Chery Fora (Elara A520). Manual — part 172

CHERY A520 SERVICE MANUAL QR519 TRANSMISSION

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25. Screw out the reverse shift fork

mechanism assembly bolts and remove
the reverse shift fork;

Figure 25

26. Remove the split baffle ring with a

caliper;

Figure 26

27. Take hold of the input shaft assembly,

output shaft assembly, 1st-2nd shift fork,
3rd-4th shift fork and 5th-reverse fork
shaft together with your hands and take
them

out;

finally,

take

out

the

differential assembly;

Figure 27

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VII EXPLODED VIEW

INPUT SHAFT ASSEMBLY

1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 10 8 7 16 17

Figure 28

1. Input shaft assembly
2. Front input shaft bearing
3. Input shaft
4. 3rd-5th needle roller bearing
5. 3rd driving gear assembly
6. 3rd driving gear
7. 3rd-4th synchronizer cone
8.

Synchronizer

ring-

3rd-4th

synchronizer
9. 3rd-4th synchronizer assembly

10. Steel wire spring for 3rd-4th synchronizer
11. Guide block for 3rd-4th synchronizer
12. Gear sleeve for 3rd-4th synchronizer
13. 4th gear needle roller bearing
14. 4th driving gear assembly
15. Gear hub for 3rd-4th synchronizer
16. 4th driving gear
17. 4th-collar

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DISASSEMBLY:

If a special tool is available, you can directly
use it to disassemble the input shaft
assembly. Otherwise, use the detacher to
carefully pull out the 4th-collar, 4th driving
gear, 4th gear needle roller bearing, 3rd-4th
synchronizer assembly and 3rd driving gear
in sequence.

In addition, pull out the front input shaft
bearing from the front end of input shaft.

NOTICE FOR INSTALLATION:

(1) Clean all components.

(2) Check the input shaft:

① Check whether there is any damage,

abnormal wear or lockup of the needle
roller bearing's outer-diameter portion to
be mounted.

② Check whether there is any damage or

wear of the spline.

Check the needle roller bearing – whether the
input shaft and gears are correctly assembled,
whether the gears can rotate smoothly, and
whether there is any part looseness or noise.

Check the 3rd and 4th driving gears:

① Check whether there is any damage or

wear on tooth surfaces of helical gear (A
in Figure 29) and clutch gear (B in
Figure 29).

② Check whether there is any damage,

wear or coarsening on the synchronizer's
conical surface.

③ Check whether there is any damage or

wear on their inner-diameter, front and
rear surfaces.

Figure 29

A

B

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Check the gear sleeve and gear hub of the
3rd-4th synchronizer:

① Assemble the gear sleeve and gear hub

together and check whether they can
slide smoothly or whether they are
locked up (as shown in Figure 30).

② Check whether there is any damage in

the front and rear of the gear sleeve's
inner surface.

Note: if it is necessary to replace the gear
sleeve or hub, you shall use a new complete
set of these components for substitution.

Figure 30

(3) Clean the inner conical surfaces of

synchronizer rings by steel wire brush
(as shown in Figure 31).

Check whether there is any damage or wear
on the gear tooth surfaces of the synchronizer
ring, whether there is any damage or wear on
the

inner-diameter

surface

of

the

synchronizer's conical portion, and whether
the screw thread is damaged due to crushing.

(4) Press the synchronizer rings in turn onto

their respective gears' conical surfaces
and check the values of the clearance
"A". The standard values of A are as
shown in the following table (unit: mm):

Synchronizer

Ring

Value of A

Wearing

Limit

1st-2nd gear

1.10-1.17

0.05

3rd-4th gear

1.35-1.90

0.05

5th gear

1.10-1.17

0.05

INSTALLATION:

The procedure to assemble the input shaft
assembly is opposite to its disassembly
procedure.

Figure 31

Figure 32