Great Wall Hover. Service Manual — part 18

2. Install the rear bearing of drive bevel gear and ad

justing washer

a. Select the proper adjusting washer according to “Meshing Condi

tion of Drive Bevel Gear and Driven Bevel Gear”.

b. Install the rear bearing and selected adjusting washer by press

machine.

3. Install the spacer.

a.Select the adjusting washer between the rear bearing and spacer

based on the experience.

b.Install the spacer.

4. Install the front bearing inner race, oil baffle disc

and oil seal of drive bevel gear

a. Place the front bearing inner race in the reducer housing; place the

oil baffle disc.

b. Coat the position of reducer housing oil seal and lip of oilseal

with grease uniformly; place the oil seal in position. Start the

press machine for installation.

5. Install the drive bevel gear, flange and dustproof

cover assembly

a. Install the flange and dustproof cover assembly in the reducer

housing, Press it to level by hand.

b. Insert the drive bevel gear installed with the spacer, rear bearing

and adjusting washer into the flange through the spline; screw on

the nut.

c. Use the nut to tighten the flange, plain washer and drive gear.

special tools

level

special tools

6 Use the special tools to clamp the flange; use the

torque wrench to tighten the nut.

Tightening force: 140

160N

m

7. Measure the rotation pretightening force of bearing

For new bearing : 1.2

1.7N

m

For reused bearing : 0.4

0.6N

m

If does not meet the requirement, replace the adjusting washer

under the spacer until meet the requirement.

Tightening torque : 0-3.5N

m

a. Reduce the thickness of adjusting washer if the measured value

is less than standard value;

b. Increase the thickness of adjusting washer if the measured value

is more than standard value.

8. Install the driven bevel gear on the differential

housing.

a. Use the bolt and lock plate to connect the driven bevel gear to the

differential housing.

b. Screw on for three rounds at least by hand; then use the pneu

matic wrench to tighten it properly.

c. Use the torque wrench to tighten it.

Tightening force: 65-95N

m

Caution: Tighten the bolt in diagonal .

Use the hand hammer and flat head punch to lock the lock plate.

Special tools

9. Install the differential side bearing by press.

Use the press machine and special tools to install the side bearing

on the differential housing by press.

10. Install the differential assembly

a.Remove the bearing gland. Do not mix the left up with right.

b.Install the differential assembly in the reducer housing.

11.Install the adjusting ring

Use the adjusting ring to press the bearing outer race in position;

tighten it properly. Adjust the clearance between the drive and

driven gear to the proper dimension.

12. Install the bearing gland

a. Align the assembly mark on the bearing cover with that on re

ducer housing; Press down the press cover by hand.

b. Install the lock washer with double ears and nut; tighten the

hexagon nut by pneumatic wrench properly.

13. Adjust the engagement clearance between the drive

and driven gear.

a. Use the torque wrench to tighten four bolts on bearing cover by

torque wrench.

Tightening force: 78-115N

m

special tools

special tools

assembly mark

b. Adhere the measuring meter base on the end surface of reducer

housing; the measuring head contacts the tooth surface; rotate

the driven gear by hand and measure the engagement clearance be

tween the drive and driven gear.

c. If the engagement clearance does not meet the requirement, use

the special tools to adjust the left and right adjusting ring until it

meets the requirement.

d. Recheck the engagement clearance between the drive and driven

gear.

Engagement clearance: 0.13-0.18mm

14. Check the meshing mark of drive and driven bevel

gear.

a. Paint 3-4 teeth with the red lead in three different positions of

driven bevel gear.

b. Rotate the driven bevel gear in clockwise and anticlockwise by

hand.Check the engagement of gear.

sound contact

toe contact

dedendum contact

arge end contact

small end contact

select the shim which can make the small drive gear

close to the driven bevel gear

select the shim which can make the small drive gear away from the driven bevel gear

Select the proper washer from the table for correction if the intertooth

contacting status is bad. The thickness tolerance of washer is

0.01mm.

15. Install the stop washer and stop plate

a. If the drive and driven gear engagement mark meets the requirement,

then use the hand hammer and punch to lock the stop washer.

b. Install the stop plate, spring shim and bolt; tighten the bolt.

Tightening force: 18-25N

m

c. Use the punch and hand hammer to knock the lower end of stop

plate in the adjusting ring hole.

