normal malfunction of geely cars analysis and solution (20)(1-10)

7/30/2019 Normal Malfunction of Geely Cars Analysis and Solution (20)(1-10)

1/14

Normal malfunction of Geely cars analysis and solution

(20)


2/14

Sequenc

e

Malfunction

phenomenon

Possible cause Remedy Reference

data

01. Noise in

gear box

1. A Transmission output shaft second

gear and the reverse middle gear of

size deflection than standard(the angle

of the gear edge not enough ),which

leads to the two gears touching,at the

same time ,the middle gear of reverse

wearing gear box makes noise

B transmission output shaft third

gear,fourth gear engaged too

much(+0.20mm),whats more , the

angle of the gear edge not enough,so

after put into third or fourth gear,whichtouching the individual synchronizer

and make noise.

1. Revise the angle of gear edge

and transmission case;output

shaft third, fourth gear

also.change better quality

planetary gear and adjust the

space according to Prescribed

one;change loosen bearing of

difference;change difference

gear ,planetary gear and

adjustable washers with

couple;replace wearing serious

bearings;replace bearingsinside difference : 6205 2

6305 6008 6208 change

engaged gears with couple.

2. The adjustable washer between gear

and planetary gear not hard

enough,wearing seriously and bigger

space ,so make noise.

2. Adjust washer and replace if

necessary.

3. Differential bearings become loose 3. Adjust Differential bearingsand change if necessary.

4. One of Differential gears wearing

seriously,or adjustable washers of

planetary gear bad wearing or bearings

wearing seriously.

4. Change Differential gears,or

planetary gears and adjustable

washers with couple, change

badly wearing bearings.

5. The gears inside transmission noise:the 5 change the bearings inside


3/14

02. Transmissi

on jump

gear

1.the spring inside the fourth gaer auto-lock

system too soft

1. change the position spring, jump

gear can solution

2.the 3-4 shift fork deformation,contortion. 2. change 3-4 shift york

3. check concerning gear wearing : mostly

because reverse gear locking device locatedselecter lever bracket destroy or the

beginning of reverse shift york abnormal

wearing.

3. five gear transmission change

selecter lever and reverselocking device.

02. Transmissi

on jump

gear

1.the lining of selecter level wearing 1. change selecter lever assemble

2.the lock located shift york shaft wearing 2. change york shaft

3.synchronizer gear sleeve or tapered gear

wearing

3. change synchronizer gear sleeve

or tapered gear wearing

4.the spring of synchronizer not hard enough 4. change synchronizer spring

5.the block of synchronizer wearing 5. change synchronizer,block.

6.the function of shifting locking system out of

control

6. change the shifting locking

system.

7.the space of every gears too big, cant engage

to proper position

7. adjust gear space, if wearing

change them

8.shifting gear york wearing 8. change abnormal waering

shifting york

9. synchronizer space too big, 9. change wearing synchronizer


4/14

02. Transmissi

on jump

gear

1.the spring inside the fourth gaer auto-lock

system too soft

1. change the position spring, jump

gear can solution

4.reverse gear jump because of the wearing of

reverse shifting york, which result in the gears

can not completely engage

4. change reverse shifting york and

selecter lever .

14.The fifth gear outside tapered spring pad broken

which leads to fifth gear loosen,cant engage

completely,so jump. Spring pad has quality problem,

no enough spring and broken easily.

14.Change the fifth gear outside

tapered spring pad


5/14

02. Transmissi

on jump

gear

15.The beginning of the reverse shift arm

wearing seriously ,so reverse idle gear cant

engage thoroughly

15.Change reverse york shift

assemble

16.Shift shaft size or its locking device slot size

incorrect;gear sleeve and gear hub big space

;gear teeth size also affect it

16.Check the exact position of the

reverse shift york shaft and revise

it ,make sure the reverse gear

engage completely

17.shift locking mechanism material too soft and

deformation easily. 17.change shift locking mechanism

and harden it18.the slot position isnt precision

18.change correct york shaft

with precise slot size

19.engage not completely 19.adjust shift lever position of

shift mechanism or change the

system levers which out of control

and lead to the gears abnormal.

03.

Tires

wearing

1. front axle toe not correct 1. adjust front axle toe four whe

els

alignment front

axle toe out

-1~0mm,rear

axle according

to standard data

2. low control arm bearingjoint ball loose

and bushing aging.

