QR513 Transmission Case
Contents
1. ccececssssssssesessseecceceeeceeeeesaeaaasssseeeeeeeeeeees 10 6 Separation of interior transmission parts and fork module from the housing ccccceees 11 7 Separation of differential assembly and clutch housing cece ccccessssseeeseseeeeeeeeeeeeeeeeeaaas 12 Disassembly of searshifr fork MeECHANISIN x 1siciiee ten n n acd E 12 9 Disassemblyor SCArSIN Fl TCC MANIS Mecce e a 13 10 Disassembly or Mput Shall ecen a bia dened eS hie bed 13 EEs DISAaSSEMDLY or OULDUL SNAG so trais6 scares eeneesnascs E A 15 12 Disassembi yor CUS SILA asen a le ohn hn eich dail ada shea laine Dash chpa arene eat 15 13 Disassembly of release mechanism Of CLUECH senienas S a 16 14 Disassembly of transmission housing cccccsecccccceeeeccceecaaessssssseeeeececeeeeeseeeaaaaaesesseseeeeeeeeess 17 Chapter Three Assembly and Regulation of QR513 Transmission cccccccccccccccceeeeesesseseseeeeeeeeeeeeeeeeeaaas 18 Assembly of ORD 13 ans Missio ssni E O 18 Ic sASSEMDIY OF Giferential ASSCIMD Vie cecereonsgswsss caeres saneexacaceeeiatesis a caeaeacasisensiachestesaioeea sa ceeanauaces 18 2 AssemDly of clute NOUSING 3 inssuientee ia ee Onno ame eed 19 FASS MDI Of THANSIMISSION NOUSING orai E E E R ERT 23 4 Assembly of gearshift mechanism assembly ccccssssssesssseeeececcceeceeeeeaeaesseseeeeeeeeeeeeeeeeeeaaas 23 5 Assembly of gearshift fork ASSEMBLY ice ste ices seca ects acess a aoe ges ead eeattge sade2. Aca TR 24 6 Regulation and assembly of input shaft assembly cesssssssssseeeccccceeeeceeeeaeeseesesseeeeeeeeees 24 7 Regulation and assembly of output shaft assembLy ce eeessssssseeeccceeeceeceeeaeeseessessseeeeeeeess 26 8 Assembly and regulation of transmission assembly ce cccccccccccsssssseseeseeeeeecceeeeeeeeeeeaaeaeeeeeees 28 9 Disassembly of external accessories Of transmission cccsssseesesssesccccceeeecceeeeaaaeessesesseeeeeeeess 31 10 Refilling and volume regulation of transmission lubricant cccccccccceceeeecceeeseeeeessseeeeeeeeees 32 Ie Tre htenme Torque Table Tot Fasteners sco sec sa teahct iss ses saeescaan a A E 34 Chapter Four General Failures and Iroubles hoolin Siessen e a dls Seias ve cakes ES 35 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 During maintenance and use please inform us of any problem in and improvement idea on QR513 transmission and this service manual so that we can correct and perfect this service manual for which we express
3. bearing of input shaft Clip gear baffle 4 gear driving gear assembly 3 4 gears synchronizer assembly Front clip spring 25 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 t Clamp gear fender ibly on three conical surfaces of the sync 3 4 gears synchronizer assembly that the syncmumze uug assembly envelops loosely on the synchronize cune vi we wusi gear utiviny auu 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 wit 4 t
4. transmission housing and then remove oil drain channel fork shaft bush and linear bearing 17 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 b
5. R number of shift gears of the transmission maximum transmission torque characteristic code and structure specification number A complete transmission case model is as follows Oo Or iO O O L pi Structure specification number Characteristic code Maximum transmission torque kg m Number of shift gears of the transmission case Code QR Among which o indicates an Arabic numeral while o indicates a letter 2 Leaving factory number Leaving factory number is composed of endnote of assembly part number for that without endnote us AA character code of the year of production character code of the month of production sequence number of this transmission case among the transmission cases manufactured in that month and start stop sign See Table 1 and Table 2 for check list of character codes of the year and of the month Complete form of leaving factory number of a transmission case is as follows i a O 00000 Sequence number among the product of the same model manufactured in that month Character code of the month Character code of the year Endnote of assembly part number Among which indicates an Arabic numeral o indicates a letter and indicates an Arabic numeral or a letter The endnote locates at tail end of the part code for a fundamental model no endnote The endnote should be modified when modification is made to structure dimension material heat treatment requirements and surface treatment etc of the part
