Chery S11 / Chery QQ. Manual — part 1

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Chery QQ Service Manual Transmission System

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Explanation

1,This manual book is applicable to the usage and maintenance of the gearboxes

of model DABS10-4 and DABS10-8 manufactured by our factory.

2,The DABS10-4,DABS10-8 front-wheel-drive transaxles, with fine functions,

advanced structures, made with high precise, compared with the current local
products, it is in the leading position.

3,《DABS10-4 Gearbox Usage & Maintenance Manual Book 》 is edited at

the request of our customers. It describes in details each parts of the gearbox and the
relations between every part of the gearbox, according to this manual, customers and
technicians dismantle the gearbox for maintenance and repair by themselves.

4,In process of maintain and use, please inform us of the existing problems of

DABS10-4 gearbox and the existing problems in the manual book and forward your
written improvement opinions to us at any time, we would like to express our sincere
gratitude.

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Chery QQ Service Manual Transmission System

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Chapter 1 The Clutch

Section 1 Summarization

The clutch used in this car is dry type, a diaphragm spring disc spring, often press

type clutch.

The clutch disc assembly is consist of six pieces of absorber springs, and is fixed

on the input axle of the transmission through splined hub.

The clutch platen assembly is fixed on the flywheel, the fixing state of

diaphragm spring is in this mode: when the Release bearing draws back, the
edges of diaphragm spring is beginning to drive the platen against the flywheel。
This is the clutch jointing state.

Step on the clutch pedal to move release bearing forward, diaphragm spring. At

this time, diaphragm spring pulls the platen and comes away from the flywheel,
thereby disconnect driving from the flywheel via to input shaft.

For the vehicles with three-way catalyst, the clutch switch is located on the upper

position of the clutch pedal.

1,Pressure plate assembly 2,Pressure plate 3,Diaphragm spring 4,Release bearing

5,Release fork 6,Clutch housing 7,Clutch disc 8,Cushion or damper spring 9,

Input shaft 10,Input shaft 11.Crankshaft 12,Flywheel

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Chery QQ Service Manual Transmission System

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Section 2 Fault Diagnosis

Fault

Phenomenon

Reasons Solution

The Clutch

Skids

The free journey (free moving clearance) of

the clutch pedal is unavailable.

The clutch disc has been frayed or has greasy

dirt.

The surface of clutch disc pressure plate

flywheel has been distorted.

Diaphragm spring has become weaker.

Clutch cable has rusted.

Adjust the pedal free play

Replace the clutch disc,

Pressure plate or flywheel.

Replace the clutch cable.

The clutch does

not come away

completely.

The free journey (free moving clearance) of

the clutch pedal is unavailable.

Diaphragm spring has become weaker。

Input shaft splined hub has been frayed.

The clutch disc swings excessively.

The clutch disc has been damaged or has

greasy dirt.

Adjust the free journey

Replace the pressure plate

assembly。

Lubricate

Replace the input shaft

Replace the clutch disc.

The clutch

vibrate

The clutch disc has been frayed as clean as

whistle.

The clutch disc have greasy dirt 。

The Release bearing glides badly on the

Spacer.

The clutch disc shakes or the clutch disc

contacts badly.

The clutch disc Cushion or damper spring has

become weaker.

The clutch disc rivet has become loose.

The Pressure plate was damaged or bolt has

become loose.

Repair or replace the clutch disc

Replace the clutch disc

Lubricate.

Replace the clutch disc

Replace the clutch disc

Replace pressure plate assembly

or flywheel

Tighten or replace gasket

The clutch

contain noise

The release bearing has frayed or damaged.

The input shaft front bearing was frayed.

The clutch disc has unwonted noise.

The clutch disc has cracks.

The Pressure plate diaphragm spring have

unwonted noise.

Replace the release bearing.

Replace the input shaft bearing.

Replace the clutch disc

assembly.

Replace the pressure plate

assembly.

The clutch can't

take off

The clutch disc was dipped by oil liquid.

The clutch disc was frayed badly.

The rivet comes out.

The cushion or damper spring has become

weaker.

Replace the clutch disc assembly

Chery QQ Service Manual Transmission System

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Section 3 Maintenance on car

Ⅰ.Maintenance

(1) The Clutch Pedal Height
According to the following regulations, use pedal bracket adjusting bolt to adjust the

clutch pedal height. It is normal if the height of clutch pedal is higher 8mm(0.3in)than the
height of brake pedal..

(2) The free play of the clutch pedal.

Step on the clutch pedal till you feel the resistance, stop stepping and mensurate

the distance clutch pedal free play. The free play must be within the following stated
ranges.

If the free play is wrong, please adjust the clutch cable free play according to the

diagram below.

While checking clutch pedal free play, be sure to check if the working state of the

clutch is normal under the circumstance that the engine is running.

(3) Clutch Switch

Attention:
This switch is applicable to the vehicles with catalyst.
Adjust:

1. Pull the parking brake handle, push the shift lever to the neutral positon.

2.Take apart the connect beside the pedal Bracket.
3.Loosen the lock nut.

4. Adjust the installation position of the gearing position of clutch pedal, the clearance

between switch connect and clutch bracket is the size A, then tighten the lock nut.

5. Connect.

N.m

Kg-m

1b-ft

The clutch switch

lock nut adjustment

torque

10-15 1.0-1.5

7.5-10.5

（4）Clutch Cable

Unload:

Dismantle the clutch cable connect nut , and move off connection lock on the

inner cable.

Take apart two bolts from the front wainscot, cable top from the table, at last take out

the cable.

Check:

Check the clutch cable, if appears one of the following status, replace the cable.