H13 Maintenance Manual

(QR530MZB Gearbox)

After-sales Service Department of Chery Automobile Sales Co., Ltd.

 Contents

I. QR530MZB Gearbox Assembly Diagram......................................................................3

II. Structure and Characteristic of QR530MZB Gearbox..................................................3
III. Technical Parameters..................................................................................................4
IV. Torque Breakdown...................................................................................................... 4
V. Gearbox Assembly Removal........................................................................................5
1. Preparations............................................................................................................5
2. Precautions.............................................................................................................5
3. Removal Steps and Inspection of Gearbox Assembly............................................5
4. Installation Steps.....................................................................................................9
VI. Disassembly of Gearbox Assembly..........................................................................10
1. Preparations..........................................................................................................10
2. Precautions...........................................................................................................10
3. Removal of Gearbox Assembly............................................................................ 10
VII. Schematic Diagram of Gearbox Assembly...............................................................15
1. Schematic Diagram of Gearbox Assembly............................................................15
2. Schematic Diagram of Selector Shaft and Central Connecting Plate Assembly...16
3. Schematic Diagram of Output Shaft Assembly.....................................................17
4. Schematic Diagram of Intermediate Shaft Assembly............................................18
5. Schematic Diagram of Input Shaft Assembly........................................................18
6. Schematic Diagram of Rear Housing Assembly...................................................19
7. Schematic Diagram of Gearshift Control Mechanism Assembly...........................19
8. Technical Parameters for Assembly and Adjustment of the Gearbox...................20
VIII. Basic Diagram of Gearbox Structure.....................................................................21
1. Diagram of Working Principles..............................................................................21
2. Diagram of Gear Transmission.............................................................................22
IX. Bleeding Methods of Hydraulic Clutch......................................................................25
X. Methods of Use/Operation and Precautions..............................................................25
XI. Common Malfunctions and Troubleshooting.............................................................26

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 I. QR530MZB Gearbox Assembly Diagram

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2
1

1. Input shaft 2. Intermediate shaft 3. Output shaft 4. Clutch housing

II. Structure and Characteristic of QR530MZB Gearbox

QR530MZB gearbox is a tri-shaft mechanical step speed change gearbox, whose forward gear
employs a gearshift mechanism with inertial synchronizer. Gears 1 and 2 employ a multi-cone
synchronizer, while gear 5 and reverse gear employ a lever-type synchronizer, which makes gearshift
more smooth and fast, greatly reducing noise and increasing the working life of gears. The gear shift
fork is made of die-casting aluminum alloy to achieve high abrasion resistance and lightness.
The control mechanism of the gearbox is equipped with locking balls and springs, which make gearshift
more flexible, accurate and the hand feeling of gearshift clearer. Moreover, five-speed gearbox employs
an interlocking mechanism that prevents wrongly reverse gear engagement to enhance driving
reliability and comfort.

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 III. Technical Parameters
Model
QR530MZB
Parameter
Gear 1 4.313
Gear 2 2.330
Gear ratio

Gear 3 1.436
Gear 4 1
Gear 5 0.789
Reverse gear 4.220
Lubricant grade GL-4 75W-90 gear oil
Volume of lubricating oil 2.4L
Maximum input torque 235N·m
Center distance 82 mm
Control mode Indirect control
Net weight (kg) 53
Matched engine 2.0TCI

IV. Torque Breakdown

No. Part Name Specifications Torque Applied Quantity

Gearbox housing and clutch

1 M10X1.25 29-44 9
housing
Gearbox housing and front
2 M10X1.5 11.6-21.5 8
cover
Gearbox housing and
3 M8X1.25 25.9-48.1 1
hexagonal head screw plug
4 Reverse gear switch assembly M18X1.5 35.2-52.8 1
Intermediate connecting plate
5 M10X1.25 25.9-48.1 10
and rear housing
Reverse gear shift rocker arm
6 M8 12.6-23.4 2
bracket
Stop plate of output shaft
7 M8 45±5 4
bearing
8 Retaining spring screw plug M12X1.25 13-24 4
9 Rear housing screw plug M10X1.25 13-24 1
10 Rear housing lifting cover M8 14.4-21.6 6
Pressure plate and oil guide of
11 M8 7.7-14.3 2
rear housing
12 Gear shift block of selector shaft M10x1.0 29.8-36.8 1

13 Shift fork shaft M6x0.75 15.6-23.4 2

14 Housing control cover M8 14-26 6

Selector shaft of selector rocker
15 M6 5.3-9.8 1
arm
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 V. Gearbox Assembly Removal
1. Preparations
1.1. Tools
1 double offset ring spanner, 1 set of sockets, 1 torque spanner, cross and slotted screwdrivers, vernier
caliper, dial indicator, pincer pliers, long nose pliers, plastic hammer and iron hammer etc.

