Great Wall. Service manual for chassis and body (2006) — page 16

SA-79

Rear Axle Shaft

Element figure

rear axle housing

O rubber O-ring seal

rear brake

brake drum

inner oil seal seat of
rear wheel bearing

bearing seat

oil seal of rear
wheel bearing

liner

half-shaft

grooved ball
bearing

rear brake

oil-guard tray

Parts that cannot be reused after being used

Suspension System and Automobile Axle (rear)

Rear Axle Shaft

flat steel retainer ring for shaft

SA-80

Dismantle of Rear half Axle Shaft

1.

Tear down the wheels.

2.

Tear down the rear brake drum.

3.

Tear down the grab end of the bracing wire of hand brake

from the rear brake.

4.

Tear down the half-shaft and the rear brake assembly

from the rear axle housing.

5.

Tear down the flat steel retainer ring for shaft from the

half-shaft;

Tear down the flat steel retainer ring for shaft with the ring

calipers.

6.

Tear down the half-shaft:

Put down a wooden plate on the flat ground, and thrust the end

of spline of half-shaft and rear brake assembly toward the

wooden plate to separate the shaft and the rear brake assembly.

Inspection on and repairing of half-shaft parts

1.

Check the wear, damage and swing difference half-shaft

and the flange.

Max shaft run-out: 2 mm

Max flange run-out: 0.2 mm

In case the half-shaft is damaged, or wearied or the measuring

value of the swing difference is excessive, change the half-

shaft.

2.

Check he oil seal of rear wheel bearing:

Check to see whether there is wear or damage, and change the

oil seal if necessary.

3.

The disassembly of the outer oil seal of rear wheel

bearing;

Tear down the outer oil seal of rear wheel bearing with SST.

Suspension System and Automobile Axle (rear)

Rear Half Axle Shaft

SA-81

4.

Check the grooved ball bearing

Check the grooved bearing to see whether there is damage or

wear.

5.

Change the bearing where necessary:

(a)

Press out the grooved ball bearing with SST.

(b)

Press in the new grooved ball bearing with SST.

6.

Mount the new oil seal of rear wheel bearing.

Press in the new oil seal of rear wheel bearing with SST

Coat moderate lithium base grease on the lip open of oil seal.

7.

Check the bearing seat.

Check the wear or damage situation.

8.

Change the bearing seat where necessary:

(a)

Tear down the oil seal of rear wheel bearing and the

grooved ball bearing with SST.

(b)

Tap the bolts with copper bar to tear down the bearing seat.

(c)

Mount the new grooved ball bearing and the oil seal of

rear wheel bearing on the bearing seat

(d)

Press the rear brake, which is put on with bolts, in the

bearing seat.

9.

Check the wear or damage of the inner oil seal of the rear

wheel bearing.

10. Change the rear wheel bearing where necessary:

(a)

Tear down the oil seal of rear wheel bearing with SST.

Suspension System and Automobile Axle (rear)

Rear half Axle Shaft

SA-82

11. Mount the new inner oil seal of rear wheel bearing.

Coat the hyperbolic gear oil on the axle housing where matches

with the oil seal; and plaster the moderate lithium base grease

on the lip open of the oil seal, then put them on the pressure

head and press them in.

Mount of Rear Axle Shaft

1.

Press the rear brake and the bearing seat assembly on

the haft shaft.

2.

Press the heated inner oil seal seat of rear wheel bearing

on he half shaft;

Notice: the face at the chamfering end of inner oil seal of

rear bearing should contact the oil seal closely, do not

mount it at the incorrect position.

Requirement for heat mount: heat the inner oil seal seat into the

22# oil (GB443-1989) to 100

, after the part is heated

completely, take it out for mount.

3.

Mount on the flat steel retaining ring with the ring calipers.

4.

Encase the half-shaft rear brake in the axle housing,

screw on the self-locking nut.

