Great Wall. Service manual for chassis and body (2006) — page 11
PR-12
Drive Shaft
Drive Shaft
Mount of Drive Shaft
(2WD)
1.
Insert the universal joint yoke in the gearbox.
(a)
Tear down the SST tools.
(b)
Push the universal joint yoke into the gearbox.
2.
Connect the universal joint flange of the rear joint of rear
axle drive shaft and the relative the differential flange.
(a)
Align the assembly marks on the two flanges and connect
the flanges with four sets of bolt and nut.
(b)
Screw up the sets of bolt and nut according to the
specified torque.
Fastening torque
(74
5)N
m
3.
Mount the center support bearing on the frame beam
(three-joint type)
(a) Use two bolts to mount the center support bearing on the
frame beam and tighten them manually.
(b) Check the bearing seat, which shall be vertical with the
drive shaft, and change it where necessary.
(c) Check the central line of the central bearing and ensure
that the central lines of the central bearing and the bear-
ing seat shall be the same when the vehicle is in the non-
loaded stage. And adjust the bearing seat only it is
necessary.
(d) Screw up the mounting bolts according to the specified
torque.
Fastening torque
(40
5)N
m
(4WD)
1.
Connect the universal joint flange fork of the front axle
drive shaft with the flange that matches with the transfer
box.
Align the assembly marks and use four sets of bolt and nut to
connect the flange fork with the flange, screw up the sets of bolt
and nut according to the specified torque.
Fastening torque
(74
5)N
m
forward
SST
assembly mark
assembly mark
PR-13
Drive Shaft
Drive Shaft
2.
Mount on the front axle drive shaft.
Mount on it and screw up the four bolts according to the
specified torque.
Fastening torque
(74
5)N
m
3.
Connect the universal joint flange fork of the rear axle
drive shaft on the relative differential flange.
(a)
Align the assembly marks on flanges and connect the
flanges with four sets of bolt and nut, and
(b)
Tighten the sets of bolt and nut according to the specified
torque.
Fastening torque
(74
5)N
m
4.
Mount the center support bearing on the frame beam
(three joint type)
(a)
Use two mounting bolts to mount the center support
bearing on the frame beam and screw up them manually.
(b)
Check the bearing seat, which shall be vertical with the
drive shaft, and adjust the bearing seat when necessary.
(c)
Check the central line of the central bearing. The central
line of the central bearing shall be the same with that of
the bearing seat when vehicle is in the non-loaded stage.
(d)
Adjust the bearing seat if necessary, and
(e)
Screw up the mounting bolts according to the specified
torque.
Fastening torque
(40
5)N
m
assembly mark
forward
SA-1
Suspension System and Automobile Axle
Page
Troubleshooting . . . . . . . . . . . . . . .. SA-2
Alignment of Front Wheel . . . . . . . . . . . SA-3
(Dr/2WD)
Front Wheel Hub and Steering Knuckle . . . . . .. SA-10
Front Wheel Hub . . . . . . . . . . . . . . SA-11
Steering Knuckle . . . . . . . . . . . . . . SA-14
Front Suspension . . . . . . . . . . . . . . SA-16
Ball Stud . . . . . . . . . . . . . . . . .. SA-17
Torsion bar . . . . . . . . . . . . . . . .. SA-19
Lower Arm and Vibration Damper . . . . . . ... SA-21
Upper Arm . . . . . . . . . . . . . . . ... SA-24
Guide Level . . . . . . . . . . . . . . . . SA-26
Lateral Stabilizer . . . . . . . . . . . . . . SA-27
(SF/2WD)
Front Wheel Hub and Steering Knuckle . . . . . .. SA-28
Front Wheel Hub . . . . . . . . . . . . . . SA-29
Steering Knuckle . . . . . . . . . . . . . . SA-32
Front Suspension . . . . . . . . . . . . . . . SA-36
Ball Stud . . . . . . . . . . . . . . . . ... SA-37
Torsion bar . . . . . . . . . . . . . . . ... SA-38
Lower Arm and Vibration Damper . . . . . . . SA-39
Upper Arm . . . . . . . . . . . . . . . . SA-42
Guide Level . . . . . . . . . . . . . . . .. SA-43
Lateral Stabilizer . . . . . . . . . . . . . ... SA-43
(SF/4WD)
Front Wheel Hub and Steering Knuckle . . . . . ... SA-44
Front Wheel Hub . . . . . . . . . . . . . .. SA-45
Steering Knuckle . . . . . . . . . . . . . . SA-49