6. Service Manual for Chery QQ6 QR513 Transmission Case After Sales Service Department of Chery Automobile Sales Co Ltd CONTENTS PO WV eA EE EE 2 Chapter One Introduction or ORSI Mans Miss Olassri ana N A NEN 3 LAssembly Drawing o OR3913 TransnissiOn iio ee O es 3 H Drivine Characteristics oF ORS13 Frans missi Oesa a a a AA 4 HSNO ORS Transmis SION na E tokonbaavsiaceotaiovsnamesad eit auaabitact ta boteck endian sateen 4 I Print position of SN of QRSI3 transmisSsiOn wissessssecsici e A casa cta bee elise sa beese 4 2 Composition and connotation of SN of QR513 transmission cccccccccecceeeceeceeeseeeessseeeeeeeeeees 4 IV Spec Nedi oror ORS 13 FransimSsiOn asicescceds dasamsa a agen a avon esa ae Aeneas 6 WIV Tamme Mame CS EOC LOIN stead sa as actesaade ates a aaa aa 7 Chapter Two Decomposition of ORS 1 3 Trans muSsiOn wsssisisavisacccsscaarisietiiseasssia aa R AA eines 8 F Decomposition Process for QRS 13 Transmission suensoni oases das ae ae E ET 8 Is Bieedins IUDEICAME n TEANSTNIS SION sisaan A 8 2 Disassembly of external parts Of transmission cccccccccccececeseeseeeeeessseceeceeeeeeeeeeaaaaeeesseeeseeeeeeees 8 3 Separation of gear shift mechanism and traMSMISSiON cccssseesessssssececceecceceeeeeaaeeesesesseeeeeeeeees 9 4 Disassembly of the connecting bolts for clutch and transmission housings ccceceeeeeeeees 10 5 Separation of transmission and clutch MOUSINGS
7. 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 Needle bearing for 1 2 gears 1 2 gears synchronizer assembly Front clip ring 2nd gear driven gear assembly Rear bearing of output shaft rear snap ring Fifth gear driven gear Gear spacer Third gear driven gear ourth gear driven gear Figure 27 27 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 When assembling wrap front end spline of input sh
8. aft 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 Use tape to wrap the spline Figure 29 28 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 YAPO2 92 on it and then install the magnet See Figure 30 Reverse gear fork mechanism assembly Idler assembly Apply sealant on junction part of clutch and transmission housings PHR Sc BR WE GTZ J kA 25 2Nm Figure 30 29 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 2542Nm 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 bolt of transmission and clutch
9. 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 arm bolt with tightening Release return torque as 20 2Nm Release fork torsion spring Release shaft assembly a ar Ta eee al 22 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 1s 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 23 Selector lever bracket i bolt with tightening w i torque as 25 2Nm Reverse gear locking i w mechanism bolt with Y torque as 18 2Nm Ae Figure 25 5 Assembly of g
10. earshift 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 chec
11. eeding 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 Disassembly of external parts of transmission Switch the transmission to NEUTRAL position use an appropriate tool to remove the locating seat of the fork shaft as shown in Figure 2 Connecting bolts for gearshift housing and transmission housing and the screws for backup lamp switch and idler shaft Locating seat of fork shaft Assembly of locating for all gears 3 seat of fork shaft Screws for idle gear shaft ETT air Erai PI x E hr yy N z Ke sift if Bolts for gearshift housing and Backup lamp switch assembly Transmission housing 5 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 to knock on the bulge at flank of housing of the gearshift mechanism and then take out the whole gearshift mechanism assembly until the two housings completely separate remember to be slow when taking out the gearshift mechanism assembly so as to prevent the return spr
12. he synchronizer ring to make Front snap ring and then make sure that the its guide block completely enter the groove corresponc 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 26 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
13. housings 13 Reverse gear rocker arm bracket bolt with tightening torque as 2542Nm bolts are longer Bracket 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 YAPO2 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 30 Connecting bolts of gearshift housing and transmission housing 5 tightening torque 2542Nm 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 324 2 5Nm and install backup lamp switch assembly before installation apply thread fastening glue 262 type a
