Chery QQ6 (QR513 Transmission Case). Service Manual — part 2

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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.

Release bearing of clutch

Bolts for release fork Release fork Release arm

Bush Release return spring

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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.

Oil seal

Fork shaft bearing (3)

Outer ring of bearing

Oil duct

Figure 16

14. Disassembly of transmission housing

As shown in Figure 17, use a special tool to remove the oil seal of transmission housing, and then

remove oil drain channel, fork shaft bush and linear bearing.

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Linear bearing

Fork shaft bush

Oil seal 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. Assembly of differential assembly

Fit adjustment gaskets respectively at backsides of the two half axle gears, and then install the two half

axle gears together with their gaskets into the differential. When fitting adjustment gaskets for the half axle

gears, select the gasket with thickness as 1.2mm first. Fit spherical washers for the planetary gear, and then

simultaneously engage the two planetary gears with the two half axle gears (fit them to correct positions

while turning the gears). Insert the planetary gear shaft; note that the fixing pin hole on the shaft should align

correctly with that on the differential housing both in the position and along the direction. Measure the

clearance between the half axle gear and the planetary gear, and the normalized value should be

0.025~0.150mm; if the clearance does not conform to the normalized value, replace the adjustment gaskets

for the half axle gear, and then re-measure the clearance until it conforms to the standard with uniform

clearance at both sides. Drive down the fixing pin of planetary gear shaft from the fixing pin hole at the side

of differential housing with flange with the pin with end surface of the pin hole. Install driven gear of main

decelerator and ensure that the installation end surface of the gear fits well with the end surface of the

differential housing, and then fix the driven gear of main decelerator with bolts (apply sealant to full thread

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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. Note that the lubricant applied onto

adjustment gaskets for half axle gears, planetary gear gaskets, junction surface of planetary gear and

planetary gear shaft, junction surface of half axle gear and differential housing should be the same as that

used inside the transmission. Refer to Figure 18.

Planetary gear (2) Planetary gear shaft Connecting bolt (8)

Half axle gear (2)

Figure 18

2. Assembly of clutch housing

Use a hammer and a special tool to fit oil seal of input shaft with spring side of the oil seal up and

grease applied to lip of the oil seal. Use a special tool and a hamper to fit right side oil seal of differential

with end surface of the oil seal flush with the housing surface, and then apply grease to lip of the oil seal. See

Figure 19.

Inner ring of

bearing (2)

Adjustment gasket

for planetary gear

(2 sheets)

Fixing pin of planetary

gear shaft

Adjustment gasket for half

axle gear (2 sheets)

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Right side oil seal of differential

Special tool for installation

Oil seal of input shaft

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.

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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.

Special tool Bush

Gap of bush

Figure 21

Opening direction of installation position of

clutch housing bearing

22

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). See Figure 23.

Release fork

Release shaft assembly

Release arm bolt (with tightening

torque as 20±2Nm)

Release return

torsion spring

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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.

Special tool for installation of oil seal Oil seal of differential Oil drain channel Bush Linear bearing

Figure 24

4. Assembly of gearshift mechanism assembly

Assembly of gearshift mechanism assembly is comparatively simple, which can refer to the disassembly

process of the gearshift mechanism assembly. Remember to check the amount of parts to prevent neglected

installation. Please refer to Figure 25 for tightening torque of the bolt.

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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. Regulation and assembly of input shaft assembly

Place the input shaft with its end with clutch spline down, and then set the third gear needle bearing

applied with the gear oil of the same designation as that used inside the transmission assembly onto the input

shaft. Set the third gear driving gear assembly in from upside of input shaft with the end with synchronizer

cone of the gear assembly up, and then check and make sure that the gear assembly can rotate freely. Set a

3/4/5 gears synchronizer ring in from upside of input shaft with conical surface of the synchronizer ring

applied with the gear oil of the same designation as that used inside the transmission assembly, and then

check and make sure that the synchronizer ring should envelop loosely on synchronizer cone of the third

gear driving gear assembly and can rotate relative to the synchronizer cone. Press 3/4 gears synchronizer

assembly onto the input shaft with the end surface of gear hub with two oil grooves down, turn the

synchronizer ring to make its guide block completely enter the groove corresponding to the gear hub, and

then make sure that the synchronizer ring is not locked. Fit front snap ring of input shaft; when fitting, try to

use the thicker snap ring, if really unsuitable, select the snap ring of next thinner level, and then check if the

snap ring has really enter the groove with the clearance between the snap ring and the groove not exceeding

0.05mm. Set a 3/4 gears 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. Set a 3/4/5 gears synchronizer

ring applied with the gear oil of the same designation as that used inside the transmission assembly in from

upside of the input shaft. Set the fourth gear driving gear assembly in from upside of input shaft with the end

with synchronizer cone of the gear assembly down (the guide block of 3/4 gears synchronizer ring should

completely enter the groove corresponding to the gear hub), and then make sure that the gear assembly can

Selector lever bracket

bolt (with tightening

torque as 25±2Nm)

Reverse

gear

locking

mechanism bolt (with

torque as 18±2Nm)

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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.

