Great Wall. Service manual for chassis and body (2006) — page 4

MT-7

Gear Box

Mount of Gear Box

Mount of gear box

1.

Put down the gearbox at the mounting place.

2.

Mount the bolts of gearbox, clutch bracket and starter.

Tightening moment:

(a) Setting bolt of gear box (82

10)N

m

(b) Enforcement plate bolt (37

5)N

m

(c) starter bolt (39

5)N

m

Notice: the bolts of gear box and clutch shall be mounted

with the clutch pipe clip together.

3.

Mount the pawl washer and bracket of gearbox

Two-gear driving:

(a) Mount the gearbox pawl washer and fasten the relative

bolts.

Tightening moment: 23

3)N

m

(b) Lift the rear part of engine with jack and wooden block so

that the gearbox is raised a little.

(c) Mount the bracket of gear box on beam and fasten the

relevant bolts (this process may skip over in wielding

structure)

Tightening moment

(23

3)N

m

(d) Connect the gearbox bracket and supporter with bolts,

then tighten the bolts.

Tightening moment: (23

3)N

m

MT-8

Gear Box

Mount of Gear Box

4WD:

(a)

Mount the bracket and supporter of leg washers of rear

engine in 4WD vehicle;(SF)

(b)

Mount and tighten the third beam of 4WD vehicle. (SF)

4.

Remove the wooden spill.

5.

Mount exhaust pipe.

Mount the exhaust pipe on the branch exhaust pipe.

Tightening moment

(62

3)N

m

6.

Mount the wheel-brake cylinder of clutch.

Tightening moment

(18

2)N

m

7.

Mount odometer sensor and plugging elements of backup

switch.

8.

Connect the drive shaft.

(See page PR-12)

9.

Add oil into the gearbox.

Lubricating oil grade: GL-5 85W/90

Volume: 2.4L(dry)

Remark: the Tightening moment of oil filling/draining

plug: (30

50)N

m

4WD

4WD

MT-9

Gear Box

Mount of Gear Box

10.

Drop the vehicle.

11.

Mount the dust cover and gear change lever.

12.

Mount storage box.

13.

Mount the manual ball, and

14.

Mount the fan cover and fasten the bolts.

Mount on them and screw up the four bolts.

15.

Connect the cell cable to the cathode of storage cell; and

16.

Conduct the load test

Check whether there is abnormal noise and whether the

operation is stable.

MT-10

Gearbox

Disassembly of Gear Box

Disassembly of Gear Box

1.

Tear down the separation toggle fork and separation

bearing.

2.

Tear down the backup switch, the driven gear of

speedometer.

3.

Tear down the clutch from the gearbox frame.

Take apart the nine boits.

4.

Tear down bolts of locating spring of the five-speed

toggle fork, locating spring and locking ball.

(a) Dismantle the bolts from the rear cover with the torque

socket spanner.

(b) Take out the spring and locking ball with magnetic rod.

5.

Tear down the operating seat of gear change lever.

(a) Dismantle the setting bolts of the operating seat of gear

change lever.

(b) Take away the operating seat lightly and put it at the

suitable place.

6.

Tear down axial locating pin assembly of shifting gear.

7.

Tear down the fastening nuts of extension frame.

(a) Tear down the fixing bolts of gearshift shaft.

(b) Tear down the fastening nuts of expansion shell.

MT-11

Gearbox

Disassembly of Gear Box

(c) Dismantle the nuts of the four-gear driven extension fram.

(d) Tap the extension frame lightly with rubber hammer to tear

down the selective gearshift shaft and selective rocker

arm.

8.

Tear down front cover.

Dismantle the eight bolts and front cover and axial oil seal.

9.

Tear down the input shaft, axial/bearing open ring and

countershaft bearing open ring.

10. Dismantle the gearbox frame from the central link plate,

(a) Put the gearbox straightly as shown in the drawing.

(b) Tap out the gearbox frame out carefully with the rubber

hammer. And

(c) Pull out the gearbox frame out from the central link plate

as the drawing shows

4WD

MT-12

Gearbox

Disassembly of Gear Box

11. Grip the central link plate in the table vice,

(a) Use two clutch bolts, washers and suitable nuts as shown

in the drawing.

