2009 CHERY TIGGO clutch

Downloaded from www.Manualslib.com manuals search engine MEASURE STATUSSTANDARD FLUID PRESSURE KPA (PSI)
GEAR LEVER POSITION GEAR
POSITION ENGINE
SPEED (RPM) DECELERATION
CLUTCH
PRESSURE REVERSE
GEAR
CLUTCH
PRESSURE OVERDRIVE
CLUTCH
PRESSURE LOW/
REVERSE GEAR
CLUTCH
PRESSURE SECONDARY
BRAKE
PRESSURE TORQUE
CONVERTER PRESSURE
P -2,500 - --310 - 390
(45-56) -250 - 390 (36
- 56)
R Reverse Gear 2,500 -1,270 - 1,770 - 1,270 - 1,770 - 500 - 700 (73
- 101)
N Neutral Gear 2,500 ---310 - 390 (45
- 56) -250 - 390 (36
- 56)
D Gear 1 2,500
1,010 - 1,050
(146 - 152) -- 1,010 - 1,050
(146 - 152) -500 - 700 (73
- 101)
Gear 2 2,500 ----1,010 - 1,050
(146 - 152) 500 - 700 (73
- 101)
Gear 3 2,500 590 - 690 (85 -
100) -590 - 690
(85 - 100) -- 450 - 650 (65
- 94)
Gear 4 2,500 --590 - 690
(85 - 100) -590 - 690 (85
- 100) 450 - 650 (65
- 94)
•In accordance with the shown status of standard fluid pressure measurement table, measure the fluid pressure
of each measurement port. The measurement of each port should be within the standard range.
• If some measurement values is beyond the standard range, please refer to the fluid pressure measurement and
diagnosis table for causes.
Is the check result normal?
Ye s>>Go to step 5 for disc or plate abrasion.
No
>>Go to the next step.
3.CHECK VALVE BODY ASSEMBLY AND FLUID PUMP AND PIPELINE
• Turn the ignition switch off.
• Disassemble and repair F4A4 automatic transaxle assembly (See Automatic Transaxle Removal & Installation in
Section 08 Transaxle & Transfer Case).
• Check valve body and fluid pump and pipeline.
Is the check result normal?
Ye s>>Go to the next step.
No
>>Replace damaged components and low speed clutch and reverse gear clutch for low pressure burned.
4.COMPRESSED AIR TEST
• Check low speed clutch system: Low speed clutch piston should be active and maintain pressure when com-
pressed air is applied to the fluid hole.
• Check reverse gear clutch system: Reverse gear clutch piston should be active and maintain pressure when
compressed air is applied to the fluid hole.
Is the check result normal?
Ye s>>Go to the next step for disc or plate abrasion.
No
>>Replace damaged components and low speed clutch and reverse gear clutch for low pressure burned.
DIAGNOSIS & TESTING
08–234Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 5.CHECK LOW SPEED CLUTCH SYSTEM
• Stop vehicle and turn ignition switch off.
• Disassemble and repair F4A4 automatic transaxle assembly (See Automatic Transaxle Removal & Installation in
Section 08 Transaxle & Transfer Case).
• Check low speed clutch system:
Check low speed clutch plate
Check low speed clutch disc
Snap ring
Clutch reaction disc
D-Ring
Spring retainer
Low speed clutch drum
Low speed clutch piston
Is the check result normal?
Ye s>>Go to the next step.
No
>>Replace the damaged components.
6.CHECK REVERSE GEAR CLUTCH SYSTEM
• Check reverse gear clutch system:
Reverse gear clutch plate
Reverse gear clutch disc
Central support
Snap ring
Clutch reaction disc
Spring retainer
Reverse gear clutch piston
Is the check result normal?
Ye s>>Go to the next step.
No
>>Replace the damaged components.
7.CHECK DTC
• Assemble all disassembled components.
• Install the transaxle assembly (See Automatic Transaxle Removal & Installation in Section 08 Transaxle &
Transfer Case).
• Fill the transaxle with new ATF:
Fill the ATF from the fill tube.
Reinstall the hose connector disassembled in step 1 and reinstall the dipstick (clean the dipstick before
installing).
Shift the gear selector lever to each gear position and then shift to gear “N”.
Drive the vehicle until the ATF reaches operating temperature (70° - 80°C) and re-check the fluid level. The fluid level must be within the HOT range of dipstick.
Reinstall the dipstick into the transaxle.
• With the X-431 scan tool, read TCM DTCs.
• Refer to DTC Confirmation Procedure.
Is DTC 46 present?
