Great Wall Sing (2006 year). Service Manual — part 13
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)
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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)
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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
(140160)Nm
4.
Measure the pre-tightening torque of the bearing:
New bearing
(1.2-1.7)Nm
The reused bearing
(0.9-1.3)Nm
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)
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SA-90
5.
Mount the axle driven bevel gear on the differential housing:
(a)
Mount on the lock plate and screw up the bolts to the
specified torque.
Tightening moment
(65-95)Nm
Notice: screw up the bolts diagonally.
(b)
Tighten the lock plate with hand hammer and flat head
pinch.
6.
Mount the inner race and roller assembly of bearing
200719E;
Mount the bearing inner race and roller assembly in differen-
tial housing with the pressure machine and SST.
7.
Mount the differential assembly;
Mount the differential in the speed reducer housing.
When mounting the differential that hasnít changed the inner
race and roller assembly of bearing 200719E, ensure the outer
race of the left and the right bearings that has disassembled
should match with their inner racers respectively.
8.
Mount the adjusting ring;
Adjust the clearance between the driving bevel gear and the
axle driven bevel gear to the moderate size. And press the
bearing outer race to flatten it with adjusting ring, and then
screw up moderately.
Notice: the two adjusting rings should be adjusted
synchronically in the movement of same direction.
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)
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SA-91
9.
Mount on the differential bearing cover:
(a)
Align the assembly marks on differential bearing cover
and the speed reducer housing, and press down the
differential bearing by hand.
(b)
Mount on the double-eared stop washer and the hex nut.
10. Adjust the clearance between the driving bevel gear and
the axle driven bevel gear
(a)
Screw up the hex nuts connecting the differential bearing
cover to the specified torque.
Tightening moment
(80-110)Nm
(b)
Attach the measuring meter seat on the face of speed
reducer housing with the measuring head touching the
teeth face, run the axle driven bevel gear with hand to
measure the teeth engagement clearance, and then com-
pare it with the clearance value in step (d) to decide the
order of the adjusting ring tightening according to the
values.
(c)
Adjust and screw up the adjusting rings with SST.
Tightening moment
(115-135)Nm
(d)
Check the engagement clearance again until the clear-
ance value of the three spots evenly locates on the
circumference of axle driven bevel gear. Otherwise,
adjusting ring adjustment is suggested.
Engagement clearance
(0.13-0.25)mm
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)
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SA-92
tooth top engagement
select the adjusting washers that make the main teeth apart from the axle driven bevel gear.
teeth convex
=
teeth concave
11. Check the engagement situation of the axle driven bevel
gear and the driving bevel gear:
(a)
Coat four teeth locating on different spots of axle driven
bevel gear with red powder.
(b)
Rotate the axle driven bevel gear in different directions.
(c)
Check the teeth engagement situation.
The teeth trace of axle driven bevel gear should satisfy
this requirement. If not, select the suitable adjusting
washer to correct according to the poor teeth engagement
situation.
Washer thickness (unit: mm) see the following table:
Suspension System and Automobile Axle (Rear)
Rear Speed Reducer (Disassembly of Speed Reducer)
heel end engagement
toe end engagement
teeth root engagement
select the adjusting washer that make the main teeth
contact the axle driven bevel gear more closer.
Group NO.
Washer thickness
Group NO.
Washer thickness
1
1.60
7
1.90
2
1.65
8
1.95
3
1.70
9
2.00
4
1.75
10
2.05
5
1.80
11
2.10
6
1.85
12
2.15
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SA-93
12. Lock the double-eared stop washer to mount the stop
gasket and bolts:
(a)
If the engagement trace satisfies the requirement, lock
tightly the double-eared stop washer with hand hammer
and pinch.
(b)
Mount on the stop gasket, spring gasket and bolts, and
then screw up the bolts.
Tightening moment
(18-26)Nm
(c)
Tap in he adjusting ring with the pinch and hammer.
13. Measure the total preload:
Preload: (1.8-2.4) N
m
If the preload is beyond the specified range, change the gas-
kets between the jacket and bearing 7607E, until they meet
the requirement.
(a)
If the preload is larger than the specified value, change
the adjusting washer.
(b)
If the preload is smaller than the specified value, screw up
the nuts again slowly but not exceed 160N.m.
Notice: if the screwing torque exceeds the max torque,
change the adjusting washer and repeat the preload
process. Do not screw back the main-tooth nut to reduce
the preload.
14. Check and adjust the flange bouncing
(a)
Attach the dial indicating lamp seat on the speed reducer
housing with the measuring head contact the flange face,
run the flange to observe the swing out range of the dial
indicating lamp hand.
Radial full bouncing tolerance
0.10mm
Remark: the two bouncing values should be controlled within
0.10 mm, as for the parts of bounce exceeding the tolerance,
loosen the nut-driving bevel gear to assembly them in another
angle, measure the bounce value again. Observe carefully the
swing direction of the hands, which can be referred when
changing the locations of flange and the driving bevel gear. If
the requirement cannot be satisfied after several trials, change
the new flanges until the requirement is met.
