Service Manual for Chery QQ6 (QR513 Transmission Case) After Sales Service Department of Chery Automobile Sales Co.
CONTENTS Foreword ........................................................................................................................................................... 2 Chapter One Introduction of QR513 Transmission........................................................................................... 3 I. Assembly Drawing of QR513 Transmission.......................................................................................... 3 II. Driving Characteristics of QR513 Transmission.............
Foreword 1. This service manual applies to use and maintenance of QR513 transmission manufactured by Chery Automobile Co., Ltd. 2. Service Manual for QR513 Transmission describes relations among various parts and assemblies of this transmission, which provide the maintenance personnel with a reference when maintaining and repairing QR513 transmission. 3. Due to restrictions of the compiler’s level and other conditions, errors and imperfections may exist in this service manual.
Chapter One Introduction of QR513 Transmission I. Assembly Drawing of QR513 Transmission 1 2 3 1. Input shaft 2. Clutch 4 3. Output shaft 3 4.
II. Driving Characteristics of QR513 Transmission This transmission achieves five forward gears and one reverse gear through three groups of synchronizers and two shafts-input shaft and output shaft; all forward gears adopt conventional engagement system while reverse gear adopts a gliding idler device. The synchronizers of the first and second gears are installed on output shaft while the synchronizers of the third, fourth and fifth gears are installed on input shaft.
1) Model of the transmission case Model of the transmission case is composed of code QR, number of shift gears of the transmission, maximum transmission torque, characteristic code and structure specification number. A complete transmission case model is as follows: □□ ○ ○○ □□ □ Structure specification number Characteristic code Maximum transmission torque (kg·m) Number of shift gears of the transmission case Code QR Among which, ○ indicates an Arabic numeral while □ indicates a letter.
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 2 Character Codes Indicating 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 For example: QR513MHA MH5H00001 indicates the first transmission case with the model as QR51
Speedometer 0.806 29/36 0.806 Largest input torque 130 Nm Lubricant oil type GL-4 75W-90 Volume of lubricant 1.8L 29/36 V. Maintenance Instruction l l l In order to ensure maintenance quality of the transmission, when operating, please be careful and ensure cleanness of each part of the transmission. Use appropriate tools or special tools. Strictly follow the specification to assembly or adjustment to maintain so as to ensure that the transmission can accomplish a favorable working position.
Chapter Two Decomposition of QR513 Transmission I. Decomposition Process for QR513 Transmission 1. Bleeding lubricant in transmission First, drive the vehicle onto a maintenance platform or hoist the vehicle and keep it on a horizontal plane, screw off the bleeding plug as shown by the arrowhead, and then use a clean container to accommodate lubricant of the transmission to completely bleed the lubricant in the transmission. Figure 1 2.
Assembly of locating seat of fork shaft Locating seat of fork shaft for all gears (3) Bolts-for gearshift housing and Transmission housing (5) Screws for idle gear shaft Backup lamp switch assembly Figure 2 3. Separation of gear shift mechanism and transmission Remove the gearshift mechanism assembly from the place as shown in Figure 3; as a result of sealant, the disassembly process may be difficult, so, use such tools as a hand hammer etc.
Figure 3 4. Disassembly of the connecting bolts for clutch and transmission housings Use a tool to remove the connecting bolts for transmission and clutch housings as shown in Figure 4. Remember to remove the bolts both inside and outside the clutch housing when disassembling, and a sleeve with long connecting rod is required when removing the bolts inside the clutch. Connecting bolts for transmission and clutch housings Figure 4 5.
Transmission housing Clutch housing Figure 5 6.
7. Separation of differential assembly and clutch housing Separate differential assembly and clutch housing, and then simply take out the differential assembly as shown in Figure 7. Differential Assembly Figure 7 8.
Figure 8 9. Disassembly of gearshift mechanism As shown in Figure 9, remove the gearshift arm bracket bolts and reverse gear lockup mechanism bolts first, use a hammer and a special tool to knock off all spring pins, use a special tool to remove the split washer, and then disassemble each part of the gearshift mechanism. Gearshift arm bracket bolts (2 in total) Reverse gear lockup mechanism bolts (2 in total) Split washer Figure 9 10.
Bearing (when disassembling, be careful and use a special tool) Rear snap ring Fifth gear synchronizer Figure 10 After the fifth gear synchronizer assembly is removed, remove the remaining parts such as shift gears, needle bearings and synchronizers in turn as shown in Figure 11; when disassembling, be sure to keep the synchronizer of each gear concurrent with its corresponding synchronizer ring.
11. Disassembly of output shaft The method and process for disassembly of output shaft are basically the same as those for input shaft and the output shaft can be disassembled to the status as shown in Figure 12. Figure 12 12.
Figure 14 13. Disassembly of release mechanism of clutch As shown in Figure 15, take off release bearing of the clutch first, remove the bolts for release fork, and then draw the release shaft assembly off the clutch housing (during the drawing off process, be sure to prevent the release return spring from ejection); also, remove the bush and dismount release mechanism of the clutch from the clutch housing.
Figure 15 Be sure to use special tool and be careful to remove the oil seal on the clutch housing, because excessive deformation or damage of the oil seal may result in oil leak of the transmission. Use a special tool to remove the two oil seals on the clutch housing, and then remove the remaining bushes, oil ducts and outer rings of bearings as shown in Figure 16. Replacing with new oil seals after the former ones are removed is recommended.
Linear bearing Oil seal Fork shaft bush Oil drain channel Figure 17 Chapter Three Assembly and Regulation of QR513 Transmission I. Assembly of QR513 Transmission After disassembly, visually inspect parts for any abnormal condition such as deformation etc, and make records; Replace the damaged parts, clean and wash all parts, then reassemble. 1.
of the bolt before installation); screw the bolts home with the torque as 130±5Nm cornerwise and alternately; respectively press in an inner ring of front and rear bearings from each of both ends of the differential housing and check if it has been pressed to the designated position.