Ye s>>Replace the TCM.
No
>>The system is now operating properly.
DIAGNOSIS & TESTING
08
08–235Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 5-SPEED MANUAL TRANSAXLE
GENERAL INFORMATION08-247
Description 08-247
Operation 08-250
Specifications 08-251
Special Tools 08-253
DIAGNOSIS & TESTING08-259
Abnormal Noise 08-259
Symptom Diagnostics 08-259
ON-VEHICLE SERVICE08-260
Manual Transaxle Assembly 08-260
Removal & Installation 08-260
Gear Selector & Shifter Assembly 08-264
Removal & Installation 08-264
Disassembly 08-267
Assembly 08-268
MANUAL TRANSAXLE UNIT REPAIR08-270
Transaxle 08-270
Specifications 08-270
Disassembly 08-270
Inspection 08-274
Assembly 08-275
Input Shaft 08-278
Specifications 08-278Disassemble
08-279
Assemble 08-281
Inspection 08-285
Output Shaft 08-287
Disassemble 08-287
Assemble 08-290
Output Gear For Reverse Gear 08-296
Disassemble 08-296
Inspection 08-296
5th-Reverse Gear Shift Fork 08-297
Disassemble 08-297
Assemble 08-298
3rd-4th Gear Shift Fork 08-298
Disassemble 08-298
Assemble 08-299
1st-2nd Gear Shift Fork 08-299
Disassemble 08-299
Assembly 08-300
Transaxle Clutch Housing Assembly 08-301
Disassemble 08-301
Assembly 08-303
Transaxle Main Housing Assembly 08-305
Assembly 08-305
08–246Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Shift cables
QR523 External View
1 - Transaxle Housing Assembly
2 - Bearing Cap Assembly
3 - Stud Bolt
4 - Gear-Shifting Mechanism Assembly5 - Release Fork Dust Boot
6 - Release Fork
7 - Clutch Housing Assembly
8 - Hydraulic Clutch Line Bracket
GENERAL INFORMATION
LTSM080021
08–248Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine QR523 Internal View
1 - Idler Assembly
2 - Pinion Gear, 4th Gear
3 - 3rd-4th Gear Synchronizer
4 - Pinion Gear, 3rd Gear
5 - Transaxle Housing
6 - Clutch Housing
7 - Release Bearing Saddle
8 - Input Shaft9 - Output Shaft
10 - Differential Assembly
11 - Driven Gear of 1st Gear
12 - 1st-2nd Gear Synchronizer
13 - Driven Gear, 2nd Gear
14 - Driven Gear, 5th Gear
15 - Synchronizer of 5th-Gear and Reserve Gear
16 - Gear, Reverse Gear
GENERAL INFORMATION
LTSM080020
08
08–249Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Operation
The following are the details of the manual transaxle:
Neutral
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. Since no synchro-
nizers are engaged on either the input or output shafts, power is not transmitted to the output shafts, power is not
transmitted to the output shaft and the differential does not turn.
1st Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft first
gear is integral to the input shaft, and is in constant mesh with the intermediate shaft first speed gear. Because of
this constant mesh, the output shaft first speed gear freewheels until first gear is selected. As the gearshift lever is
moved to the first gear position, the 1-2 fork moves the 1-2 synchronizer sleeve towards first gear on the output
shaft. The synchronizer sleeve engages the first gear clutch teeth, engaging the gear to the output shaft, and allow-
ing power to transmit through the output shaft to the differential.
2nd Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft
second gear is integral to the input shaft, and is in constant mesh with the output shaft second speed gear. Because
of this constant mesh, the output shaft second speed gear freewheels until second gear is selected. As the gearshift
lever is moved to the second gear position, the 1-2 fork moves the 1-2 synchronizer sleeve towards second gear on
the output shaft. The synchronizer sleeve engages the second gear clutch teeth, engaging the gear to the output
shaft, and allowing power to transmit through the output shaft to the differential.
3rd Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft third
speed gear is in constant mesh with the output shaft 3-4 cluster gear which is fixed to the output shaft. Because of
this constant mesh, the input shaft third speed gear freewheels until third gear is selected. As the gearshift lever is
moved to the third gear position, the 3-4 fork moves the 3-4 synchronizer sleeve towards third gear on the input
shaft. The synchronizer sleeve engages the third gear clutch teeth, engaging the gear to the input shaft, and allowing
power to transmit through the output shaft to the differential.