1.2. Auxiliary Material

Gearbox fluid
1.3. Appliances for Protection
Gloves, work clothes, safety helmet and work shoes

2. Precautions
2.1. Please wear necessary articles for labor protection, so as to avoid accidents.
2.2. The gearbox fluid is toxic. If it contacts with the skin or eyes incautiously, please rinse them with
plenty of water immediately. If necessary, go to the hospital without delay.
2.3. Use a container for disused gearbox fluid. It is forbidden to dump it into the sewer, or pile it up
together with domestic rubbish.

3. Removal Steps and Inspection of Gearbox Assembly

3.1. Removal (take off the gearbox assembly from the vehicle)
3.1.1. Pull out the connectors of odometer and reverse gear switch
harnesses.

3.1.2. Pull out the connector of crankshaft position sensor harness.

3.1.3. Use the pliers to remove the 2 circlips between the selector
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cable and the selector arm, and loosen the selector cable.

3.1.4. Use a 10# socket spanner to remove the 2 bolts connecting

the selector cable bracket and the gearbox.

3.1.5. Use the pliers to take out the white circlip from the
clutch hard pipe, and take out the clutch hard pipe
from the bracket; be careful not to distort it while doing this.

3.1.6. Use a 13# socket spanner to remove the 2 bolts connecting

the clutch slave cylinder and engine cylinder block, and slightly
take down the clutch slave cylinder.

3.1.7. Use a 12# socket spanner to remove the engine

grounding wire.
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3.1.8. Use a 22# socket spanner to remove the drain bolt of
the gearbox, use special engine oil saver to recover the used
oil, and prevent the oil in contact with your skin or clothes in
the process of oil dumping.

3.1.9. Use the 13# and 15# socket spanners to remove 4 bolts
connecting the drive shaft and rear axle.

3.1.10. Use a 13# socket spanner to remove 2 bolts

connecting the drive shaft and the center of car body.
While doing this, hold up the drive shaft and then
put it down slowly after the bolts are totally loosened.

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3.1.11. Use a 13# socket spanner to remove the 2 bolts
connecting the starter and engine, take down the engine
assembly.

3.1.12. Use a 13# socket spanner to remove the 8 bolts

connecting the flywheel housing and engine.

Attention: In the process of removing other bolts, you should

loosen all of them by 2 or 3 steps rather than by one step.
When all of the bolts are loosened enough for hand operation,
lift the support trolley to the forepart of gearbox so as to prop
it up fully, and then screw down all the bolts.

3.1.13. Use an 18# double offset ring spanner and a 22#

socket spanner to remove the bolts connecting the gearbox
mounting and the car body.
Attention: please keep safety in mind during the process
of removal so as to avoid accidents.

3.1.14. Take down the gearbox assembly from

the vehicle.

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4. Installation Steps
4.1.1. First lift the vehicle to a proper position, then use the support trolley to lift up the gearbox.
4.1.2. Push the input shaft of the gearbox into the clutch facing spline, and screw the bolt connecting
the flywheel housing and the engine by hand after the spline is totally engaged, then tighten it with the
specified torque.
4.1.3. Fit the gearbox rear mounting bolt through the sheet metal, and tighten it with the specified
torque.
4.1.4. Align and engage the starter gear with the flywheel, and tighten the bolt with specified torque.
4.1.5. After the forepart of drive shaft is aligned with the spline of the gearbox output shaft, tighten the
bolt connecting the drive shaft central fixed point and the car body with the specified torque.
4.1.6. Tighten the 4 bolts connecting the drive shaft rear end and the drive axle with the specified
torque.
4.1.7. Lower the vehicle after lubricating the gearbox.

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 VI. Disassembly of Gearbox Assembly
1. Preparations
1.1. Tools
1 set of double offset ring spanner, 1 set of sockets, torque spanner, cross and slotted screwdrivers,
vernier caliper, dial indicator, pincer pliers, long nose pliers, plastic hammer and iron hammer etc.

