Great Wall. Service manual for chassis and body (2006) — page 8

MT-43

Gearbox

Assembly of Gearbox

(g)

Tap the pin in the five-speed gearshift toggle fork with

the drift punch and hammer.

(h)

Mount the five reverse gearshift guide shaft in the five-

speed reverse guide block and central link plate, and

(i)

Tap the spring cylindrical pin in the five-speed reverse

guide block with drift punch and hammer.

16. Mount the retainer ring gripped by the gearshift fork axle.

Mount the clamp retainer ring with the steel bar and hammer

MT-44

sealed material

Gearbox

Assembly of Gearbox

17. Mount the steel ball, locating spring and locating spring

plug

(a)

Mount the steel ball and locating spring.

Remarks:

Mount the short spring at the bottom of the central link plate.

(b)

Coat the sealing agent on the plug thread.

(c)

Mount the plug and tighten them with the torque socket

spanner.

Tightening moment

(17

22)N

m

18. Tear down the central link plate from the table vice

(a)

Tear down central link plate from the table vice.

(b)

Dismantle the bolts, nuts and washers

19. Mount the gearbox frame

(a)

Coat the sealing material on the coupling face of the

gearbox frame as shown in the drawing.

(b)

Put down the central link plate straightly as shown in the

drawing.

(c)

Mount the gearbox frame on the central link plate as

shown in the drawing.

MT-45

sealed material

Gearbox

Assembly of Gearbox

20. Mount the stop ring of the front bearing

(a)

Mount the two stop rings in the input shaft bearing and

countershaft front bearing with the split-ring-type pliers.

(b)

Mount the coated component elements of front cover.

(c)

Coat the sealing agent on the bolt thread, and

(d)

Mount and propel tightly the bolts.

Tightening moment

(15

20)N

m

21. Mount the rear body, gear-change bar and selection bar

and their housings

(a)

Coat the sealing materials on the rear body as shown in

the drawing.

(b)

Mount the gearshift shaft and gearshift yoke block in the

rear body.

(c)

Mount the gearshift catching head in the groove of guide

block, and

(d)

Mount the catching head with the rear body together.

(e)

Mount and propel tightly the bolts.

Tightening moment

Shang chi

(30

40)N

m

Tang chi

(30

45)N

m

MT-46

4WD

Gearbox

Assembly of Gearbox

(f)

Fasten the rear cover bolts of the four-gear driving

gearbox

Tightening moment:(30

45)N

m(Tang tooth)

(g)

Mount and propel tightly the setting bolts of the gearshift

yoke block.

Tightening moment

(17

22)N

m

22. Mount the steel ball spring and plug

(a)

Coat the sealing agent on the plug thread.

(b)

Mount the steel ball, setting spring and setting spring

plug.

Tightening moment

(17

22)N

m

23. Check the following items after mounting the rear body

or gearbox

(a)

Check the stability of the running input shaft and output

shaft.

(b)

Check the gearshift stability of each speed

24. Mount the component elements of the locating mecha-

nism

(a)

Mount the black component elements of the locating

mechanism on the side of the five-speed reverse gear.

(b)

Mount another component element of locating mecha-

nism and propel it tightly.

Tightening moment

(30

40)N

m

25. Mount the gearshift cover of the gearbox.

(a)

Mount the gearshift cover coated with sealing agent.

(b)

Mount six bolts and then tighten them.

Tightening moment

(15

20)N

m

MT-47

Gearbox

Assembly of Gearbox

26. Mount the clutch frame

(a)

Mount the clutch frame.

(b)

Coat the sealing agent on the bolt thread.

(c)

Mount the nine bolts and then tighten them.

Tightening moment

Upper tooth

(60

70)N

m

Tang tooth

(30

45)N

m

27. Mount the back-up lamp switch.

Tightening moment

(20

40)N

m

28. Mount the driven gear of odometer

(a)

Mount the driven gear of odometer.

(b)

Mount the bolts and tighten them.

Tightening moment

(10

15)N

m

TF-1

page

Notice . . . . . . . . . . . . . . . . . . ... TF-2

Troubleshooting . . . . . . . . . . . . . . ... TF-3

Product Description and Simple Maintenance . . . . TF-5

Dismantle and Mount of Transfer Box . . . . . . .. TF-7

Disassembly of Transfer Box . . . . . . . . . ... TF-9

Assembly of Transfer Box . . . . . . . . . . . TF-14

Washing, Inspection, Maintenance and Change . . .. TF-24

Washing . . . . . . . . . . . . . . . . ... TF-24

Inspection . . . . . . . . . . . . . . . . TF-25

Maintenance and Change of Gear and Chain gear .. TF-28

Attachment for Inspection, Maintenance and

Change of Parts. . . . . . . . . . . . . ... TF-30

Transfer Box

TF

TF-2

Transfer Box

Notice

Notice

Notice on transfer box disassembly and assembly

Notice shall be taken on the soft handling of the parts (coupling face in particular) during the process of

transfer box disassembly to avoid the collision; each parts shall put down in order so as to avoid of missing

or mistaking.

