2009 CHERY TIGGO clutch

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
Abnormal Noise
Transaxle noise is most often a result of worn or damaged components. Chipped, broken gear or synchronizer teeth,
and worn bearings all cause noise.
Inspect the following:
•Insufficient lubrication
• Incorrect lubricant
• Mis-assembled or damaged internal components
• Improper operation
Symptom Diagnostics
Hard Shifting
•Hard shifting may be caused by a mis-adjusted crossover cable. If hard shifting is accompanied by gear clash,
synchronizer clutch and stop rings or gear teeth may be worn or damaged.
Slips Out Of Gear
•Transaxle disengagement may be caused by misaligned or damaged shift components, or worn teeth on the
drive gears or synchronizer components. Incorrect transaxle assembly also causes gear disengagement.
Low Lubricant Level
•Insufficient transaxle lubricant is usually the result of leaks, or inaccurate fluid level check or refill method. Vehi-
cle must be level to accurately check fluid level. Leakage is evident by the presence of fluid around the leak
point. If leakage is not evident, the condition is probably the result of an under fill.
• If air-powered lubrication equipment is used to fill a transaxle, be sure the equipment is properly calibrated.
Equipment out of calibration can lead to an under fill condition.
Clutch Problems
•Worn, damaged, or misaligned clutch components can cause difficult shifting, gear clash, and noise.
• A worn or damaged clutch disc, pressure plate, or a faulty slave cylinder can cause hard shifting and gear
clash.
Abnormal Noise
•Transaxle noise is most often a result of worn or damaged components. Chipped, broken gear or synchronizer
teeth, and worn bearings all cause noise.
Inspect the following: Insufficient lubrication
Incorrect lubricant
Improperly assembled or damaged internal components
08
08–259Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 8. Remove the two shift cables (1) from the transaxle.
9. Remove the shift cable clamp (1) from the shiftcable bracket.
10. Remove the clutch master cylinder outlet pipe (1) from the clutch slave cylinder.
(Tighten: Outlet pipe bolt to 17 ± 1 N·m)
11. Remove the starter motor (See Starter Removal & Installation in Section 05 Starting & Charging).
12. Support the engine using an engine support fixture or suitable jack.
13. Remove the engine to transaxle upper bolts and remove the bracket.
(Tighten: Engine to transaxle upper bolts to 80
N·m)
ON-VEHICLE SERVICE
BESM080051
VISM080026
LTSM080191
08
08–261Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine MANUAL TRANSAXLE UNIT REPAIR
Transaxle
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Gear Shift Mechanism Housing Bolt 18
Gear Positions Self-Locking Bolt 35
Reverse Gear Bolt 20
Reverse Gear Cap Bolt 20
Rear Transaxle Bearing End-Plate Bolt 6.9
Transaxle To Clutch Housing Bolt 44
Bearing Input Shaft Bolt 18
Disassembly
1. Place the transaxle on a workbench.
2. Remove the clutch fork (2) and remove the release
bearing (1).
NOTE: The release bearing (1) is not serviceable.
3. Set the transaxle gear in the neutral position. Remove the gear shift mechanism housing retain-
ing bolts (1), and remove the gear shift mechanism
housing.
(Tighten: Gear shift mechanism housing bolts to
18 N·m)
LTSM020229
LTSM080119
08–270Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 8. Remove the 10 rear transaxle bearing end-platebolts (1), and then remove the bearing cap.
(Tighten: Rear transaxle bearing end-plate bolts to
6.9 N·m)
9. Remove shaft clip (3) and shaft clip (1) from the shafts, and then remove bearing collar (2).
10. Remove the transaxle to clutch housing bolts (1), and then use a pry bar to remove the transaxle
housing.
(Tighten: Transaxle to clutch housing bolts to
44 N·m)
11. Perform the following steps to remove the transaxle housing (1).
MANUAL TRANSAXLE UNIT REPAIR
LTSM080124
LTSM080125
LTSM080126
LTSM080022
08–272Chery Automobile Co., Ltd.

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 4. Gear Hub and Hub of Synchronizer•Assemble the gear bushing together with the
gear hub of synchronizer, and then inspect for
smooth operation without lockup.
• Inspect the front/rear of the interior surface of
the gear bushing for any damage.
• Inspect the synchronizer springs for any weak
springs or damage.
NOTE: If it is necessary to replace the gear
bushing and gear hub of the synchronizer,
they are only serviced as a complete set.
5. 3rd-4th Driven Gear •Inspect the gear surface of the skew gear and
clutch gear (1) for any damage.
• Inspect the conical surface of the synchronizer
(2) for thickening, damage or wear.
• Inspect the internal diameter of the front/rear
surface of the gear.
MANUAL TRANSAXLE UNIT REPAIR
LTSM080059
LTSM080085
08–286Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 14. Using special tools MB-998812 (1) and MB-998818(2), install the reverse driven gear/needle bearing-
reverse gear/sleeve-reverse gear (3).
15. Using special tools MB-9988112 (1) and MB-998818 (2), install the input shaft rear bearing
(3).
16. Install the outer ring-1st-2nd gear synchronizer ring/steel ring-1st-2nd gear synchronization ring/in-
ner ring-1st-2nd gear synchronization ring (1).• Inspect the conical surface of the clutch gear
for any damage or breakage on the gear
surface.
• Install the outer ring (2) and inner ring (4), and
then press them down to the gear (1) to mea-
sure the clearance “A”. If “A” is less than the
limit value, the rings (3) should be replaced-
.Limit Value: 0.5 mm
CAUTION:
The outer ring, inner ring or steel, are replaced
as a complete set.
MANUAL TRANSAXLE UNIT REPAIR
LTSM080081
LTSM080082
LTSM080083
LTSM080084
08–294Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 17. Install the gear bushing and hub of synchronizer:•Assemble the gear bushing together with the
gear hub of synchronizer, and then inspect for
smooth operation without lockup.
• Inspect the front/rear of the interior surface of
the gear bushing for any damage.
• Inspect the synchronizer springs for any weak
springs or damage.
CAUTION: The gear bushing or gear hub of
the synchronizer are replaced as a com-
plete set.
18. Install the transaxle gear: •Inspect the gear surface of the skew gear and
clutch gear (1) for any damage.
• Inspect the conical surface of the synchronizer
(2) for thickening, damage or wear.
• Inspect the internal diameter of the front/rear
surface of the gear.
MANUAL TRANSAXLE UNIT REPAIR
LTSM080059
LTSM080085
08
08–295Chery Automobile Co., Ltd.