Set NO. Thickness

Set NO. Thickness

16. Measure the total pre-applied load

Pre-applied load : 1.8-2.4N

m

If the pre-applied load is beyond the specified; it should replace the

shim between the spacer and rear bearing until meet the requirement.

a. It should replace the adjusting washer if the pre-applied load is

more than specified value.

b. If the pre-applied load is less than specified value, it can retighten

the nut slowly and the torque should be no more than 160N

m.

Caution: When tighten the nut, if is beyond the Max. torque, re-

place the adjusting washer and repeat the pre-applied load process.

Do not reduce the pre-applied load by the method of screw off the

drive gear nut to loose.

washer

rear bearing

17. Check and adjust the run-out of flange.

a.Adhere the dial indicator base on the reducer housing; make the

probe of dial indicator contact with the end surface of flange;

rotate the flange and watch the rotation range of the dial.

Full run-out tolerance of end surface: 0.10mm

b.Adhere the dial indicator base on the reducer housing; make the

probe of the dial indicator contact with the inner diameter of

flange; rotate the flange by hand , and watch the rotation range of

the dial.Radial full run-out tolerance: 0.10mm

18. Rivet the nut of drive bevel gear

Installation of reducer and differential assembly

1.Install the new stiffening ring

2.Install the reducer and differential assembly

Install the reducer and differential assembly in the rear axle housing;

place the washer and nut. Tighten the nut to the specified torque.

Tightening force: 18-25N

m

3.Install the reducer and differential assembly flange

on the drive shaft flange and align the assembly

mark; use four bolts and nuts to connect them.

Tighten the bolt and nut to the specified torque.

Tightening force: 78

5N

m

4.Install the oil drain plug; fill the differential with the

gear oil

oil number : GL-5 hyperbolic gear oil

Viscosity: SAE80W/90

Amount: Filled with oil until the oil flow out from the oil filling

port.

Tighten the oil filling plug.

Tightening force: 140-150N

m

assembly mark

Differential

Differential

1

Remove the reducer and differential assembly

(Refer to “Removal of reducer”)

2

Remove the differential from the reducer and dif

ferential assembly.

(Refer to “Disassembly of reducer”)

Replacement of differential components

1.Disassembly of differential

Use the hammer and punch to knock out the pin. Remove the

planetary gear shaft, two half axle gears, two planetary gears and

two lock washers, two thrust plates.

2. Assembly of differential

a.Install the half axle gear and thrust plate of axle shaft gear

(Unit: mm)

b.Install the planetary gear and planetary gear lock washer in the

differential by rolling. (Unit: mm)

differential housing

thrust plate

half axle

gear

straight pin

planetary gear

lock washer

half axle

gear

thrust plate

planetary gear

lock washer

planetary gear shaft

Set NO. 1 2

Thickness 1.2 1.5

Set NO.

Thickness

c.Use the feeler to measure the clearance between the thrust plate

and differential housing; it can be replaced by the thrust plate with

different thickness if the clearance is beyond the specified range.

Standard clearance: 0.45-0.75mm

d.Install the straight pin

Use the hammer and punch to knock in the pin through the hole

on the differential housing and planetary gear shaft. Rivet the pin

with the differential housing.

Installation of differential

1 Install the differential assembly in the reducer hous

ing

(Refer to “Assembly of Reducer”)

2 Install the differential

(Refer to “Installation of Reducer and Differential Assembly”)

f

eeler

Rear suspension

N

m: specified torque

bush clip

bush

rear stabilizer bar

rear connecting rod of stabilizer bar assembly

plain washer

short longitudinal
pull-rod fixed bolt

rubber pad

short longitudinal
pull-rod fixed bolt

long longitudinal
pull-rod assembly

long longitudinal
pull-rod fixed bolt

long longitudinal
pull-rodassembly

short longitudinal
pull-rod assembly

rear axle

assembly

coil spring

upper support pad

of coil spring

short longitudinal pull-rod assembly

long longitudinal

pull-rod assembly

rear vibration damper

cross pull-rod assembly

cross pull-rod

connecting bolt

Removal of vibration damper

1. Use the lifter to raise the car firstly, then support

the rear axle by bracket.

2. Remove the upper and lower fixing nut which is used

to fix the vibration damper; compress the vibration

damper by hand.

Remove the upper end firstly, then the

lower end; take out the vibration damper .

Installation of vibration damper:

1. Lower tightening force of vibration damper:

1 7 0

5 N

m .

Upper tightening torque : Compress the rubber block to 2/3 of

total height.

Caution: If the fixing nut of vibration damper is the lock nut, it

should be replaced by the new lock nut after replace the vibra-

tion damper.

