Great Wall. Service manual for chassis and body (2006) — page 10

TF-28

Transfer Box

Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear)

Maintenance or Change of Gear or Chain

Sprocket Gear

1.

Maintenance principle

(a) Conduct the maintenance for the partial, small peel off

with the suitable manual high-speed grinding tool.

(b) Do not clear away the metal as can as possible when

grinding the matrix metal.

(c) All pointed angles and sides must be repaired as the slip-

pery contour line. Because the pointed angle or edges

may be peeled off again or developed into crack.

(d) Clear away the burr with the suitable grinding stone. Take

notice not to damage the matrix when clearing away the

projecting materials, and

(e) When substituting the non-repaired parts (such as

bearing), if the part is doubted in its re-application

capability, it must be changed.

2.

Cases for gear or chain sprocket maintenance or substi-

tuting

(a)

The gear, being peeled off at the two sides of tooth top in

contact face, may be repaired for reuse.

(b)

The gear, being peeled off at the central tooth top of

contact face, may be repaired for reuse.

(c)

The gear, being peeled off at one side of the non-contact

face, may be repaired for reuse.

TF-29

Transfer Box

Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear)

(d)

The gear, being peeled off at the center of one side of

contact face, may be repaired for reuse

(e)

The gear, being peeled off in the center of contact area,

shall be changed.

(f)

The gear, being peeled off at two sides of tooth top, shall

be changed.

TF-30

Transfer Box

Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts)

Change the parts and fittings as requirement

Attachment for Inspection Maintenance or Change of Parts

Checking items

Acceptance/Refusal

Parts (items)

All parts (including

all springs)

Crack inspection, distortion inspection and ero-

sion inspection

All parts with crack, all parts that are bended,

distorted or poor in round bouncing are refused.

All threaded parts

Thread inspection for buckle missing or other

damage

Those parts cannot be threaded or bottomed in

overlap manner shall be refused.

F l a n g e a n d f o r k

flange

Please refer to the paragraph of

inspection

to

check the spline.

Please refer to the

inspection paragraph

for

spline inspection.

Velocity sensor, mo-

tor assembly

Parts of electric clutch

system

Please refer to the part of electric appliance

Sliding bearing

Inside surface inspection for the sliding bearing

In the case that the bearing has pitting corrosion

or other damage, refuse it.

Ball bearing

Check visually the ball and track of the ball

bearing to see whether there is damage such as

adhesive bonding, pitting corrosion, etc.

Ensure that the bearing are all lubricated, run the

outer race of the bearing while holding the inner

one to feel whether there is poor running or

corrosion, the bearing shall be run smoothly

without excessive clearance.

Refuse to use the damaged bearing;

Refuse to use the damaged or loose bearing; or

Check the axial clearance to see whether it

exceeds 0.23mm.

Needle bearing

Check the bearing needle roller and track to see

whether there is damage such as adhesive

bonding, pitting corrosion, etc.

Refuse to use the damaged bearing.

The rear cover, front

body and front hous-

ing of transfer box

Check to see whether there is burr on the cou-

pling face or other damage that impedes assem-

bling or sealing.

Clear away the burr according to the paragraph

of

inspection

, otherwise, change the dam-

aged element

Rear cover of trans-

fer box

Check the bearing hole

Refuse to use the assembly that has pitting

corrosion

Odometer gear

Check the gear teeth referring to the Inspection

Paragraph

Refer to the gear or chain sprocket inspection in

inspection paragraph

.

Clutch shell, joint

outer gear sleeve and

joint cover

Check the spline according to the Inspection

paragraph

Refer to the spline inspection of

inspection

paragraph

Locking sleeve

Check the wear or damage of the toggle fork

groove

Refuse the parts with step slipping or damage.

Shift guide shaft

Check the deformation situation

Check the burr or other damage on outer race

Check the wear of outer race

Refuse to use the bend shaft; clear away the burr

according to the

inspection

paragraph, oth-

erwise refuse to use.

Refuse to use the shaft with step slipping or

other damage.

Shift toggle fork

Check whether there is wear or damage at the

location where the toggle fork combines with

the shifting cam and gear sleeve.

If any step slipping or damage is found, refuse

to use it.

