Great Wall. Service manual for chassis and body (2006) — page 7

MT-27

Transmissio

Output Shaft Assembly(Assembly of Output Shaft Assembly)

SST

SST

(b) Smear the gear oil on the needle bearing of gear of 1st gear.

(c) Assembly the gear components of 1st gear,synchronized

ring,needle bearing and sleeve of gear of 1st gear.

(d) Install the assembly on the output shaft,and align the notch

of synchronized ring and sliding block .

(e) Turn the sleeve of 1st gear shaft to align the it with the

locking ball.

8.

Installation for rear bearing of output shaft

Fix the bearing of output shaft to the output shaft with SST and

pressing machine, make the notch of locking ring of output

shaft rear bearing expose to the tail.

Remark: Hold the sleeve of gear of 1st gear and don

t let it fall

off.

9.

Install the gear of 5th gear

Fix the gear of 5th gear with SST and pressing machine.

10. Assembly the snap ring of shaft

(a) To choose one snap ring which make the axial clearance

be Min, and install it on the shaft.

Max clearance

0.1mm

(b) Knock the snap ring of shaft of 5th gear tightly with

screwdriver and hammer.

11. Measure the axial clearance of gear of 1st gear

Measure the axial clearance of gear of 1st gear with feeler

gauge

Standard clearance:

For the transmission made by Shang Chi:(0.15

0.33)mm

For the transmission made by Tang Chi:(0.09

0.33)mm

MT-28

Transmission

Output Shaft Assembly(Installation of Output Shaft Assembly)

12. Fix the drive gear of speedometer

(a) Install the locking ball and drive gear.

(b) Install the drive gear of tachometer with plier for shaft

shield ring

MT-29

Gear Box

Countershaft Assembly and Reverse Idle Gear Assembly (Element Drawing, Countershaft Assembly Disassembly, Testing and Assembly)

Countershaft Assembly and Reverse Idle Gear Assembly

Element drawing

Disassembly, Testing and Assembly of

Countershaft

1.

Tear down the coupling gear, sliding block and the five-

speed spring collar.

Tear down the coupling collar, three sliding blocks and the two

five-speed spring collars with screwdriver.

2.

Measure the radial clearance of the reverse idle gear

with dial gauge

Standard clearance:

Shang chi:0.05mm

Tang chi:(0.10~0.30)mm (Tang chi is the close Spline

match, which belongs to radial clearance)

Max clearanle:

Shang chi:0.05mm

Tang chi:(0.10~0.30)mm (Tang chi is the close spline

match, which belongs to radial clearance)

front bearing of
countershaft

intermediate-gear shaft

steel ball

rear bearing of
countershaft

stop ring of the rear bearing
of countershaft

five-speed thrust washer

five-speed needle
bearing

sliding block of
synchronize

five-speed cluster

engagement sleeve of the

five-speed synchronizer

spring collar

synchronizer tooth
of spring collar

axial pressing plate
for reverse idle gear

reverse idle
gear shaft

reverse idle gear
cluster

coupling gear around
the five-speed gear

retainer ring for front
countershaft

stop ring for front bearing
of countershaft

MT-30

Gear Box

Countershaft Assembly and Reverse Idle Gear Assembly ( Countershaft Assembly Disassembly, Testing and Assembly)

3.

Reverse gear inspection

Measure the diameter of needle bearing with micrometer.

Standard diameter

Shang Chi

26.000mm

Tang Chi

(25.98

26.00)

Limit Diameter

Shang Chi

25.984mm

Tang Chi

25.86mm

4.

Check the synchronizing ring

(a)

Run the retainer ring for shaft and put it onto the shaft to

check itsstopping performance

(b)

Measure the clearance between the rear section of the

synchronizing ring and the spline.

Standard clearance:

Shang Chi

(1.5

1.8)mm

Tang Chi

(1

2)mm

Limit clearance: 0.8mm

5.

Measure the clearance of the shift fork and gear sleeve.

Test the clearance of the shift fork and gear sleeve with the

feeler gauge.

Max clearance:

Shang Chi: 0.54mm

Tang Chi:1.0mm

6.

Change the bearing

The front bearing of the reverse gear shall be changed when

necessary

(a)

Pry down the retainer ring for shaft with a split-ring-type

pliers.

MT-31

Gear Box

Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly)

SST

sleeve wrench

front

(b)

Press out the bearing with SST.

