Chery A15. Manual - part 285

 
(24) Unfix the shifting fork of the first and second gears off the output shaft (Figure 41). 
 
 
 
1-Clamp  
2- Shifting fork of the first and second gears 
 
 
 
 
 

Figure 41 Unfixing the Shifting Fork 
of the First and Second Gears 
 
 

(25) Unfix the input and output shaft assemblies from the clamp (Figure 42). 
 
 
 
 
1-Clamp 
2-Input shaft and output shaft 
 
 
 
 

Figure 42 Unfixing the Input and 
Output Shaft Assemblies 

 
II. Assembling Gearbox 
Note: the output shaft assembly can 
only be repaired as a whole but can’t 
be disassembled for maintenance. In 
the case of 1

st

-gear and 2

nd

-gear 

synchronizer or gear faults, the whole 
output shaft assembly must be 
replaced.  
1. Cleaning 
Clean the gears, bearings, shafts, 
synchronizers, thrust gasket, oil seal, 
gear-shifting mechanism, gearbox and 
clutch cover with detergents and blow 
them dry (except bearings) with 
compressed air. Bearings can be dried in 
the air or with clean cloth.  

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 
 
Check the gears, bearings, shafts and 
thrust gaskets and replace the bearing 
and seat ring if any roller is found to be 
worn-out, broken or damaged. Replace 
any gear with worn-out or broken tooth. 
Replace the assembly in the case of 
worn-out, deformed or burned 
synchronizer or failing spring.  
 
2. Assembly 
Note: the output shaft of the gearbox 
can only be repaired as a whole but 
not disassembled or assembled. Or the 
gearbox will be damaged. The sealant 
is used to seal the gearbox body and 
the bearing rear cover as well.  
(1) Take the gasket out of the clamp.  
(2) Fix the input and output shafts into 
the clamp.  
 
1-Clamp 
2-Gear 
 
 
 
 
 
 
(3) Fix the guide ruler and shifting fork 
into the clamp (Figure 44) 
 
 
1-Clamp 
2-Shifting fork 
 
 
 
 
 
 
 
 
 
 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 43 Clamp 
 
 
 
 
 
 
 
 
 
 
 
Figure 44 Fixing the Guide Ruler 
 
 
 
 
 
 

 
(4) Fix the gear lockup assembly into the 
clamp (Figure 45). 
 
 
1-Clamp 
2-Gear position lockup assembly 
 
 
 
 
 
(5) Fix the reverse brake retainer ring 
(Figure 46) 
 
 
1-Reverse brake retainer ring 
 
 
 
 
 
 
(6) Fix the reverse brake conical friction 
wheel (Figure 47). 
 
 
 
 
1-Reverse brake conical friction wheel 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 
 
 
 
 
 
 
Figure 45 Fixing the Gear Position 
Lockup Assembly  
 
 
 
 
 
 
 
 
 
 
 
 
Figure 46 Reverse Brake Retainer Ring 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 47 Fixing Reverse Gear Brake 
Conical Friction Wheel 
 
 
 
 
 
 
 
 
 
 

 
(17) Fix the lower half of the gearbox 
onto the clamp.  
 
 
 
1-Gearbox body 
2-Clamp 
3-Gear 
 
 
 
 
(8) Array the reverse brake conical 
friction wheel in the gearbox (Figure 49) 
and make sure that the position of 
reverse brake conical friction wheel is 
correct.  
 
 
 
1-Gearbox body 
2-Reverse brake conical friction wheel 
3-Input shaft 
 
 
 
 
 
(9) Place the input shaft and output shaft 
bearings onto the shafts. Press the 
bearings onto the input and output shafts 
with a special tool until they are properly 
positioned on the gearbox body (Figure 
50). 
 
 
 
 
 
1-Input and output shaft bearing 
2-Special tool 
 
 
 
 

 
 
 
 
 
 
 
 
 
 
Figure 48 Gearbox 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 49 Arraying Conical Friction 
Wheel 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure 50 Fixing Input and Output shaft 
bearings