Great Wall. Service manual for chassis and body (2006) — page 3

CL-1

CL

Page

Troubleshooting . . . . . . . . . . . . . . .. CL-2

Inspection and adjustment of clutch pedal . . . . ... CL-3

Air exhausting of clutch . . . . . . . . . . . . CL-3

Clutch master cylinder . . . . . . . . . . . . CL-4

Clutch wheel-brake cylinder . . . . . . . . . . . CL-6

Clutch cluster . . . . . . . . . . . . . . . ... CL-7

Clutch

CL-2

Clutch

Troubleshooting

Troubleshooting

Trouble

Causes

Repairing approaches

Difficulty in gearshift

or non-gearshift

Overlarge free stroke of clutch pedal

There is air in clutch pipe

Failure of clutch brake-wheel cylinder

Failure of clutch master cylinder

Overlarge clutch pendulum difference due to incorrect mounting, the

friction liner is stained with oil or is breaking

There is dirty or adhesive materials on spline of input shaft or clutch rib

Failure of clutch pressure plate

Adjust the free stroke of pedal

Exhaust the air in clutch pipe

Change the clutch brake-wheel cylinder

Change the master cylinder

Check the clutch rib

Repair according to requirement

Change the clutch pressure plate

Disengagement of gear

box or clutch slip

Abrasion of clutch guide shaft

Insufficient free stroke of clutch pedal

The friction liner of clutch rib is stained with oil or is worn

Failure of clutch pressure plate

Seize up of separation fork

Change the guide shaft

Adjust the free stroke of pedal

Check the clutch rib

Change the clutch pressure plate

Check the separation fork

Clutch seize-up or

shaking

The friction liner of clutch rib is stained with oil or is worn

Failure of clutch pressure plate

Looseness of engine seat

Check the clutch rib

Change the clutch pressure plate

Repair according to requirement

Looseness of clutch

pedal

There is air in clutch pipe

Failure of clutch brake-wheel cylinder

Failure of clutch master cylinder

Exhaust the air in clutch pipe

Change the clutch brake-wheel cylinder

Change the master cylinder

Over-loud clutch noise

Seize up of separation fork;

Abrasion or stained spot of separation bearing

Abrasion of guide bearing

Parts looseness in clutch pressure plate

Repair according to requirement

Change the separation bearing

Change the guide bearing

Change the clutch pressure plate

CL-3

Clutch

Inspection and Adjustment of Clutch Pedal, Air Exhausting of Clutch

Air-exhausting of clutch

Remark: in case operation needs to be conducted for the clutch

system or if there is air in clutch, exhaust the air.

Notice : Do not stain the painted surface with brake liquid,

if any brake liquid is left, wash it away immediately.

1.

Fill the brake liquid into the oil cup of clutch master cylinder;

The oil cup of master cylinder shall often be checked and, if

necessary, added with brake liquid.

2.

Connect the ethene resin pipe to the air-exhausting valve.

Insert the other end of the pipe into the container, half of which

is filled with brake liquid.

3.

Air-exhausting in clutch system

a) Move the clutch pedal up and down slowly for several times.

b) Loosen the air-exhausting valve when pressing the pedal

increasingly until there is brake liquid overflowing, then

tighten the air-exhausting valve.

c) Repeat this operation until the bubble in brake liquid disappears.

Inspection on and adjustment

of clutch pedal

1.

Check whether the pedal height is correct

Pedal height that begins from front wall board:

Dr SF

(165

5)mm

SL SK SY SJ

(190-200)mm

2.

Adjust the pedal height where necessary

Loosen the locking nut and screw off the adjusting bolts until

the pedal height is correct. Then screw up the locking nut.

Pedal free stroke

3.

Check whether the pedal free stroke is correct

Press the pedal lightly until the resistance generated by clutch

occurs.

pedal free stroke: (5-15)mm

4.

Adjust the pedal free stroke where necessary;

a) Loosen the locking nut and rotate the push-rod until the

stroke is correct;

b) Screw up the locking nuts;

c) Check the pedal height after the adjustment of pedal free

stroke.

adjusting spot in

pedal height

pedal height

pedal free stroke

CL-4

Clutch

Clutch Master Cylinder

Clutch Master Cylinder

Element drawing

SST

Disassembly of master cylinder

1.

Tear down the pin of push-rod

2.