Constant Speed Drive Shaft . . . . . . . . . . SA-54
Front Speed Reducer . . . . . . . . . . . . .. SA-57
Change of Oil Seal of Driving Bevel Gear Of
Front Speed Reducer . . . . . . . . . . . . SA-57
Dismantle of Front Speed Reducer . . . . . . . SA-61
Change of Axle Shaft Oil Seal . . . . . . . . . SA-63
Disassembly and Assembly of Front Speed Reducer . SA-65
Assembly of Front Speed Reducer . . . . . . . SA-74
(Back)
Rear Axle Shaft . . . . . . . . . . . . . . ... SA-79
Rear Speed Reducer . . . . . . . . . . . . .. SA-83
On-vehicle Change of Oil Seal of Main Teeth . . . SA-84
Dismantle of Rear Speed Reducer . . . . . . .. SA-85
Disassembly of Rear Speed Reducer . . . . . . SA-85
Assembly of Rear Speed Reducer . . . . . . .. SA-89
Mount of Rear Speed Reducer and
Differential Assembly . . . . . . . . . . . .. SA-94
Rear Differential . . . . . . . . . . . . . . .. SA-95
Rear Suspension . . . . . . . . . . . . . . . SA-97
SA
SA-2
Troubleshooting
Suspension System and Automobile Axle
Troubleshooting
Change the tire or inflate to the proper pressure
Balance the wheels
Change vibration damper
Check Alignment of Front Wheel
Change or adjust the wheel bearing
Check ball joint) or liner
Tighten or change steering linkage
Adjust or repair the steering device
Discharge the oil and change with new one
Check the wandering clearance
Check the gears
Change the bearing
Change the bearing
Tighten or change the bearing
Trouble
Causes
Inspection items
Body wandering/body
dragging
Tire wear or improper air inflation
Incorrect alignment of front wheel
Over-tightened wheel bearing
Part looseness or damage of front/rear sus-
pension
Wear or looseness of steering rod system
Poor connection or damage of steering de-
vice
Inflate the tire to the proper pressure or change
the tire.
Check the situation of alignment of front wheel
Adjust the wheel bearing
Tighten or change the suspension element
Tighten or change the steering rod system
Adjust or repair the steering device
Body sink
Overloaded vehicle
Wear of vibration damper
Poor spring performance
Check the loading mass
Change vibration damper
Change spring
Left-right vibration/up-
down bouncing
Improper air inflation
Bending or damaged lateral stabilizer
Vibration damper wear
Inflate the tire to suitable pressure
Change stabilizer
Change vibration damper
Front wheel vibration
Tire wear or improper air inflation
Imbalance of wheels
Vibration damper wear)
Improper Alignment of Front Wheel
Wheel bearing wear or improper adjustment
Ball joint or liner wear
Steering linkage looseness or wear
Poor adjustment or damage of steering mecha-
nism
Abnormal tire wear
Improper air inflation
Vibration damper wear
Poor Alignment of Front Wheel
Suspension system wear
Inflate the tire to the proper pressure
Change vibration damper
Check the Alignment of Front Wheel
Change suspension element
Speed reducer leakage
Over-high oil level or improper oil quality
Oil seal wear or damage
Flange looseness or damage
Discharge the oil for change
Change oil seal
Tighten or change the flange
Noise inside the
axleNoise inside the axle
Over-low oil level or inferior oil quality
Over-large wandering clearance between
driving bevel gear and driven bevel gear
Wear and disintegration of driving bevel
gear and driven bevel gear
Bearing wear of driving bevel gear
Bearing wear of rear axle shaft
Bearing looseness or wear of speed reducer
SA-3
Suspension System and Automobile Axle
Alignment of Front Wheel (Dr SL SK SY SJ)
Alignment of Front Wheel
(Dr SL SK SY SJ)
1.
Inspection should be conducted for the following items to
remove the trouble
(a)
Check the tire abrasion and air inflation situation
Tire inflation pressure:
Front (220
0)kPa
Back (240
0)kPa
(b)
Check the front wheel bearing to see whether it is loose.
(c)
Check the front suspension to see whether it is loose.
(d)
Check the steering driving device to see whether it is
loose, and
(e)
Check the front vibration damper work to see whether it
is loose.
2.
Measure the ground clearance of the chassis.
