• Chery QQ Service Manual Transmission System

6. Check if the oil level is right.

Disassembly:
1. Disconnect the cathode of the battery.
2. Disconnect the speed sensor connect.

3. Remove the speed sensor

1-SPEED SENSOR
2- O--ring
3-Speedometer driven
gear

Fig.2-10

Installation:
1. Check if there is any crack and disfigurement on the surface of the o-ring and
SPEED SENSOR case, spread lubricant on the o-ring and Speedometer driven gear,
install them on the transaxle assembly.

Screw tightly the torque : 8--12N·m.

1- SPEED SENSOR
2- O-ring
3- Speedometer driven gear

Fig.2-11
2.Connect the SPEED SENSOR connector.

3.Connect the cathode of the battery .

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VI． Shift and select lever shaft control system

1.Shift handle assembly 2.Shift mechanism assembly 3.Shift cable assembly 4.Bolt
5.Bracket 6.Nut 7.Clip 8.Washer 9.Cotter pin 10.Bolt

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1.Strengthen pole 2. Nut 3. Control shift lever retainer 4.

Control shift lever retainer bolt 6.NO.1 exhaust pipe
5. Shift and select lever shaft 7. Shift lever 8. Shift and
select lever shaft bolt and nut
Disassembly:
On the lift.
1． Remove the shift and select lever shaft bolt and nut, take apart the shift and select
lever shaft from the shift lever.
2． Remove the 4 pieces of control shift lever retainer bolt. Demount the strengthen
pole nut beside the transaxle, and move the strengthen pole aside.
In the cab.
1． Have shift lever shaft housing，disassembly 2 bolt from shift lever shaft housing.
2． Demount the 4 nuts on the shift lever assembly, push the shift lever
into the floor hole and pull out the shift lever assembly from the floor.

1 .Bolt
2 .Bracket

On the workbench;
1． Use the clamp to fix the holder of the shift lever, demount the bolt, remove
the shift lever.
2． Demount the 2 shift lever assembly nut, break down the shift lever .

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Installation
1．According to the reverse demounting order, install the shift lever , if necessary,
replace the used parts.
Notice:
After installation, please check if the shift lever works smoothly.
Shift lever vertical 0-0.2mm(0-0.007in)
free play
Thickness of the 0.8,1.0,1.2 and 1.4mm(0.03,0.04,0.05 and 0.06in)
optional adjust washer

2． Spread whorl glue, fix the

handle on the shift lever ,check the handle level
3． Install shift lever assembly
and the related parts on the original
position. When fixing the position of 1.Shift
the shift lever, first install the 4 lever
2.Shift
pieces of control shift lever retainer lever
bolt and 4 pieces of shift lever assembly
assembly nut, adjust the position of, 3.Adjust
screw the bolt and nut tightly. washer
4. Shift
lever
5. Snap
ring
6. Shift
lever

Notice:
·Do not spread lubricant on the strengthen pole spacer beside the transaxle.
· Spread lubricant on the shift and select lever shaft boot.
· Check if the boot has been installed correctly.

The position of the shift lever ：Distance 270mm

from A

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Section 3 Disassembly and installation of the transaxle

I Dismantle transaxle
Under the engine lid.
1． Disconnect the battery ground; remove the battery and the bracket.
2． Screw the clutch cable nut off, Remove the connector from the cable and
dismantle the cable from the bracket.
3． Disconnect the wiring harness and connector.
4． Remove the speedometer cable boot, and dismantle the speedometer cable.
5． Remove the fixing transaxle bolt.
6． Remove the 2 starter bolt and starter, meanwhile disconnect the starter cable.
7． Disconnect the vacuum hose from the map.
8． Hang engine and bracket chain，keep engine calm.
Caution:
Put gasket under the chain in order to prevent the damage of the vehicle surface.
On the Lift:
1． Use 10mm special tool and spanner to let out the transaxle oil.

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2． Screw off the shift and select lever shaft bolt and nut, remove the control
from the shift shaft.
3． Screw off the strengthen pole nut, remove the strengthen pole and gasket.
4． Disconnect the exhaust pipe.
5． Meanwhile, remove the exhaust pipe nut。
6． Remove the clutch down clapboard.
7． Remove Ball joint bolt and nut from the Steering, then remove each
Suspension arm.
8．Use big drive screw disassembly drive shaft snap ring from differential side.
9． Screw the bolt and nut of the transaxle ,engine assembly.
10．Support the transaxle by transaxle jack.
11．From engine retainer bracket，disassembly 2 blot。
12． First remove the 3 bolt and 2 nut, then remove the bracket.
13． Down the jack and the transaxle, disassembly the bolt between the engine
and transaxle, separate input shaft and clutch disc, take the transaxle.

1 Drive shaft universal

coupling
1 Bolt 2 Engine bracket 3
2 Driven screw

II, Install transaxle

The following Fig. Shows the fastened torque:
Torque N·m kg·m 1b·ft
· Transaxle, engine assembly bolt, 40-60 4.0-6.0 29.0-43.0
nut。
· Engine nut
· Engine bracket bolt
· Exhaust pipe / nut
· Exhaust pipe / muffler nut
Ball joint bolt nut 50-70 5.0-7.0 36.5-50.5
Strengthen pole nut 25-40 2.5-4.0 18.5-28.5
Shift and select lever shaft 15-20 1.5-2.0 11.0-14.5
bolt , nut

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·When lifting the transaxle, push drive shaft right universal coupling into
differential.
·Push the drive shaft universal coupling to the right position, and joggle the
Drive shaft and Differential.
Caution:
Spread lubricant on the shift and select lever shaft spacer, do not spread lubricant
on the strengthen pole spacer.
Caution:
·When hang the transaxle，drive shaft, do not scrape oil seal.
·When put the drive shaft universal coupling on the differential gear, do not
hammer the universal coupling.