Tear down the clutch pipe

Disconnect the jointed pipe nuts with SST

3.

Tear down the master cylinder

a) Tear down the fixing nuts;

b) Pull out the master cylinder.

spring pin with groove

clutch master

cylinder

18

2

19

1

ring pipe

oil cup of clutch master cylinder

spring

piston

U-clamp

pin

open pin of nut

open ring

push-rod

gasket

dust cover

N*m

specified torque

Parts that cannot be reused after using.

nut

CL-5

Clutch

Clutch Master Cylinder

Disassembly of oil cup of master cylinder

1.

Tear down the oil cup

a) Use the pinch and hammer to tap out the spring pin with

groove;

b) Tear down the oil cup and ring pipe.

Assembly of master cylinder

1.

Mount the oil cup

a) Mount the oil cup and the new ring pipe.

b) Use the pinch and hammer to tap in the spring pin with

groove.

Mount of master cylinder

1.

Mount the master cylinder

Mount the fixing nuts and screw them up.

2.

Connect the clutch pipes;

Connect the clutch pipes with SST

3.

Connect the push-rod and mount the pin;

Encase the pin of push-rod with clamping pliers.

4.

Exhaust the air in clutch system and adjust the clutch

pedal.

CL-6

Clutch

Clutch Brake-Wheel Cylinder

Clutch brake-wheel cylinder

Element drawing

clutch brake-wheel cylinder

spring

piston

dust cover

push-rod

air-exhausting plug

N*m

specified torque

Disassembly of brake-wheel cylinder

1.

Tear down the clutch pipeline.

Remove the pipeline with SST

2.

Tear down the two bolts to take down the clutch

brake-wheel cylinder

mount of brake-wheel cylinder

1.

Mount the brake-wheel cylinder with two bolts;

2.

Connect the clutch pipeline;

Connect the pipeline with SST;

3.

Exhaust the air in clutch system.

18

2

19

1

CL-7

Clutch

Clutch Cluster

Clutch cluster

Element drawing

flywheel

clutch rib

clutch pressure plate

separation

bearing

clamp

separation fork

dust cover

30

specified torque

N*m

Disassembly of clutch cluster

1.

Tear down the gear box;

Remark: do not leave the gear oil in drying

2.

Tear down the clutch pressure plate and the clutch rib

a) Make aligning marks on the clutch pressure plate and the

flywheel.

b) Loosen the fixing bolts gradually until the spring tension

is released;

c) Tear down the fixing bolts to pull out the clutch pressure

plate and clutch rib.

3.

Tear down the bearing and separation fork from the gear

box;

a) Tear down the clamp to pull out the bearing;

b) Tear down the separation fork and dust cover.

CL-8

Clutch

Clutch Cluster

Inspection on clutch parts

1.

Check whether there is abrasion or damage of clutch rib;

Measure the depth of the rivet head with calipers.

Min depth of rivet head: 0.3mm

If the depth of rivet head exceeds the limit value, change the

clutch rib.

2.

Check the radial pendulum difference of the clutch

Check the radial pendulum difference of the clutch rib with

multi-meter.

Max radial pendulum difference: 0.8mm

If the radial pendulum difference exceeds the max value,

change the clutch rib.

3.

measure the rdial pendulum difference of the flywheel;

Check the radial pendulum difference of flywheel with multi-

meter;

Max radial pendulum difference: 0.2mm

If the radial pendulum difference exceeds the max value,

change the flywheel.

4.

Check the guide bearing

Exert the force in radial direction to rotate the bearing by hand.

If the guide bearing doesn

t run or if there is great resistance,

change the guide bearing.

Remark: as this bearing is lubricated permanently, it needs not

to be cleaned or lubricated.

5.

Change the guide bearing where necessary.

a) Tear down the guide bearing with SST;

SST

CL-9

Clutch

Clutch cluster

b) Mount the guide bearing with SST.

Remark: the bearing shall be verified in good running after it

is encased in the flywheel hub.

2.

Check whether there is abrasion on the diaphragm spring.

Check the abrasion depth and width of diaphragm spring with

calipers.

Limit value: Max depth: 0.6mm

Max width: 5mm

If the abrasion depth or width of the diaphragm spring exceeds

the limit value, change the diaphragm spring .

3.

Check the separation bearing

Exert force in radial direction by hand to rotate the bearing.

