Chery A11. Manual — part 139

Unscrew the screw plug of shifting shaft with

special tool, take out spreader spring and

shifting shaft assy.

Take out the snap ring and disk-shape closing

ring, and remove the output flange.

Remove the stoppers of reverse gear shaft (as

indicated by arrow)

Shift to gear 5 and reverse gear

—Slide the synchronizer down as indicated by

arrow 1 and shift to gear 5.

—Move the first fork down as indicated by

arrow 1 and shift to reverse gear.

Remove left and right blind covers of output

flange

Unscrew the fixing bolts and gaskets of gear-5

synchronizer with special tool.

Special tool

Special tool

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Pry up the gear-5 fork locking board to let it

loosened; left unscrew the gear-5 fork bush with

special tool and remove gear-5 fork assy.

Unscrew the clamping bolt of rear shaft gasket of

input shaft with special tool.

Remove the gear-5 driving gear and its

synchronizer assy. If necessary, with special tool.

Unscrew the fastening bolts of fore and rear housing

of transmission, remove the transmission housing

and the gaskets of fore and rear housings.

Take down the snap ring of gear-5 driven gear and

gear-5 driven gear.

Remove the transmission fork shaft and its upper

and lower spring, take out gear-5 fork guide block

assy., reverse gear fork guide block, gear-3 and gear

4 forks and gear-1 and gear-2 forks.

Special tool

Special tool

Special tool

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Remove the snap ring of gear-4 driven gear, with

special tool if necessary

Up knock the reverse gear shaft with reverse gear

idler until knocking down the reverse gear idler

and shaft from the clutch housing.

Take out assy. A of input shaft, pay attention that

gear B of the reverse gear should not be on the gear

position.

Pull out gear-1 and gear-2 synchronizer

assemblies of input shaft with special tool, gear-1

synch ring, gear-1 driven gear, needle roller gear

and take out gasket.

Remove snap ring B of gear-3 driven gear from the

output shaft, then gear-3 driven gear; remove the

gear-2 driven gear, needle roller bearing and synch

ring from output shaft; use special tool if necessary.

Unscrew the fastening screws of fore bearing

baffle of output shaft, take out the fore bearing

baffle and output shaft.

Take out differential gear assy.

Remove reverse gear fork and its bracket, release

spring and buttonhead.

Special tool

Special tool

Special tool

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Assembly of Transmission

The procedures to assemble transmission are the

basically reverse to that of dismantlement. Pay

attention to the followings:

When mounting differential gear assy. onto clutch

housing, do not install the output flange first.

Mount the output shaft and put on the fore bearing

baffle of output shaft, put on fixing bolts and

tighten with 40Nm torque.

Mount the reverse gear idler and idler shaft onto

clutch housing.

Put on the thrust plate and needle roller bearing.

Notice the direction of thrust plate, the inner

diameter of thrust plate A should well contacted

with bearing seat B.

When mounting gear-1 and gear-2 synch ring,

never confuse them; gear-1 synch ring is not moly

coated and has no teeth in three places.

Mount the needle roller bearings, synch rings

and gears of gear-2 and gear-3 driven gear.

When mounting gear-3 driven gear, the side with

dummy club should be toward the gear-2 driven

gear.

When mounting gear-1 and gear-2 synchronizers,

the side A with teeth should be toward gear-1

driven gear B.

After mounting gear-3 driven gear, adjust the

axial sizes with snap ring. When installing,

select the snap ring among the allowable types

that is the thickest and can be inserted into the

groove. When mounting snap ring, pay attention

not to expand it too much and ensure that it has

been installed into the groove.

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