Chassis ground clearance:
Dr
295
0
+5
mm
SL SK
(255
2)mm
SY
(310
2)mm
SJ
(295
1)mm
If the chassis ground clearance of the vehicle is sub-standard,
push down the body or raise it for a trial adjustment, if fails,
check the spring or suspension element to see whether they are
normal.
Remarks: adjust the chassis ground clearance to a specified
value before checking the Alignment of Front Wheel
parameters.
3.
Mount on the four-wheel locating device.
The mount should be conducted according to the manufacturerís
instructions.
SA-4
Suspension System and Automobile Axle
Alignment of Front Wheel (Dr SL SK SY SJ)
5.
Adjustment for inner tilt angle of kingpin, outer tilt angle
of front wheel and back tilt angle of kingpin
Item
Inner tilt
angle of
kingpin
Outer tilt
angle of
front
wheel
Applicable vehicle type
Dr SL SK SY
SJ
M e c h a n i c
steering
Dr SL SK SY
Power
steering
Dr
SL SK SY
SJ
Back tilt
angle of
kingpin
M e c h a n i c
steering
Dr SL SK SY
Power steer-
ing
Dr SL SK SY
SJ
9
30
45
14
52
0
30
20
0
10
10
0
20
10
0
30
15
2
45
15
3
15
Location parameter
4.
Adjust the wheel angle
Take apart the limit bolts of the steering knuckle to check the
steering angle A of inner wheel.
Inner wheel steering angle
Dr SL SK SY
( 36
40
)
SJ
( 32
34
)
Remark: The wheel should not contact the body or brake hose
when the steering wheel reaches the limit position.
In case the steering angle of inner wheel doesnít conform to the
standard value, adjust the wheel angle through adjusting the
limit bolts of the steering knuckle.
Fastening torque
(90
0)N
m(SJ)
If the wheel angle fails to be adjusted within the standard value,
change the weary or damaged parts of steering system.
If the tilt angle fails to fall within the specified values, make an
adjustment through adding or reducing the gaskets on the
location of upper arm.
Gasket thickness: 3.0, 2.0 and 1.0mm
Once the gasket thickness increases by 1mm, the outer tilt
angle of wheel will change by 7', while the back tilt angle of
kingpin will change 20'.
After the wheel outer tilt angle and the back tilt angle of kingpin
are adjusted, if the inner tilt angle of kingpin still fails to the
specified value, check the steering knuckle or front wheel to
see whether they are bending or loose.
1
50
-20
adjusting bolt
outer tilt
angle of
front wheel
inner tilt angle of kingpin
back tilt angle of
kingpin
front
A
B
A
B
HPM
SA-5
7.
Check the sliding measuring situation.
Check the sliding situation with the sliding measuring tester.
Sliding measuring value:
.5m/km
push forward the vehicle;
forward
A=B
B
A
6.
Wheel toe-in adjustment
(a)
Verify that each wheel has been located forward in a line.
(b)
Mark the tire center at the bearing height on the tread of
left and right tire, and measure the distance between the
marks on left and right treads.
(c)
Push forward the vehicle until the mark on the back tread
of tire moves to the front.
Remark: the toe-in measurement should be conducted from the
same spot at the same height.
(d)
Measure the distance between the two marks on the front
of two treads.
Toe-in value: (0-2)mm
(e)
Loosen the clamping bolts of connecting pipe.
(f)
Adjust the toe-in angle through the approach according to
which rotate the left and right drag rod tube by a same
angle.
Remark: check the lengths of the two drag rods to see whether
the two rods are same in length.
Length error of the left and right drag rod should not
be larger than 2.0mm.
(g)
Tighten the clamping bolts.
Fastening torque
(20
) N
m
(h)
Locate the split pin well.
Suspension System and Automobile Axle
Alignment of Front Wheel (Dr SL SK SY SJ)
SA-6
Suspension System and Automobile Axle
Alignment of Front Wheel
Alignment of Front Wheel (SF)
Alignment of Front Wheel
(SF)
1.
The following items should be checked to remove the
troubles.
(a)
Check the tire abrasion and the air inflation to see it is
suitable or not.
Tire inflation pressure: (250
0)kPa
(b)
Check the front wheel bearing to see whether it is loose.
(c)
Check the front suspension to see whether it is loose.
(d)
Check the steering driving device to see whether it is
loose, and
(e)
Check the front vibration through elastic force test to see
whether it is normal in performance.