14. ial 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 19 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 20 Special tool for installation Outer ring of of outer ring of bearing 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 Opening direction of installation position of Special tool Bush Gap of bush clutch housing bearing Figure 21 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
15. ing as shown in the figure from dropping out inside the transmission during disassembly be careful not to damage the junction planes of the two housings so as to avoid oil leak after re assembly Gearshift mechanism assembly Return spring remember to prevent it from dropping out 7 Pui T4 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 ine Figure 4 5 Separation of transmission and clutch housings After the bolts for transmission and clutch housings are removed separate clutch housing and transmission housing Figure 5 as a result of sealant the separation process may be difficult so use such tools as a hand hammer etc to knock on the bulge at flank of housing of the transmission and then take out the whole transmission housing until the two housings completely separate during disassembly be careful not to damage the junction planes of the two housings so as to avoid oil leak of the transmission after re assembly 10 Transmission housing Clutch housing DTI m E i apg Figure 5 6 Separation of interior transmission part
16. isassembly 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 Disassembly of input shaft As shown in Figure 10 Use a special tool such as bearing remover etc to remove the two bearings on the input shaft first use a special tool to remove the rear snap ring and then take off the fifth gear synchronizer assembly 13 Bearing when disassembling be Rear snap ring Fifth gear synchronizer careful and use a special tool 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 Figure 11 14 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 Disassembly of differential As shown in Figure 13 use a special tool to take off the t
17. k 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 24 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
18. naerobic adhesive on the thread and the tightening torque for the bolts are 20 2Nm See Figure 33 Locating seat of 1 2 gears fork shaft Locating seat of 3 4 5 gears fork shaft oo oo with tightening torque as 2042Nm with tightening torque as 2042Nm Locating seat of gearshift shaft with l asi tightening torque as 324 2 5Nm eas E 4a mg SE Th Switch assembly of backup light with tightening torque as MTs T i i 20 2Nm A 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 3842 5Nm after that tighten bleeding plug with tightening torque as 444 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 Bleeding plug with tightening torque tightening torque as 3842 5Nm as 44 3Nm Oil Limiting Plug Figure 34 10 Refilling and volume regulation of transmission lubricant After the transmission is installed onto the vehicle park the vehicle on a flat road surface then use the tool for refilling to refill transmission lubricant The lubricant refilled should at least conform to API GL 4 SAE 75W 90 specification Refill through installation hole of speed sensor as shown in Figure 35 with the refilling volume as 1 8L after refilling open the oil limit pl
19. or assembly on the basis of original product The English letter in the code should be upper case letter use in sequence with A as the first in order to avoid confusion do not use T O and X When the modification does not affect interchangeability use A as the first when the modification affects interchangeability skip A use B as the first Table 1 Character Codes Indicating the Years Table 2 Character Codes Indicating the Months O rey igus O mea o e se apt i a E My o E ove o O w r e a M 3 Illustration For example QR513MHA MHS5H00001 indicates the first transmission case with the model as QR513MHA manufactured in August 2005 IV Specification of QR513 Transmission if QR513 Series Transmission Velocity Velocity Gear shift Teeth Ratio Teeth Ratio Ratio Ratio ssas on aus aad Largest input torque 130 Nm Lubricant oil type GL 4 75W 90 ase 2906 oso 2906 V Maintenance Instruction 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 Bl
20. oth 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 18 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 Adjustment gasket Inner ring of for planetary gear bearing 2 2 sheets Planetary gear 2 Planetary gear shaft Connecting bolt 8 Fixing pin of planetary Adjustment gasket for half Half axle gear 2 axle gear 2 sheets gear shaft 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 spec