If it cannot be rotated or if the resistance is too large, change

the separation bearing.

Remark:

Remark: as this bearing is lubricated permanently, it doesnít

need to be cleaned or lubricated.

Mount of clutch cluster

1.

Mount the clutch rib on flywheel;

Mount the clutch rib on flywheel with SST.

2.

Mount the clutch pressure plate

a) Align the marks on clutch pressure plate and that on flywheel;

b) Screw up the bolts in even manner around the clutch pressure

plate until pressure plate and the flywheel contact closely,

then tighten the bolts.

Tightening moment: 30 N

m

Remark: tighten the uppermost bolt of the three that is near to

the locating pin.

SST

flywheel side

SST

alignment

mark

CL-10

Clutch

Clutch Cluster

3.

Check the alignment of the diaphragm spring end.

Check the alignment of diaphragm spring end with SST.

Max dislocation: 0.5mm

if the difference is more than the specified value, adjust the

alignment of diaphragm spring end with SST.

4.

Coat the lithium base grease;

Coat the lithium base grease on the following parts:

Contact spot of separation fork and bearing

Contact spot of separation fork and push-rod;

Support spots of separation fork

Spline of clutch rib

5.

Encase the dust cover, separation fork, separation bearing

seat and bearing into the gearbox;

6.

Mount the gearbox.

SST

MT-1

Gear box

page

Notice . . . . . . . . . . . . . . . . . . ... MT-2

Troubleshooting . . . . . . . . . . . . . . ... MT-3

Dismantle of Gear Box . . . . . . . . . . . . . MT-4

Mount of Gear Box . . . . . . . . . . . . . ... MT-7

Disassembly of Gear Box . . . . . . . . . . . . MT-10

Input Shaft Assembly . . . . . . . . . . . . ... MT-18

Element Drawing . . . . . . . . . . . . . .. MT-18

Inspection on Synchronizing Ring . . . . . . . MT-18

Bearing Change . . . . . . . . . . . . . ... MT-18

Output Shaft Assembly . . . . . . . . . . . . . MT-20

Element Drawing . . . . . . . . . . . . . .. MT-20

Disassembly of Output Shaft Assembly. . . . . MT-21

Inspection on Output Shaft Assembly . . . . . .. MT-23

assembly of Output Shaft Assembly . . . . . . . MT-25

Countershaft Assembly And Reverse Idle Gear

Assembly . . . . . . . . . . . . . . . . . .. MT-29

Element Drawing . . . . . . . . . . . . . .. MT-29

Disassembly Inspection and Assembly of

Countershaft Assembly . . . . . . . . . . . . MT-29

Assembly of Reverse Gear . . . . . . . . . .. MT-31

Rear Housing assembly . . . . . . . . . . . ... MT-33

Element Drawing . . . . . . . . . . . . . .. MT-33

Change of Oil Seal . . . . . . . . . . . . ... MT-33

Change of Shaft Bush . . . . . . . . . . . .. MT-33

Inspection on and change of Position-Limit

Mechanism Cluster . . . . . . . . . . . . ... MT-34

Front Cover of Bearing . . . . . . . . . . . . . MT-36

Element Drawing . . . . . . . . . . . . . .. MT-36

Change of Oil Seal . . . . . . . . . . . . ... MT-36

Assembly of Gear Box . . . . . . . . . . . . . MT-37

MT

MT-2

Gear Box

Notice

Notice

Notice for disassembly and assembly of gearbox

Notice shall be taken during the gear disassembly and assembly on the soft handle for the parts, especially

for the coupling faces so as to avoid the collision; each part shall be put down in order to avoid the missing

or mistaking.

Notice shall not only be taken in the aforesaid aspects, but also in the following items

1.

Wash all parts before assembly (rubber fittings and washers excluded).

2.

Various oil seals, retainer rings for shafts, spring-type pins shall not be reused.

3.

Lubricating oil shall be coated on the friction surfaces, and lubricating grease shall be coated on the lips

of oil seals.

4.

Rolling elements shall not be used to transfer the pressure during the various bearing assembly.

5.

Lip-type oil seal must not be sloping when assembling it.

6.

The openness at the two ends of the spring collar shall be misfit when assembling the component

elements of the synchronizing instrument, and

7.