Notice shall, during assembly process, not only on the aforesaid items, but also on the following items:

1.

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

2.

Oil seal, clip for shaft and spring pin of various kinds shall not be reused.

3.

Lubricating oil is required to coat on the various friction surface and lubricant on lips of various oil seal.

4.

Rolling body is not allowed to use for pressure transmission when mounting various bearings.

5.

Lip-type oil seal is not allowed to mount slantwise.

6.

The openness on the two sides of spring collar shall not be coupled face-to-face when assembling the

component elements of synchronizer. And

7.

No parts is allowed the lubricant leakage and penetration when the transfer box locates at the working

location.

TF-3

Transfer Box

Troubleshooting

Common troubles

Causes

Resolving approaches

Change the lubricant or supplement the
lubricant volume.
Guarantee the torque of all connecting
elements stand at the specified value.
Open the transfer case to check the
bearing and othe parts whether is weared
or daamaged,if this happened,change
the parts.

Difficulty in mechanic gearshift or
outplace gear engagement

Troubleshooting

Incorrect lubricant or insufficient
lubricant volume.
Looseness of connecting bolt or other
connecting element.
Noise from the transfer box bearing

Noise, which is spreader by the transfer
box instead of clutch, engine, drive shaft
and other parts, occurs in each speed.

No driving of front wheel in the four-
gear engagement

Drive chain break

Disassemble and check the damage of
inner parts, and change the chain.

Adjust or repair shift lever.Open the
transfer box to check the toggle fork and
guide shaft, and change the parts as
requirement.Open the transfer box to
check whether the parts is wearied or not,
and, if any, change the weary parts.Open
the transfer box to check whether the
parts is wearied or not, and, if any, change
the weary parts.Open the transfer box to
check whether the parts is wearied or not,
and, if any, change the weary parts.

Overlarge loose fit clearance of the
shift toggle fork on the shift guide
shaft.
Wear of the shift toggle fork
assembly including pin and contact
roller.
Wear of the shift cam hub and the
liner.
Attainment of coupling gear

Mechanic gearshift seizing at a certain
location

Engagement failure of the mechanically
shift transfer box

Damage or unsuitable adjustment of
the shifting mechanism.
Damage or serious wear of the inner
shifting parts, or looseness or
attainment of the shift toggle fork
assembly on the guide shaft.
Unsuitable adjustment of shift lever.

Adjust or repair the shift lever mechanism.

Change the seriously wearied parts.

Change the loose or weary parts.

Refer to the vehicle manual for correct
operation.
Add the specified oil of given volume.

Open the rear cover of transfer box to check
and changer the damaged parts.
Open the rear cover of the transfer box to
check whether the sliding parts can slide
freely along the axle, if not, dismantle it and
change the damaged parts.

Incorrect operation.

Lubricant of inferior quality or
insufficient volume.
Adhesive bonding of shift toggle fork.

Adhesive bonding of the sliding joint
cover, locking sleeve or gear.

Mechanic gearshift failure under the
movement of shifting handle

Break or damage of the shift rocker
arm or shift lever.
Damage of the guide plate of shifting
cam;

Change the damaged element.

Open the rear cover of the transfer box to
check the damaged element and change
it.

Electric gearshift trouble

Damage or failure of electrically
controlled element, electric module,
speed sensor, electric motor, electric
clutch, or built-in wire harness.
Damage or worn of shifting cam,
joint cover, locking sleeve, toggle
fork or shift guide axle.Adhesive
bonding shift

Refer to the vehicle usage manual to
diagnose the failure element and change
it as requirement.
Dismantle the weary or damaged parts
and change it as requirement.
Dismantle and check the free movement
of sliding element, and change it as
requirement

TF-4

Transfer Box

Troubleshooting

Common troubles

Causes

Resolving approaches

Unsuitable tire pressure.

Noise, which is spread by the transfer
box instead of the clutch, engine or other
parts, occurs at each speed.

Gear noise.
Damage or wear of chain gear or
chain.

Open to check whether there is weary
element or damaged element (including
the odometer gear) and, if any, change
them

Noise occurs in the high-speed or low-
speed four-gear driving.

