Chery A15. Manual — part 285

(24) Unfix the shifting fork of the first and second gears off the output shaft (Figure 41).



1-Clamp
2- Shifting fork of the first and second gears

Figure 41 Unfixing the Shifting Fork
of the First and Second Gears

(25) Unfix the input and output shaft assemblies from the clamp (Figure 42).




1-Clamp
2-Input shaft and output shaft

Figure 42 Unfixing the Input and
Output Shaft Assemblies

II. Assembling Gearbox
Note: the output shaft assembly can
only be repaired as a whole but can’t
be disassembled for maintenance. In
the case of 1

st

-gear and 2

nd

-gear

synchronizer or gear faults, the whole
output shaft assembly must be
replaced.
1. Cleaning
Clean the gears, bearings, shafts,
synchronizers, thrust gasket, oil seal,
gear-shifting mechanism, gearbox and
clutch cover with detergents and blow
them dry (except bearings) with
compressed air. Bearings can be dried in
the air or with clean cloth.

Check the gears, bearings, shafts and
thrust gaskets and replace the bearing
and seat ring if any roller is found to be
worn-out, broken or damaged. Replace
any gear with worn-out or broken tooth.
Replace the assembly in the case of
worn-out, deformed or burned
synchronizer or failing spring.

2. Assembly
Note: the output shaft of the gearbox
can only be repaired as a whole but
not disassembled or assembled. Or the
gearbox will be damaged. The sealant
is used to seal the gearbox body and
the bearing rear cover as well.
(1) Take the gasket out of the clamp.
(2) Fix the input and output shafts into
the clamp.

1-Clamp
2-Gear






(3) Fix the guide ruler and shifting fork
into the clamp (Figure 44)


1-Clamp
2-Shifting fork

Figure 43 Clamp











Figure 44 Fixing the Guide Ruler

(4) Fix the gear lockup assembly into the
clamp (Figure 45).


1-Clamp
2-Gear position lockup assembly





(5) Fix the reverse brake retainer ring
(Figure 46)


1-Reverse brake retainer ring






(6) Fix the reverse brake conical friction
wheel (Figure 47).




1-Reverse brake conical friction wheel

Figure 45 Fixing the Gear Position
Lockup Assembly












Figure 46 Reverse Brake Retainer Ring












Figure 47 Fixing Reverse Gear Brake
Conical Friction Wheel

(17) Fix the lower half of the gearbox
onto the clamp.



1-Gearbox body
2-Clamp
3-Gear




(8) Array the reverse brake conical
friction wheel in the gearbox (Figure 49)
and make sure that the position of
reverse brake conical friction wheel is
correct.



1-Gearbox body
2-Reverse brake conical friction wheel
3-Input shaft





(9) Place the input shaft and output shaft
bearings onto the shafts. Press the
bearings onto the input and output shafts
with a special tool until they are properly
positioned on the gearbox body (Figure
50).





1-Input and output shaft bearing
2-Special tool

Figure 48 Gearbox













Figure 49 Arraying Conical Friction
Wheel
















Figure 50 Fixing Input and Output shaft
bearings