Great Wall. Service manual for chassis and body (2006) — page 14

SA-47

Assembly of Front Wheel Hub

1.

Mount on the inner race and roller assembly of front hub

bearing as well as the oil seal of front hub.

Coat the lithium base grease of (4-5)mm on the inside surfaces

of the bearing outer race and the front wheel hub, put in the

inner race and roller assembly of front hub bearing (inner),

then plaster the lubricant. Plaster a little lubricant on the lips of

front wheel hub oil seal, and finally tap the front hub in place

with special service tool.

Notice: Do not plaster the lubricant on the face of front

brake disc.

2.

Mount the inner race of front hub bearing (outer) and

roller assembly

Coat 4

5 mm of lithium base grease on the outer race of

bearing, and then put the inner race of front hub bearing (outer)

and roller assembly in it, finally plaster with lubricant.

(c)

Loosen the steering knuckle nut to ensure the front brake

disc can run freely. Screw up the steering knuckle nut

again to the specified torque.

Fastening torque

25N

m

(d)

Mount on the lock plate and mount on another steering

knuckle nut.

Fastening torque

60N

m

3.

Mount the front wheel hub on the steering knuckle

Coat a little lubricant on the oil seal of steering knuckle, and

then mount the front wheel hub and front brake disc on the

steering knuckle, finally mount on the stop washer.

4.

Adjust preload:

(a)

Mount on the steering knuckle nut and screw it up

according to the specified torque.

Fastening torque

(100-120)N

m

(b)

Run the front wheel hub by 1/4-1/3 round so as to seat the

bearings.

Suspension System and Automobile Axle (SF/4WD)

Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-48

(e)

Hold the bolt of front wheel hub with the spring-tension meter

and drag slowly in the direction of the spot tangent line.

Suitable tension range

(29-54)N

The nut should be screwed up again within the suitable range if the

tension value is overlarge or over small.

(f)

Check the bearing to ensure it cannot leap excessively (the

axial clearance should not be more than 0.05mm).

(g)

Measure the bouncing value of the front brake disc, which

should not be more than 0.11mm, and

5.

Mount the liner and the free hub:

(a)

Tear down the free wheel hub cap firstly.

(b)

Mount the liner and the free hub on the front wheel hub.

Fastening torque

(25-29)N

m

(c)

Mount on the free wheel hub cap.

Fastening torque

(6-12)N

m

6.

Mount the brake caliper:

(a)

Mount the brake caliper on the steering knuckle and screw

up the bolts according to the specified torque.

Fastening torque

123N

m

(b)

Connect the Bundy tube.

Fastening torque

20-22N

m

7.

Check the height of brake liquid level and, if required, add

the brake liquid, exhaust the gas from the brake system.

Suspension System and Automobile Axle (SF/4WD)

Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

(h)

Bend one tooth of lock plate inside and other teeth outside

so as to lock the steering knuckle nut.

SA-49

Steering Knuckle

Dismantle of Steering Knuckle

1.

Tear down the brake caliper, he front wheel and the front

brake disc.

2.

Tear down the dust cover and the brake shell;

3.

Tear down the steering knuckle arm from the steering

knuckle;

4.

Tear down the vibration damper from the lower arm;

6.

Tear down the steering knuckle:

(a)

Tear down the split pin and groove nut from the position

where the ball stud locates.

(b)

Tear down the steering knuckle from the position where

the ball stud locates with the special service tool.

5.

Tear down the transverse stabilizer rod from the lower

arm;

Suspension System and Automobile Axle (SF/4WD)

Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-50

(c)

Tear down the split pin and groove nut from the position

where the lower ball stud.

(d)

Tear down the steering knuckle from the position where

the lower ball stud with the special service tool, and

(e)

Press down the lower arm to tear down the steering

knuckle.

7.

Tear down the Lower ball stud assembly from the posi-

tion where the steering knuckle locates.

Steering knuckle inspection and change

Inspection on and Change of Steering

knuckle

1.

Check the steering knuckle

Check the steering knuckle with the dye penetration agent to

see weather has crack, if any crack is found, change the

steering knuckle.

2.

Tear down the inner oil seal

drive shaft and the thrust

plate

steering knuckle.

Prize out the inner oil seal

drive shaft from the steering

knuckle with the screwdriver to take out the thrust plate

steering knuckle.

Suspension System and Automobile Axle(SF/4WD)

Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-51

3.