Tightening moment

(63-79)N

m

Notice: protect the oil seal lip open, bracing wire assembly

and the oil-guard sleeve.

5.

Mount on the hand brake wire and the brake pipe.

6.

Mount on the liner and rear brake drum;

7.

Make a trial gas exhaust on the braking system, and

8.

Mount on the rear wheels.

Suspension System and Automobile Axle (rear)

Rear Half Axle Shaft

SA-83

Rear speed reducer

Element figure

column bolt

bearing7306E

oil-guard tray

oil seal

flange and dust
cover assembly

flat washer

adjusting ring

bearing 200719E

speed reducer housing and
differential bearing cover

stop gasket

80-110

18-26

washer

adjusting washer

driving bevel gear

Bearing 7607E

jacket

adjusting washer

65-95

=

lock plate

differential housing

axle driven

bevel gear

Parts that cannot be reused after being used

:specified torque

N

M

Suspension System and Automobile Axle (Rear)

Rear Speed Reducer

double-eared stop washer

SA-84

On-vehicle Change of main-teeth oil seal

1.

Disconnect the drive shaft from the speed reducer:

(a)

Mark the assembly mark on the two flanges;

(b)

Tear down the four sets of bolt and nut.

2.

Tear down the flange and dust cover assembly.

3.

Tear down the oil seal.

Tear down the oil seal with SST.

4.

Mount on the new oil seal:

(a)

Coat the lithium base grease on the lips of oil seal;

(b)

Tap in the new oil seal with SST.

Remark: tap the new oil seal until it is in place.

5.

Mount the flange and dust cover assembly.

6.

Screw up the nut to the specified torque.

Specified torque: (140-160)N

m

7.

Rivet the nut.

8.

Connect the drive shaft flange with the speed reducer

flange:

Align the assembly mark and connect the flanges with bolts.

Tightening moment

(69-79)N

m

9.

Check the oil level of the speed reducer.

Change the gear oil where necessary.

Oil brand: heavy-duty oil of grade

GL-5

Oil volume: add the oil until it overflows from the oil filler

outlet.

Viscosity: SAE 85W/90

Suspension System and Automobile Axle (Rear)

Rear Speed Reducer

SA-85

Dismantle of Rear Speed Reducer

1.

Take out the oil drain plug to drain the oil in the speed

reducer up.

2.

Tear down the rear axle shaft.

3.

Disconnect the drive shaft from the speed reducer.

4.

Tear down the nuts on the bolts that connect the rear axle

housing and the speed reducer.

5.

Tear down the rear speed reducer.

Disassembly of Rear Speed Reducer

Remark: in case the noise is over loud, the following item

should be checked before taking apart it to find out the causes.

If the speed reducer has serious drawback, take it apart for

repairing where necessary.

1.

Check the play between the axle driven bevel gear;

In case the play value fails to be within the specified range,

adjust the preload of bearing 200719E or repair it where

necessary.

(see page SA-91)

Standard play: (0.13-0.25)mm

2.

Check the teeth engagement of the driving bevel gear

with the axle driven bevel gear.

(See Page SA-92)

Record the teeth engagement positions.

3.

Check the clearance between the half-shaft gear thrust

gasket and the differential housing.

Check the clearance between the half-shaft gear thrust gasket

and the differential housing with the feeler.

Standard clearance

(0.45-0.75)mm

Remark: in case the clearance value fails to fall within the

above range, change the half-shaft gear stop gasket, and

ensure the half-shaft gear stop gaskets on the left and right

sides are same in thickness.

(See Page SA-95)

Suspension System and Automobile Axle (Rear)

(Dismantle of Rear Speed Reducer)

SA-86

4.

Tear down the differential and the axle driven bevel gear:

(a)

Mark the assembly marks on the differential bearing

cover and the speed reducer housing.

(b)

Tear down the stop gasket and take down the adjusting

ring.

(c)

Loosen the double-stop washer and screw off the nut to

take down the differential bearing cover.