TF-31

Transfer Box

Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts)

Attachment for Inspection Maintenance or Change of Parts

Parts (items)

Checking items

Acceptance/Refusal

Shift toggle fork as-

sembly

Check the wear and damage of the inserted face

that is combined with gear sleeve;

Check to see whether the contact roller can

rotate freely or is damaged or not

If any step wear or damage is found, the inserted

face shall be refused to use.

If the contact runs difficultly or is damaged, a

new pin-contact roller and new cage assembly

shall be used.

Driving and driven

chain sprocket

C h e c k t h e s p r o c k e t t e e t h a c c o r d i n g t o

the

inspection

paragraph

Refer to the sprocket teeth inspection of

inspection

paragraph

Shift toggle fork as-

sembly

Check the inner diameter that matches with the

output shaft

If any pitting corrosion or damage is found,

refuse to use it.

Driving chain

Check the step sliding, looseness or damage of

pin or connecting element

Refuse to use the weary or damaged driving

chain

Filtering screen

Check to see the filtering screen is clean or with

small hole or damage

Clean it where necessary, and abandon the dam-

aged one.

TF-32

Transfer Box

Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection

Maintenance or Change of Parts

Pump shell

Check to see whether there is pitting corrosion

or step slipping

Abandon it in case it is seriously damaged or

worn

Output shaft

Check the spline, check the surface that matches

with bearing and check the distortion according

to

inspection

paragraph

Refer to the spline inspection of

inspection

paragraph;

Refuse to use the one with pitting corrosion or

damage;

Refuse to use the one that is bending or poor in

round bouncing.

Deceleration hub

Check the spline of chain sprocket and check the

wear or damage of the location where matches

with the toggle fork according to the

inspection

paragraph

Refer to the spline inspection of

inspection

paragraph; refuse to use the one with step slid-

ing or damage.

Front output shaft

Check the surface where matches with the

bearing;

Check the spline according to the

inspection

:

paragraph

Refuse to use the one with pitting corrosion or

damage

Input shaft

Check the spline according to the

inspection

paragraph

Check the distortion

Refer to the spline inspection of

inspection

paragraph;

Refuse the one that is bending or poor in round

bouncing.

Thrust washer and

thrust disc

Check the pitting corrosion

Refuse to use the one with pitting corrosion or

damage

Sun wheel

Check the gear teeth and spline according to the

inspection

paragraph

Refer to the gear teeth inspection and spline

inspection of

inspection

paragraph.

Planetary mechanism

assembly

Check the gear teeth according to the

inspection

paragraph;

Check the wear and looseness of the planetary

gear pin; check the wear of thrust gasket

R e f e r t o t h e g e a r t e e t h i n s p e c t i o n o f

inspection

paragraph;

If any step sliding or pitting corrosion is found,

refuse to use it

Electric shifting cam

Check to see whether there is step slipping or

pitting corrosion

If any step sliding or pitting corrosion is found,

refuse to use it

Shift guide shaft

Check to see whether there is step slipping or

pitting corrosion

Check the distortion situation

If any step sliding or pitting corrosion is found,

refuse to use it

Refuse to use the bending one

Planetary gear ring

Check the match performance of it with the

transfer box housing

Check the gear teeth according to the

inspection

paragraph

Check the transfer box housing assembly to see

whether the gear ring is loose or not in the

housing

R e f e r t o t h e g e a r t e e t h i n s p e c t i o n o f

inspection

paragraph

Transfer box housing

Check the holes matches with the bearing

Abandon the one with pitting corrosion or

damage.

PR-1

Drive shaft

page

Notice . . . . . . . . . . . . . . . . . . .. PR-2

Troubleshooting . . . . . . . . . . . . . . .. PR-2

Drive shaft . . . . . . . . . . . . . . . . ... PR-3

PR

PR-2

Drive Shaft

Notice and Troubleshooting

Notice

Notice: do not grip the drive shaft sleeve too tight with vice

so as to avoid the deformation.

troubleshooting

Trouble

Causes

Resolving approaches

Noise

Wear of universal joint yoke spline;

Wear of central bearing;

Wear or seize-up of cross shaft bearing

Change the drive shaft;

Change the central bearing;

Change the bearing of cross shaft

Vibration

Oscillation difference of the drive shaft;

