2008 GEELY MK differential

Table of Contents II Section 4 Fuel Emission Control System ....................................................................... 3-18
Section 5 Carbon Canister Replacement ....................................................................... 3-19
Chapter 4 Exhaust System................................................................................................. 3-21
Chapter 5 Cooling System................................................................................................. 3-22
Section 1 System Inspection .......................................................................................... 3-22
Section 2 Radiator Replacement ................................................................................... 3-24
Chapter 6 Manual Transaxle Assembly............................................................................. 3-25
Section 1 Frequent Problem Diagnosis .......................................................................... 3-25
Section 2 Vehicle Speed Sensor Replacement ............................................................. 3-26
Section 3 Manual Transaxle Replacement ..................................................................... 3-27
Section 4 Transmission/Transaxle Case Oil Seal Replacement .................................... 3-28
Chapter 7 Automatic Transaxle Assembly........................................................................ 3-29
Section 1 Frequent Problems Diagnosis ........................................................................ 3-29
Section 2 Hydraulic Torque Converter and Transaxle .................................................... 3-30
Section 3 Differential Front Oil Seal (ATM) .................................................................... 3-33
Section 4 Neutral Switch Assembly ................................................................................ 3-35Part IV ChassisChapter 1 Transmission Control........................................................................................ 4-1
Section 1 Introduction of Transmission Control ............................................................. 4-1
Section 2 Cable Type Transmission Control .................................................................. 4-3
Section 3 Manual Transmission Shift Mechanism .......................................................... 4-5
Section 4 Automatic Transmission Shift Mechanism ...................................................... 4-7
Chapter 2 Accelerator Pedal Device................................................................................. 4-11
Section 1 Introduction of Accelerator Pedal ................................................................... 4-11
Chapter 3 Clutch Control System...................................................................................... 4-12
Section 1 Introduction of Clutch Centrol ......................................................................... 4-12
Section 2 Clutch Pedal ...................................................................................................4-13
Chapter 4 Propeller Shaft/Driveshaft................................................................................ 4-17
Section 1 Propeller Shaft, Driveshaft and Transaxle ..................................................... 4-17

2-12Section 2 Maintenance Category and Content of MK SedanAs the vehicle is being used, its technical performance changes as the mileage accumulates and being affected by
various factors, which results in decrease of power, fuel economy, safety, and increase of emission pollutions,
noise and incidents. So timely maintenance during vehicle usage eliminates potential risks and prevents incidents
from happening, improves vehicle integrity and technical functionality, and prolongs useful life of the vehicle.
According to the vehicle technical requirements and usage history, maintenance of freedom Cruiser sedan can be
classified into several categories.I. first time maintenanceFirst time maintenance is also called breaking-in maintenance. It is performed when the vehicle mileage has
accumulated to 1500~2500km in breaking-in period. First time maintenance must be conducted at the appointed
service shops. It includes:
1. Check if there is any leak in engine, transmission, and differential. Fix if there is any.
2. Replace engine oil filter, engine oil and ATF for A/T.
3. Check the level of engine coolant, braking fluid, windshield washing fluid, power steering fluid and if there
is any leak. Refill if the level is too low and repair if there is any leak.
4. Check if there is any damage in triangle arm and ball joint, connection ball joint, triangle arm flexible hinge,
or the ball joint is loose. If there is, fix or replace it.
5. Check if the drive shaft dust cover is damaged. If there is, replace it.
6. Check if there is any leak in steering mechanism, or front and rear absorber and fix it there is any.
7. Check the tire pressure, front 230kpa, and rear 210kpa.II. Regular maintenanceAfter first time maintenance, the vehicle is in regular usage life. During regular use, the vehicle needs to be
maintained regularly according to the way it is used in.
1.Regular maintenance for vehicles used under extreme bad conditions. Any of the condition below is defined
as extreme bad condition:
(1) Frequent start.
(2) Often drive the vehicle in dusty circumstances.
(3) Drive the vehicle in hot areas (such as in summer in the south).
(4) Often drive in cold areas (often runs short trips, engine temperate cannot reach regular work temperature).
Vehicles ran under extreme bad conditions need to be maintained every 5000km.
2. Regular maintenance for vehicles Vehicles that have not been through extreme bad conditions need to be
maintained every 7500km.
Regular maintenance is required to be performed at Geely service shop, too.
List of parts that need to be replaced regularly is in table 1.
Maintenance timetable is in table2.III. Geely maintenance programGeely recommends following Geely maintenance program.
The intervals of maintenance schedules are determined by mileage meter or time periods. Maintain the vehicle
when either meets the schedule. For details, please refer to the schedule.Usage and Maintenance of MK Series - Maintenance Category and Content of MK Sedan