2. change low control arm and

bushing

3. balance lever bushing aging 3. change balance lever bushing

4. suspension top bracket bushing aging 4. change suspension top bracket

5. rear axle toe incorrect 5. adjust rear axle toe

6. tie rod ,steering motor bearing jointballwearing seriously

6. change damaged bearing

7. tyre inclination angle incorrect 7. alignment adjust inclination

angle

8.Because of collision, the alignment data of

chassis changed and without repair in time,

tyres no replace with regular period,tyre

pressure,driving habits also can affect it .

8. maintenance and service

regularly to sure the car in the

best habitus;according to

instruction change tyres position

and rotate direction in exact

period,never start to run,brake

hastely and steering at high

speed,to avoid tyre wearing

advanced


6/14

03.

Tires

wearing

8. front and rear suspension system plastic

bushing wearing,aging and deformation.

9. change front and rear suspension

system plastic bushing

9. local alignment data is different compare

with manufacturer supply,

10.update four wheel alignment

data in time according to

manufacturers instruction ortechnical notice ,insure checking

correction

10. front,rear bearing and suspension fixture

bolts loose ;which make front and rear

wheels camber ,inside inclination angle

incorrect.

11. tighten bolts ,re-alignment and

adjust the data

11.have deflection between left and right

axle

12.adjust the distance between left

and right axle

12.chassis bushing material too soft aging

and deformation ,which lead to alignment

data change too much 2. front rear

suspension bracket ,suspension and its

spring damage deformation ,so car body

unbalance 3.tyre pressure difference,and

driver dont maintenance the car depends

on standard period.

1.after change damage bushing ,four

wheel alignment.2. repair rear axle bolt

hole size to change rear axle toe

adjustable range or change modified

bolts to enhance toe adjustable

range;change damaged parts completely

and check toe 3.check tyre pressure

every maintenance and wheel alignment

in exact mileage

13. front rear suspension and its top bracket

and arm bushing problem,ULfront right

tyre wearing because front wheel

inclination angle incorrect ,suspension

quality problem,suspension top bracket

material too soft result in data cant adjust

13.change better quality

suspension and bracket and

plastic rubber,UL and other type

car tyre wearing must remove

suspension and bigger bolts

hole ,adjust again .


7/14

03.

Tires

wearing

15. Aplastic rubber too soft ,toe change too

much B four wheel alignment datd

incorrectC front axle toe is effected by

steering motor,when adjust without

load,steering motor position higher,after

load steering motor down and tie rod out

so front toe change and wearing tyre

15.Achange plastic rubberBadjust

camber to -1.5-2,toe adjust to

negative,front toe max -20.5

C holding steering motor and

check front suspension

components loose.

16. Atyre inside outside wearing lies in low

control arm whose bushing aging Bframe

shock absorber member change,steering

angle too big etc.

16. A change low control arm or

bushing Bput balance bracket to

frame shock absorber member to holding frame.

17. low control arm bearing loose leads to

inclination angle change

17.change low control arm

assemble

18.tie rod bearing lose and change front 18.change steering tie rod bearing

19.suspension bracket plastic rubber aging

and change inclination angle

19. change suspension bracket

assemble

20. rear tyre wearing lies in suspended arm

deformation and change the toe ,bushing

aging change inclination angle

20.change 1,2 suspension arm or

longitudinal lever,or change

chassis bushing ,adjust rear toe.

21. tyre pressure incorrect 21. according to standard data

22. front wheel alignment parameter 22. front axle alignment


8/14

23. wheel bearing wearing abnormally,

bearing loose

23. change wearing bearing


9/14


10/14

04. Clutch

heaviness,

cable

broken

1. clutch cable dirty 1. change clutch cable

2. clutch cable too crudity and wearing with

connecter so hairpin and heaviness

2.repair or change clutch cable

3. clutch cable bolt position steel material

too soft ,easy to deformation and

deflection with clutch pedal hook

position ,so heaviness,noise,even broken

2. strengthern lutch cable bolt

position steel material,

4. clutch pedal hook deformation 4.change clutch pedal

5. fire wall thin,which leads to cable position

deflection when apply clutch pedal,so

wearing

5. change thicker fire wall

6. clutch pedal not stiff enough anddeformation

6. change harder clutch pedal

7. clutch pedal axial space too big 7. put washer to clutch cable fix

position ,adjust the fix position

with pedal or change the cable

hole position;remove

dashboard ,widen the clutch

bracket hole and change position

to left 1CM,make sure two endsstraight.

