Chery QQ6 User manual

Service Manual forChery
QQ6
(QR513 TransmissionCase)
AfterSales ServiceDepartmentofChery
AutomobileSalesCo., Ltd

1
CONTENTS
Foreword...........................................................................................................................................................2
ChapterOneIntroduction ofQR513Transmission...........................................................................................3
I.AssemblyDrawingofQR513 Transmission..........................................................................................3
II. Driving CharacteristicsofQR513 Transmission..................................................................................4
III. SNofQR513 Transmission................................................................................................................4
1. Printposition ofSNofQR513transmission.................................................................................4
2. CompositionandconnotationofSNofQR513transmission.......................................................4
IV. SpecificationofQR513 Transmission.................................................................................................6
V. Maintenance Instruction.......................................................................................................................7
ChapterTwoDecompositionofQR513Transmission......................................................................................8
I.Decomposition Process forQR513Transmission.................................................................................8
1. Bleedinglubricantintransmission................................................................................................8
2. Disassemblyofexternalpartsoftransmission..............................................................................8
3. Separation ofgearshiftmechanismandtransmission...................................................................9
4. Disassemblyoftheconnecting boltsforclutchand transmission housings................................10
5. Separation oftransmissionand clutchhousings..........................................................................10
6. Separation ofinteriortransmission partsandforkmodulefromthehousing.............................11
7. Separation ofdifferentialassemblyandclutchhousing..............................................................12
8. Disassemblyofgearshiftforkmechanism..................................................................................12
9. Disassemblyofgearshiftmechanism..........................................................................................13
10.Disassemblyofinputshaft........................................................................................................13
11.Disassemblyofoutputshaft......................................................................................................15
12.Disassemblyofdifferential.......................................................................................................15
13.Disassemblyofreleasemechanismofclutch............................................................................16
14.Disassemblyoftransmissionhousing.......................................................................................17
ChapterThree Assemblyand RegulationofQR513 Transmission.................................................................18
I.AssemblyofQR513 Transmission.......................................................................................................18
1.Assemblyofdifferentialassembly..............................................................................................18
2.Assemblyofclutchhousing........................................................................................................19
3.Assemblyoftransmissionhousing..............................................................................................23
4.Assemblyofgearshiftmechanismassembly...............................................................................23
5.Assemblyofgearshiftforkassembly..........................................................................................24
6. Regulationandassemblyofinputshaftassembly.......................................................................24
7. Regulationandassemblyofoutputshaftassembly.....................................................................26
8.Assemblyand regulationoftransmissionassembly....................................................................28
9. Disassemblyofexternalaccessoriesoftransmission..................................................................31
10.Refillingandvolume regulationoftransmissionlubricant.......................................................32
II.TighteningTorqueTableforFasteners...............................................................................................34
ChapterFour GeneralFailuresandTroubleshooting...........................................................................35

2
Foreword
1.Thisservicemanual applies touseandmaintenance ofQR513transmission
manufacturedby Chery AutomobileCo., Ltd.
2. ServiceManualforQR513 Transmission describesrelations among various
parts and assemblies of this transmission,whichprovidethe maintenance
personnelwith areference whenmaintaining andrepairingQR513transmission.
3.Due torestrictionsofthe compiler slevel andother conditions,errorsand
imperfectionsmayexistin this servicemanual.Duringmaintenanceanduse,
pleaseinformus ofanyproblemin andimprovementideaonQR513
transmissionand this servicemanual,sothatwe cancorrect andperfect this
servicemanual,forwhichwe express our thanksherein.

