Great Wall service chassis and body Manual — part 1
CL-2
Clutch
Troubleshooting
Troubleshooting
Trouble
Causes
Repairing approaches
Difficulty in gearshift
or non-gearshift
Overlarge free stroke of clutch pedal
There is air in clutch pipe
Failure of clutch brake-wheel cylinder
Failure of clutch master cylinder
Overlarge clutch pendulum difference due to incorrect mounting, the
friction liner is stained with oil or is breaking
There is dirty or adhesive materials on spline of input shaft or clutch rib
Failure of clutch pressure plate
Adjust the free stroke of pedal
Exhaust the air in clutch pipe
Change the clutch brake-wheel cylinder
Change the master cylinder
Check the clutch rib
Repair according to requirement
Change the clutch pressure plate
Disengagement of gear
box or clutch slip
Abrasion of clutch guide shaft
Insufficient free stroke of clutch pedal
The friction liner of clutch rib is stained with oil or is worn
Failure of clutch pressure plate
Seize up of separation fork
Change the guide shaft
Adjust the free stroke of pedal
Check the clutch rib
Change the clutch pressure plate
Check the separation fork
Clutch seize-up or
shaking
The friction liner of clutch rib is stained with oil or is worn
Failure of clutch pressure plate
Looseness of engine seat
Check the clutch rib
Change the clutch pressure plate
Repair according to requirement
Looseness of clutch
pedal
There is air in clutch pipe
Failure of clutch brake-wheel cylinder
Failure of clutch master cylinder
Exhaust the air in clutch pipe
Change the clutch brake-wheel cylinder
Change the master cylinder
Over-loud clutch noise
Seize up of separation fork;
Abrasion or stained spot of separation bearing
Abrasion of guide bearing
Parts looseness in clutch pressure plate
Repair according to requirement
Change the separation bearing
Change the guide bearing
Change the clutch pressure plate
CL-3
Clutch
Inspection and Adjustment of Clutch Pedal, Air Exhausting of Clutch
Air-exhausting of clutch
Remark: in case operation needs to be conducted for the clutch
system or if there is air in clutch, exhaust the air.
Notice : Do not stain the painted surface with brake liquid,
if any brake liquid is left, wash it away immediately.
1.
Fill the brake liquid into the oil cup of clutch master cylinder;
The oil cup of master cylinder shall often be checked and, if
necessary, added with brake liquid.
2.
Connect the ethene resin pipe to the air-exhausting valve.
Insert the other end of the pipe into the container, half of which
is filled with brake liquid.
3.
Air-exhausting in clutch system
a) Move the clutch pedal up and down slowly for several times.
b) Loosen the air-exhausting valve when pressing the pedal
increasingly until there is brake liquid overflowing, then
tighten the air-exhausting valve.
c) Repeat this operation until the bubble in brake liquid disappears.
Inspection on and adjustment
of clutch pedal
1.
Check whether the pedal height is correct
Pedal height that begins from front wall board:
Dr SF
(165 5)mm
SL SK SY SJ
(190-200)mm
2.
Adjust the pedal height where necessary
Loosen the locking nut and screw off the adjusting bolts until
the pedal height is correct. Then screw up the locking nut.
Pedal free stroke
3.
Check whether the pedal free stroke is correct
Press the pedal lightly until the resistance generated by clutch
occurs.
pedal free stroke: (5-15)mm
4.
Adjust the pedal free stroke where necessary;
a) Loosen the locking nut and rotate the push-rod until the
stroke is correct;
b) Screw up the locking nuts;
c) Check the pedal height after the adjustment of pedal free
stroke.
adjusting spot in
pedal height
pedal height
pedal free stroke
CL-4
Clutch
Clutch Master Cylinder
Clutch Master Cylinder
Element drawing
SST
Disassembly of master cylinder
1.
Tear down the pin of push-rod
2.
Tear down the clutch pipe
Disconnect the jointed pipe nuts with SST
3.
Tear down the master cylinder
a) Tear down the fixing nuts;
b) Pull out the master cylinder.
spring pin with groove
clutch master
cylinder
18
2
19
1
ring pipe
oil cup of clutch master cylinder
spring
piston
U-clamp
pin
open pin of nut
open ring
push-rod
gasket
dust cover
N*m
specified torque
Parts that cannot be reused after using.
nut
CL-5
Clutch
Clutch Master Cylinder
Disassembly of oil cup of master cylinder
1.
Tear down the oil cup
a) Use the pinch and hammer to tap out the spring pin with
groove;
b) Tear down the oil cup and ring pipe.
Assembly of master cylinder
1.
Mount the oil cup
a) Mount the oil cup and the new ring pipe.
b) Use the pinch and hammer to tap in the spring pin with
groove.
Mount of master cylinder
1.
Mount the master cylinder
Mount the fixing nuts and screw them up.
2.
Connect the clutch pipes;
Connect the clutch pipes with SST
3.
Connect the push-rod and mount the pin;
Encase the pin of push-rod with clamping pliers.
4.
Exhaust the air in clutch system and adjust the clutch
pedal.
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