(d)

Tear down the differential and axle driven bevel gear

from the rear speed reducer.

(e)

Tear down the outer race of bearing 200719E.

5.

Tear down the flange and dust cover assembly:

(a)

Loosen the riveted part of the nut with hammer and

chisel;

(b)

Lock the flange with SST to tear down the nuts.

Notice: those nuts should not be reuse.

left

right

(c)

Tear down the flange and dust cover assembly with

copper bar.

Suspension System and Automobile Axle (Rear)

(Dismantle of Rear Speed Reducer)

Remark: mark the label on the parts to clarify the position for

re-assembling

SA-87

6.

Tear down the oil seal and oil-guard tray:

(a)

Support the face at the teeth end of the driving bevel gear

to tear down the oil seal with SST.

(b)

Take out the oil-guard tray.

7.

Tear down the inner race and roller assembly of bearing

7306E;

Tear down the inner race and roller assembly of bearing 7306E

with SST.

8.

Tear down the driving bevel gear;

Tear down the driving bevel gear, which is mounted with

adjusting washer and inner race of bearing 7306E, together

with another adjusting washer and jacket

9.

Change the bearing 7306E:

(a)

Press out the bearing from the driving bevel gear with

pressure machine and SST.

(b)

Mount the new inner race and roller assembly of bearing

7306E on he driving bevel gear with pressure machine

and SST.

Suspension System and Automobile Axle (Rear)

(Dismantle of Rear Speed Reducer)

SA-88

10. Change for the bearing 7306E and the outer race of

bearing 7607E:

(a)

Tap out the bearing outer race with hammer and copper

bar.

(b)

Press in the new bearing outer race with pressure ma-

chine and SST.

12. Tear down the axle driven bevel gear.

(a)

Tear down the lock plate and bolts on the axle driven

bevel gear.

(b)

Mark the assembly marks on the axle driven bevel gear

and the differential housing.

(c)

Tap down the axle driven bevel gear with rubber hammer

and copper bar.

11. Tear down the inner race and roller assembly of bearing

200719E from differential.

Pull out the inner race and roller assembly of bearing 200719E

from the differential housing with SST.

Suspension System and Automobile Axle (Rear)

(Dismantle of Rear Speed Reducer)

SA-89

Assembly of Rear Speed Reducer

1.

Mount the inner race and roller assembly of bearing

7306E, oil-guard tray and oil seal.

(a)

Put the inner race and roller assembly of bearing 7306E in

the speed reducer housing, and put the oil-guard tray on it.

(b)

Coat the lithium base grease on the position of speed

reducer where oil seal locates and on the lips of oil seal,

align the oil seal and press it to mount.

2.

Mount the flange and dust cover assembly

Encase the flange and dust cover assembly in the speed reducer

housing, then flat it by hand.

3.

Mount the driving bevel gear:

(a)

Put the adjusting washer, jacket on the driving bevel gear,

which is mounted with adjusting washer and inner race

and roller assembly of bearing 7607E, then encase the

driving bevel gear in the speed reducer housing.

(b)

Screw up the nuts to tighten the flange, flat washer and

the driving bevel gear with SST, and the thread locking

agent is required to be coated when screwing.

Tightening moment

(140

160)N

m

4.

Measure the pre-tightening torque of the bearing:

New bearing

(1.2-1.7)N

m

The reused bearing

(0.9-1.3)N

m

Remark: if the requirement is not satisfied, change the adjust-

ing washer under jacket until the requirement is satisfied.

(a)

If the measure value is smaller than the standard one,

reduce the thickness of adjusting washer;

(b)

If the measure value is larger than the standard one,

increase the thickness of adjusting washer.

Suspension System and Automobile Axle (Rear)

(Dismantle of Rear Speed Reducer)

SA-99

4.

Mount the central bolt of leaf spring;

(a)

Align the bolt with the spring hole after clamping the

steel spring with a table vice.

(b)

Mount on and tighten the spring central bolt.