(c)

Press in the bearing, side race and inner race with the

socket spanner.

(d)

Select the split ring that leave the radial clearance to

minimum level, and mount it on the shaft.

7.

Mount the engagement sleeve of synchronizer, sliding

block and the five-speed spring collar.

Remark: the opens of the spring collar shall be in non-

alignment

Encase the sliding pad into the gear hub and then cover the

gear sleeve.

Mount the spring retainer under the sliding pad.

Notice, the opening direction of the spring retainer shall

not face-to-face.

Mount of Reverse Gear Assembly

1.

Check the reverse idle gear

Measure the radial clearance of the reverse idle gear with dial

gauge.

Standard clearance:

Shang Chi

0.05mm;

Tang Chi

(0.04

0.08)mm

Max clearance

Shang Chi

0.05mm;

Tang Chi

0.13mm

MT-32

Gear Box

Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly)

2.

Measure the clearance between the reverse idle gear

and gearshift yoke block

Measure the clearance between the reverse idle gear and the

gearshift yoke block with feeler.

Standard clearance:

Shang Chi

0.2mm

Tang Chi

(0.05

0.27)mm

Max clearance

Shang Chi

0.35mm

Tang Chi

0.5mm

MT-33

Gearbox

Rear Housing Assembly (Element Drawing, Change of Oil Seal, Change of Shaft Bush)

Rear Housing Assembly

Element drawing

Change of Oil Seal

1.

The rear housing oil seal shall be changed where necessary.

(a) Dismantle the oil seal with SST.

(b) Press in the new oil seal with SST

2.

The driven oil seal of speedometer shall be changed

where necessary

(a) Pry out the oil seal with SST.

(b) Tap the new oil seal into the shaft bracket with SST.

Change of Shaft Bush

The shaft bush shall be changed where necessary

(a) Tear down the oil seal and dust bush.

(b) Heat the ending parts of extension frame to 80

-100

in

the oil groove.

(c) Tear down the shaft bush with SST and mount on the new

shaft bush.

SST

SST

SST

SST

SST

oil reservoir

locating spring bolts and
spring cylindrical pin

rear housing oil seal
assembly

rear housing dust
cover

oil groove

component element
o f p o s i t i o n - l i m i t
mechanism

rear housing
cluster

MT-34

Gearbox

Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism)

Inspection on and change of the component

elements of position-limit mechanism

1.

Tear down the component elements of position-limit

mechanism

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

(b) Punch out the spring cylindrical pin with the drift punch

and hammer.

(c) Tear the component elements of position-limit mechanism

down.

2.

Check the component element of position-limit mechanism.

Run and propel the limit stop and the limit stop can return

to the original location automatically, otherwise, change the

limit stop.

3.

Mount the component element of position-limit mechanism

(a) Mount the component elements of position-limit mecha-

nism in the rear housing.

(b) Tap the spring cylindrical pins in with drift punch and

hammer as shown in the drawing.

MT-35

Gearbox

Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism)

(c) Coat the sealing agent on the bolt thread.

(d) Propel the plug with the torque socket spanner.

MT-36

Gearbox

Bearing Front Cover Assembly (Element Drawing, Change of Oil Seal)

Bearing Front Cover Assembly

element drawing

bearing front cover
assembly

washer

front cover oil seal
assembly

Change of oil seal

The oil seal of the bearing front cover shall be changed where

necessary

(a)

Pry out the oil seal with screwdriver

(b)

Press in the new oil seal with SST.

Depth of oil seal:

Upper tooth

9.5mm

Tang tooth

(12.4

0.4)mm

SST

MT-37

Assembly of Gearbox

1.

Mount the output shaft in the central link plate

(a)

Tap the output shaft in the central link plate while pulling

it, until mounting it in the central link plate.

(b)

Mount the stop ring of the rear bearing of output shaft in

with the split-ring-type pliers.

Remarks: The stop ring shall flush with the surface of central

link plate.

2.

Mount the input shaft in output shaft

(a)

Coat the MP lubricant on the bearing with 13 needle

rollers, and mount the needle rollers in input shaft.

(b)

Propel the input shaft in the output shaft and flush the

groove of synchronizing ring with the sliding block.

3.