2.
Height adjustment of vehicle
Adjust the vehicle height to the standard value so as to make
the Alignment of Front Wheel inspection.
A-B-58 5mm
A: The height of steering knuckle shaft center.
B: The center height of the adjusting cam bolt at front end
The standard value for the unloaded height is: the
difference of the center height of drive shaft climax and
the front adjusting cam bolt is 58.5mm.
3.
Mount on the four wheel locating device
This approach should be conducted according to the detailed
instruction of the equipment manufacturer.
4.
Adjust the outer tilt angle of front wheel and the back tilt
angle of kingpin
The outer tilt angle of front wheel: 0
5'
0'
The back tilt angle of kingpin: 2
0'
0'
Outer inclination of front wheel:
B
A
the outer tilt angle of
front wheel
the back tilt angle
of kingpin
front
SA-7
Suspension System and Automobile Axle
Alignment of Front Wheel
Alignment of Front Wheel (SF)
In case the outer tilt angle of front wheel or the back tilt angle
of kingpin fails to conform to the specified value, adjust the
cam forward or backward may amend them.
5.
Wheel angel adjustment
Take apart the limit bolt cap of the steering knuckle to check
the inner wheel steering angle A.
The inner wheel steering angle: =32
Notice:The wheel should not touch the body brake hose
when the steering wheel is rotated to the bottom.
In case the max steering angle is not in the conformity with the
standard value, adjust the wheel angle through the limit bolts
of steering knuckle.
In case the wheel angle still fails to fall within the standard
range, make a inspection and change the weary and damaged
steering mechanism parts.
6.
Wheel toe-in adjustment
Adjust the wheel toe-in according to the following approach
(a)
Raise or reduce the vehicle until the suspension stands in
balance.
(b)
Push the vehicle on the ground 5 meters forward under
the condition that the front wheels locate forward in a
line.
front cam adjustment
rear cam adjustment
reduce
increase
increase
reduce
A
B
A
B
front
SA-8
Suspension System and Automobile Axle
Alignment of Front Wheel (SF)
(c)
Mark the center of the back of front wheel, and measure
the distance ìBî between the remarks on the left and right
tires.
(d)
Push the vehicle forward so that the mark on the back of
tire moves to the measuring height of the instrument.
Remark: if the tire moves too far, repeat the approach (b).
(e)
Measure the distance ìAî between the marks on the front
of tire.
(f)
Measure the wheel toe-in.
Toe-in = B-A
Inspection standard: (0-2)mm
In case the toe-in fails to conform to the specified value, it can
be amended through adjusting the left and right drag rods.
(g)
Loosen the clamping bolt and nut.
(h)
Adjust the toe-in situation by the approach of rotating the
left and right drag rod by a same angle.
(i)
Ensure the left and the right drag rods are same in length.
B
forward
move the vehicle forward
A
front
A
B
A=B
SA-9
Suspension System and Automobile Axle
Alignment of Front Wheel (SF)
(j)
Tighten the clamping bolts and lock them with split pin.
Remark: the clamping bolt should face the front of the vehicle.
(k)
Side-slip inspection
Sideslip: =5m/km
front
SA-10
Front wheel hub and steering knuckle
Element Drawing
front wheel hub snap ring
25-28
front wheel hub oil seal
brake caliper
plain washer
bearing 32007
front wheel hub and
front brake disc
bearing 30205
locking nut
front wheel hub cap
stop washer
dust cover
steering knuckle arm
steering knuckle
85-105
98-118
100-120
132-152
Used component which can not be used any more
N
m
: specific torque
Dr
front brake shell
Suspension System and Automobile Axle (Dr/2WD)
Front Wheel Hub and Steering Knuckle
SA-11
4.
Take apart the front wheel hub oil seal, the inner race and
roller assembly of bearing 32007.
(a)
Pry out the oil seal.
(b)
Take out the bearing inner race and roller assembly.
Front Wheel Hub
Disassembly of Front Wheel Hub
1.
Take apart the brake caliper.
2.
Take apart the front wheel hub cap.
3.
Take apart the front wheel hub and front brake disc:
(a)
Take apart the split pin to take down the lock cover.
(b)
Screw off the lock nuts of the hub bearing with spanner
and take down the stop washer.
(c)
Take apart the front wheel hub and front brake disc with
the bearing 30205 together.