No part is allowed to leak the lubricating oil when the gearbox locating at its working place.

MT-3

Troubleshooting

Gear Box

Troubleshooting

Non-use of clutch

Non-full separation of clutch

Severely warned tooth rings of synchronizing

fittings

Over-hard locating spring

Use the right driving approach

Checking for adjustment

Change

Change

Difficulty in gear engagement

Over-low oil level

Lubricating oil of inferior quality

Non-timely oil change

Unsuitable axial location or clearance of gears

Bearing damage

Burr or collision on gear

Add oil to the specified level

Change it with the specified oil

Change the oil and damaged parts

Check for adjustment

Change

Repair or change the gear

Oil leakage, oil penetration

Oil added above the specified level

Loss or missing of bolts

Vent plug trouble

Sealing element damage

Adjust oil to the given level

Reassembling or fasten the bolt according to

the specified torque

Change

Change

Damage of synchronizer

Overexert in gear shift

Non-use of clutch

Damage on spring collar of synchronizer

Incorrect mounting of drive shaft

Change

Use the right driving approach

Change

Check for adjustment

Non-engagement of gear

Trouble in controlling mechanism

Incorrect assembling the locating spring or

steel ball

Invalidation of locating spring

Severely worn gear sleeve or fork groove

Seriously worn toggle fork

Check for adjustment

Reassembly

Change

Change

Change

Burning bearing, burning gear

Over-low oil level

Inferior lubricating grease

Non-timely oil change, over-dirty oil

Inter-use of differential oil or usage of

additive

Change damaged parts and add oil

Change the damaged parts and lubricating oil

Change damaged parts and lubricating oil

Change damaged parts and lubricating oil

Difficult in gear disengagement

Spring invalidation of synchronizer

Warn inner groove of tooth ring of synchronizer

Tooth ring of synchronizer choked on conical

face

Toggle fork deformation or toggle fork axle

deformation

Severely worn toggle fork

Change

Change

Change

Change

Change

Methods for troubleshooting

Over-loud or abnormal noise

Common Failures

Causes

MT-4

Gearbox

Dismantle of Gear Box

3.

Tear down the shifting ball of gear change lever

Loose the locking nuts by dextroroting the ball.

4.

Tear down the glove box

Dismantle the four bolts of the glove box and put the glove box

into the suitable place.

5.

Tear down the dust cover.

6.

Tear down the gear change lever.

7.

Raise the vehicle to discharge the oil in gearbox.

Warning: the reliability of vehicle shall be verified.

8.

Tear down the drive shaft.

(See page PR-5)

9.

Tear down the odometer sensor and the plugging

elements of backup switch

10.

Tear down the vent pipe.

Tear down the heading exhaust pipe from branch exhaust pipe

Dismantle of gearbox

1.

Disconnect the cathode wire from the cathode of storage

cell.

2.

Tear down the setting bolts of fan cover.

Tear down 4

MT-5

Gearbox

Dismantle of Gear Box

4WD

11.

Tear down the wheel-brake cylinder of clutch.

(a)

Dismantle the setting bolts of the wheel-brake cylinder of

clutch with spanner.

(b)

Hang the wheel-brake cylinder with a thread on the side

of engine without oscillation.

Remark: Do not disconnect the pipeline of the wheel-brake

cylinder.

12.

Tear down the pawl washer and bracket of the rear part

of gearbox:

Two-wheel driving:

(a)

Dismantle the four bracket bolts (skip over this process

for the wielding structure).

(b)

Lift the engine with jack to raise the gearbox a little.

(c)

Dismantle the pawl washer from the rear part of gearbox.

Four-wheel driving:

Dismantle the bolts from the pawl washer and bracket of the

rear part of gearbox to tear down the pawl washer and bracket.

13.

Insert the wooden plate between the bottom frame and

the beam.

MT-6

Gearbox

Dismantle of Gear Box

4WD

14. Dismantle the eight bolts that fasten the beam of gearbox.

15. Tear down the starter

Put the starter on the side of engine.

16. Dismantle the bolts of clutch frame and bracket (wrapping

angle).

17. Tear down the remaining bolts of gear box

18. Tear down the gear box

(a)

Pull out the gear box in backward direction;

(b) Put down the engine at the front and tear down the

gearbox from the vehicle.

Notice: be careful not to damage the dust cover of

expansion shell.