Removal of coil spring:

1

. Remove the vibration damper (As previous )

2. Use the special tools to clamp the coil spring.

3. Place the car in the bounce status, take out the

coilspring

4. Remove the special tools from the coil spring.

Installation of coil spring:

1. Firstly, use the special tools to clamp the coil spring

to certain height (height when car is in bounce

status).

2. Cautions for installation: Adjust the rubber gasket on

the spring to ensure the spring in flat status.

3. Remove the special tools.

special tools

Removal of connecting rod of stabilizer bar:

1.Shown as figure, firstly screw off the nut in the con

necting place between the connecting rod of stabi

lizer bar and carriage. (Need the inner hexagon

spanner ).

2.Screw off the nut connected to stabilizer bar in same

method; screw off the connecting rod.

Installation of connecting rod of stabilizer bar:

Tighten it to the specified torque during installation:

6 3

5 N

m

Brake-1

Chapter 8

Brake

Cautions. . . . . . . . . . . . . . . . . . . . . .. 2

Troubleshooting. . . . . . . . . . . . . . . . . . . 2

Check and adjustment. . . . . . . . . . . . . . . . ..5

Brake pedal. . . . . . . . . . . . . . . . . . . . ..7

Parking brake. . . . . . . . . . . . . . . . . . . ...8

Front brake. . . . . . . . . . . . . . . . . . . . ...9

Rear brake. . . . . . . . . . . . . . . . . . . . ...16

Rear parking brake. . . . . . . . . . . . . . . . . ..22

Sensor load proportional valve. . . . . . . . . . . . . .29

Antilock Braking System (ABS). . . . . . . . . . . . ..31

Brake-2

Troubleshooting

Cautions

Failure cause

Inspection

content

Pedal is low or soft

brake pad is worn

brake block is worn

brake system is leaked

master pump has failure

Brake system has air

Brake pump has failure

Auto adjuster of rear brake has failure

Replace the brake shoe

Replace the brake block

Repair the leakage

Repair or replace the master pump

Drain the air from brake system

Replace the brake pump

Repair or replace the adjuster

Lag of brake

Parking brake is adjusted badly.

Pull wire of parking brake is locked

Assist push rod is adjust badly

Extension spring or return spring has fault

Pipeline is blocked

brake pad is broken or deformed

brake block is broken or deformed

Auto adjuster is damaged

Master pump has failure.

Adjust the parking brake

Repair if necessary

Adjust the push rod

Replace the extension spring

Repair if necessary

Replace the brake shoe

Replace the brake block

Replace the adjuster

Replace the master pump

Brake is stagnant

Improper inflation of tyre

There is grease spot or lubricant oil on the

brake shoe or brake block.

The brake shoe is deformed ; the brake pad

is worn or smoothed

The brake block is deformed, worn or

smoothed

The brake drum or brake disc is deformed

Extension spring or return spring has failure

Wheel pump has failure

Pump has failure

Brake block is blocked

Charge the tyre to the proper pressure.

Find out the cause. Replace the brake shoe or block.

Replace the brake shoe

Replace the brake block

Replace the brake drum or brake disc

Replace the spring

Repair the wheel pump

Replace

Replace the brake block

brake pedal is hard

There is the grease spot or lubrication oil on

the brake disc or brake block.

The brake shoe is deformed; the brake pad is

worn or smoothed

The brake block is deformed, worn or

smoothed

Brake pump has failure.

Brake assist has failure

Improper vacuum degree

The brake pipeline is blocked.

Find out the cause .

Replace the brake shoe or brake block

Replace the brake block

Replace

Replace the assist

Repair if necessary

Repair if necessary

Brake-3

Troubleshooting (continued)

failure cause

Inspection

content

The brake generates the

crack clatter during

operation.

(drum brake)

The brake shoe is blocked in the rear apron flange

The rear apron flange is worn

The brake shoe pull-out piece spring is loose or lost

The fixed bolt of rear apron is loose (disc brake )

Brake block support plate is loose or lost

Installation bolt is loose

Filled with lubricated oil

Replace the lubricant flange

Replace

tighten

replace

tighten

It has the rustle or rattler

when use the brake

The brake shoe gasket or brake block is worn

The brake caliper and wheel or rotor are disturbed

mutually

The dustproof cover and rotor, rear apron and brake

drum are disturbed mutually

Failure of other brake system component

Tyre generates the abrasion with the tyre and chassis

Replace, if the scratch is heavy,

then fine machine the brake drum or

rotor again

Replace it according to requirement

Correct or replace

Repair or replace it according to

requirement

Check or maintain

It has the squeak, continuous

scream, rattler or vibration

noise when use the brake .