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Chapter OneIntroductionofQR513 Transmission
I.AssemblyDrawingofQR513 Transmission
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3 4
1.Inputshaft2.Clutch3.Outputshaft4.Differential

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II. DrivingCharacteristicsofQR513 Transmission
Thistransmission achievesfiveforwardgearsandonereversegearthroughthree groupsof
synchronizersandtwoshafts-inputshaftandoutputshaft;allforwardgearsadoptconventionalengagement
systemwhilereversegearadoptsaglidingidlerdevice. Thesynchronizersofthefirstand second gearsare
installedon outputshaftwhilethesynchronizersofthethird,fourthandfifthgearsareinstalledon input
shaft.Whenthe transmissionisshiftedtovariousgears,thesesynchronizerswill engage withcorresponding
gearhub toenabletransmission ofpower,andthenthedrivinggearofmaindeceleratorwilldrivethedriven
gearofmaindeceleratorand differentialassemblytorotate, whichwilldrivethedriveshafttodrivethe
wheelstorotate.
III. SNofQR513 Transmission
1. Print positionof SNof QR513 transmission
Theprintposition ofSNofQR513seriestransmission isasshowninthe figure:
2. Composition andconnotationof SNof QR513transmission
SNofQR513seriestransmission isconsistedofmodelandleavingfactorynumberofthetransmission case.
Positionofnumber

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1)Modelofthetransmission case
ModelofthetransmissioncaseiscomposedofcodeQR,numberofshiftgearsofthetransmission,
maximumtransmissiontorque,characteristic code andstructure specification number.
Acompletetransmission casemodelisasfollows:
□□○○○ □□□
Structure specificationnumber
Characteristic code
Maximumtransmissiontorque (kg·m)
Numberofshiftgearsofthetransmission case
Code QR
Amongwhich, ○indicatesanArabic numeralwhile □indicatesa letter.
2)Leavingfactorynumber
Leavingfactorynumberiscomposedofendnoteofassemblypartnumber(forthatwithoutendnote,us
AA),charactercodeoftheyearofproduction,charactercodeofthemonthofproduction,sequence
numberofthistransmission caseamongthetransmissioncasesmanufacturedinthatmonthandstart
stopsign “*”. See Table 1and Table2forchecklistofcharactercodesoftheyearandofthe month.
Completeformofleaving factorynumberofa transmissioncaseisasfollows:
* □□ □□○○○○○ *
Charactercodeofthemonth
Amongwhich, ○indicatesanArabicnumeral, □indicatesaletterand indicatesanArabicnumeralora
letter.Theendnotelocatesattailendofthepartcode,forafundamentalmodel,noendnote. Theendnote
shouldbemodifiedwhenmodificationismade tostructure,dimension, material, heattreatmentrequirements
andsurfacetreatmentetc. ofthepartorassemblyon thebasisoforiginalproduct. TheEnglishletterinthe
codeshouldbeuppercaseletter(useinsequencewith “A”asthefirst),inordertoavoidconfusion,do not
use “I”, “O”and “X”.Whenthemodificationdoesnotaffectinterchangeability,use “A”asthefirst; when
themodification affectsinterchangeability, skip “A”,use “B”asthe first.
Table 1CharacterCodesIndicatingtheYears
Year Code Year Code
1999 X 2015 F
2000 Y 2016 G
2001 1 2017 H
2002 2 2018 J
2003 3 2019 K
Sequencenumberamongthe
productofthe
samemodelmanufacturedinthatmonth
Charactercodeoftheyear
Endnoteofassemblypartnumber

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2004 4 2020 L
2005 5 2021 M
2006 6 2022 N
2007 7 2023 P
2008 8 2024 R
2009 9 2025 S
2010 A 2026 T
2011 B 2027 V
2012 C 2028 W
2013 D 2029 X
2014 E 2030 Y
Table 2CharacterCodesIndicating the Months
Month Code Month Code
January A July G
February B August H
March C September J
April D October K
May E November L
June F December M
3)Illustration
Forexample:QR513MHAMH5H00001indicatesthefirsttransmissioncasewiththemodelas
QR513MHAmanufacturedinAugust, 2005.
IV. SpecificationofQR513 Transmission
QR513SeriesTransmission
Type Machine GearMesh
Model QR513MHA QR513MHB
GearshiftVelocity
Ratio TeethRatio Velocity Ratio TeethRatio
FirstGear 3.545 39/11 3.167 38/12
SecondGear 2.05 41/20 2.05 41/20
ThirdGear 1.423 37/26 1.423 37/26
FourthGear 1.065 33/31 1.065 33/31
FifthGear 0.865 32/37 0.865 32/37
Reverse Gear 3.364 37/11 3.364 37/11
Mainreduction ratio 4.056 73/18 75 16