Open to check whether there is wear or
damage, and if any, adjust the tire pressure
to suitable value.

Oil leakage in transfer box.

Frame Break of transfer box.
Oil leakage of other element.
Ventilation pipe block

Over-added lubricant or lubricant of
unsuitable brand
Looseness of the bolts on sealing
face.
Sealing glue of different brand or
unused sealing glue.
Oil seal wear or damage.

Change the frame.
Check the leakage by wiping dry.
Open and clean it and, if necessary,
change it.
Use the specified lubricant and adjust the
lubricant to suitable volume.
Propel the bolts tightly as requirement.

Use the specified sealing glue and propel
the bolts tightly as required.

TF-5

Transfer Box

Product Description and Simple Maintenance

Transfer Assembly NO. of Manufacturer

product assembly NO.

display

termnumber

displaythe last digit of the year
displaythe specific monthly
manufactuer data
displaythe month numnber

Example display:From January (A) to December (L)
Product instruction and simple maintenance

Manufactuer data

Product instruction and simple mainte-

nance

1.

Product Introduction

The transfer box adapted by our company is the transfer box

of 45-55 manufactured by Bogeguana, which is two-speed

and time driving, a set of planetary mechanism used is to

obtain the speed-reducing performance, while the driving

force is transmitted to the front driving gear by a highly precise

chain. The planetary gear train and rear output shaft element

of transfer box is lubricated initiatively through oil bath and oil

pump. This transfer box has four gears:

2H-stands for the two high gears

in which, only the two

rear wheel are driven, and the gear ratio of the transfer box

is 1:1

4H-stands for the four high gears, in which , all of the four

wheel are driven, and the gear ratio of the transfer box is

1:1

N- neutral location (this location only exists in the transfer

box of manual gearshift )

No driving force is transmitted

to the wheel when the input shaft and output shaft are

disconnected.

4L-stands for low gears, the four wheels are all driven, and

the gear ratio of transfer box is 2.48:1.

The gearshift of the mechanical gearshift transfer box is

obtained through the shifting-cam-type guide plate that is

operated by the shift rocker arm.

Sign board:

which is fastened at the obvious external location

of transfer box, and on which the detailed data are marked.

borgwarner

TF-6

5D

5D-Oil filling plug
5L-Oil drain plug

5L

2.

Regular lubricant change

(a)

The oil level of lubricant in transfer box shall be checked

when exchanging the engine lubricant or after the vehicle

covers 8000 kilometers, and the lubricant shall be added

as requirement.

(b)

The lubricant shall be changed with the specified one

every year or after the vehicle covers 48000 kilometers.

3.

Lubricant inspection approach

(a)

Clean the oil filling plug and the around area.

(b)

Open the oil-filling plug to check whether the lubricant

can flows out or not.

(c)

if the lubricant can flow out, which means the real

lubricant volume is under the prescribed value, and the

specified lubricant shall be added into the transfer box

until the lubricant can flow from the oil filler hole.

(d)

Propel the oil-filling plug tightly according to the given

Tightening moment.

Tightening moment

(19

30)N

m

Notice: The vehicle shall run for a certain time before

checking or exchanging the lubricant so that the

temperature of lubricant in transfer box may be a little

higher. Do not use hammer or other punching tools to

open or propel the oil drain plug or oil filling plug, otherwise,

the thread hole on the frame will be damaged

4.

Lubricant change

(a)

Clean the oil filling plug and oil drain plug and the around

area.

(b)

Put down a oil container under the transfer box.

(c)

Open the oil drain plug.

(d)

Open the oil-filling plug.

(e)

Drain the lubricant up.

(f)

Mount the oil drain plug and screw it up according to the

given Tightening moment.

Tightening moment

(19

30)N

m

(g)

Add the lubricant through the oil filler hole until the

lubricant overflows. Mount the oil-filling plug and tighten

it according to the Tightening moment.

Tightening moment : (19

30)N

m

Transfer Box

lubricant grade: ATF--3

Product Description and Simple Maintenance

TF-7

Transfer Box

Disassembly and Mount of Transfer Box

Disassembly and Mount of Transfer Box

1.

Transfer Box Disassembly

(a)

Drive the vehicle on the lifting jack.

(b)

Locate the gear of transfer box at the neutral

position, shift the transfer box to the 2H and

extinguish the engine.

(c)

Disconnect the cell cathode.

(d)

Lift the vehicle.

(e)

Put down an oil disc under the transfer box, tear

down the oil drain plug and oil filling plug of the

transfer to drain all the lubricant up, then re-

mount the two plugs.