Tighten torque:

(50

5)N

m

5.

Bend the spring clip to a correct angle.

Bend the spring clip to the correct position with a hammer.

Mount of leaf spring

1.

Mount the steel spring;

(a)

Encase the front end of leaf spring into the front bracket;

(b)

Mount on the bolt of front ear pin.

(c)

Screw on the nut of front ear pin with fingers;

(d)

Encase the rear end of leaf spring into the rear bracket and

mount on the rear ear pin.

(e)

Mount on the leaf and tighten the nuts with fingers.

2.

Mount the U-shaped bolt;

(a)

Mount the U-shaped bolt on the axle housing.

(b)

Mount the spring seat and nut under the steel spring.

(c)

Tighten the mounting nut of U-shaped bolt.

Tightening moment: (110

0)N

m

Suspension System and Vehicle Axle

Rear Suspension (Leaf Spring Type)

SA-100

Suspension System and Vehicle Axle

Rear Suspension (Leaf Spring Type)

Remark: Tightening U-shaped bolt to the degree that the

protruding lengths of all U-shaped bolts under the spring seat

are the same.

3.

Mount the rear vibration damper

(a)

Connect the vibration damper to the vehicle frame with

bolts and then tighten the bolts.

Tightening moment: (25

)N

m

(b) Connect the vibration damper to the sprint seat with bolts

and tighten these bolts.

Tightening moment: (25

)N

m

4.

Keep the suspension frame in stable status;

(a)

Mount on the wheel;

(b)

Remove the bracket, and make the vehicle bounce verti-

cally for several times so as conduce it in stable status.

5.

Tighten the front ear pin and rear ear pin;

Tighten the nuts of front ear pin;

Tightening moment: (90

0)N

m

Tighten the nuts of rear ear pin;

Tightening moment: (90

0)N

m

all lengths of bolts protruding are same

BR-1

Braking System

Notice . . . . . . . . . . . . . . . . . . .. BR-2

Troubleshooting . . . . . . . . . . . . . . .. BR-2

Inspection and Adjustment . . . . . . . . . . .. BR-5

Master Cylinder . . . . . . . . . . . . . . ... BR-8

Vacuum Booster . . . . . . . . . . . . . . .. BR-10

Front Brake . . . . . . . . . . . . . . . . . BR-13

Dr

. . . . . . . . . . . . . . . . . . .. BR-13

SF . . . . . . . . . . . . . . . . . . .. BR-20

Rear Brake . . . . . . . . . . . . . . . . .. BR-26

Dr

. . . . . . . . . . . . . . . . . . .. BR-26

SF . . . . . . . . . . . . . . . . . . .. BR-34

Load sensing proportion valve . . . . . . . . . BR-42

Page

BR

BR-2

Braking System

Notice and Troubleshooting

Notice:

1.

Carefully change each part where necessary because any

mistake will affect the brake system properties, and will lead

accidents during driving. And the parts to be changed must

be the same in part number or equal in quality.

2.

Keep the parts and each position clean when repairing the

braking system.

Troubleshooting

Trouble

Causes

Inspection items

Lower or soft pedal

Abrasion of brake shoe

Abrasion of brake pad

Oil leakage of braking system

Master cylinder failure

Air in braking system

Wheel-brake cylinder failure

Failure in the automatic regulator of rear brake.

Change the brake shoe; Change the brake

pad;

Repair the oil leakage;

Change the master cylinder;

Drain out the air from braking system;

Change the wheel-brake cylinder;

Repair or change the regulator

Brake stagnant

Poor adjustment of parking brake;

The bracing wire of parking brake is seized;

Poor adjustment of vacuum booster pushrod)

Failure of the drag spring or the return spring

Pipe line blockage

Brake shoe breakage or deformation

Brake pad breakage or deformation

Seizing of the wheel-brake cylinder or the brake

caliper piston

Automatic regulator breakage

Master cylinder failure

Adjust the parking brake;

