Chery QQ6 (S21) / S12LHD. Manual — part 195

24

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)

25

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

26

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

27

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