Drive shaft imbalance;

Wear of the liner of rear bearing in the lengthening shell of

gear box;

Spline seize-up of the universal joint yoke

Change drive shaft

Change drive shaft

Change the liner

Change drive shaft

PR-3

Drive Shaft

Element Drawing

2WD

two-joint type

snapping ring

bearing of cross shaft

universal joint flange fork

rear axle drive shaft

universal joint foke

cross shaft

three-joint type

snapping ring

bearing of cross shaft

universal
joint foke

cross shaft

front joint of rear
axle drive shaft

center support
bearing

flange

washer

washer

74

5

40

5

universal joint
flange fork

74

5

74

5

universal joint
flange fork

rear section of
rear axle drive
shaft

N*m

: specified torque

Parts that cannot be reused after being used

Drive Shaft

Drive Shaft

PR-4

Drive Shaft

Drive Shaft

Element Drawing(continued)

4WD

front axle drive shaft

front axle drive shaft

74

5

74

5

rear axle drive shaft

two-joint type

snapping ring

bearing of cross shaft

74

5

74

5

cross shaft

universal joint yoke

rear axle drive shaft

universal joint flange fork

three-joint type

74

5

40

5

snapping ring

bearing of cross shaft

center support
bearing

flange

front joint of rear
axle drive shaft

washer

universal joint flange fork

74

5

74

5

rear section of
rear axle drive
shaft

universal joint
flange fork

Parts that cannot be reused after being used

N*m

: specified torque

PR-5

Drive Shaft

Drive Shaft

(4WD)

Rear axle drive shaft

1.

Take apart the universal joint flange fork of rear axle drive

shaft from the differential flange.

(a)

Label the two flanges with assembly marks.

(b)

Take apart the four sets of bolt and nut.

Disassembly of Drive Shaft

(2WD)

1.

Take apart the universal joint flange fork of the drive shaft

from the differential flange.

(a)

Label the two flanges with assembly remarks.

(b)

Take apart the four sets of bolt and nut.

assembly mark

2.

Take apart the center support bearing from the frame

beam (for the three-joint type)

3.

Take apart the drive shaft from the gearbox

(a)

Pull out the universal joint yoke from the gearbox.

(b)

Insert the SST in gearbox for oil leakage prevention.

2.

Take apart the center support bearing from the frame

beam (three-joint type

SST

assembly mark

PR-6

Drive Shaft

Drive Shaft

3.

Take apart the drive shaft from the gearbox.

(a)

Pull out the universal joint yoke from the gearbox.

(b)

Insert the SST in gearbox to prevent the oil leakage

Front axle drive shaft

4.

Tear down the front universal joint flange fork of the front

drive shaft.

(a)

Hang he front end of the front axle drive shaft.

(b)

Label the assembly mark on the flange

(c)

Take apart the four sets of bolt and nut.

5.

Disconnect the rear universal joint flange fork from the

front axel drive shaft along the transmission path.

(a)

Label the assembly marks on each flange.

(b)

Take apart the four sets of bolt and nut.

Drive shaft disassembly

1.

Separation of the rear joint of the rear axle drive shaft

from the front joint of rear axle drive shaft

(a)

Label the assembly marks on each flange.

(b)

Take apart the four sets of bolt and nut.

2.

Take apart the center support bearing from the front joint

of the rear axle drive shaft.

(a)

Loosen the riveted nut by chiseling with a chisel and

hammer.

SST

assembly mark

assembly mark

PR-7

Drive Shaft

Drive Shaft

(b)

Lock the flange with SST tools to tear down the nuts.

(c)

Label the assembly marks on flange and shaft.

SST

SST

assembly mark

assembly mark

(d)

Tear down the flange from the front joint of rear axle

drive shaft with SST tools.

3.

Take apart the universal joint yoke from the rear joint of

rear axle drive shaft.

(a)

Label the universal joint yoke and the shaft with assem-

bly marks.

(b)

Pull out the universal joint yoke from the shaft.

Inspection on Drive Shaft Parts

1.

Cross shaft bearing inspection

Check the wear or damage situation of the cross shaft bearing

and change the weary or damaged bearing where necessary.

2.

Check the wear and damage situation of the central

bearing.