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Speedometer 0.806 29/36 0.806 29/36
Largestinputtorque 130 Nm
Lubricantoiltype GL-475W-90
Volume oflubricant 1.8L
V. Maintenance Instruction
l Inordertoensuremaintenancequalityofthetransmission,whenoperating,pleasebecareful
and ensurecleanness ofeachpartofthe transmission.
l Useappropriate toolsorspecialtools.
l Strictlyfollowthespecificationtoassemblyoradjustmenttomaintainsoastoensurethatthe
transmissioncanaccomplisha favorable workingposition.

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Chapter Two DecompositionofQR513 Transmission
I. DecompositionProcessforQR513 Transmission
1. Bleeding lubricant in transmission
First,drivethevehicleontoamaintenance platformorhoistthevehicleandkeepit onahorizontal
plane, screwoffthebleedingplugasshownbythearrowhead,and thenuseacleancontainerto
accommodatelubricantofthe transmissiontocompletelybleedthe lubricantinthetransmission.
Figure 1
2. Disassembly of externalpartsoftransmission
SwitchthetransmissiontoNEUTRALposition;useanappropriatetooltoremovethelocatingseatof
theforkshaftasshowninFigure2;Connecting boltsforgearshifthousingand transmission housing and the
screwsforbackuplampswitchandidlershaft.

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Screwsforidle gearshaft
Bolts-forgearshifthousingand Backuplampswitchassembly
Transmissionhousing (5)
Figure 2
3. Separationof gear shiftmechanismandtransmission
Removethegearshiftmechanismassemblyfromtheplace asshowninFigure3;asaresultofsealant,
thedisassemblyprocess maybedifficult,so,usesuchtoolsasahandhammeretc. toknockon thebulgeat
flank ofhousingofthegearshiftmechanism,andthentakeoutthewholegearshiftmechanismassembly
untilthetwohousingscompletelyseparate;remembertobeslowwhentaking outthegearshiftmechanism
assembly,soastopreventthereturnspring asshowninthefigurefromdropping outinside thetransmission;
duringdisassembly,becarefulnottodamagethejunction planesofthe twohousings, soastoavoidoilleak
afterre-assembly.
Gearshiftmechanismassembly
Locatingseatofforkshaft
forall gears(3)
Assemblyoflocating
seatofforkshaft
Returnspring(remembertoprevent
itfromdroppingout)

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Figure3
4. Disassembly of theconnectingbolts forclutch andtransmissionhousings
Useatooltoremovetheconnecting boltsfortransmission andclutchhousingsasshowninFigure4.
Remembertoremovetheboltsbothinsideandoutsidetheclutchhousing whendisassembling,and asleeve
withlong connecting rod isrequiredwhenremoving the boltsinsidethe clutch.
Connecting boltsfortransmission andclutchhousings
Figure 4
5. Separationof transmissionandclutchhousings
Aftertheboltsfortransmission andclutchhousingsareremoved,separateclutchhousing and
transmissionhousing (Figure5).asaresult ofsealant,theseparationprocess maybedifficult,so,usesuch
toolsasahand hammeretc. toknockonthebulgeatflankofhousingofthetransmission,and thentakeout
thewholetransmissionhousinguntilthetwohousingscompletelyseparate;duringdisassembly,becareful
nottodamagethejunctionplanesofthetwohousings,soastoavoidoilleakofthetransmissionafter
re-assembly.