Disassembly the wheel hub and suspend it with tightwire.
Remark: Donít dismantle the brake hose and brake metal pipe
Takeapart the front wheel hub cap from the gap between the
front wheel hub cap and the front wheel hub.
5.
Bearing outer race inspection and tear-down
(a)
Inspect the bearings
Clean each bearing and check them to see whether there is wear
or damage.
(b)
Take apart the bearing outer race
Tap out the bearing outer race with copper bar and hammer.
Notice: bind the disassembled inner and outer bearing
race together to avoid of mixing.
Suspension System and Automobile Axle (Dr/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)
SA-12
6.
Inspection and replacement for front brake disc
(a)
Check the wear situation of the front brake disc. (see Dr
the brake caliper).
(b)
Use the spanner to tear down the bolts that connect the
front wheel hub and the front brake disc.
(c)
Connect the front wheel hub and the front brake disc with
bolt and spring washer, and screw up the bolts with a
moment spanner to the specified torque in the diagonal
order.
Fastening torque
(60-79)N
m
(d)
Conduct the equilibrium test on the dynamic balancer,
the amplitude value displayed should not be larger than
13.5g under the condition that the measuring rotating
velocity is 796 r/m and the locking rotating velocity is
786 r/m, when the amplitude value is larger than 13.5 g,
encase the counter balanced clip, which is 4 g each, at the
corresponding phase, the number of the clip encased
should not be more than four.
7.
Bearing outer race change
Press in the new bearing outer space with the special service
tools.
Notice: the bearing inner and outer races should be changed at
one time.
Assembly of Front Wheel Hub
1.
Mount on the Bearing 32007 inner race and roller assem-
bly as well as the front wheel hub oil seal.
Coat the lithium base grease of (4-5)mm on the inner surfaces
of bearing outer race and the front wheel hub, encase the
Bearing 32007 inner race and roller assembly, plaster the
lubricant again. Coat a little lubricant on the lips of front wheel
hub oil seal and then tap it in place.
Notice: do not make the lubricant contact the front brake
disc face.
2.
Mount on the Bearing 32007 inner race.
After coating the bearing outer race with the lithium base
grease of 4-5 mm, encase the inner race and roller assembly of
Bearing 30205, and plaster the lubricant again.
Suspension System and Automobile Axle (Dr/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)
SA-13
3.
Mount the front wheel hub on the steering knuckle.
Coat a little lubricant at the position of the steering knuckle
where the oil seal locates, mount the front wheel hub and front
brake disc on the steering knuckle, and then mount on the stop
washer.
4.
Preload adjustment
(a)
Mount on the lock nut and screw up according to the
specified torque.
Fastening torque
(130-150)N
m
(b)
Run the front wheel hub about 1/4-1/3 of circle, and
combine it with the bearing seat.
(c)
Loosen the locking nut to ensure the front brake disc run
freely, and then screw up the nuts to the specified torque.
Fastening torque
(25-35)N
m
(d)
Hook the front wheel hub with the spring-tension meter
and pull the spring-tension meter slowly in the tangential
direction of this spot.
The reasonable range of tension force: (16-33)N.
Remark: if the tension force is larger or smaller of the reason-
able range, screw up the nuts again until the tension force falls
within the reasonable range.
(e)
Measure the bouncing value of the front brake disc,
which should not be larger than 0.11mm.
5.
Mount on the lock cover and the split pin
Suspension System and Automobile Axle (Dr/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)
SA-14
6.
Tap in the front wheel hub with a rubber hammer
7.
Mount the brake caliper on the steering knuckle.
Fastening torque
(85-105)N
m
Steering Knuckle
Disassembly of Steering Knuckle
1.
Take apart the brake caliper, the front wheel hub and the
front brake disc.
2.
Take apart the front brake shell:
(a)
Tear down the two bolts (M8X16).
(b)
Tear down the two split pins, grooved nuts, washer and
bolts that connect the steering knuckle arm.
3.
Tear down the steering knuckle
(a)
Support the lower arm with jack;
(b)
Tear down the two split pins and the grooved nuts
(c)
Disconnect the steering knuckle from the upper and
lower ball studs and take apart it.
Inspection on Steering Knuckle
Check the steering knuckle
Check the steering knuckle with the dye penetration agent to
see whether the steering knuckle has a crack or not.
If the crack is found, the steering knuckle is required to be
changed.
Suspension System and Automobile Axle (Dr/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)
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