Set fifth gear driving gear assembly in from upside of input shaft with the end with synchronizer cone of the

gear assembly up, and then make sure that the gear assembly can rotate freely. Set a 3/4/5 gears synchronizer

ring in from upside of input shaft with conical surface of the synchronizer ring applied with the gear oil of

the same designation as that used inside the transmission assembly, and then check and make sure that the

synchronizer ring should envelop loosely on synchronizer cone of the fifth gear driving gear assembly and

can rotate relative to the synchronizer cone. Press fifth gear synchronizer assembly onto the input shaft with

the end surface of gear hub with oil groove down, turn the synchronizer ring to make its guide block

completely enter the groove corresponding to the gear hub, and then make sure that the synchronizer ring is

not locked. Fit rear snap ring of input shaft; when fitting, try to use the thicker snap ring, if really unsuitable,

select the snap ring of next thinner level, and then check if the snap ring has really enter the groove with the

clearance between the snap ring and the groove not exceeding 0.07mm. Simultaneously press front and rear

bearings of input shaft onto the input shaft with the side of front bearing of input shaft having word down

and the side of rear bearing of input shaft having word up, and then check and make sure that the outer rings

of the bearings can rotate freely. Refer to Figure 26.

Note: There are two friction balls between the bearing baffles (2 sheets). Be careful to install them in

full.

Input shaft 3/4 gears needle bearing Third gear driving gear assembly 3/4/5 gears synchronizer ring Rear bearing of input shaft

Front bearing of input shaft

Front clip spring

3/4 gears synchronizer assembly

5 gear synchronizer assembly

5 gear needle bearing

5 gear driving gear assembly

Gear baffle

Clip-gear baffle

Rear clip spring

4 gear driving gear assembly

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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. Set first gear driven gear

assembly in from upside of output shaft with the end with synchronizer cone of the gear assembly up, and

then check if the gear assembly can rotate freely. Set a 1/2 gears synchronizer ring assembly in from upside

of output shaft and the three finger jaws of balking ring of the synchronizer ring should completely enter the

three corresponding grooves on the first gear driven gear assembly; before installation of the synchronizer

ring assembly, apply the gear oil of the same designation as that used inside the transmission assembly on

three conical surfaces of the synchronizer ring; check and make sure that the synchronizer ring assembly

envelops loosely on the synchronizer cone of the first gear driving and driven gears assembly and can turn a

certain angle relative to the synchronizer cone. Press 1/2 gears synchronizer assembly onto the input shaft

with the end of external gear of 1/2 gears hub sleeve with section down, turn the synchronizer ring to make

its guide block completely enter the groove corresponding to the gear hub, and then make sure that the

synchronizer ring is not locked. Fit front snap ring of output shaft; when fitting, try to use the thicker snap

ring, if really unsuitable, select the snap ring of next thinner level, and then check if the snap ring has really

enter the groove with the clearance between the snap ring and the groove not exceeding 0.05mm. Set a 1/2

gears synchronizer ring assembly in from upside of output shaft; before installation of the synchronizer ring

assembly, apply the gear oil of the same designation as that used inside the transmission assembly on three

conical surfaces of the synchronizer ring. Set a second gear needle bearing onto output shaft from upside of

Front snap ring

3/4 gears synchronizer assembly

Clamp-gear fender

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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. Set the third gear driven gear in from

upside of output shaft with the end with boss of the gear up, and then check and make sure that the 1/2 gears

synchronizer ring assembly is not locked. Set 3/4 gears driven gear bush and then fourth gear driven gear in

from upside of output shaft, with the end with boss of the gear down. Set fifth gear driven gear in from

upside of output shaft with the end with boss of the gear up. When fitting, try to use the thicker snap ring, if

really unsuitable, select the snap ring of next thinner level, and then check if the snap ring has really enter

the groove with the clearance between the snap ring and the groove not exceeding 0.05mm. Simultaneously

press inner rings of front and rear bearings of output onto the output shaft. See Figure 27.

1/2 gears synchronizer ring assembly First gear driven gear assembly 1/2 gears needle bearing Output shaft Front bearing of output shaft

Rear bearing of output shaft rear snap ring Fifth gear driven gear Fourth gear driven gear Gear spacer Third gear driven gear

Figure 27

Front clip ring

2nd gear driven gear assembly

Needle bearing for 1/2 gears

1/2 gears synchronizer assembly

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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

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. When assembling, wrap front end

spline of input shaft with polyvinyl chloride adhesive tape to prevent damage to oil seal. After installation,

turn each gear to ensure favorable engagement.

Gearshift fork assembly Input shaft assembly Output shaft assembly

Figure 29

Figure 28

Use tape to wrap the spline

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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.

Reverse gear fork mechanism assembly Idler assembly

Magnet

Figure 30

Apply sealant on junction part

of clutch and transmission

housings

倒档摆臂支架
螺栓（拧紧力
矩 25±2Nm）

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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.

Figure 31

To install the assembled gearshift mechanism assembly onto the transmission, clean the junction part of

gearshift housing and transmission housing and apply sealant on it (oil resistance silicone sealant,

HZ1213Q/320222 YAP02-92), align one end of gearshift shaft with the linear bearing inside the transmission

and align the locating hole on gearshift housing with the locating pin on transmission housing, and then

tighten the connecting bolts of gearshift housing and transmission housing with the tightening torque as

25±2Nm. See Figure 32.

Reverse gear rocker arm bracket bolt

(with tightening torque as 25±2Nm)

Connecting bolt of transmission and clutch housings (13)

Bracket

The two connecting

bolts are longer

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. Then install locating seat of gearshift shaft, before installation, apply thread fastening glue (262 type

anaerobic adhesive) on the thread, and the tightening torque for the bolts are 32±2.5Nm; and install backup

lamp switch assembly, before installation, apply thread fastening glue (262 type anaerobic adhesive) on

the thread, and the tightening torque for the bolts are 20±2Nm. See Figure 33.

Locating seat of gearshift shaft (with

tightening torque as 32±2.5Nm)

Switch assembly of backup light

(with

tightening

torque

as

20±2Nm)

Locating seat of 3/4/5 gears fork shaft

(with tightening torque as 20±2Nm)

Locating seat of 1/2 gears fork shaft

(with tightening torque as 20±2Nm)