Make repairing according to real situation;

Adjust the drag rod;

Change the drag spring or the return spring

Make repairing according to real situation;

Change the brake shoe

Change the brake pad

Make repairing according to real situation;

Change the regulator

Change the master cylinder

Over large braking

distance

Unsuitable tire inflation

There is oil stain or lubricant on the brake shoe or

brake pad;

Brake shoe deforms, the brake liner is worn or polished;

Brake pad deforms or is worn or polished;

Brake drum or brake disc deforms

Drag spring or return spring has trouble

The wheel-brake cylinder has trouble

The inner piston of wheel-brake cylinder is seized;

The brake pad is seized;

Inflate the air to suitable pressure;

Change the brake shoe or the brake pad;

Change the brake shoe;

Change brake pad

Change the brake drum or the brake disc;

Change the spring;

Change the wheel-brake cylinder;

Change the wheel-brake cylinder

Change the brake pad

The brake pedal is hard

but doesn

t work;

There is oil stain or lubricant on the brake shoe or

brake pad;

The brake shoe deforms, brake liner is worn or

polished, or the brake wheel is worn;

The brake pad deforms, or is worn or polished;

The piston of wheel brake pump is seized;

The vacuum booster has trouble

The vacuum degree is unsuitable

The brake pipe line is blocked

Change the brake shoe brake pad;

Change the brake shoe

Change the brake pad;

Change the wheel-brake cylinder;

Change the vacuum booster;

Make repairing according to real situation;

Make repairing according to real situation;

BR-3

Troubleshooting (continued)

Braking System

Notice and Troubleshooting

Trouble

Causes

Inspection items

There is clatter noise when using

the brake

(Drum-type brake)

The brake shoe is seized on the flange of rear baffle;

The flange of rear baffle is worn;

The pressure spring of brake shoe is loose or missing;

The fixed bolts of brake bottom plate is loose;

(disc type brake)

The brake pad support plate is loose or missing

The mounting bolts are loose;

Add lubricant

Change the lubricating flange

Change

Tightening it

Change

Tightening it

There is hoarse noise or quack-

quack when using the brake

The brake shoe or brake pad is worn;

The brake caliper, the wheel or the rotator interferes each

other.

There is friction between the dust cover and brake disc,

the brake bottom plate and the brake drum;

The other braking part has trouble

There is friction between the tire and body

Change the part, and re-process

precisely the brake drum or

rotator if the abrasion is serious;

Make change according to real

situation;

repair or change

Make repairing according to

real situation;

Change

Check or maintain the part

T h e r e i s s u c h n o i s e a s

continuous screaming, quack-

quack, oscillating sound, etc.

Notice: the braking materials

may generate the natural noise

and heat during friction, and

thus emit the energy. Therefore,

i t i s n o r m a l t o h a v e t h e

s c r e a m i n g n o i s e . T h e s e

phenomena will be more serious

under the condition of frigidity,

torridity, and over humidity,

s n o w i n g a n d m u d . t h e

screaming noise occurring

occasionally will not lead the

fatal brake trouble nor reduce

the effective properties of the

brake.

The brake drum, brake liner, liner or brake pad is worn

or scraped

The brake liner or brake pad is dirty or with oil stain or

polished.

The brake liner or brake pad is improperly used.

The brake pedal or vacuum booster drag rod is unsuitably

adjusted.

(disc type brake)

The brake pad silent pad is loss or damaged;

The brake pad is worn to the degree that the abrasion-

indicating lamp of brake pad has friction with the rotator.

There is burr or rust on the brake caliper.

(Drum type brake)

The pressure spring of brake shoe is soft in rigidity, or is

damaged or unsuitable.

The pressure spring pin or spring of brake shoe is loose

or damaged;

There is crack on the brake bottom plate flange

Check, repair or change

Clean or change

Check or change

Check for adjustment

Change

Change

Clean or polish the burr

Check, repair or change

Check, repair or change

Check, repair or change