Tear down the needle bearing;

Tap out the steering knuckle small sleeve with hammer and

copper.

4.

Tear down the needle bearing.

Tap out the needle bearing with the hammer and copper bar.

5.

Mount the steering knuckle small sleeve;

Tap in the steering knuckle small sleeve with the special

service tool.

6.

Mount on the needle bearing;

Tap in the needle bearing with the special service tool.

7.

Mount on the thrust plate- steering knuckle;

Coat the needle roller of the needle bearing with the lithium

base grease, and plaster the lubricant on the both sides of the

thrust plate ñsteering knuckle.

Suspension System and Automobile Axle(SF/4WD)

Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-52

8.

Mount the inner oil seal óon the steering knuckle.

Check the oil seal visually, if any deformation or glue lack is

found, change the oil seal

Mount of Steering Knuckle

1.

Mount the lower ball stud on the steering knuckle;

Connect the lower ball stud and the steering knuckle with

bolts, and screw up the bolts according to the specified torque.

Fastening torque

(70-90)N

m

2.

Mount on the steering knuckle

(a)

Coat the lubricant HP-R on the drive shaft.

(b)

Press down the lower arm to mount on the steering

knuckle.

(c)

Mount on the groove nut of lower ball stud and screw up

the nut according to the specified torque, and then mount

on the split pin.

Fastening torque

(132-152)N

m

(d)

Mount on the groove nut of upper ball stud and screw up

the nut according to the specified torque, and then mount

on the split pin.

Fastening torque

(132-152)N

m

Suspension System and Automobile Axle (SF/4WD)

Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-53

3.

Mount the stabilizer rod on the lower arm.

Fastening torque

(20-26)N

m

4.

Mount the vibration damper on the lower arm.

Fastening torque

(127-147)N

m

5.

Mount the steering knuckle arm and the brake oil pipe

bracket on the steering knuckle, and coat the sealing

agent 1271 on the bolt thread.

Fastening torque

180N

m

6.

Mount on the dust cover and the brake shell.

Align the locating hole of dust cover and the groove of the

steering knuckle so as to guarantee the dust cover and the

steering knuckle are concentric.

Fastening torque

(25-29)N

m

7.

Mount the front wheel hub and the front brake disc as well

as the brake caliper.

8.

Check the height of the brake liquid level and, if required,

add the brake liquid, exhaust the gas of the braking

system.

Suspension System and Automobile Axle (SF/4WD)

Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-54

Constant Speed Drive Shaft

Element figure

Suspension System and Automobile Axle (SF/4WD)

Constant Speed Drive Shaft

axially movable three-ball
universal joint

triangular joint

mobile joint
snapping ring

extensible-end large
gripping hoop

extensible-end
dust cover

extensible-end small
gripping hoop

shaf

fixed-end small gripping hoop

fixed-end large gripping hoop

fixed-end dust cover

steel retainer ring

ball-cage type universal joint

inner oil seal- drive shaft

front drive axle shaft

sleeve assembly

Parts that cannot be reused after being used

N

M

specified torque

SF4WD

front speed reducer and
differential assembly

constant speed
drive shaft

SA-55

3.

Tear down the retainer ring from the drive shaft with the

calipers, and take down the washer-steering knuckle

shaft spline.

4.

Tear down the front wheel hub and the steering knuckle

together.

5.

Screw off the nuts that connect the constant speed drive

shaft to take down the constant speed drive shaft.

6.

Check and repair the constant speed drive shaft

Inject the molybdenum disulphide lithium grease of 100-110

g in the end of ball-cage type universal joint and the end of

axially movable tripod universal joint.

The ball-cage type universal joint and the axially movable

tripod universal joint should swing freely, and no clipping

stagnant is allowed. The dust cover should be prevented from

deformation and every gripping loop shall be clamping tightly.

Disassembly of Constant Speed Driving

Shaft

1.

Tear down the brake caliper.

2.

Tear down the free hub

Suspension System and Automobile Axle (SF/4WD)

Constant Speed Driving Shaft

SA-56

Mount of Constant Speed Drive Shaft

1.

Mount the constant speed drive shaft on the flanges of

the long and short axle shafts.

2.

Mount on the front wheel hub and the steering knuckle.

3.

Mount on the washer-steering knuckle shaft spline, and

then use the caliper to mount on the retainer ring.

4.

Mount on the free hub.

5.

Mount on the brake caliper.

