Great Wall service chassis and body Manual — part 20

TF-21

Q

R

N

O

P

NM

S

T

N

U

V

N

O

P

Q

R

S

(d)

All of the following aligning conditions shall be satisfied

when the rear cover assembly is mounted on the transfer

box front housing:

a)

Align the pin hole in the rear cover to the pin on the

housing.

b)

Align the rear output shaft to the inner bearing in

cover rear hole.

c)

Align the blind hole in the rear cover and the shift

guide shaft; ensure the return spring is not tilted.

Check the hole in velocity sensor of the rear cover

with a pen.

d)

Align the shift shaft and the inner bearing in rear

cover.

(e)

Screw up the nine bolts after locating the sign bolts

correctly.

(f)

Encase the gear of odometer in the rear cover assembly

through the spline of the rear output shaft.

(g)

Press the new oil seal in the cover assembly

N

O

P

Q

Transfer Box

Transfer Box Assembly

1. bolt

2. wire harness

3. magnet

4. return spring

5. shift guide shaft

6. transfer box rear

body assembly

7. sign board

8. driving gear of Odometer

9. oil seal

10. transfer box front housing

1. locating pin

2. output shaft

3. shift shaft

4. return spring

5. shift guide shaft

6. output shaft.

12.

Assembly of Rear Cover

Mount the aforesaid accomplished cover assembly on the

transfer box housing according to the following process:

(a)

Mount the return spring on the shift guide shaft of the

transfer box.

(b)

Mount the magnet in the groove of the housing.

(c)

Coat the Letai glue 598 of 1.6mm on the coupling face of

housing, steer clear of the screwed hole when coating

continuously.

Notice: try to button the rear cover on the transfer box front

housing with the moderate force during the following process.

Not too much force is required when mounting the rear cover

on the front housing when all aligning conditions are satisfied,

in case the rear cover cannot be mounted on the front housing,

take down the rear cover assembly to check the aligning

condition

1. wire harness clip

2. motor assembly

3. bolt

4. sign board

TF-22

1

2

3

4

6

7

8

9

5

2

1

Transfer Box

Transfer Box Assembly

1. motor assembly

2. shift shaft

1. fixed sensor bracket

2. bolt

3. sensor assembly

4. velocity sensor

5. o-ring

6. motor assembly

7. bolt

8. gasket

9. transfer box rear body

12. Mount the external electric shifting element (for the elec-

tric shift transfer box)

(a)

Locate the motor assembly by aligning the triangle

groove on motor to the shift shaft.

(b)

Move the motor to combine the shift shaft and keep it

close to the rear cover. Then run the motor clockwise

until the motor locates the correct place and the mooting

holes are aligned.

(c)

Mount the O-ring on the velocity sensor and encase the

velocity sensor assembly in rear cover. A clip and three

bolts shall be mounted on the velocity sensor.

Fastening torque

(811)Nm

(d)

Mount the bolts and gaskets on the end of motor clip.

Fastening torque

(811)Nm

TF-23

5

4

3

1

6

2

Transfer Box

Transfer Box Assembly

1. transfer box rear body

2. flange

3. oil seal

4. gasket

5. nut

6. oil plug

13. Flange assembly

The parts mount process is as follows:

(a)

Encase the two oil plugs in the rear cover.

(b)

Encase the flange, sealing ring and gasket, and then

screw up the nuts.

Fastening torque

(203244)Nm

TF-24

Transfer Box

Washing, Checking, Up-Keeping and Exchanging (Washing)

1.

Washing

Notice: check the metal rag around the magnet first before washing, large granule or irregular metal

granule shows the disintegratation or similar damage. Small or fine metal granule shows the uneven

or serious wear. If the metal rag is founded, notice shall be taken on damage and wear inspection

during checking the rotating parts and the element matched with the rotating parts.

(a)

Common washing

Wash the parts in cleaning agent to clean away the old lubricant and deposit. Clean away the deposit in oil hole

with brush. Take notice not to scrape the metal coupling face when washing the parts cannot be cleaned with

brush.

(b)

Dry the washed parts by blowing

Dry the washed parts by blowing the low-pressure compressed air (max pressure is 137.9kPa), because cloth

thread may be left during cleaning the parts with cloth. The bearing shall be held by hand to prevent it from

rotating when blowing it.

(c)

Bearing lubrication

The ball bearing and needle bearing shall be lubricated with the lubricant for transfer box after washing. As

the non-lubricated bearing may cause damage when be dry. Cover the lubricated bearing to prevent dust

entering in.

Washing, Inspection, Maintenance or Change