Chery Fora (Elara A520). Manual — part 177

CHERY A520 SERVICE MANUAL QR519 TRANSMISSION

36

REAR COVER ASSEMBLY

4 3 2 1

5

Figure 51

1.

Rear Cover

2. Oil Drain Tube for Input Shaft

3. Reverse Synchronizer Cone

4. Screw – Reverse Synchronizer Cone

5. Rear Cover Assembly

CHERY A520 SERVICE MANUAL QR519 TRANSMISSION

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VIII TRANSMISSION ASSEMBLY & NOTICE

The transmission assembly procedure is reverse to its disassembly procedure, and the
followings need attention:

1. It is necessary to use Mobilux EP2 (sealant) for the rear cover assembly, clutch housing

assembly and gearshift mechanism assembly.

2. Installation of the output shaft adjusting washers:

After fixing the transmission housing, make sure that the bearing outer ring has a full contact
with the roller, and the pre-tightening torque of the shaft with the washers is 0.8-1.5N•m after
assembly.

3. Installation of the adjusting washer for input shaft rear bearing:

The thickness range of adjusting washer is A2-0.1≤S2＜A2, in which A2 is the channel width
and S2 is the thickness of adjusting washer. Use six M6x1-16 countersunk head screws to fix
the rear bearing retainer and their tightening torque is 10.5N•m;

4. When installing the input shaft oil seal and differential oil seal, you shall smear

lubricating grease onto their lips and use a special tool to press them into the transmission
housing sufficiently.

IX AIR EXHAUST METHOD OF HYDRAULIC CLUTCH

QR519MHA transmission adopts full hydraulic clutch mechanism and thus its air exhaust can
be easily done. When implementing air exhaust with regard to an finished vehicle, firstly
remove the black plug from the hydraulic release bearing coupler and turn on the switch on it
(i.e. rotate it 90 degrees), and then step the clutch pedal to the bottom for some times until all
of the air flows out of the hydraulic release bearing coupler. Note: the switch can only be
turned off in case of stepping on the clutch pedal to the bottom. If you feel strong resistance
force when stepping on the clutch pedal, it is indicated that the air has been exhaust entirely.

Air Exhaust Switch

CHERY A520 SERVICE MANUAL QR519 TRANSMISSION

38

X USE/OPERATION METHOD & NOTICE

1. Employ the Double-Clutching method for upshifting and downshifting. When you shift

gear, please depress the clutch pedal to the bottom and rapidly control the gearshift lever
after the transmission is free from torque force of the engine.

2. When the vehicle runs downhill or makes a turn, please shift into some low gear and it is

not allowed that the vehicle coasts under the condition that the clutch is released.

3. Trip stop is not allowed during the upshifting procedure; otherwise the service life of the

synchronizers will be reduced.

4. It is prohibited to start the engine by using synchronizer to force into gear in the condition

of flameout & neutral gear; otherwise the service life of the synchronizers will be
reduced.

5. No flap (i.e. rapid push and release) is allowed for gear shifting and you shall hold the

shift lever all the time during the procedure so as to considerably reduce the sliding
friction time of synchronizer locking ring as well as their wear and tear.

6. During the driving, you shall not put your hand onto the gearshift lever; otherwise it will

cause the shift forks to be rapidly worn.

7. If the transmission sends out any abnormal sound, it is obviously difficult to control the

shift lever, etc. during its use, you shall immediately stop and check the vehicle. You can
drive again only after the troubleshooting.

CHERY A520 SERVICE MANUAL QR519 TRANSMISSION

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XI COMMON FAULTS & TROUBLESHOOTING

Fault

Possible cause

Troubleshooting

Damaged

input

or/and

output

shaft

bearing(s)

Replace the bearing

Gear tooth faces damaged due to knocking,
burr or pit corrosion existing, or poor
contact between them.

Repair or replace the gear

Incorrect gear shaft position and clearance

Check and adjust

Low oil level, insufficient lubrication

Fill oil to the specified
level

Excessive

or

abnormal noise

Foreign matter(s) existing in the assembly

Check and remove

Excessively worn or damaged oil seal(s)

Replacement

Uneven sealant smearing or damaged seal
gasket(s)

Replace

the

seal

gasket(s) or sealant

Failure to timely recondition junction
surface(s) damage due to knocking

Check and repair

Oil leakage

Damaged differential bearing

Replacement

Improper clutch adjustment and incomplete
release.

Adjustment

Improper gearshift transmission system
adjustment

or

movement

obstruction

occurring

Check and adjust

Difficult

to

implement

gear

shift

Synchronizer ring(s) fails to work

Replacement

Worn synchronizer gear sleeve(s) or tooth
cone surface(s) of gear junction

Replace

related

components

Gear jump

Improper gearshift transmission system
adjustment

Check and adjust

Loose gearshift transmission system

Overhauling

No gear

Loose gearshift arm of transmission

Repair

Metal impurities contained in transmission
oil

Replacement

Insufficient

lubrication

or

unqualified

transmission oil

Replacement

Abnormally
damaged
bearing(s)

Using of unqualified bearing(s)

Replacement