1.2. Auxiliary Material

Gearbox fluid
1.3. Appliances for Protection
Gloves, work clothes, safety helmet and work shoes
2. Precautions
2.1. Please wear necessary articles for labor protection, so as to avoid accidents.
2.2. The gearbox fluid is toxic. If it contacts with the skin or eyes incautiously, please rinse them with
plenty of water immediately. If necessary, go to the hospital without delay.
2.3. Use a container for disused gearbox fluid. It is forbidden to dump it into the sewer, or pile it up
together with domestic rubbish.

3. Removal of Gearbox Assembly

3.1. Removal (Disassembly of gearbox assembly)
3.1.1. Take down the release lever and release bearing of
the clutch, check if there is any obvious distortion and
abrasion on the lever and bearing.

3.1.2. Rotate the gearshift arm of the gearbox to the neutral

position, and use a 12# socket spanner to remove the 6 bolts of
the gearshift mechanism.

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3.1.3. Use a13# spanner to remove the odometer sensor.

3.1.4. Use a 12# socket spanner to remove the 6 bolts

connecting the rear mounting and gearbox, take down
the mounting assembly.

3.1.5. Use a 14# socket spanner to remove the 9 bolts

connecting the clutch housing and the gearbox housing, and
take down the clutch housing assembly.

3.1.6. Tap the clutch housing slightly with a wooden hammer

till it is separated from the clutch, and then take down the
clutch housing.

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3.1.7. Use a 14# socket spanner to remove the 10 bolts
connecting the front and rear housings of the gearbox.

3.1.8. Tap the gearbox rear housing slightly with a

wooden hammer till it is separated from the gearbox,
then take down the gearbox rear housing assembly

3.1.9. Use a 12# socket spanner to remove the 8 bolts

connecting the input shaft and the intermediate shaft bearing
stop plate with the front housing, then take down the bearing
cover plate.

3.1.10. Use the circlip pliers to remove the input shaft and the
adjusting gasket of intermediate shaft bearing, check if
there is any distortion and abrasion on the adjusting gasket.

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3.1.11. Tap the front housing of the gearbox slightly with a
wooden hammer till it is separated from the gearbox, then
take down the front housing assembly of the gearbox.

3.1.12. Use the circlip pliers to remove the gear hub circlips
of the gear 5 synchronizer.

3.1.13. Use the special tool (puller) to pull out the gear
hub and gear of the gear 5 synchronizer.

3.1.14. Use an inner double offset ring spanner to remove

the 3 self-locking screws of selector shaft, and take out
the spring and the steel balls.

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3.1.15. Use a 10# socket spanner to remove the 2 bolts
connecting the gear shift fork and the selector shaft.

3.1.16. Use the special tool to knock out the flexible

cylindrical pin of the gear shift fork limit stop.

3.1.17. Use the circlip pliers to remove the circlip from the
three selector shafts, take out the selector shaft slowly and
then take down the interlocking steel balls.

3.1.18. Use a 13# socket spanner to remove the 4 bolts of

the bearing stop plates of output and intermediate shafts,
then take down the bearing stop plates.

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 VII. Schematic Diagram of Gearbox Assembly
1. Schematic Diagram of Gearbox Assembly

1. Clutch housing 2. Shift fork strut 3. Release fork 4. Release bearing

component assembly
5. Release fork shroud 6. Front cover 7. Stopper ring of input 8. Stopper ring of
component shaft bearing intermediate shaft front
bearing
9. Gearbox housing 10. Bowl-shaped 11. Cylindrical pin 12. Hollow dowel pin
patch
13. Rear housing 14. Rear housing 15. Reverse gear 16. Selector shaft
subassembly lifting cover switch subassembly
17. Return spring 18. Spring seat 19. Elastic cylindrical 20. Shifting block of
pin selector shaft
21. Hollow pin 22. Dust boot 23. Selector rocker arm 24. Control cover
component component
25. Selector rocker arm 26. Limit stop 27. Pressure torsion 28. Elastic cylindrical pin
component spring

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2. Schematic Diagram of Selector Shaft and Central Connecting Plate Assembly

1. Shift fork positioning 2. Gear 3/4 shift 3. Gear 1/2 shift fork 4. Bolt with washer
bolt fork
5. Reverse gear shift 6. E-type retainer 7. Reverse gear shift 8. Reverse gear shift fork
rocker arm bracket ring rocker arm
9. Self-locking 10. Fork shaft 11. Steel ball 12. Central connecting
positioning spring plug positioning spring plate
13. Clamp retainer ring 14. Gear 3/4 shift 15. Limit stop of gear 16. Gear 1/2 shift fork shaft
fork shaft shift fork
17. Elastic cylindrical 18. Gear 5 shift 19. Interlocking guide 20. Gear 5 shift fork shaft
pin fork component pillar
21. Short interlocking 22. Reverse gear 23. Reverse gear 24. Gearshift guide block
pin shift fork shaft positioning spring
25. Gearshift guide
block

