boot GEELY MK 2008 Workshop Manual

2-15
VI. Table 2 Maintenance Timetable of Geely Freedom Cruiser SedanMaintain the vehicle when either mileage or time has reached maintenance requirements. User should keep
maintaining the vehicle to no less than 100000km. User can send the vehicle for inspection and repair in advance
if it has been through special conditions.SystemInspection itemX1000km
Year7.5 15 22.5 30 37.5 45 52.5 60 67.5 75
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5Steering
SystemSteering-wheel Play,Fastening and abnormal noiseOperation
Oil Leak
FasteningFastening,abnormal noise and damage
Steering link,joint,rack and dust bootcrack and damage
Abnormal noise at a joint
Wheel adjustment
Left and right rotation angle
Trie pressure
Tire crack and damage
Tire thread and uneven wearMetal dust,stone and foreign materialLoose hub nut and boltFront wheel bearing abnormal noise
Rear wheel bearing abnormal noiseFree play
Operation
Oil leak and oil level
Operation system abnormal noise
Replace oil
Replace ATF
Oil leak and oil level
Joint fasteningUniversal joint,dust root crack and damageSpline abnormal noise
Universal joint abnormal nosie
Free play and Function
Function
Operating travel
FunctionParking brake cable fastening,abnormal noise and damageo......Inspect ......ReplaceTable 2 Drive
line
Drive
Train
Braking
SystemSteering
Wheel
Steering
Gear
Steering
Link and
Joint
Knuckle
Front
Wheel
Wheel
Clutch
ManualTransmissionAutomaticTransmissionDriveshaftBrake
Pedal
Parking
BrakeUsage and Maintenance of MK Series - Maintenance Category and Content of MK Sedano
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tripod jointPropeller Shaft/DriveshaftFront Driveshaft4-20outboard rzeppa joint
outboard joint big clamp
outboard joint boot
outboard joint small clamp
drive shaft damper clamp
right front drive
shaft damper
inboard joint small clamp
inboard joint boot
inboard joint big clamp
tripod
retainerComponent ViewRH:
Non-reusable parts -

10. Separate left lower swing arm assembly
(1) Remove cotter pin and nut
(2) On steering knuckle, remove the left lower swing arm
assembly with ball joint puller.
11. Separate steering gear with tie rod assembly
(1) Remove cotter pin and nut
(2) On steering knuckle, remove the steering gear with tie rod
assembly with ball joint puller.Propeller Shaft/DriveshaftFront Driveshaft4-2212. Separate LF steering knuckle assembly
Using a plastic hamper, separate left front drive shaft assembly from left front steering knuckle assembly
Notice:

Do not damage the boot.

With ABS:
Be careful not to damage the vehicle speed sensor rotor.
13. Remove left constant velocity drive shaft assembly
Using a differential side gear shaft remover, remove the left
constant velocity drive shaft assembly.
Notice:

Do not damage the boot and oil seal.
Be careful not to drop the drive shaft assembly.
14. Remove right constant velocity drive shaft assembly
Using a brass bar and a hammer, remove the right constant
velocity drive shaft assembly.
Notice:
Do not damage the boot and oil seal.
Be careful not to drop the drive shaft assembly. -

15. Install LF steering knuckle assembly
Notice:
The hub bearing could be damaged if it is subjected to the vehicle
weight, such as when moving the vehicle with the drive shaft
bearing removed.
Therefore if it is absolutely necessary to place the vehicle weight
on the hub bearing, first support it with the special service tool for
front hub bearing.
16. Check left constant velocity drive shaft assembly
(1) Check the outboard joint for apparent looseness.
(2) Check that the inboard joint slide smoothly.
(3) Check the inboard joint for radial looseness.
(4) Check the boot for damage.
Notice:
Place the drive shaft assembly on level surface during the
inspection.
17. Remove inboard joint big clamp
Using a screw driver, loosen the inboard joint big clamp.
18. Remove inboard joint small clamp
Using a screw driver, loosen the inboard joint small clamp.
19. Separate inboard joint boot
Separate the outboard joint boot from the outboard Rzeppa joint
assembly.
20. Remove left tripod joint assembly
(1) Wipe off the old grease from the tripod joint assembly.
(2) Place the matchmarks between the tripod joint assembly and
the outboard Rzeppa joint.
Notice:
Do not punch the matchmarks.Propeller Shaft/DriveshaftFront Driveshaft4-23Mark -

Propeller Shaft/DriveshaftFront Driveshaft4-24 (3) Remove the tripod joint assembly from the Rzeppa joint
assembly.
(4) Using a snap ring plier, remove the left drive shaft inner snap
ring.
(5) Place matchmarks on the tripod joint assembly and outboard
Rzeppa joint assembly.
Notice:
Do not punch the matchmarks.
(6) Using a brass bar and a hammer, remove the tripod joint from
the outboard Rzeppa joint assembly.
Notice:
Do not tap the roller.
(7) Remove the inboard joint boot clamp, boot, inner boot and left
boot small clamp.
21. Remove drive shaft damper clamp
Hint:
Perform the following operations only when disassembling the
right drive shaft.
Using a screwdriver, loosen the damper clamp.
22. Remove right drive shaft damper
Hint:
Perform the following operations only when disassembling the right drive shaft.
Remove the right driver shaft damper clamp.
23. Remove left constant velocity outboard joint boot big clamp
Using a screwdriver, loosen the left constant velocity drive shaft
outboard joint boot big clamp.Markbrass bar -