8.clutch cable fix position deformation 8. change clutch cable

8. clutch pedal and cable not straight 9. before fix cable ,check cable bolt

position and clutch pedal hook

straight or revise it


11/14

04. Clutch

heaviness,

cable

broken

11.cable is multi-thigh and more

involved,outside husk and inside guide

nylon bushing easy to damage,leads to

clutch heaviness

11.Remove clutch cable ,adjust

clutch pedal left and right angle,if

wearing

Position located up and

down,adjust and fix washer tochange up and down angle.

12.clutch pedal hook and clutch cable not

straight.so wearing ,heaviness even cut.

11.A: adjust clutch pedal bracket

B:adjust two screws which bolt

the cable accordance with pedal

hook;

05.

Window

glass up

and downheaviness,

sometimes

binding

1electrical motor horsepower small,while

binding damage motor

1. repaire or change motor

2glass guide rail tighten 2adjust the space

3glass loose,guide rail deformation 3.check and adjust glass position

;tighten glass guide and bracket

4power window lift inside mechanism

damage and out of control

4change power window lift

5glass lift moving parts corrode ,dirty and

deformation

5clean or change lift

6 glass guide rail dont adapt to the glass

shape

6adjust glass guide rail or change

7glass guide rail dirty or aging 7clean or change glass guide rail

8lift bracket deformation or too tighten 8adjust bracket


12/14

06. Steering-

wheel

shaking

during 80-

110KM/H

1.tyres and wheels unbalance 1.balance tyres and wheels

2.tyre surface not smooth 2.change tyre

3.steering motor fix not good,bearing space

too big

3.tighten steering motor;adjust or

change new steering motor

4.wheel hub deformation, tie rod

bearing,steering knucklebearing and control

arm loose.

4.change wheel hub, steering

knuckle bearing and control arm

05.

window

glass up

and down

heaviness,sometimes

binding

9glass position unbalance 9adjust balance

10lift fix position incorrect 10re fix or adjust lift

11glass guide rail bracket too

narrow,compress glass ,so enhance its up

and down resistance

11.widen the glass guide rail

bracket

12rear window triangle glass bracket

position change,which result in glass guide

rail space not enough,then enhance glass

up and down resistance

12.Adjust rear window triangle

glass bracket position

13glass lift guide pulley and its guide rail

lubrication not good ,friction become big

13.put grease on glass lift guide

pulley rail

14glass guide rail friction big ,which leads

to front part of glass touch inside guide rail

when rear window glass sidesway,so

enhance friction

14 put slippery thin plastic

between inside glass guide rail

and glass surface to reduce

friction

15glass lift itself too tighten 15change glass lift


13/14

5.alignment data incorrect 5.four wheels alignment

6.steering system loose, wearing 6.adjust or change problemer parts

7.suspension system loose,wearing 7.adjust or change problemer parts

07. Car body

vibrating

during 20-

40KM/H

1.tyres balance value difference 1.balance tyres

2.low control arm bearing and bushing loose 2.change low control arm

orbushing

3.steering motor and bearing loose 3.change steering motor or bearing

4.tyre pressure toobig or small 4.adjust tyre pressure to standard

value

5.front axle toe difference 5.adjust front axle toe to prescript

value

6.suspension no function ,spring too hard 6.change suspension or spring

08. Car body

sealing

leaking

1.door weatherstrip deformation,the material

too hard

1.change new weatherstrip

2.the pace between car body and door too

big

2.adjust the space ,use proper

weatherstrip attach along the edge

of the door and adjust the door

properly

3.door or trunk fix improper 3.refix and adjust

4.door lining deformation or space too big 4.change new door lining or adjust

09. Levity at

high speed

1.yre pressure too high 1.adjust pressure to prescript value

2.rear longitudinal drag lever bushing loose 2.change new bushing

3.wheel hub bushing loose 3.change new bushing

4.rear stable support lever bushing loose 4.change new bushing

5.suspension spring too hard 5.change new suspension, spring

10. Suspensio

n noise

1.suspension sealing leaking leads to no

pressure or pressure not enough and make

noise

1.change suspension


14/14

2.the rubber inside suspension expansion too

much and result in more pressure make noise

2.change suspension

3.rubber wearing leads to pressureless and

make noise

3.change suspension

4.suspension axle wearing with sealing

covering, no grease so make noise

4.change suspension

5.suspension deformation or parts loose 5.adjust suspension and tighten

loose parts

6.tyre pressure too high 6.adjust tyre pressure

7.suspension top axle wearing with

suspend ,which generate big space

7.tighten suspension or change

assemble

8.between suspension axle and suspension

wearing

8.change suspension

normal malfunction of geely cars analysis and solution (20)(1-10)

Documents