out interlocking pin with magnetic stick
Take out clip spring of fork shaft, liking that shown in figure.
Clamp the upside of fork shaft which is protected by some
cloths and take it out, liking that shown in figure.
Take out reverse gear and reverse gear shaft
Disassemble two bolts and swing arm bracket of reverse gear,
liking that shown in figure.
 166 

Transmission—Disassemble assembly
Disassemble interlocking pin with magnetic stick and take out
fork shaft and fork.
Disassemble bolt and fork shaft liking that shown in figure.
Disassemble clip spring liking that shown in figure.
Take out fork by disassembling clip spring.
 167 

Disassemble lubricating oil pipe.
Take our bushing liking that shown in figure.
Take our oil seal.
Take our exterior ring of tapered shaft with special tool liking
that shown in figure.
Disassemble oil guide cover.
Transmission—Disassemble assembly
 168 

Five gear
Check the axial clearance of third gear with clearance gauge,
its standard value is: 0.1—0.35 mm.
Check the axial clearance of fifth gear liking that shown in
figure, its standard value is: 0.1—0.50 mm.
Check the radial clearance of forth gear and fifth gear liking
that shown in figure, its standard value is less than 0,058mm.
Transmission—Disassemble assembly
 169 
Third gear