Mount the countershaft in the central link plate

(a)

Mount the stop ring on the rear bearing of countershaft

with split-ring-type pliers.

alignment

Gearbox

Assembly of Gearbox

MT-38

Gearbox

Assembly of Gearbox

(b)

Mount the intermediate-gear shaft in the central link

plate, and mount the backup rear bearing with SST while

holding the intermediate-gear shaft.

4.

Mount the baffle of rear bearing of output shaft

Mount and propel the bolts with torque socket spanner.

Tightening moment

Tang tooth

(17

22)N

m

Upper tooth

(12

17)N

m

5.

Mount the reverse idle gear and shaft

(a)

Mount the reverse idle gear and shaft.

(b)

Mount the axial pressing plate of the reverse idle gear,

and then propel the bolts tightly.

Tightening moment

(15

20)N

m

6.

Mount the bracket cluster of reverse rocker arm

Mount the reverse rocker arm bracket and propel the two bolts

tightly.

SST

MT-39

locking ball

socket spanner

Gearbox

Assembly of Gearbox

7.

Mount the steel ball and the five-speed thrust washer.

8.

Mount the five-speed gear cluster

(a)

Coat the gear oil on the needle bearing.

(b)

Mount the five-speed gear cluster.

9.

Mount the synchronizing ring and the fifth coupling gear

(a)

Mount in the synchronizing ring and the fifth coupling

gear.

(b)

Dismantle the old central link plate from the table vice.

(c)

Put the gearbox straightly as shown in the drawing.

(d)

Flush the groove of synchronizing ring with the sliding

block and mount the fifth coupling gear with pressure

machine.

(e)

Mount the new central link plate in the table vice.

MT-40

Gearbox

Assembly of Gearbox

10. Mount the split ring

(a)

Select the retainer for shaft that leaves the minimum

radial clearance, which is not larger than 0.1mm.

(b)

Mount in the retainer for shaft with copper bar and

hammer.

(c)

Mount the spring cylindrical pin of third-fourth-speed

gearshift fork.

Notice: The pin port should align with the direction of the

shaft.(Same sa below)

11. Measure the radial clearance of the five-speed gear

cluster.

Measure the radial clearance of the five-speed gear cluster

with the measuring gauge.

Standard clearance

Shang chi

(0.135

0.325)mm

Tang chi

(0.1

0.3)mm

12. Mount the third-fourth-speed gearshift fork axle and the

first-second-speed gearshift toggle fork as well as the

third-fourth-speed gearshift toggle fork

(a)

Mount the first-second speed and third-fourth speed

gearshift toggle forks.

(b)

Mount the third-fourth-speed gearshift fork axle in the

central link plate and the gearshift toggle fork.

MT-41

Gearbox

Assembly of Gearbox

13. Mount the first gearshift fork axle and first gearshift fork

(a)

Coat the MP lubricating on the interlocking guidepost

and mount the interlocking guidepost on the first-second-

speed gearshift fork axle.

(b)

Mount the interlocking pin in the central link plate with

the magnetic bar.

(c)

Mount first-second gearshift fork axle in the first gear-

shift toggle fork and central link plate.

d)

Mount the setting bolts of the first toggle fork and tighten

them.

Tightening moment

Upper tooth

(15

20)N

m

Tang tooth

(13

17)N

m

14. Mount the reverse yoke rod, reverse rocker arm and

reverse yoke block

(a)

Mount the reverse yoke rod, reverse rocker arm and

reverse yoke block together.

(b)

Mount the reverse rocker arm on the reverse rocker arm

bracket.

(c)

Coat the MP lubricant on the interlocking guidepost and

mount the guidepost on the reverse gearshift fork axle.

MT-42

Gearbox

Assembly of Gearbox

(d)

Mount the interlocking pin in the central link plate with

the magnetic bar.

(e)

Mount the reverse gearshift fork axle in the reverse yoke

rod and central link plate.

(f)

Mount the spring cylindrical pin with the drift punch and

hammer.

15. Mount the five-speed reverse gearshift guide block and

five-speed reverse gearshift fork axis.

(a)

Mount the five-speed reverse gearshift guide block in the

five-speed reverse gearshift guide shaft.

(b)

Mount the reverse gearshift fork axle in the next step.

(c)

Mount the steel ball in the five-speed gearshift guide

block with the magnetic bar.

(d)

Mount the five-speed gearshift fork axle as shown in the

drawing.

(e)

Mount the steel ball in the central link plate with mag-

netic bar.

(f)

Mount the five-speed gearshift fork axle in the central

link plate.