Suspension System and Automobile Axle (Rear)
Rear Speed Reducer (Disassembly of Speed Reducer)
30mm
15. Rivet the driving bevel gear nuts.s
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SA-94
Mount of Rear Speed Reducer and
Differential Assembly
1.
Mount the speed reducer and differential assembly on
the rear axle housing.
Tightening moment
(18-26)Nm
Remark: in case the sealing gasket is mounted, it should be
checked to see whether it is damaged before mounting, if
damaged, change with the new sealing gasket, and the dam-
aged sealing gasket should be clear away; if no sealing gasket
is mounted, no mount is required to mount. Clean the contact
face of the mounted axle housing and coat it with silicon-
rubber plain sealing agent.
2.
Connect the drive shaft and flange well and be careful to
align the assembly marks marked when disassembling.
Tightening moment
(69-79)Nm
Screw up the oil drain plug with the Tightening moment
of (140-150)N
m
Mount on the half-shaft and the brake assembly to adjust the
brake oil path so that the wheel brake pump is filled with brake
liquid.
3.
Inject in the heavy-duty oil.
Oil brand: heavy-duty oil graded GL-5;
Viscosity: SAE 85W/90
Oil volume: add the oil until it overflows from the oil filler
outlets.
Screw up the oil-filling plug.
Tightening moment
(140-150)Nm
Suspension System and Automobile and Axle (Rear)
Rear speed reducer (Mount of Rear Speed Reducer and Differential Assembly)
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SA-95
Rear Differential
Element Figure
half axle gear
thrust gasket
differential housing
pin
planetary
gear shaft
planetary gear
stop gasket
half-axle gear
planetary gear
1.
Tear down the speed reducer and the differential
assembly.
2.
Tear down the differential from the speed reducer and
differential assembly.
Change of Differential Parts
1.
Disassembly of Differential
(a)
Tap out the pin with hammer and pinch.
Suspension System and Automobile Axle (Rear)
Rear differential
(b)
Tear down the planetary gear shaft, the planetary gear,
planetary gear stop gasket, half-shaft gear and half axle
gear thrust gasket.
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SA-96
2.
Assembly of Differential
(a)
Put the half-axle gear thrust gasket on the half-axle gear
and then encase them in the differential housing.
(b)
Encase the planetary gear stop gasket, planetary gear and
encase the planetary gear shaft.
(c)
Check the clearance between the half-axle gear thrust
gasket and the differential housing.
Remark: the half-axle gear and the planetary gear should run
freely without stagnant, push the planetary gear inside, then
measure the clearance between the half-axle gear thrust gasket
and the differential housing with dial indicating lamp.
Reasonable clearance range: (0.45-0.75)mm.
Remark: if the clearance value fails to fall within the above
range, change the half axle gear thrust gasket, at the same time,
ensure the left and right half axle gear thrust gasket are same
in thickness.
(d)
Tap the pin in the pinhole, and rivet the end of the pinhole
so as to prevent from the pin missing.
Mount of Differential
1.
Encase the differential assembly in the speed reducer
housing.
2.
Mount the speed reducer and differential.
Suspension System and Automobile Axle (Rear)
Rear differential
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SA-97
Suspension System and Vehicle Axle
Rear Suspension (Leaf Spring Type)
Rear suspension(leaf spring)
Leaf spring and shock absorber
N
m
specified torque
90
10
110
10
liner
rront ear pin
rear ear pin
liner
u-shaped bolt
spring seat
90
10
Dismantle of leaf spring and vibration
damper
1.
Raise the vehicle body with a jack and support it with a
bracket;
(a)
Raise the vehicle body with a jack and support it with a
bracket;
(b)
Lower the axle housing until the leaf spring is loosened
to the degree there is no tension existing. Keep the leaf
spring in such status.
2.
Tear down the vibration damper.
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SA-98
3.
Tear down the U-shaped bolt;
(a)
Tear down the mounting nuts of U-shaped bolts.
(b)
Tear down the spring seat;
(c)
Tear down the U-shaped bolts.
4.
Tear down the leaf spring;
(a)
Tear down the mounting nuts of front ear pin;
(b)
Tear down the front ear pin;
(c)
Disconnect the leaf spring from the bracket;
(d)
Tear down the rear ear pin and the leaf, and then take
apart the leaf spring.
Change of leaf spring
1.
Loosen the spring clip;
Loosen the spring clip with a chisel.
2.
Tear down the central bolt;
Clamp the spring with a table vice at the position near to the
central bolt to take apart the central bolt.
3.
Change the spring clip if necessary;
(a)
Cut the rivet-head with a drill-head and tap the rivet out.
(b)
Tap a new rivet in the hole of leaf spring and spring clip
and rivet it with pressure machine.
Suspension System and Vehicle Axle
Rear Suspension (Leaf Spring Type)
-------------------------------------------------------------------------------------------------------------------------------------------------------------
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)Nm
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)Nm
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
)Nm
(b) Connect the vibration damper to the sprint seat with bolts
and tighten these bolts.
Tightening moment: (25
)Nm
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)Nm
Tighten the nuts of rear ear pin;
Tightening moment: (90
0)Nm
all lengths of bolts protruding are same
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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;
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