Geely Diagnosis Flow. Manual part — 50

197

No. 146 Gear shifting lever swinging, hard to shift

Malfunction Causes

Solution

Gear shifting lever loosens, shifting
incorrect;

Check nylon cover of gear shifting lever is unusually worn; if
so, replace it;

Gear shifting
lever swinging,
hard to shift

Gap between shift ball head and swing lever
too large, shifting incorrect;

Check shift ball head and swing lever loosen; if so, replace it;

Gear shifting lever swinging, hard to shift

Shift bar loosens, shifting incorrect

Clearance between shift ball head and swing

lever too large, shifting incorrect

Repaiar or replace

Repair

Normal

Abnormal

Abnormal

198

No. 147 Sounding when releasing throttle of third, fourth gears and decelerating

Malfunction Causes

Solution

Transmission oil quality, quantity

Check viscosity of transmission oil is too small, and quantity is
too little. Fill API GL-4

SAE 80W-85, and oil level shall be

flush with lower plane of oil filler.

Gear clearance of third, fourth gear too large

Check driving gear and driven gear of third, fourth gear.
Abrasion of tooth shall not exceed 30% of original tooth length,
and abrasion of its depth no more than 0.5mm. Meshing area
of gear shall be no less than 2/3 of working surface; meshing
clearance no larger than 0.5mm; change gear pair if too large;

Bearing with abnormal sound(major

inspection)

Mainly check abrasion of bearing of input shaft 6205 (without
slot), output shaft 6305 (with slot). And the bearing shall be
operating without abnormal sound or jamming. Ball track with
the bearing shall not be fallen. Shaking with hands shall be
without loosening sound. In case of above-mentioned
problems, change bearing;

Large play of one shaft

If play of one shaft is too large, check bearing of one shaft is
loosening; replace it if so;

Sounding when
releasing throttle
of third, fourth
gears and
decelerating

Synchronizer malfunction

Check synchronizer of third, fourth gear is loosening; replace it
if so;

Sounding when releasing throttle of third,

fourth gears and decelerating

Transmission oil quality, quantity

Gear clearance of third, fourth gear too

large

Bearing with unusual noise

Large play of one shaft

Synchronizer malfunction

Repair

Repaiar or replace

Fill up accordingly

Repair

Replace

Normal

Abnormal

Abnormal

Abnormal

Abnormal

Abnormal

Normal

Normal

Normal

199

No. 148 Fifth gear not easily shifted up

Malfunction Causes

Solution

Shift lever malfunction

Check gear shifting lever is bent or deformed, rubber sleeve is
aging, loosening

Transmission shift operation
mechanism malfunction

Check swing link support is worn, loosening or deformed, and shift
shaft and device of fifth gear is smoothly put into gear; if not, replace
swing link support assembly; check shift fork of fifth gear is vertical
to shift fork shaft; if not, replace shift fork of fifth gear;

Synchronizer assembly of fifth gear
malfunction

1. Toothed ring of fifth-gear synchronizer is excessively worn, and
clearance of toothed ring pressed at gear no less than 0.5mm, with
specified value between 0.85-1.45; area of joint face of fifth-gear
synchronizer and gear shall be larger than 80%; replace
synchronizer ring if not;
2. Check height of slide block of synchronizer is no less than 5mm;
replace slide block of synchronizer if less than 5mm;
3. Check synchronizer hub and cover is too loosening or too
tightening. Hub shall be assembled within the cover freely. Joint part
of cover and gear shall be triangular. Replace synchronizer
assembly if damaged, worn, or its edge angle turning round;

Fifth gear not
easily shifted up

Transmission input, output shaft
fifth-gear malfunction

Replace transmission input, output shaft fifth-gear;

200

No. 149 Fifth gear, first gear blocks, relieved only when the vehicle stops

Malfunction

Causes

Solution

Gear shifting lever malfunction

⑴

Check gear shifting lever is bent or deformed, rubber cover

①

is aging or loosening;

Clutch not fully separated

⑵

Check free clearance of pedal is at 1

①

-3mm; clearance of

bearing and pressure plate is better at 2-3mm; if too large,
adjust accordingly; (empirical data)

If clutch spring is too soft, replace it;

②

If clutch friction disk is excessively worn, replace it;

③

Check clutch plate and flywheel surface is bent, deformed

④
(replace it if amount of deformation is above 0.5mm);

Fifth gear, first
gear blocks,
relieved only
when the vehivle
stops

Transmission inner malfunction

⑶

Check swing link support, right

①

-angle shaft is deformed,

loosening. Right angle is 90 degree by visual measurement,
and if bending angle diminishes, replace swing link support;

Check fifth

②

-gear synchronizer, and cover within hub is too

loosening and slanted around; if too loosening, replace
synchronizer assembly;

Check height of slide block of synchronizer; if less than

③
5mm, replace slide block;

Check soldered tooth of driven gear of one gear is too

④

far

from engaging tooth of another gear, and clutch collar may be
too deep inside. Press soldered tooth by forcing machine;

Check clearance between rear end plate of fifth gear

synchronizer and hub is too large; after fifth-gear is put, slide
block turns up, and blocks when to be relived. clearance shall
be within 2mm; if too large, replace rear end plate;

Fifth gear not easily shifted up

Shift lever

Transmission shift operation

mechanism

Fifth-gear synchronizer

Transmission input, output shaft

fifth-gear

Repair

Replace

Repair

Replace

Normal

Abnormal

Normal

Normal

Abnormal

Unusual

Abnormal