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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