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3. Schematic Diagram of Output Shaft Assembly
1. Retainer ring for gear 3/4
synchronizer gear hub shaft
4. Slide block of gear 3/4
synchronizer
7. Third speed gear needle
bearing
10. Pin
13. Ring gear cone of gear 1
synchronizer
16. Slide block of gear 1/2
synchronizer
19. Gear sleeve of gear 1/2
synchronizer
22. Middle ring of gear 1
synchronizer ring gear
25. First speed gear needle
bearing
28. Output shaft bearing
31. Spacer sleeve
2. Gear sleeve of gear 3/4 3. Expansion ring of gear 3/4
synchronizer synchronizer
5. Gear hub of gear 3/4 6. Ring gear of gear 3
synchronizer synchronizer
8. Third speed gear 9. Output shaft
component
11. Second speed gear 12. Second speed gear needle
component bearing
14. Middle ring of gear 1 15. Gear 2 synchronizer ring gear
synchronizer ring gear cup
17. Compression spring 18. Gear hub of gear 1/2
synchronizer
20. Ring gear cone of gear 21. Ring gear cone of gear 1
1 synchronizer synchronizer
23. Gear hub retainer ring 24. First speed gear needle
of gear 1/2 synchronizer spacer sleeve
26. Gear 1 component 27. First speed gear thrust gasket
29. Output shaft bearing 30. Fifth speed gear of output
stop collar shaft
32. Rear bearing of output 33. Retainer ring for rear shaft of
shaft output shaft
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4. Schematic Diagram of Intermediate Shaft Assembly

1. Retainer ring for front shaft of intermediate shaft

2. Front bearing of intermediate shaft
3. Union gear of intermediate shaft

5. Schematic Diagram of Input Shaft Assembly

1. Retainer ring for Input shaft 2. Input shaft bearing

3. Input shaft component 4. Input shaft needle bearing
5. Ring gear of gear 4 synchronizer

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6. Schematic Diagram of Rear Housing Assembly

1. Hexagon bolt with washer 2. Oil guide 3. Oil nozzle

4. Rear housing component 5. Screw plug
6. Rear housing bushing 7. Oil seal 8. Dust boot of rear housing

7. Schematic Diagram of Gearshift Control Mechanism Assembly

1. Control cover component 2. Selector rocker arm 3. Selector rocker arm component
4. Dust boot 5. Hollow pin 6. Shifting block of selector shaft
7. Elastic cylindrical pin 8. Spring seat 9. Return spring
10. Selector shaft 11. Elastic cylindrical pin 12. Pressure torsion spring
13. Limit stop 14. Small cotter

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8. Technical Parameters for Assembly and Adjustment of the Gearbox
4.1. Technical parameters for assembly and adjustment of the gearbox

a). Axial clearance between the synchronizer ring gear and the gear

Gear 1 2 3 4 5

Standard
1.2±0.55 1.2±0.55 1.2±0.45 1.2±0.50 1±0.32
clearance (mm)
Clearance limit
0.65 0.65 0.75 0.70 0.68
(mm)

b). Axial gear clearance for different gears

Gear 1 2 3 5

Axial clearance
0.2~0.45 0.10~0..25 0.10~0.25 0.10~0.35
(mm)
4.2. Precautions for assembly of the gearbox
1). Wash all parts (except for rubber parts and pads) before installation;
2). Do not reuse all kinds of oil seals, retainer rings for shaft and spring pins;
3). Apply lubricating oil to friction surfaces and lubricating grease to the lip of oil seals;
4). Do not tilt while adapting lip oil seals;
5). Do not use the roller to transmit pressure while installing bearings;
6). Stagger the open ends of the spring expansion ring on both sides while assembling the synchronizer
components;
7). Apply seal glue while assembling the gearbox housing.