Caution: The abrasion

material in the brake will

generate the inherent noise

and heat during the

abrasion, then emit the

heat. So it is normal that

generate the squeak by

accident. The condition

will be serious in extreme

environment, such as cold,

hot, high humidity,

snowing, saliferous and

mud. The accident squeak

will not cause the fatal

failure of the brake, and

will not reduce the effective

performance of the brake.

The brake drum and brake shoe gasket, rotor and

brake block is worn or scratched.

The brake pad or block is dirty, with oil or smoothed.

The brake pedal or assistor push bar is adjusted

incorrectly

(disc brake )

The brake block silencing plate is lost or damaged.

The abrasion of the brake block makes the brake

block abrasion indication plate contacts the rotor

The brake caliper has burr or is corrosive

(drum brake)

The pull-out piece spring of brake shoe is soft,

damaged or improper. The pull-out piece spring pin

and spring of brake shoe is loose or damaged; and

rear apron flange has crack

Check, repair or replace

clean or replace

check, replace

check and adjust

replace

replace

clean or remove the flash

check, repair or replace

Brake-4

failure cause Inspection

content

It has the continuous

scream and squeak

when does not use the

brake

The brake pedal or assist push bar is adjusted

incorrectly

The return of brake assist or master pump or wheel

pump is bad

(disc brake )

The piston is corrosive or blocked

The brake block in brake caliper is in improper

position

Shell abrasion of rotor and brake caliper

The brake block support plate in disc brake is

installed improperly

The brake block abrasion indication plate contacts

the rotor for the abrasion of brake block

(drum brake)

The press spring of brake shoe is soft, damaged or

improper.

The flange of rear back rear apron is cracked

The rear apron interfere with the brake drum

mutually after bent or warp

Improper machining of brake drum, cause the mutual

interference of rear apron and brake shoe

components of other brake system:

Brake system has loose or redundant components

The brake pad is smoothed for the rear brake drum is

adjusted too tight

The wheel bearing is worn damaged or under

lubricated

Check and adjust

Check, repair or replace

Check and fill with lubrication oil if

necessary.

Repair or replacement

Repair or replacement

Repair or replacement

Repair

Repair

Repair or replacement

Repair or replacement

Replace the brake drum

Check, maintain and replace if

necessary.

It still has the rattler,

click or cackle noise

when does not use the

brake.

The stone or foreign enters into the inside of wheel

protecting hood

The hub nut is loose

The brake pedal or assistor push bar is adjusted

improperly

The wheel bearing is worn, damaged or lubricated

insufficiently

(disc brake )

The muffler spring is soft or lost; the brake block

support plate or external end of brake block is coiled

silencing plate is unsound

The slide bush is worn

The installation bolt is loose

Piston returns unsoundly

(drum brake)

Have loose or redundant component

Remove the foreign materials such as

the stone

Tighten it to the specified torque, it

should be replaced if the bolt hole is

enlarged

Check and adjust

Check, lubricate or replace

Repair or replacement

Check and replace if necessary

Check and replace if necessary

Check and tighten if necessary

Check , repair or replace

Check, take out or repair

Brake-5

Check and adjustment

Check and adjustment of brake pedal

1. Check the correctness of height of pedal

Distance from pedal to lower front apron: 152mm, Operating stroke

of pedal push bar is 1mm.

a. Disconnect the brake lamp switch wire connector; loose the

tightened nut; rotate the brake switch to the position not contacted

to limit block of brake pedal

b. Loose the lock nut of operating connecting rod; use the thinnose

pliers to rotate the operating connecting rod to adjust the height

of brake pedal to the standard value; lock the block nut tightenedly

when reach the standard value.

c. Rotate the brake lamp switch to contact with the limit block of

brake pedal; then rotate 1/2

1 round continuously; tighten the

block nut;

d. Connect the wire connector of brake lamp switch;

e. The brake lamp should not be light when the brake pedal is

released.

3. Check the free stroke of pedal

Free stroke of pedal: 4

6mm

In the status of engine is stop, step on the brake pedal for 2

3 times

after eliminate effect of the brake assist, push down the brake pedal

by hand to just with the resistance, then measure its displacement

(free stroke). It should be in accordance with the standard value.

pedal push rod

parking lamp switch

free stroke of pedal

pedal push rod