Propeller Shaft/DriveshaftFront Driveshaft4-2524. Remove outboard joint boot small clamp
Using a screw driver, loosen the outboard joint boot small clamp.
25. Remove outboard joint boot
(1) Remove the outboard joint boot from the outboard Rzeppa joint assembly.
(2) Wipe off the old grease from the Rzeppa joint assembly.
26. Remove left front drive shaft tripod retainer
Using a screw driver, loosen the left front drive shaft tripod
retainer.
27. Install left front tripod retainer
Install the new tripod retainer.
28. Install outboard joint boot
(1) Wrap vinyl tape around the spline of the Rzeppa joint to prevent damaging the boots.
(2) Install the new parts on the tripod joint in the following sequence.
a. Outboard joint boot big clamp
b. Outboard joint boot
c. Outboard joint boot small clamp
(3) Coat the left Rzeppa joint assembly with grease.
Grease amount: 69-79g
(4) Install the outboard joint boot on the Rzeppa joint assembly.
29. Install outboard joint boot small clamp
As shown in the illustration, use a screwdriver to install the
outboard joint boot clamp. -

Distance (A) 470 ± 4.0mmPropeller Shaft/DriveshaftFront Driveshaft4-2630. Install outboard joint boot big clamp
As shown in the illustration, use a screwdriver to install the
outboard joint boot big clamp.
31. Install right front drive shaft damper
Hint:
Perform the following operations only when disassembling the
right drive shaft.
Set the following distance:
32. Install drive shaft damper clamp
Hint:
Perform the following operations only when disassembling the
right drive shaft.
(1) Slide the damper clamp on the shaft.
Notice:
Make sure the clamp is correctly installed.
(2) As shown in the illustration, use a screwdriver to install the
damper clamp.
33. Install tripod joint assembly
Before installing the boot, wrap vinyl tape around the spline of the Rzeppa joint to prevent damaging the boots.
(1) Install the new parts on the tripod joint in the following sequence.
a. Inboard joint boot small clamp
b. Inboard joint boot
c. Inboard joint boot big clamp
(2) Align the matchmarks, install the tripod assembly on the
tripod joint outer shaft assembly.
(3) Using a brass bar and a hammer, install the tripod assembly.
Notice:
Do not tap the roller.

Make sure the tripod is correctly installed.Mark -

Propeller Shaft/DriveshaftFront Driveshaft4-27 (4) Using a snap ring plier, install the new retainer.
(5) Coat the tripod joint assembly with grease.
Grease amount: 99-109g
(6) Align the matchmarks, install the left intermediate shaft
assembly on the tripod joint assembly.
34. Install inboard joint boot
Install the inboard joint boot on the intermediate shaft and
35. Install inboard joint boot small clamp
As shown in the illustration, use a screwdriver to install the
inboard joint boot small clamp.
36. Install inboard joint big clamp
As shown in the illustration, use a screwdriver to install the
inboard joint big clamp.
37. Check front drive shaft
(1) Check the outboard joint for apparent looseness.
(2) Check that the inboard joint slide smoothly.
(3) Check the inboard joint for radial looseness.
(4) Check the boot for damage.
Notice:
Place the drive shaft assembly on level surface during the
inspection.Mark - tripod joint outer shaft.

Propeller Shaft/DriveshaftFront Driveshaft4-28 Hint:
Please refer to the following table for dimension (A).LH mm
528.3±5.0
527.0±5.0RH mm
859.3±5.0
860.0±5.0 M/T manual transmission
A/T automatic transmission38. Install left constant velocity drive shaft assembly
(1) M/T
Coat the spline of the tripod joint assembly with gear oil.
(2) A/T
Coat the spline of the tripod joint assembly with ATF
(Automatic Transmission Fluid).
(3) Align the spline, use a brass bar and hammer to install the left
drive shaft assembly.
Notice:
Face the retainer open end downward.
Be careful not to damage the boot and oil seal.
Hint:
You can find out whether the tripod joint shaft contact the pinion shaft by rotating the shaft assembly, listening
to the sound and feeling.
39. Install right constant velocity drive shaft assembly
Hint:
The installation of the right side is the same as that of the left side.
Notice:

Install the retainer with its open end facing downward.
Be careful not to damage the boot and oil seal.
40. Install left steering knuckle assembly
Install the left constant velocity drive shaft assembly on the left steering knuckle assembly.
Notice:
Be careful not to damage the outboard joint boot.

With ABS:
Be careful not to damage the vehicle speed sensor rotor.
41. Install left steering gear with tie rod assembly
(1) Install the steering gear with tie rod assembly on the steering knuckle assembly with nuts.
Torque: 33N.m
(2) Install the new cotter pins.
Notice:
If the pin holes are not aligned, further tighten the nut by 60°.
42. Install left lower swing arm assembly
(1) Install the left lower swing arm assembly on the steering knuckle assembly with nuts.
Torque: 98N.m -

(2) Using sst, remove inner race of the left axle hub bearing from
the left axle hub sub assembly.
13. Remove front left brake disc boot
Remove 3 bolts and front left boot.
14. Remove left front axle hub bearing
(1) Place the left axle hub bearing inner race into the left axle hub
bearing outer race.
(2) Remove the left axle hub bearing from the steering knuckle
with press and sst
15. Install left front axle hub bearing
Install the new left axle hub bearing on the steering knuckle with
press and sst
16. Install front left brake disc boot
Install the front left boot with 3 bolts.
Torque: 8.3N.m
17. Install left front axle hub subassembly
Install left axle hub assembly with press and sst.
18. Install left front axle hub snap ring
Install the new left snap ring with snap ring plier.Propeller Shaft/DriveshaftFront Wheel Hub4-32 -