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 VIII. Basic Diagram of Gearbox Structure
1. Diagram of Working Principles

1. Input shaft 6. Gear 1/2 synchronizer 11. Gear 5 synchronizer

2. Constant-mesh gear of input 7. First speed driven gear 12. Fifth speed driving gear
shaft
3. Gear 3/4 synchronizer 8. Fifth speed driven gear 13. Idle gear of reverse gear
4. Third speed driven gear 9. Output shaft 14. intermediate shaft union
gear
5. Second speed driven gear 10. Fifth speed union gear

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2. Diagram of Gear Transmission
2.1. Gear 1

Input shaft → Constant-mesh gear of input shaft → Union gear of intermediate shaft → First speed
driven gear → Gear 1/2 synchronizer → Output shaft
2.2. Gear 2

Input shaft → Constant-mesh gear of input shaft → Union gear of intermediate shaft → Second speed
driven gear → Gear 1/2 synchronizer → Output shaft

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2.3. Gear 3

Input shaft → Constant-mesh gear of input shaft → Union gear of intermediate shaft → Third speed
driven gear → Gear 3/4 synchronizer → Output shaft

2.4. Gear 4

Input shaft → Constant-mesh gear of input shaft → Gear 3/4 synchronizer → Output shaft

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2.5. Gear 5

Input shaft → Constant-mesh gear of input shaft → Union gear of intermediate shaft → Gear 5 union
gear → Gear 5 synchronizer → Fifth speed driving gear → Fifth speed driven gear → Output shaft

2.6. Reverse gear

Input shaft → Constant-mesh gear of input shaft → Union gear of intermediate shaft → Reverse gear
→ Gear 1/2 synchronizer → Output shaft

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 IX. Bleeding Methods of Hydraulic Clutch
QR530MZB gearbox employs a full-hydraulic clutch mechanism, which makes bleeding more
convenient. It is necessary to depress the clutch pedal repeatedly before performing bleeding on the
complete vehicle. First, fully depress the pedal and then open the black screw plug on the connector of
the hydraulic release bearing, unscrew the switch on the connector and rotate it by 90º, and after the
air is bled from the connector, screw down the switch. Repeat this operation several times until there is
no air left in the clutch, and then screw down the switch.
X. Methods of Use/Operation and Precautions
1. The clutch pedal should be totally depressed down in gear shifting, and after the drive gets rid of
the torque force of the engine, the shift lever should be operated rapidly for gear shifting.
2. Low speed gears should be applied on the downhill or in turning, and coasting with clutch released
is not allowed.
3. Do not skip any gear while shifting up; otherwise the synchronizer’s service life may be shortened.
4. When the engine stalls, it is strictly forbidden to use the synchronizer compulsorily for gear shift to
start the engine; otherwise the synchronizer’s service life will be affected.
5. It is strictly forbidden to flap the gearshift lever (i.e. pushing and releasing it intermittently) in gear
shifting, while the gearshift lever should be held by hand all the time, which can greatly reduce the
sliding friction time of the synchronizer lock ring and the wear of the lock ring itself.
6. Do not put your hand on the selector lever when the vehicle is traveling; otherwise premature wear
may occur.
7. While using the gearbox, if there is any abnormal phenomenon such as abnormal sound, obviously
heavy operation etc., immediately stop and check the vehicle to eliminate the malfunction before
continuous driving.

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 XI. Common Malfunctions and Troubleshooting
Malfunction Possible Cause Troubleshooting
Input and output shaft bearings are damaged Replace the bearing
Bumping, burr or pitting on gear surface or poor contact Repair or replace the
gear
Excessive or
Improper axial position and clearance of the gears Inspect and adjust it
abnormal
Too low oil level and insufficient lubrication Refill to the specified
noise
level
Some foreign materials inside the assembly Inspect and eliminate
any foreign materials
Excessive wear or damage to the oil seal Replace it
Sealant not applied evenly or the packing is damaged Replace the packing,
Oil leakage glue
The bumping on the joint surface is not repaired in time Inspect and repair it
Differential bearing is damaged Replace it
The clutch is not separated entirely because of improper Adjust it
adjustment to it
Difficult
Improper adjustment to gearshift drive train or the Inspect and adjust it
gearshift
presence of motor disturbance
Synchronizer ring failure Replace it
Synchronizer gear sleeve or the joint taper surface of the Replace related parts
Gear-off gear is worn
Improper adjustment to gearshift power train Inspect and adjust it
Gearshift Gearshift power train becomes loose Inspect and repair it
failure The rocker arm of driver gearshift is loosening Repair it
Lubricating oil contains some metal impurities Replace it
Abnormal
The lubricating oil applied is insufficient or doesn’t conform Replace it
damage of
to relevant requirements
bearings
A defective bearing is being used Replace it

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