(f)

Disconnect all wires and wire harnesses that

connected with the transfer box.

(g)

Take apart the hose on the venting valve of

transfer shaft.

(h)

Disconnect the linkage of the front drive shaft

with the front flange of the transfer box.

(i)

Disconnect the linkage of the rear drive shaft

with the rear flange of the transfer box.

(j)

Raise the transfer box up with the jack.

Notice: The transfer box shall be guaranteed to

support by the lifting jack before tearing down

the sets of bolt and nut that connected with the

transfer box and gearbox. The transfer box is

not allowed to hang directly on the gearbox

through spline because such operation will

damage the transfer box parts.

(l)

Tear down the connecting nuts between the

transfer box and gearbox and take down the

transfer box.

(m) Move the transfer box backward directly until

the linkage between the input shaft of transfer

box and the gearbox spline.

(n)

Put down the lifting jack of the transfer box, and

(o)

Tear down the gasket between the transfer box

and gearbox. Clean the gasket or glue on the

coupling face of front body of transfer box with

rear body of the gearbox. Take notice not to

damage the coupling face.

1

2

3

4

5

6

7

8

9

1. input shaft
2. front frame of transfer box
3. rear cover of transfer box
4. flange
5. front output fork flange
6. venting valve
7. gasket
8. rear body of gearbox
9. bolt

TF-8

Transfer Box

Disassembly and Mount of Transfer Box

2.

Transfer box mount

a)

Coat the lubricant grease on the output axial

spline of the gearbox with a thin sleeve contain-

ing lubricant grease.

b)

Mount a new gasket on the mounting face of the

transfer box.

c)

Lift the lifting bracket of transfer box and align

it to the same axle with the gearbox.

Notice: The transfer shall be guaranteed to flush

with the gearbox before connecting the spline.

Do not handle it forcefully to press the transfer

box spline into the gearbox. Otherwise, damage

will be caused, run the rear output shaft where

necessary to aim at the spline.

(d)

Move the transfer box forward slowly so that

the spline and pin of the input shaft of gearbox

reach the front body of the transfer box, and the

gasket attaches on the gearbox completely.

(e)

Ensure that the mounting holes of the front

body of transfer box, gasket, and gearbox are in

alignment and then mount the sets of bolt and

nut.

Fastening torque

(35-48)N

m

(f)

Connect the rear drive shaft and the rear output

flange of the transfer box.

(g)

Connect the front drive shaft and the front

output fork flange of the transfer box.

(h)

Connect the venting valve and the soft ventila-

tion pipe.

(i)

Connect the cables of odometer that locates

nearby the transfer box.

(j)

Connect all wire harnesses that connected with

the transfer box, and

(k)

Add the lubricant of right brand.

Notice: when starting the engine, if the lubricant

is added incorrectly or in unsuitable volume,

which may lead the transfer box to damage.

Notice: as for the transfer box mounted on

vehicle, oil pump shall be used when adding oil

for it.

Notice: In case the transfer box is taken apart for

maintenance or inspection, there will be no

lubricant supplied by oil pump in the oil passage

on the top of transfer box. Therefore, it is not

accurate to control the oil volume by opening the

oil filling plug, in such condition, the oil passage

will be filled with oil once the oil pump runs. If the

wheel can run, such operation can be conducted

on the lifting jack. The oil level shall be rechecked

once the oil pump runs.

(l)

Put down the vehicle after finishing the lubri-

cant inspection, and connect the cell cathode.

TF-9

5

4

3

1

6

2

1. rear body of transfer box

2. flange

3. oil seal

1. sensor bracket

2. bolt

3. speed sensor

4. o-ring

5. sensor assembly

6. bolt

7. gasket

8. rear body of transfer box

2

1

5

3

4

4

6

7

8

Transfer Box

Disassembly of Transfer Box

4. gasket

5. nut

6. oil plug

Disassembly of Transfer Box

1.

Brief instruction

In case the transfer box is required to be repaired for the

damaged specific element, it shall be taken apart to the degree

on which the damaged element is taken out. And the parts

taken apart from the transfer box, if it doesnít include the

damage element, can exist in the form of sub-assembly or

group instead the individual form, otherwise, the parts will be

taken apart individually.

2.

Transfer Box Disassembly

Put the transfer box on the worktable and ensure the rear part

or the rear cover faces upward. Put the wooden block under the

front part of transfer box to keep the transfer box stands

horizontally. The disassembly process is as follows:

(a)

Fasten the flange with the torque arm typed T-13-54-

002, screw off the nut to take down the gasket, then take

apart the flange and oil seal.