Right side oil seal of differential Oil seal of input shaft Special tool for installation Special tool Figure 19 First, install the oil duct of output shaft to its designated position as shown in Figure 20 (note that the oil inlet and outlet of the oil duct should align with those on the housing), and then use a special tool to respectively install the outer rings of the front bearing of output shaft and the differential bearing.
Special tool for installation of outer ring of bearing Outer ring of output shaft Oil duct Figure 20 The tool for installation of oil seal can be used to install the three bushes. When installing the bushes, stagger the gap on the bush and that on the clutch housing (the two gaps can not coincide), as shown in Figure 21.
Wearing bush Now start to install release bearing assembly and release bearing as shown in Figure 22. First, install the two wearing bushes to their designated positions, and then put the release bearing through bush, release return torsion spring, release fork (release fork and release bearing should be assembled properly in advance, and then set the release bearing onto the housing) and bush in turn up to its designated position, finally, tighten the release arm bolts (with torque as 20±2Nm).
Figure 23 3. Assembly of transmission housing First, use a special tool to fit oil seal of the differential to its designated position (when fitting the oil seal, care should be taken to prevent oil leak in the future, and replacement with new oil seal is recommended), and then respectively install oil drain channel, bush (note: the installation process for this bush is the same as that for the bush of clutch housing above), linear bearing etc. to their designated positions. See Figure 24.
Selector lever bracket bolt (with tightening torque as 25±2Nm) Reverse gear locking mechanism bolt (with torque as 18±2Nm) Figure 25 5. Assembly of gearshift fork assembly Assembly of gearshift fork assembly is comparatively simple, which can be assembled with reference to the disassembly drawing. 6.
rotate freely. Set friction ball of gear, fender and clamp in from upside of input shaft, and then perform axial orientation for the fourth gear driving gear. Set fifth gear needle bearing applied with the gear oil of the same designation as that used inside the transmission assembly onto the input shaft from upside of the input shaft.
Gear fender Friction ball Figure26 7. Regulation and assembly of output shaft assembly With the end of output shaft with driving gear of main decelerator down, set first gear needle bearing in onto output shaft from upside of the output shaft; before installation of the needle bearing, apply the gear oil of the same designation as that used inside the transmission assembly on it.
the output shaft; before installation of the needle bearing, apply the gear oil of the same designation as that used inside the transmission assembly on it. Set second gear driven gear assembly in from upside of output shaft with the end with synchronizer cone of the gear assembly down (the three grooves on the gear assembly should completely envelop the three corresponding finger jaws on 1/2 gears synchronizer cone), and then check and make sure that the gear assembly can rotate freely.
8. Assembly and regulation of transmission assembly Place the clutch as shown in Figure 28 first, and then assemble the differential assembly to its designated position. Clutch housing assembly Differential assembly Figure 28 Assemble gearshift fork assembly, input shaft assembly and output shaft assembly together as shown in Figure 29, and then install them together onto clutch housing assembly.
Install the assembled idler assembly (assembly of idler assembly is comparatively simple, please refer to its disassembly process) onto clutch housing, and then install reverse gear fork mechanism assembly with tightening torque of the two reverse gear rocker arm bracket bolts as 25±2Nm. Clean the junction part of clutch and transmission housings and apply sealant (oil resistance silicone sealant, HZ1213Q/320222 YAP02-92) on it, and then install the magnet. See Figure 30.
Assemble transmission housing and clutch housing together and then fasten them with connecting bolts. Before fastening, apply thread locking glue (262 type anaerobic adhesive) on the bolts properly. Tighten the diagonal bolts first as possible to ensure favorable fastening and sealing effects, and the tightening torque for the bolts are 25±2Nm. Note: the two connecting bolts at oil drain hole are a little longer than other connecting bolts, and the bracket should be installed first. See Figure 31.
Connecting bolts of gearshift housing and transmission housing (5, tightening torque: 25±2Nm) Figure 32 9. Disassembly of external accessories of transmission Respectively install locating seats of 1/2 gears fork shaft and 3/4/5 gears fork shaft. Before installation, apply thread fastening glue (262 type anaerobic adhesive) on the thread, and the tightening torque for the bolts are 20±2Nm. Note: the locating seat of 1/2 gears fork shaft is longer than that of 3/4/5 gears fork shaft.
Figure 33 Follow by installation of screw of reverse gear idler shaft. Align the screw of reverse gear idler shaft with the threaded hole on the idler shaft, and then tighten it with the tightening torque as 38±2.5Nm; after that, tighten bleeding plug with tightening torque as 44±3Nm; finally, install oil limit plug onto the transmission, but do not tighten it then. See Figure 34. Screw of reverse gear idler shaft (with tightening torque as 38±2.
Installation hole of speed sensor Oil limit plug (with tightening torque as 44±3Nm) Figure 35 After the above steps, assembly and regulation to the transmission assembly are accomplished.
II. Tightening Torque Table for Fasteners Position Tightening torque (N.m) Reverse gear rocker arm bracket bolt 25±2 Connecting bolts for clutch and 25±2 transmission housings Reverse gear idler shaft screw 38±2.5 Connecting bolts for gearshift and 25±2 transmission housings Gearshift shaft locating seat assembly 32±2.
Chapter Four Failure General Failures and Troubleshooting Possible reason Troubleshooting status Damaged input or/and output shaft bearing(s) Replace the bearing Excessive Gear tooth faces damaged due to knocking, burr Repair or replace or or pit corrosion existing, or poor contact between the gear abnormal them.