Check the bearing to see whether it can run freely.

In case that the bearing is damaged or wearied or cannot run

freely, change it in time.

PR-8

Drive Shaft

Drive Shaft

3.

Inspection for the front axle drive shaft

(a)

Check the wear or damage situation of the shaft.

(b)

Check the wear or damage situation of the two universal

joints

grease nozzle

rear axle drive shaft

front axle drive shaft

assembly mark

assembly mark

SST

A

4.

Inspection for the drive shaft lubrication

If the drive shaft is not lubricated completely, add the Lithium

base lubricant grease with SST.

Cross bearing change

1.

Label the shaft and universal joint yoke with assembly

marks.

2.

Take apart the snapping ring.

(a)

Tap in the outer bearing race lightly.

(b)

Take apart the four snapping rings in the grooves with

two screwdrivers.

3.

Take apart the cross shaft bearing

(a)

Pull out the bearing from the drive shaft with SST tools.

Remarks: Pull up the part A in the drawing to a enough height

so that it cannot contact the bearing.

PR-9

Drive Shaft

Drive Shaft

SST

(c)

Mount the two outer bearing races that are taken apart on

the cross shaft.

(d)

Pull out the bearing on the universal joint yoke with SST

tool, and

(b)

Grip the outer bearing race with a vice to tap out the drive

shaft lightly with a hammer.

Remarks: Take apart another bearing with the same approach.

4.

Cross shaft bearing mount

(a)

Coat the lithium base grease on the cross shaft and the

bearing.

Remarks: do not over coat the lubricant.

(b)

Align the assembly marks on the universal yoke and on

the shaft.

(e)

Grip the outer bearing race in the vice and tap lightly out

the universal joint yoke with a hammer.

Remarks: the bearing at the other end may be taken apart with

the same approach.

PR-10

Drive Shaft

Drive Shaft

5.

Snapping ring mount

(a)

Mount two snapping rings with the same thickness.

Remarks: Do not use the used snapping ring.

(b)

Tap the universal joint yoke lightly with a hammer until

there is no clearance between the outer bearing race and

the snapping ring.

6.

Cross shaft bearing inspection

Check the cross shaft bearing to see whether it can run freely

Remarks: the approach for mounting the cross shaft bearing at

the bearing end is the same.

(c)

Encase the new cross shaft in the universal joint yoke.

(d)

Mount the new bearing on the cross shaft with SST tool,

and

SST

(e)

Adjust the two bearings with SST tool so that the widths

of two snapping ring grooves are equal and maximum.

PR-11

Drive Shaft

Drive Shaft

Drive shaft assembly

1.

Mount the center support bearing on the front joint of rear

axle drive shaft.

Remarks: The notch of the center support bearing shall face

backward when mounting it.

2.

Mount the flange joint on the front joint of rear axle drive

shaft.

(a)

Coat the spline of front joint of rear axle drive shaft with

lithium base grease.

(b)

Mount flange joint on the shaft and align the assembly marks.

Remarks: if the central flange joint or the front joint of the rear

axle drive shaft is required to change, the front and back

universal joint yokes of the rear axle drive shaft shall face in the

same direction when re-assembling.

(c)

Lock the flange joint with SST and screw up the newly-

changed nut to press the bearing in place.

(d)

Loosen the nuts.

(e)

Tighten the nuts again, and

(f)

Rivet the nuts with hammer and punch.

3.

Drive shaft mount

(a)

Align the assembly marks on flanges, and connect the

two flanges with four sets of bolt and nut.

Remarks: if the central flange or the front joint of the rear axle

drive shaft is required to be changed, the front and back

universal joint yokes of the front joint of rear axle drive shaft

shall face in the same direction when reassembling them.

(b)

Screw up the sets of bolt and nut according to the

specified torque.

Fastening torque: (74

5)N

m

4.

Insert the universal joint yoke in the universal joint yoke

(4WD).

(a)

Coat the lithium base grease on the sliding surfaces of the

drive shaft spline and the universal joint yoke.

(b)

Align the assembly marks on universal joint yoke and

drive shaft.

(c)

Insert the universal joint yoke in drive shaft.

assembly mark

2WD

4WD

forward

assembly mark

SST

assembly mark