The valve body fails.
12. The vehicle shifts before or after some gear points in the running status.
The vehicle switch or parking switch fails.
13. The vehicle has poor acceleration in running.
(1)The clutch or brake fails.
(2)The engine system fails.
14. The vehicle vibrates when it runs at a constant speed or accelerating speed.
(1)The hydraulic torque clutch pressure or hydraulic torque meter fails.
(2)The engine system or valve fails.
15. The acceleration switch system fails.
(1)The acceleration switch or ignition switch fails.
(2)The connector or automatic transmission control unit fails.I. Automatic transmissions Removal1. Put the select lever in "N" position
2. Remove 3 bolts of the flexibility plate (engine side)
3. Remove starter and 2 cooling hoses.
4. Disconnect neutral switch connector and odometer sensor.
5. Loosen the drain screw under the housing to bleed ATF and tighten the drain screw with sealing glue when
assembling. Tightening torque is 29~35N.m
6. Loosen the locking bolt for select lever cable.
7. Remove Drive Shaft LH&RH, using plastic stopper in the oil sealing of differential.
8. Detach suspension bolts.
9. Separate transmission from engine after bolts between engine and transmission remove.II. Automatic Transmission Installation1. Check whether torque converter of the transmission is in the right position, the methods as follows:
Check whether the distance from 3 anchor point of torque converter to front contact face of the transmission
box A 28mm , If the space A<28 mm, try install again. The way to install is that left hand catch hold of the
central anchor column of the converter and make it in alignment with input shaft as near as possible, push the torque
converter in rotating way by right hand until it gets to the bottom to meet the requirement of A 28 mm. (See
figure 7-1 and 2)
2. Install Flexibility plate and central plate on the crankshaft end face with 6 bolts in the direction of Figure 2.
Tightening torque is 45~55 N.m. Turn the longer hole of the Flexibility plate to the lowest of the engine position
in order to connect torque converter.Section 2 Hydraulic Torque Converter and TransaxleAutomatic Transaxle Assembly Hydraulic Torque Converter and Transaxle3-30 -

Figure 7-93-33Replacement1. Discharge the automatic transmission oil.
(1) Remove the discharge plug and washer to discharge the ATF oil.
(2) Install the discharge plug and new washer.
Torque: 25N.m
2. Remove the front wheel.
3. Remove the left/right front wheel hub nuts.
4. Unfix the front stabilizer bar.
5. Unfix #1 left/ring front suspension sub-assembly.
6. Unfix the left/right ball extension rod sub-assembly.
7. Unfix the left/right front axles.
8. Remove the differential front oil seal (on the transaxle housing).Section 3 Differential Front Oil Seal (ATM)1. Check the hydraulic torque converter assembly.
(1)Measure the status of the hydraulic torque converter.
(2)Replace the ATF in the hydraulic torque converter.
(3)Wash and check oil freezer and oil pipe.
(4)Prevent the hydraulic torque converter being deformed and
the oil pump gear being damaged.
2. Check the drive disc and gear ring.
(1)Install a dial test indicator to measure the runout of the drive
disc. (See Fig.7-8)
(2)Check the damage of the gear ring.
Maximum runout: 0.25mm
If the runout is beyond the specified scope or the gear ring is
damaged, replace the drive disc.
Torque: 64N.m
3. Check the hydraulic torque converter. (See Fig.7-9)
Install the hydraulic torque converter on the drive disc temporarily,
and install a test indicator to measure the radial runout of the
hydraulic torque converter bushing.
Maximum radial runout: 0.20mm
If the radial runout is beyond the specified scope, readjust the
direction of installation.
Notes:
Mark the position of the torque converter to install it properly.
Remove the hydraulic torque converter.Figure 7-8Automatic Transaxle Assembly Differential Front Oil Seal (ATM) -

9. Pull out oil seal (on the transaxle housing) with a special tool.
(See Fig.7-10)
10. Remove the differential front oil seal on the transmission housing.
Pull out the oil seal on the transmission housing with a special
tool. (See Fig.7-11)
11. Install the differential front oil seal onto the transmission housing.
(1) Install a new oil seal on the transmission housing with a
special tool and hammer. (See Fig.7-12)
(2) Apply MP lube on the flange of the oil seal.
12. Install the differential front oil seal onto the transmission housing.
(1) Install a new oil seal onto the transmission housing with a
special tool and hammer. (See Fig.7-13)
(2) Apply MP lube on the flange of the oil seal.Figure 7-10
Figure 7-11
Figure 7-12Figure 7-13Automatic Transaxle Assembly Differential Front Oil Seal (ATM)3-3413. Install all parts in the sequence of removal till the front wheel is installed, and then add transmission oil.
14. Check and adjust the alignment of the front wheel. -

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. -