Chery A11. Manual — part 142

Disassembly of Input Shaft

1. Fastening bolts of gear-5 synchronizer
2. Gasket of fastening bolt
3. Gear-5 synchronizer assy.
4. Guide board stand of gear-5 synchronizer.
5. Wire

spring

6. Gear-5 tooth bush
7. Gear-5 tooth drum
8. Guide

block

9. Fastening bolt of rear bearing baffle
10. Rear bearing of input shaft
11. Rear bearing baffle
12. Gear-4 driving gear
13. Gear-4 synch ring
14. Snap ring
15. Gear-3 and gear-4 synchronizer assy.
16. Gear-3 and gear-4 tooth bush

17. Gear-3 and gear-4 tooth drum
18. Guide block
19. Wire spring
20. Input shaft
21. Clutch housing
22. Needle roller bearing
23. Oil seal at jogger of clutch
24. Clutch jogger bush
25. Gear-3 driving gear
26. Gear-3 synch ring
27. Transmission housing
28. Adjusting shim (not necessary to be used)
29. Baffle of gear-5 driving gear
30. Gear-5 driving gear
31. Gear-5 synch ring.

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Disassembly of Output Shaft

1. Rear

housing

2. Snap ring of gear-5 driven gear
3. Gear-5 driven gear
4. Transmission

housing

5. Needle roller bearing
6. Snap ring of gear-4 driven gear
7. Gear-4 driven gear
8. Snap ring of gear-3 driven gear
9. Gear-3 driven gear
10. Gear-2 driven gear
11. Gear-2 driven gear and its bush
12. Gear-2 synch ring
13. Gear-1 and gear-2 synchronizer assy.
14. Wire spring

15. Gear-1 and gear-2 tooth bush
16. Gear-1 and gear-2 tooth drum
17. Guide block
18. Gear-1 synch ring
19. Gear-1 driven gear
20. Baffle ring of gear-1 needle roller bearing
21. Adjusting shim
22. Exterior of fore bearing
23. Clutch housing
24. Fore bearing of output shaft
25. Output shaft
26. Intermediate bearing of output shaft
27. Intermediate bearing seat
28. Fixing screw of bearing seat

24

Adjustment Table

When repairing the transmission assy., if any one of parts in the

following table needs replacement, please consider to readjust

the installation sizes output shaft or differential gear assy.

To avoid useless adjustment, the following table is given:

Items to be adjusted

Parts to be replaced

Output Shaft

Differential

Gear Assy.

Transmission Housing

No

Yes

Clutch Housing

Yes

Yes

Cone Bearing of

Differential Gear

No Yes

Output Shaft

Yes

No

Intermediate Bearing Seat

of Output Shaft

Yes No

Differential Housing

No

Yes

Intermediate Bearing of

Output Shaft

Yes No

Fore Bearing of Output

Shaft

Yes No

Adjustment of Output Shaft

After replacing any one of clutch housing, output shaft,

intermediate bearing seat of output shaft, intermediate bearing

of output shaft and fore bearing of output shaft, the thickness of

adjusting shim of output shaft needs readjustment.

Adjustment:

Put in 0.65mm thick adjusting shim and press the outer loop of

fore bearing of output shaft into bearing seat.

Insert the completed output shaft assy., put on bearing

seat and tighten it with 40Nm torque.

Put a platform bench on clutch housing, then put the

micrometer with magnetic base onto the bench. Set

zero at 1mm pretightening force. Move the input shaft

up and down by arrow direction, read and record the

indications on micrometer. (i.e. 0.3mm)

Note: when measuring, never rotate the output shaft,

otherwise the shaft may fall down, and the

measurement is incorrect.

Special tool

Special tool

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Calculate the thickness of installed adjusting shim

When pre-tightening the bearing here, the thickness

of adjusting shim should be 0.20mm. if the

micrometer reads 0.30mm and the pre-put adjusting

shim is 0.65mm, the thickness of adjusting shim to

be installed should be:

0.20mm+0.30mm+0.65mm=1.15mm

Use gear lubricant to grease the bearing, insert the output shaft.

Put on bearing baffle and screw and fasten the bolts with

40Nm torque.

After replacing any one of clutch housing, transmission

housing, differential bearing and differential housing, the

thickness of adjusting shim of output shaft needs readjustment.

Unscrew the bolts of bearing baffle and take down

the output shaft

Fully press in the outer loop of differential bearing with special

tool.

Take out the outer loop of fore bearing of output

shaft, then take out the pre-put adjusting shim.

Use the minimum number of shims to form the

needed thickness and place them onto proper

position, then press in the outer loop of fore bearing

of output shaft.

Press in the outer loop of differential bearing at the

corresponding positions on differential housing.

Special tool

Special tool

Special tool

Special tool

Special tool

26