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Transmissionhousing Clutchhousing
Figure 5
6. Separationof interiortransmissionparts andfork module fromthe housing
Aftertransmissionhousingandclutchhousing are separated,keeptheclutchhousingflatatthe placeas
showninFigure6,removetheboltsforbracketofreversegearrockerarm,takeoutthereversegearrocker
armassemblyandthepinon idlerdrive,and thentakeoutinputshaft,outputshaftand forkmechanism
together(whentakingout,gentlyshake, meanwhile, press thedrivengearofmaindeceleratoralong the
directionofarrowheadasshowninthefiguretotakeouttheassemblyofinputshaft,outputshaftandidler
aswell asforkmechanism);whentaking out,remembertoavoidinterferencebetweenbearingretainerof
outputshaftandbiggearringofdifferentialandpreventthe bearing retainerfromdamage.
Boltsforreversegearrockerarmbracket(2intotal)
Reversegearrockerarm
Reverse gearidlerassembly
Figure 6

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7. Separationof differentialassemblyandclutchhousing
Separatedifferentialassemblyandclutchhousing,andthensimplytakeoutthedifferentialassemblyas
showninFigure 7.
DifferentialAssembly
Figure7
8. Disassembly of gearshiftfork mechanism
Useahammerand aspecialtooltoknockoffallspringpinsandthenuseasnapringpliersorother
specialtooltotakethesplitwasherofftheforkshaft(whentaking offthesplit washer,preventitfrom
deformation),andthendisassemble eachpartofthegearshiftmechanism.
SplitwasherSpringpin

13
Figure 8
9. Disassembly of gearshiftmechanism
AsshowninFigure9, removethe gearshiftarmbracketboltsandreversegearlockupmechanismbolts
first,useahammerandaspecialtooltoknockoffallspringpins,useaspecialtooltoremovethesplit
washer,andthendisassemble eachpartofthe gearshiftmechanism.
Gearshiftarmbracketbolts(2intotal)
Reverse gearlockup mechanismbolts(2intotal)
Split washer
Figure 9
10. Disassembly of input shaft
AsshowninFigure10,Useaspecialtool(suchasbearing removeretc.)toremovethetwobearingson
theinputshaftfirst,useaspecialtooltoremovetherearsnapring,andthentakeoff thefifthgear
synchronizerassembly.

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RearsnapringFifthgearsynchronizer
Figure 10
Afterthefifthgearsynchronizerassemblyisremoved,removetheremainingpartssuchasshiftgears,
needlebearingsand synchronizersinturnasshowninFigure11;whendisassembling,besuretokeepthe
synchronizerofeachgearconcurrentwithitscorresponding synchronizerring.
Figure 11
Bearing(whendisassembling,be
carefuland use a specialtool)

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11. Disassembly ofoutputshaft
Themethodand process fordisassemblyofoutputshaftarebasicallythesameasthoseforinput
shaftandthe outputshaftcanbe disassembledtothe statusasshowninFigure 12.
Figure 12
12. Disassembly of differential
AsshowninFigure13,useaspecialtooltotakeoffthetwobearingsfirst,removetheboltsfordriven
gearanddifferentialhousing,removethedrivengear,knockoffthefixingpinoftheplanetarygear,and then
takeouteverypartinside the differential(Figure 14).
Fixing pinofplanetarygear Boltsfordrivengearand differentialhousing(8intotal)
Figure13

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Figure14
13. Disassembly of releasemechanismof clutch
AsshowninFigure15,takeoff releasebearingofthe clutchfirst,removetheboltsforrelease fork, and
thendrawthereleaseshaftassemblyofftheclutchhousing(duringthedrawingoffprocess,besureto
preventthereleasereturnspring fromejection);also,removethebushanddismountreleasemechanismof
theclutchfromthe clutchhousing.
Release bearingofclutch Boltsforreleasefork Release forkRelease arm
BushRelease returnspring

