Great Wall. Service manual for chassis and body (2006) — page 5

MT-15

Gearbox

Disassembly of Gear Box

19. Tear down the third-fourth-speed gearshift fork axle and

the toggle forks of first-second speed gear and third-

fourth speed gear.

(a) Tap out the spring pin with the nail punch and hammer.

(b) Tear down the toggle forks of the third-fourth and first-

second-speed gearshift.

20. Tear down the coupling gear, synchronizer, gear cluster,

thrust washer and needle bearing of the five-speed

gearshift

(a) Tap down the retainer ring of the rear countershaft with

two screwdrivers and one hammer.

(b) Tear down the synchronizer assembly, coupling gear and

gear cluster of the five-speed gearshift. And

(c) Dismantle the five-speed needle bearing.

21. Tear down the thrust washer and five-speed lock ball.

(a) Tear down the thrust washer of five-speed gear.

(b) Take out the lock ball with magnetic rod.

MT-16

Gearbox

Disassembly of Gear Box

22. Tear down the reverse rocker arm bracket

Dismantle the two bolts and the reverse rocker arm bracket.

23. Tear down the reverse idle gear and reverse idle gear

axle

(a) Dismantle the setting bolts of idle gear and the pressing

plate of reverse idle gear axle.

(b) Dismantle the reverse idle gear and the reverse idle gear

shaft.

24. Take down the bearing baffle of the output shaft.

(a) Dismantle the four bolts with torque socket spanner.

(b) Take down the bearing baffle of the output shaft.

25. Dismantle the intermediate-gear shaft.

(a) Pry out the split ring of the rear bearing of the intermediate-

gear shaft with the split-ring-type pliers.

MT-17

Gearbox

Disassembly of Gear Box

SST

push down

to close

(b) Taker apart the rear bearing of intermediate shaft with

SST tool and wrench.

(c) Take down the intermediate shaft.

26. Tear down the input shaft

Tear down the bearing with 13 needles and synchronizing ring

from the input shaft.

27. Tear down the output shaft

(a) Dismantle the stop ring from the output bearing with split-

ring-type pliers.

(b) Tap lightly the central link plate with rubber hammer while

pulling the output shaft manually to tear down the output

shaft.

28. Check the back-up lamp switch

Check the terminal connection, when the switch is pressed

down, as shown in the drawing, it is connected, otherwise is

disconnected, in case the switch is not in conformity with this,

it shall be changed.

MT-18

Gearbox

Input Shaft Assembly (Element Drawing, Inspection On Synchronizing Ring, and BearingChange)

Input Shaft Assembly

Inspection on Synchronizing Ring

1.

Run the synchronizing ring and put it into the assembly

to check its stopping performance

2. Check the clearance between the rear face of

synchronizing ring and the gear.

Standard clearance:

Tung tooth

(1

1.6)mm

Upper tooth

(1.5

1.8)mm

Limit clearance

0.8mm

Bearing Change

1.

Tear down the input shaft bearing with the pressure

machine.

retainer ring

bearing stop ring

bearing

input shaft

needle bearing

synchronizing ring

element drawing

B0-20

Vehicle Body

Adhesive Strip On Body Collision Avoidance

Adhesive strip of body collision avoidance

Notices on storing the adhesive strip of body collision avoidance:

1.

The adhesive strip should be stored in the cool shadow place where can avoid the direct lighting of sun,

the high temperature and the dust.

2.

As the adhesive strip is the PVC product, do not make it touch the paint thinner, other solvents and the

boiling water.

3.

The limit storage period of adhesive strip is 9 months.

Element figure

exterior adhesive

strip at front door

exterior adhesive

strip at rear column

exterior adhesive

strip on wing panel

exterior adhesive

strip at tailgate

exterior adhesive

strip at rear body

B0-21

Disassembly of adhesive strip of body

collision avoidance

1.

Tear down the ends of adhesive strip;

Loosen the ends of adhesive strip for 31 mm with the scraper.

2.

Tear down the adhesive strip and clear away the adhe-

sive agent;

(a)

Cut down the adhesive agent with knife and pull down the

adhesive strip;

(b)

Clear away the adhesive agent with knife or abrasive

paper.

Remark: Do not reuse the adhesive strip that is disassembled.

Mount of adhesive strip of body collision

avoidance

1.

Clean the mounting face of adhesive strip;

Scrape the feculence with cleaning materials.

2.

Heat the adhesive strip;

Heat the new adhesive strip with heating lamp to the 30

60

.

Notice: do not overheat the adhesive strip and the

temperature should not higher than 80

.

3.

Pull out the separation paper from the adhesive strip

surface;

Remark: notice should be taken not to let the feculence and

dust enter into when separating the separation paper.

4.

Mount the adhesive strip along with the body pinching line.

Mount the adhesive strip along with the body pinching line as

shown in the drawing.

Remark: the convex and concave line of the adhesive strip

should be in consistent with the body pinching line.

Notice:

1.

Heat the body and adhesive strip to the moderate

temperature;

2.

Press the adhesive strip with thumb and exert

moderate pressure so as to ensure the mount is

fastening.

3.

Do not wash the vehicle within 24 hours once the

mount is finished.

Vehicle Body

Adhesive Strip On Body Collision Avoidance

B0-22

Vehicle Body

Adhesive Strip On Body Collision Avoidance

Adhesive strip of body collision avoidance (

)

Element mounting position

B: 7 mm

C: 3 mm

D:10 mm

E: 4 mm

B: 7 mm

C: 3 mm

D:10 mm

E: 4 mm

B: 7 mm

C: 3 mm

D:10 mm

E: 4 mm

B

C

D

E

B

C

D

E

B

C

D

E

SL small double-row model

SLbig double-row model

SY