Remark: mount the washer in the reverse direction, increase

and decrease the washer quantity to flush the bolts terminal

with the external face of the washer.

(b) Grip the central link plate in the table vice.

12. Tear down the locating spring bolts, locating spring and

locking ball,

(a) Dismantle each locating spring bolts with the torque socket

spanner.

(b) Take out the toggle fork axles of the first, second, third,

fourth and reverse as well as the axial locating spring and

locking ball of the fifth-gear toggle fork.

13. Tear down the axial retainer ring of the gearshift fork

Tap the axial retainer ring of gearshift fork lightly with two

screwdrivers and one hammer.

MT-13

Gearbox

Disassembly of Gear Box

14. Tear down the five-speed gearshift toggle fork,

(a) Punch out the spring pin with impact head and hammer.

(b) Tap the five-speed gearshift fork until take it out.

Notice: It must be the neutral location this time.

15. Tear down the guiding module of the five-speed gear-

shift and five-speed reverse shift fork axle.

(a) Take out the inter-locking steel ball from the guiding

module of the fifth reverse shift-shaft.

(b) Tear down the fifth reverse shift guiding module and fifth

reverse shift fork axle.

16. Take out the five-speed gearshift fork axle

MT-14

Gearbox

Disassembly of Gear Box

17. Tear down the reverse shift fork axle, reverse rocker

arm, reverse toggle lever and toggle block

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

(b) Take out the interlocking ball and interlocking guidepost

between the reverse shift fork axle and the five-speed

gearshift fork axle.

(c) Tear down the reverse shift fork axle, and

(d) Tear down the reverse rocker arm and yoke block.

18. Tear down the first-second-speed gearshift fork axle.

(a) Take out the interlock pin and interlock guide post between

the reverse shift fork axle and the five-speed gearshift fork

axle.

(b) Dismantle the locating bolts of the toggle fork of the first-

second-speed gearshift toggle fork.

(c) Dismantle the fork axis of the first-second-speed gearshift.

(d) Take out the short interlock pin between the first-second-

speed gearshift fork axle and the third-fourth-speed gear-

shift fork axle

B0-17

Assembly of rear door

1.

Coat the MP lubricant on the parts before mounting

(a)

Coat the MP lubricant on the sliding face and gear of

glass elevator;

Notice: Do not coat the MP lubricant on the spring of

glass elevator.

(b)

Coat the MP lubricant on the sliding face of door lock.

Vehicle Body

Rear Door

2.

Mount the outdoor handle with lock barrel and door lock:

(a)

Mount the lock barrel on the outdoor handle with spring

snapping ring.

(b)

Mount the outdoor handle and the lock barrel with two

bolts;

(c)

Mount the lock door with three screws; and

(d)

Connect the connecting bar to the outdoor handle.

3.

Mount the inside lock ring

Mount the inside lock ring and connect the connecting bar.

4. Mount the glass elevator:

(a)

Put in the elevator through the auxiliary hole;

(b)

Mount three fixing bolts of elevator (for manually-

operated elevator);

Mount four fixing bolts of elevator (for electric elevator)

(c)

Mount the small sliding track and tighten the fixing bolts

temporarily;

(SJ)

(a)

Put in the elevator through the auxiliary hole;

(b)

Mount three fixing bolts of elevator;

(c)

Mount four fixing bolts of elevator bracket.

SJ

SJ

B0-18

10. Adjust the door window glass

Vehicle Body

Rear Door

Adjust the balance arm upwardly or downwardly until the

dimensions A and B shown in the drawing are equal, and then

fix the balance arm.

11. Mount the outerauchi

8.

Mount lower rear glass guide track (Dr SF)

Mount the bolts and guide track.

9.

Mount the door window glass;

(Dr SF SL SK SY SJ)

Put the glass in the door cavity and then fix the glass on the

glass elevator with two bolts.

Mount on the tailgate baffle and lower dust strip (Dr)

5.

Mount the door glass channel;

6.

Mount on the quarter window glass (SF SJ)

7.

Mount the upper glass guide track (SF)

Mount the bolts and guide track.

12. Mount the door interior trim panel;

13. Mount the indoor handle:

(a) Push the indoor handle in the door paneling and slide it

backwardly.

(b)

Tighten the screws.

A

B

A=B

SF

SJ