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Figure 15
Besuretousespecialtoolandbecarefultoremovetheoilsealontheclutchhousing,because
excessivedeformationordamageoftheoilsealmayresult inoilleakofthetransmission.Useaspecialtool
toremovethetwooilsealson theclutchhousing,andthenremovetheremainingbushes,oil ductsand outer
ringsofbearingsasshowninFigure16.Replacingwithnewoil sealsaftertheformeronesareremovedis
recommended.
Oil sealForkshaftbearing(3)
Outerring ofbearing Oil ductFigure 16
14. Disassembly of transmissionhousing
AsshowninFigure17,useaspecialtooltoremovetheoilsealoftransmission housing,andthen
remove oil drainchannel,forkshaftbushand linearbearing.

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Linearbearing Forkshaftbush
Oil sealOil drainchannel
Figure 17
Chapter ThreeAssemblyand RegulationofQR513 Transmission
I.AssemblyofQR513Transmission
Afterdisassembly,visuallyinspectpartsforanyabnormalconditionsuchasdeformation etc,andmake
records;Replace thedamagedparts, cleanand washallparts, thenreassemble.
1.Assembly of differentialassembly
Fitadjustmentgasketsrespectivelyatbacksidesofthe twohalfaxlegears,andtheninstall thetwohalf
axlegearstogetherwiththeirgasketsintothedifferential.Whenfittingadjustmentgasketsforthehalfaxle
gears,selectthegasketwiththicknessas1.2mmfirst.Fitsphericalwashersfortheplanetarygear,and then
simultaneouslyengagethetwoplanetarygearswiththetwohalfaxlegears(fitthemtocorrectpositions
whileturningthe gears).Inserttheplanetarygearshaft; notethatthefixingpinholeonthe shaftshouldalign
correctlywiththatonthedifferentialhousing bothinthepositionandalongthedirection.Measurethe
clearance betweenthehalfaxlegearandtheplanetarygear,and thenormalizedvalueshouldbe
0.025~0.150mm;iftheclearance doesnotconformtothenormalizedvalue, replacetheadjustmentgaskets
forthehalfaxlegear,andthenre-measuretheclearance untilitconformstothestandardwithuniform
clearance atbothsides.Drivedownthefixingpinofplanetarygearshaftfromthefixingpinholeattheside
ofdifferentialhousingwithflangewiththepinwithendsurface ofthepinhole. Installdrivengearofmain
deceleratorand ensurethattheinstallationend surface ofthegearfitswellwiththeend surface ofthe
differentialhousing,andthenfixthedrivengearofmaindeceleratorwithbolts(applysealanttofullthread

19
oftheboltbeforeinstallation);screwtheboltshomewiththetorqueas 130 5Nm cornerwiseand alternately;
respectivelypress inaninnerring offrontandrearbearingsfromeachofbothendsofthedifferential
housing andcheckifit hasbeenpressedtothedesignatedposition.Notethatthelubricantappliedonto
adjustmentgasketsforhalfaxlegears,planetarygeargaskets,junctionsurface ofplanetarygearand
planetarygearshaft,junction surfaceofhalfaxlegearand differentialhousingshouldbethesameasthat
usedinside thetransmission. RefertoFigure 18.
Planetarygear (2) Planetarygear shaft Connecting bolt(8)
Halfaxle gear(2)
Figure 18
2.Assembly of clutchhousing
Useahammerandaspecialtooltofitoilsealofinputshaftwithspringsideoftheoil sealupand
greaseappliedtolipoftheoil seal.Useaspecialtoolandahampertofitrightsideoilsealofdifferential
withendsurface oftheoilsealflushwiththehousingsurface, and thenapplygrease tolipofthe oilseal.See
Figure 19.
Innerringof
bearing (2)
Adjustmentgasket
forplanetarygear
(2sheets)
Fixingpinofplanetary
gearshaft
Adjustmentgasketforhalf
axle gear(2sheets)