Suspension System and Automobile Axle (SF/4WD)

Constant Speed Driving Shaft

SA-57

1.

Support up the front of vehicle to tear down the front

wheel and the steering knuckle.

2.

Drain off lubricant in the front speed reducer.

3.

Disconnect the front speed reducer flange and the drive

shaft.

Notice: Mark the assembly marks on the speed reducer

and the drive shaft before disconnecting them.

4.

Tear down the front speed reducer.

5.

Tear down the flange and dust cover:

(a)

Loosen the riveted position on main-tooth nut with the

hammer and chisel.

Front Speed Reducer

Change of driving bevel gear oil seal of front speed reducer

front speed reducer and

differential assembly

oil-guard tray

driving bevel gear oil seal

flange and dust cover

140-210

Parts that cannot be reused after being used

specified torque

N

M

main-tooth nut

Suspension System and Automobile Axle (SF/4WD)

Front Speed Reducer (Change of Driving Bevel Gear Oil Seal of Front Speed Reducer)

SA-58

(b)

Lock the flange with special service tool to tear down the

main-tooth nut.

7.

Tear down the inner race of conical roller bearing;

If the bearing is damaged, change a new bearing.

8.

Mount the new bearing.

6.

Tear down the driving bevel gear oil seal and oil-guard

tray:

(a)

Tear down the driving bevel gear oil seal with special

service tool.

(b)

Tear down the oil-guard tray.

(c)

Tap down the flange and dust cover with copper bar.

Suspension System and Automobile Axle (SF/4WD)

Front Speed Reducer (Change of Driving Bevel Gear Oil Seal of Front Speed Reducer)

SA-59

12. Rivet the main-tooth nut.

10. Mount the flange and dust cover:

(a)

Encase the flange and dust cover in the front speed

reducer shell through the clinch of oil seal.

(b)

Lock the flange with the special service tool and screw up

the nuts according to the specified torque.

Fastening torque

(140-210)N

m

11. Adjust the preload of driving bevel gear bearing

Measure the play preload between the driving bevel gear and

the driven bevel gear with the torque tester.

Preload:(1.8-2.4)N

m

Remark: if the requirement is not satisfied, change the

adjusting washer between the adjusting washer jackets and

bearing 32307, see the disassembly and assembly for front

speed reducer, until the requirement is satisfied.

(a)

If the preload is larger than the specified value, change

with a thicker adjusting washer;

(b)

If the preload is smaller than the specified value,

change with a thinner adjusting washer.

9.

Mount the new driving bevel gear oil seal:

(a)

Encase the oil-guard tray.

(b)

Press the new oil seal in the speed reducer shell with the

special service tool; the mounted oil seal should be 1.5

mm away from the end face of the housing.

Notice: Coat the lithium base grease evenly on the lips of

oil seal.

Suspension System and Automobile Axle (SF/4WD)

Front Speed Reducer (Change of Driving Bevel Gear Oil Seal of Front Speed Reducer)

SA-60

13. Mount the front speed reducer assembly on the frame.

14. Connect the drive shaft to the flange:

(a)

Align the assembly mark and then connect the drive

shaft and the front drive axle flange with four sets of

bolt and nut.

(b)

Screw up the nuts according to the specified torque.

Specified torque

(69-79)N

m

Suspension System and Automobile Axle (SF/4WD)

Front Speed Reducer (Change of Driving Bevel Gear Oil Seal of Front Speed Reducer)

SA-61

Dismantle of Front Speed Reducer

constant speed drive shaft

front drive axle shaft

sleeve assembly

front drive axle hanger

front speed reducer and

differential assembly

front speed reducer shell hanger

rubber jacket and

shaft tube

constant speed

drive shaft

Parts that cannot be reused after being used

N

M

cpecified torque

Suspension System and Automobile Axle (SF/4WD)

Front Speed Reducer (DisassEmbly of Front Speed Reducer)

SA-62

1.

Disconnect the front speed reducer flange and the drive

shaft.

2.

Screw off the nuts that connect the constant speed drive

shaft.

3.

Screw off the bolts connecting the rubber jacket and

shaft tube of the front speed reducer cover and the

frame.

4.

Screw off the bolts connecting the front drive axle hanger

assembly and the front speed reducer shell hanger, and

tear down the front speed reducer.

Suspension System and Automobile Axle (SF/4WD)

Front Speed Reducer (DisassEmbly of Front Speed Reducer)