4th Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft fourth
speed gear is in constant mesh with the output shaft 3-4 cluster gear which is fixed to the output shaft. Because of
this constant mesh, the input shaft fourth speed gear freewheels until fourth gear is selected. As the gearshift lever
is moved to the fourth gear position, the 3-4 fork moves the 3-4 synchronizer sleeve towards fourth gear on the input
shaft. The synchronizer sleeve engages the fourth gear clutch teeth, engaging the gear to the input shaft, and allow-
ing power to transmit through the output shaft to the differential.
5th Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft fifth
speed gear is pressed on to the input shaft, and is in constant mesh with the output shaft fifth speed gear. Because
of this constant mesh, the output shaft fifth speed gear freewheels until fifth gear is selected. As the gearshift lever
is moved to the fifth gear position, the 5-R fork moves the 5-R synchronizer sleeve towards the output shaft fifth
speed gear. The synchronizer sleeve engages the fifth gear clutch teeth, engaging the gear to the input shaft, and
allowing power to transmit through the output shaft to the differential.
Reverse Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft
reverse gear is integral to the input shaft, and is in constant mesh with the reverse idler gear. The reverse idler gear,
which reverses the rotation of the output shaft, is in constant mesh with the output shaft reverse gear. Because of
this constant mesh, the output shaft reverse gear freewheels until reverse gear is selected. As the gearshift lever is
moved to the reverse gear position, the 5-R fork moves the 5-R synchronizer sleeve towards the output shaft reverse
gear. The synchronizer sleeve engages the reverse gear clutch teeth, engaging the gear to the output shaft, and
allowing power to transmit through the output shaft to the differential.
GENERAL INFORMATION
08–250Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Transaxle Identification Number
The transaxle serial number can be found on a metal
tag (1) fastened to the transaxle case on the clutch
housing. The third row data is the transaxle serial
number.
Specifications
Maintenance Specifications
DESCRIPTIONALLOWABLE RANGE (mm) LIMIT VALUE (mm)
Axial Clearance Of Input Shaft Front
Bearing -0.01 - 0.21
-
Axial Clearance Of Input Shaft Rear
Bearing -0.01 - 0.12
-
Axial Clearance Of Input Shaft Fifth
Gear -0.01 - 0.09
-
Axial Clearance Of Output Shaft
Front Bearing -0.01 - 0.12
-
Axial Clearance Of Output Shaft
Rear Bearing -0.01 - 0.09
-
Axial Clearance Of Output Shaft
Third Gear -0.01 - 0.09
-
Back Clearance Of Differential Case
Planetary Gear 0.025 - 0.150
-
Clearance Between The Gear And
The Back Of Synchronizer Ring -
0.05
Pretension Of Differential Case 0.05 - 0.11-
GENERAL INFORMATION
LTSM020209
08
08–251Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Sealants and Adhesives
DESCRIPTIONSPECIFIED SEALANTS AND ADHESIVES
Clutch Housing to Transaxle Housing Three Arrow 1216E
Control Case to Transaxle Housing
Lower Head to Transaxle Housing
Torque Specifications
DESCRIPTION TORQUE (N·m)
Bottom Cover-Transaxle Installation Bolts 6.2 - 7.6
Backup Lamp Switch 28.7 - 35.3
Clutch Housing-Transaxle Housing Installation Bolts 39.5 - 48.5
Clutch Release Bearing Saddle Retainer Installation
Bolts 8.8 - 10.8
Gear-Shifting Mechanism Assembly Installation Bolts 16.1 - 19.9
Gear-Shifting Staying Wire Bracket Installation Bolts 16.1 - 19.9
Idling Gear Assembly Installation Bolts 43.1 - 52.9
Main Gearbox Driven Gear Installation Bolts 118.5 - 145.5
Speedometer Gear Installation Bolts 3.5 - 4.3
Technical Data
TYPEMECHANICAL GEAR COUPLING
Gear Position Transaxle Ratio Gear Ratio
1st 3.583 43/12
2nd 1.947 37/19
3rd 1.379 40/29
4th 1.030 34/33
5th 0.820 32/39
Reverse 3.36337/11
Final Drive 4.31369/16
Transaxle Fluid Type GL-4 75W-90
Transaxle Fluid Quantity 2.2 L
Rated Torque 230 N·m
Rated Speed 5500 RPM
Rated Power 100 KW
Center Distance 204 mm
Input Shaft Spline Tooth number
20
Module 1.0583
Pressure angle 30°
External diameter 22.224 mm (0/-0.3)
Inner diameter 19.675 mm (0/-0.2)
Physical Dimension 398.5×522×355.7
GENERAL INFORMATION
08–252Chery Automobile Co., Ltd.