(b)

Take down the two oil plugs from the transfer box body.

As for the electric gearshift transfer box, tear down the

electric shifting element according to the following

disassembly approach:

(a)

Tear down the three bolts, gaskets, sensor and clip for

wire harness.

(b)

Tear down the sensor assembly and take apart the O-

ring.

(c)

Tear down the motor assembly.

TF-10

1. output shaft

2. shift engagement sleeve assembly

3. locking sleeve

4. return spring

5. engagement sleeve

6. snapping ring

7. shift lock hub

8. clutch assembly

9. fastening snapping ring

10.shift guide shaft

11.toggle fork

Transfer Box

Disassembly of Transfer Box

1. front case of transfer box

2. rear output shaft

3. cluch coil assembly

4. clip

5. bearing

6. nut

7. transfer cover assembly

8. mark plat

9. bolt

10. odometer drave gear

11. oil seal

12. oil seal

13. bearing

14. rear cover of transfer box

15. rolling needle bearing

16. shift guide shaft

17. back spring

18. magnet

19. bundle clip

10

9

8

12

13

14

15

7

7

6

5

4

3

16

17

18

2

1

19

9

11

3. The disassembly approach for rear cover is as follows (above figure)

(a)

Dismantle the nine screws and take down the clip of wire harness and

signboard in the same time.

Notice shall be taken to good keeping for the signboard, which includes the

information for the substitutes to be changed.

(b) Pry the frame lightly so that the sealing glue on the surface disengages, and

then take up the transfer box rear cover assembly directly.

(c) As for the electric gearshift transfer box, tear down the oil seal, bearing and

three nuts and clutch coil assembly.

(d) Tear down the snapping ring, pull out the bearing from the rear cover and

take apart the odometer meanwhile.

(f)

Pull out the oil seal from the rear cover of the transfer box.

(g) Tear down the magnet from the front body of transfer box.

(h) Take apart the return spring from the shift guide shaft

(i)

Clear away the sealing glue on the coupling face of the front housing and

rear cover of transfer box, take notice not to damage the coupling face of

the two housings or cause the materials removed dropping into the transfer

box.

4. Tear down the shifting element connected with the front axle.

Tear down the following parts from the remaining transfer box housing

assembly (electric gearshift).

(a) Electric gearshift assembly, tear down the snapping ring and sliding clutch

sleeve from the shift locking hub.

(b) Tear down the shift-locking hub from the rear output shaft.

(c) Tear down the shift engagement sleeve assembly and shift toggle fork from

the rear output shaft and shift guide shaft. Separate the assemblies one

another and tear down the shift guide shaft.

(d)

Disassemble the shift engagement sleeve assembly by taking apart the

snapping ring, engagement sleeve, return spring, and locking sleeve.

(e)

A plastic toggle fork that substitutes the metal toggle fork assembly and a

independent contact roller in earlier time.

1

9

8

7

6

5

Q

3

2

10

11

TF-11

5.

Tear down the Chain drive system

Take apart the following parts from the transfer box housing

assembly.

(a)

Take apart the snapping ring and washer from the front

output shaft.

(b)

Take apart the driving chain sprocket, driven chain

sprocket and drive chain together from the two output

shafts.

(c)

Separate the chain sprocket from the chain.

1

2

3

4

5

6

7

1. output shaft

2. driving chain sprocket

3. driven chain sprocket

4. washer

1

2

3

4

5

6

7

6.

Oil pump assembly

Take apart the shaft and pump assembly, pipe clip, oil pipe and

filter from the remaining transfer box housing assembly.

1

2

7

6

3

4

5

8

1. deceleration gear hub

2. inserted face of Shift

toggle fork

3. plastic sleeve

4. contact roller

5. pin

6. pin, contact roller and sleeve assembly

7. deceleration shift toggle fork

8. deceleration shift toggle fork assembly

7.

Deceleration shifting element disassembly

Tear down the following parts from the remaining transfer box

housing assembly.

(a)

Take apart the deceleration hub, and deceleration shift

fork assembly from the housing.

(b)

Take apart two plastic inserted faces from the decelera-

tion shift fork assembly

(c)

Disassembly the deceleration shift fork assembly only if

it were broken.Cut the plastic cover,and take out the pin

and truckle.

Transfer Box

Disassembly of Transfer Box

1. output shaft

2. driving chain sprocket

3. driven chain sprocket

4. washer

5. snapping ring

6. transmission chain

7. front output shaft

5. snapping ring

6. transmission chain

7. front output shaft