Great Wall service chassis and body Manual — part 10

MT-28

Transmission

Output Shaft Assembly(Installation of Output Shaft Assembly)

12. Fix the drive gear of speedometer

(a) Install the locking ball and drive gear.

(b) Install the drive gear of tachometer with plier for shaft

shield ring

MT-29

Gear Box

Countershaft Assembly and Reverse Idle Gear Assembly (Element Drawing, Countershaft Assembly Disassembly, Testing and Assembly)

Countershaft Assembly and Reverse Idle Gear Assembly

Element drawing

Disassembly, Testing and Assembly of

Countershaft

1.

Tear down the coupling gear, sliding block and the five-

speed spring collar.

Tear down the coupling collar, three sliding blocks and the two

five-speed spring collars with screwdriver.

2.

Measure the radial clearance of the reverse idle gear

with dial gauge

Standard clearance:

Shang chi:0.05mm

Tang chi:(0.10~0.30)mm (Tang chi is the close Spline

match, which belongs to radial clearance)

Max clearanle:

Shang chi:0.05mm

Tang chi:(0.10~0.30)mm (Tang chi is the close spline

match, which belongs to radial clearance)

front bearing of
countershaft

intermediate-gear shaft

steel ball

rear bearing of
countershaft

stop ring of the rear bearing
of countershaft

five-speed thrust washer

five-speed needle
bearing

sliding block of
synchronize

five-speed cluster

engagement sleeve of the

five-speed synchronizer

spring collar

synchronizer tooth
of spring collar

axial pressing plate
for reverse idle gear

reverse idle
gear shaft

reverse idle gear
cluster

coupling gear around
the five-speed gear

retainer ring for front
countershaft

stop ring for front bearing
of countershaft

MT-30

Gear Box

Countershaft Assembly and Reverse Idle Gear Assembly ( Countershaft Assembly Disassembly, Testing and Assembly)

3.

Reverse gear inspection

Measure the diameter of needle bearing with micrometer.

Standard diameter

Shang Chi

26.000mm

Tang Chi

(25.9826.00)

Limit Diameter

Shang Chi

25.984mm

Tang Chi

25.86mm

4.

Check the synchronizing ring

(a)

Run the retainer ring for shaft and put it onto the shaft to

check itsstopping performance

(b)

Measure the clearance between the rear section of the

synchronizing ring and the spline.

Standard clearance:

Shang Chi

(1.51.8)mm

Tang Chi

(12)mm

Limit clearance: 0.8mm

5.

Measure the clearance of the shift fork and gear sleeve.

Test the clearance of the shift fork and gear sleeve with the

feeler gauge.

Max clearance:

Shang Chi: 0.54mm

Tang Chi:1.0mm

6.

Change the bearing

The front bearing of the reverse gear shall be changed when

necessary

(a)

Pry down the retainer ring for shaft with a split-ring-type

pliers.

MT-31

Gear Box

Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly)

SST

sleeve wrench

front

(b)

Press out the bearing with SST.

(c)

Press in the bearing, side race and inner race with the

socket spanner.

(d)

Select the split ring that leave the radial clearance to

minimum level, and mount it on the shaft.

7.

Mount the engagement sleeve of synchronizer, sliding

block and the five-speed spring collar.

Remark: the opens of the spring collar shall be in non-

alignment

Encase the sliding pad into the gear hub and then cover the

gear sleeve.

Mount the spring retainer under the sliding pad.

Notice, the opening direction of the spring retainer shall

not face-to-face.

Mount of Reverse Gear Assembly

1.

Check the reverse idle gear

Measure the radial clearance of the reverse idle gear with dial

gauge.

Standard clearance:

Shang Chi

0.05mm; Tang Chi(0.040.08)mm

Max clearance

Shang Chi

0.05mm; Tang Chi0.13mm