Chery A15. Manual — part 294

Unfix the 3

rd

and 4

th

-gear synchronizer

and 3

rd

-gear transmission gear with the

bearing puller (Figure 124).


1-Pressure arm
2-Input shaft
3-3

rd

-speed gear

4-Synchronizer assembly



(11) Unfix 3

rd

-gear needle roller bearing

(Figure 125) and check the needle rollers.


1-Input shaft
2-3

rd

-gear needle roller bearing

(12) Check if the input shaft bearing
surface suffers any abrasion or damage
and replace if necessary.


2. Fixing
(1) Fix the input shaft.
(2) Fix the 3

rd

-gear needle roller bearing

(Figure 126).


1-Input shaft
2-3

rd

-gear needle roller bearing

Figure 124 Unfixing the 3

rd

-speed Gear

Figure 125 3

rd

-gear Needle Roller

Bearing












Figure 126 3

rd

Gear Needle Roller

Bearing

(3) Check the 3

rd

-gear and 3-4

th

-gear

synchronizers on the input shaft and
install the Special Tool C-3717 (Figure
127). The synchronizer side with “U”
marking shall face upward.


1-Pressure arm
2-Speical Tool C-3717
3-Bearing disengagement
4-3

rd

-speed gear synchronizer assembly

(4) Fix the 3

rd

-4

th

-gear synchronizer snap

ring onto the input shaft.
(5) Fix the 3

rd

-4

th

-gear synchronizer and

4

th

-gear needle roller bearing.

(6) Fix the 4

th

-speed gear onto the output

shaft.
(7) Fix the 4

th

-5

th

-gear thrust bearing

assembling pin (Figure 128).


1-Assembling pin
2-Input shaft
3-Pliers




(8) Fix the thrust bearing onto the input
shaft (Figure 129).




1-Input shaft
2-Release thrust bearing

Figure 127 3

rd

-speed Gear Synchronizer

Spline Hub












Figure 128 Thrust Bearing Assembling
Pin












Figure 129 Fixing the Thrust Bearing

(9) Fix the thrust bearing snap ring
(Figure 130).


1-Release thrust bearing ring
2-Input shaft





(10) Fix the 5

th

gear needle roller bearing

(Figure 131).



1-Input shaft
2-Needle roller bearing





(11) Use special tools to fix the 5

th

-speed

transmission gear and synchronizer
(Figure 132). The “S”-marked sides of
the 5

th

-speed transmission gear and the

synchronizer spline hub shall face
upwards.



1-Pressure arm
2-Special tool
3-Synchronizer assembly
4-Bearing bracket
5-5

th

-speed gear

(12) Fix 5

th

gear synchronizer snap ring

(Figure 133)

Figure 130 Fixing the Snap Ring











Figure 131 Fixing the Needle Roller
Bearing













Figure 132 Fixing the 5

th

Gear

1-Snap ring pliers
2-Input shaft
3-Bearing bracket
4-Snap ring

Figure 133 Fixing the 5

th

Gear

Synchronizer Snap Ring

III. Fixing and unfixing of output shaft
Note: do not try repairing the output shaft but replace the assembly as a whole. Please
replace the output shaft assembly if 1-2 synchronizers or gears have troubles.
If the synchronizer’s synchronizing ring clearance is to be checked, please measure the
clearance between the synchronizer and the transmission gear with a clearance gauge.
The nominal values are:
• 1st gear - 0.522-2.208 mm (0.021-0.087 in)
• 2

nd

gear - 0.522-2.208 mm (0.021-0.087 in)

• 3

rd

gear - 0.73-1.53 mm (0.029-0.060 in)

• 4

th

gear - 0.77-1.57 mm (0.030-0.062 in).

• 5

th

gear - 0.73-1.53 mm (0.029-0.060 in)

Any synchronizing ring whose clearance does not comply with the above criteria must be
replaced. If the abrasion of 1

st

and 2

nd

-gear synchronizer’s synchronizing ring goes

beyond the criteria, the output shaft assembly must be replaced (Figure 134).

1-1

st

gear transmission gear

2-Coupling
3-Synchronizing ring
4-Output shaft
5-2

nd

gear transmission gear

6-Reverse gear
7-Synchronizing ring

Figure 134 Output Shaft