Chery S11 / Chery QQ. Manual - part 1

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Chery QQ Service Manual                                  Transmission System 

 

 

24

 
 

Explanation 

1,This manual book is applicable to the usage and maintenance of the gearboxes 

of model DABS10-4 and DABS10-8 manufactured by our factory. 

2,The DABS10-4,DABS10-8  front-wheel-drive transaxles, with fine functions, 

advanced structures, made with high precise, compared with the current local 
products, it is in the leading position. 

3,《DABS10-4 Gearbox  Usage &  Maintenance Manual Book 》 is edited at 

the request of our customers. It describes in details each parts of the gearbox and the 
relations between every part of the gearbox, according to this manual, customers and 
technicians dismantle the gearbox for maintenance and repair by themselves. 

4,In process of maintain and use, please inform us of the existing problems of 

DABS10-4 gearbox and the existing problems in the manual book and forward your 
written improvement opinions to us at any time, we would like to express our sincere 
gratitude. 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

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Chery QQ Service Manual                                  Transmission System 

 

 

25

 

Chapter 1 The Clutch 

Section 1 Summarization 

The clutch used in this car is dry type, a diaphragm spring disc spring, often press 

type clutch. 

The clutch disc assembly is consist of six pieces of absorber springs, and is fixed 

on the input axle of the transmission through splined hub.     

 The clutch platen assembly is fixed on the flywheel, the fixing state of 

diaphragm  spring  is in this mode: when the  Release bearing draws back, the 
edges of diaphragm    spring is beginning to drive the platen against the flywheel。
This is the clutch jointing state. 

Step on the clutch pedal to move release bearing forward, diaphragm spring. At 

this time, diaphragm spring pulls the platen and comes away from the flywheel, 
thereby disconnect driving from the flywheel via to input shaft. 

For the vehicles with three-way catalyst, the clutch switch is located on the upper 

position of the clutch pedal. 

   

 

 
 

 
 
 

1,Pressure plate assembly     2,Pressure plate    3,Diaphragm spring     4,Release bearing

5,Release fork   6,Clutch  housing  7,Clutch  disc  8,Cushion or  damper  spring    9,

Input    shaft      10,Input    shaft      11.Crankshaft            12,Flywheel

 

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Chery QQ Service Manual                                  Transmission System 

 

 

26

Section 2 Fault Diagnosis 

Fault 

Phenomenon 

Reasons Solution 

 

The Clutch 

Skids 

 

The free journey (free moving clearance) of 

the clutch pedal is unavailable. 

The clutch disc has been frayed or has greasy 

dirt. 

The surface of clutch disc pressure plate 

flywheel has been distorted. 

Diaphragm spring has become weaker.   

Clutch cable has rusted.   

Adjust the pedal free play   

 

Replace the clutch    disc, 

 

Pressure plate or flywheel. 

 

Replace the clutch cable. 

The clutch does 

not come away 

completely. 

 

The free journey (free moving clearance) of 

the clutch pedal is unavailable. 

Diaphragm spring has become weaker。 

 

Input shaft splined hub has been frayed. 

The clutch disc swings excessively. 

The clutch disc has been damaged or has 

greasy dirt. 

Adjust the free journey 

 

Replace the pressure plate 

assembly。 

Lubricate 

Replace the input shaft 

Replace the clutch disc. 

 

 

The clutch 

vibrate 

 

The clutch disc has been frayed as clean as 

whistle.  

The clutch disc have greasy dirt  。 

The Release bearing glides badly on the 

Spacer. 

The clutch disc shakes or the clutch disc

contacts badly. 

The clutch disc Cushion or damper spring has 

become weaker. 

The clutch disc rivet has become loose. 

The Pressure plate was damaged or bolt has 

become loose.   

Repair or replace the clutch disc

Replace the clutch disc 

Lubricate. 

 

Replace the clutch disc 

 

Replace the clutch disc 

 

Replace pressure plate assembly 

or flywheel 

Tighten or replace gasket 

The clutch 

contain noise 

 

The release bearing has frayed or damaged. 

The input shaft front bearing was frayed. 

The clutch disc has unwonted noise. 

The clutch disc has cracks. 

The Pressure plate diaphragm spring have 

unwonted noise.   

Replace the release bearing. 

Replace the input shaft bearing. 

Replace the clutch disc 

assembly. 

Replace the pressure plate 

assembly. 

The clutch can't 

take off   

 

The clutch disc was dipped by oil liquid. 

The clutch disc was frayed badly. 

The rivet comes out. 

The cushion or damper spring has become 

weaker. 

Replace the clutch disc assembly

 

 

 

Chery QQ Service Manual                                                Transmission System

-27-  

 

 
 

Section 3 Maintenance on car 

Ⅰ.Maintenance 

  (1) The Clutch Pedal Height 
According to the following regulations, use pedal bracket adjusting bolt to adjust the 

clutch pedal height. It is normal if the height of clutch pedal is higher 8mm(0.3in)than the 
height of brake pedal.. 

 
  (2) The free play of the clutch pedal. 

Step on the clutch    pedal till you feel the resistance, stop stepping and mensurate 

the distance clutch pedal free play. The free play must be within the following stated 
ranges.  

If the free play is wrong, please adjust the clutch cable free play according to the 

diagram below. 

While checking clutch pedal free play, be sure to check if the working state of the 

clutch is normal under the circumstance that the engine is running. 

     
(3) Clutch Switch 

Attention: 
This switch is applicable to the vehicles with catalyst. 
Adjust: 

1. Pull the parking brake handle, push the shift lever to the neutral positon. 

2.Take apart the connect beside the pedal Bracket. 
3.Loosen the lock nut. 

4. Adjust the installation position of the gearing position of clutch pedal, the clearance 

between switch connect and clutch bracket is the size A, then tighten the lock nut. 

5. Connect. 

N.m 

 

Kg-m 

 

1b-ft 

 

The clutch switch 

lock nut adjustment 

torque 

 

10-15 1.0-1.5 

7.5-10.5 

 
（4）Clutch  Cable 

Unload: 

Dismantle the clutch    cable    connect    nut , and move off connection lock on the 

inner cable. 

Take apart two bolts from the front wainscot, cable top from the table, at last take out 

the cable. 

 
Check: 

Check the clutch cable, if appears one of the following status, replace the cable.