· Clip wiring harness。

· After connecting the clutch cable, be sure to adjust the pedal free play .
· Fill oil in the transaxle .
·Connect the battery cable, check if the engine, transaxle work normally.

1、 Clutch release
A: Release shaft 2-4mm

III, Transaxle disassemble

（1） 5th gear
1．Loosen 8 bolt, remove the transaxle left side case.
2．Remove snap ring use special tool.

1,5th shift fork 2,Hub

3,Snap ring 4,Special tool
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Caution:

Do not distort the left side case.

3． Remove the 5th shift fork bolt and guide ball.

4． Hammer the slotted spring pin out.
Notice: It is much easier to magnetize the guide ball.
5．Remove the 5th shift fork, hub sleeve, synchronizer ring and 5th gear with
professional tools。

Caution:

Be sure not to press the synchronizer ring spring tightly.

1, Guide ball
2, 5 th shift fork bolt
3,Slotted spring pin

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1,Gear disassembly tool

2, 5th shift fork
3,Synchronizer hub sleeve

Section 4 Maintenance of the transaxle

I, Disassemble
（1） 5th gear
1 Loosen 8 bolt , remove the rear gear box.
2 Remove the snap ring，thrust gasket.
Caution: do not distort the snap ring.

1- Snap ring
2-Thrust gasket

Fig.3-1
3 Remove the 5th shift fork bolt and placement.
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It is much easier to magnetize the placement.

4 Remove the snap ring. and slotted spring pin.

1- 5th Shift fork bolt

2- Slotted spring pin
3- Snap ring
4- Special tool

Fig.3-2

5 Remove the 5th Shift fork,5th synchronizer assembly, synchronizer ring.

1- 5th shift fork

2- 5th hub sleeve
3- 5th hub
4-5th synchronizer ring

Fig.3-3
6 Fasten the input shaft, output shaft ，5th gear, install special 5th gear lock
tool on the input shaft 5th gear and transmission case.

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1- 5th gear
2- 5th driven gear
3- Transmission case
4- Special tool

Fig.3-4
7 The output shaft nut：Use chisel to loosen the welded part of the nut.

1- 5th lock nut

2-Nut
3- Chisel

Fig.3-5
8 Remove 5th driven gear,5th gear, transmission thrust board.

（2） Shift and select lever shaft ,input shaft, output shaft
1 Loosen 3 bolt, remove the transmission cover board.

1- Transmission case
2- O-ring
3- Transmission cover board

Fig.3-6
2, Remove shift and select lever shaft fork.

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1- Shift and select lever shaft

2- Shift and select lever shaft fork
3- Bolt

Fig.3-7
3 Remove the 3 shift fork shaft bolt and gasket, take out the spring and ball.
4 Loosen the 4 bolt on the case, take out the clip,stationary rings and case.

1-Stationary rings assembly

2-Bolt
3-Case
4- Special tool
5- Clip
6- Shift fork bolt
7-Reverse,5th Interlock roller

Fig.3-8
5 Screw off the restrict bolt and gasket.
6 Remove the backup light switch.
Notice: When removing the shift and select lever shaft assembly, reserve , 5th
interlock roller need not be removed.

1-Case
2- Restrict bolt
3- Spanner
4- Backup light switch
assembly
5- Shift and select lever
shaft

Fig.3-9
7 Take out the shift and select lever shaft assembly.
8 Remove the reverse shaft bolt and gasket.
9 Loosen the 11 bolt from the case outer.
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1-Transmission case
2- Clutch housing
3- Transmission case bolt
4- Reverse idler gear shaft bolt

Fig.3-10
10 Use screwdriver separate clutch housing and transmission case.
Caution: Do not insert the tools into the joint of the two crust, otherwise the joint
can be damaged.

1- Aluminum Hammer
2- Special tool
3- Transmission case

Fig.3-11

11 Take apart the transmission assembly from the clutch case, lift the
transmission assembly, now, all the parts such as input shaft, output shaft and
differential still remain in the clutch case assembly.

Fig.3-12
12 Loosen the 2 reserve shift fork bolt, remove the reserve shift fork assembly.
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13 Remove the reverse idler gear shaft and gasket, take away the reverse idler
gear shaft.
14 Remove the reserve,5th shift fork shaft assembly.

1-Reverse ,5th shift fork shaft

assembly
2- Reverse idler gear shaft
assembly
3- Reverse idler gear
4-Reverse Shift fork bolt

Fig.3-13

15 Use a rubber hammer to hit the end of the input shaft lightly and force it out
a little, take out the input shaft assembly, output shaft assembly,1st,2nd Shift fork
assembly and 3rd,4th shift fork assembly together.
16 Remove the output shaft bearing outer race from the transmission case.
17 Remove the differential oil seal.

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