21. our thanks herein Chapter One Introduction of QR513 Transmission I Assembly Drawing of QR513 Transmission X a Pat aaa iene ieee I d 1 Input shaft 2 Clutch 3 Output shaft 4 Differential 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 When the transmission is shifted to various gears these synchronizers will engage with corresponding gear hub to enable transmission of power and then the driving gear of main decelerator will drive the driven gear of main decelerator and differential assembly to rotate which will drive the drive shaft to drive the wheels to rotate II SN of QR513 Transmission 1 Print position of SN of QR513 transmission The print position of SN of QR513 series transmission is as shown in the figure 2 Composition and connotation of SN of QR513 transmission SN of QR513 series transmission is consisted of model and leaving factory number of the transmission case 4 1 Model of the transmission case Model of the transmission case is composed of code Q
22. s and fork module from the housing After transmission housing and clutch housing are separated keep the clutch housing flat at the place as shown in Figure 6 remove the bolts for bracket of reverse gear rocker arm take out the reverse gear rocker arm assembly and the pin on idler drive and then take out input shaft output shaft and fork mechanism together when taking out gently shake meanwhile press the driven gear of main decelerator along the direction of arrowhead as shown in the figure to take out the assembly of input shaft output shaft and idler as well as fork mechanism when taking out remember to avoid interference between bearing retainer of output shaft and big gear ring of differential and prevent the bearing retainer from damage Bolts for reverse gear rocker arm bracket 2 in total Reverse gear rocker arm Figure 6 11 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 Disassembly of gearshift fork mechanism Use a hammer and a special tool to knock off all spring pins and then use a snap ring pliers or other special tool to take the split washer off the fork shaft when taking off the split washer prevent it from deformation and then disassemble each part of the gearshift mechanism Split washer Spring pin 12 Figure 8 9 D
23. stem Check and adjust adjustment a No gear Loose gearshift transmission system Overhauling Loose aS em epee ae yee ge arm of transmission Abnormall Metal Metal impurities contained in transmission oil contained in transmission oil Replace sd y damaged Insufficient lubrication unqualified Replace bearing s transmission oil Using of unqualified bearing s 35
24. 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 1s 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 oe x Rear clip spring 5 gear synchronizer assembly Gear baffle 5 gear driving gear assembly 5 gear needle bearing Front
25. ug to regulate the lubricant to specified volume and then tighten the oil limit plug with the tightening torque as 4443Nm Installation hole of speed sensor Oil limit plug with tightening torque as 4443Nm Figure 35 After the above steps assembly and regulation to the transmission assembly are accomplished 33 II Tightening Torque Table for Fasteners Reverse gear rocker arm bracket bolt 2522 Connecting bolts for clutch and 2542 transmission housings Connecting bolts for gearshift and transmission housings 34 Chapter Four General Failures and Troubleshooting Failure 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 noise Incorrect gear shaft position and clearance Check and adjust Low oil level insufficient lubrication Fill oi to the Perot neem veer peed wee Uneven sealant smearing or damaged seal Oil leakage gasket s gasket s or sealant damage due to knocking Damaged differential bearing Improper clutch adjustment and incomplete Adjustment implement Improper gearshift transmission system Check and adjust gear shift adjustment or movement obstruction occurring a Gear Worn synchronizer gear sleeve s or tooth cone Replace related i Improper gearshift transmission sy
26. wo bearings first remove the bolts for driven gear and differential housing remove the driven gear knock off the fixing pin of the planetary gear and then take out every part inside the differential Figure 14 Fixing pin of planetary gear Bolts for driven gear and differential housing 8 in total Figure 13 15 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 16 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
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