Great Wall service chassis and body Manual — part 16
TF-5
Transfer Box
Product Description and Simple Maintenance
Transfer Assembly NO. of Manufacturer
product assembly NO.
display
termnumber
displaythe last digit of the year
displaythe specific monthly
manufactuer data
displaythe month numnber
Example display:From January (A) to December (L)
Product instruction and simple maintenance
Manufactuer data
Product instruction and simple mainte-
nance
1.
Product Introduction
The transfer box adapted by our company is the transfer box
of 45-55 manufactured by Bogeguana, which is two-speed
and time driving, a set of planetary mechanism used is to
obtain the speed-reducing performance, while the driving
force is transmitted to the front driving gear by a highly precise
chain. The planetary gear train and rear output shaft element
of transfer box is lubricated initiatively through oil bath and oil
pump. This transfer box has four gears:
2H-stands for the two high gears
in which, only the two
rear wheel are driven, and the gear ratio of the transfer box
is 1:1
4H-stands for the four high gears, in which , all of the four
wheel are driven, and the gear ratio of the transfer box is
1:1
N- neutral location (this location only exists in the transfer
box of manual gearshift )
No driving force is transmitted
to the wheel when the input shaft and output shaft are
disconnected.
4L-stands for low gears, the four wheels are all driven, and
the gear ratio of transfer box is 2.48:1.
The gearshift of the mechanical gearshift transfer box is
obtained through the shifting-cam-type guide plate that is
operated by the shift rocker arm.
Sign board: which is fastened at the obvious external location
of transfer box, and on which the detailed data are marked.
borgwarner
TF-6
5D
5D-Oil filling plug
5L-Oil drain plug
5L
2.
Regular lubricant change
(a)
The oil level of lubricant in transfer box shall be checked
when exchanging the engine lubricant or after the vehicle
covers 8000 kilometers, and the lubricant shall be added
as requirement.
(b)
The lubricant shall be changed with the specified one
every year or after the vehicle covers 48000 kilometers.
3.
Lubricant inspection approach
(a)
Clean the oil filling plug and the around area.
(b)
Open the oil-filling plug to check whether the lubricant
can flows out or not.
(c)
if the lubricant can flow out, which means the real
lubricant volume is under the prescribed value, and the
specified lubricant shall be added into the transfer box
until the lubricant can flow from the oil filler hole.
(d)
Propel the oil-filling plug tightly according to the given
Tightening moment.
Tightening moment
(1930)Nm
Notice: The vehicle shall run for a certain time before
checking or exchanging the lubricant so that the
temperature of lubricant in transfer box may be a little
higher. Do not use hammer or other punching tools to
open or propel the oil drain plug or oil filling plug, otherwise,
the thread hole on the frame will be damaged
4.
Lubricant change
(a)
Clean the oil filling plug and oil drain plug and the around
area.
(b)
Put down a oil container under the transfer box.
(c)
Open the oil drain plug.
(d)
Open the oil-filling plug.
(e)
Drain the lubricant up.
(f)
Mount the oil drain plug and screw it up according to the
given Tightening moment.
Tightening moment
(1930)Nm
(g)
Add the lubricant through the oil filler hole until the
lubricant overflows. Mount the oil-filling plug and tighten
it according to the Tightening moment.
Tightening moment : (19
30)Nm
Transfer Box
lubricant grade: ATF--3
Product Description and Simple Maintenance
TF-7
Transfer Box
Disassembly and Mount of Transfer Box
Disassembly and Mount of Transfer Box
1.
Transfer Box Disassembly
(a)
Drive the vehicle on the lifting jack.
(b)
Locate the gear of transfer box at the neutral
position, shift the transfer box to the 2H and
extinguish the engine.
(c)
Disconnect the cell cathode.
(d)
Lift the vehicle.
(e)
Put down an oil disc under the transfer box, tear
down the oil drain plug and oil filling plug of the
transfer to drain all the lubricant up, then re-
mount the two plugs.
(f)
Disconnect all wires and wire harnesses that
connected with the transfer box.
(g)
Take apart the hose on the venting valve of
transfer shaft.
(h)
Disconnect the linkage of the front drive shaft
with the front flange of the transfer box.
(i)
Disconnect the linkage of the rear drive shaft
with the rear flange of the transfer box.
(j)
Raise the transfer box up with the jack.
Notice: The transfer box shall be guaranteed to
support by the lifting jack before tearing down
the sets of bolt and nut that connected with the
transfer box and gearbox. The transfer box is
not allowed to hang directly on the gearbox
through spline because such operation will
damage the transfer box parts.
(l)
Tear down the connecting nuts between the
transfer box and gearbox and take down the
transfer box.
(m) Move the transfer box backward directly until
the linkage between the input shaft of transfer
box and the gearbox spline.
(n)
Put down the lifting jack of the transfer box, and
(o)
Tear down the gasket between the transfer box
and gearbox. Clean the gasket or glue on the
coupling face of front body of transfer box with
rear body of the gearbox. Take notice not to
damage the coupling face.
1
2
3
4
5
6
7
8
9
1. input shaft
2. front frame of transfer box
3. rear cover of transfer box
4. flange
5. front output fork flange
6. venting valve
7. gasket
8. rear body of gearbox
9. bolt
TF-8
Transfer Box
Disassembly and Mount of Transfer Box
2.
Transfer box mount
a)
Coat the lubricant grease on the output axial
spline of the gearbox with a thin sleeve contain-
ing lubricant grease.
b)
Mount a new gasket on the mounting face of the
transfer box.
c)
Lift the lifting bracket of transfer box and align
it to the same axle with the gearbox.
Notice: The transfer shall be guaranteed to flush
with the gearbox before connecting the spline.
Do not handle it forcefully to press the transfer
box spline into the gearbox. Otherwise, damage
will be caused, run the rear output shaft where
necessary to aim at the spline.
(d)
Move the transfer box forward slowly so that
the spline and pin of the input shaft of gearbox
reach the front body of the transfer box, and the
gasket attaches on the gearbox completely.
(e)
Ensure that the mounting holes of the front
body of transfer box, gasket, and gearbox are in
alignment and then mount the sets of bolt and
nut.
Fastening torque
(35-48)Nm
(f)
Connect the rear drive shaft and the rear output
flange of the transfer box.
(g)
Connect the front drive shaft and the front
output fork flange of the transfer box.
(h)
Connect the venting valve and the soft ventila-
tion pipe.
(i)
Connect the cables of odometer that locates
nearby the transfer box.
(j)
Connect all wire harnesses that connected with
the transfer box, and
(k)
Add the lubricant of right brand.
Notice: when starting the engine, if the lubricant
is added incorrectly or in unsuitable volume,
which may lead the transfer box to damage.
Notice: as for the transfer box mounted on
vehicle, oil pump shall be used when adding oil
for it.
Notice: In case the transfer box is taken apart for
maintenance or inspection, there will be no
lubricant supplied by oil pump in the oil passage
on the top of transfer box. Therefore, it is not
accurate to control the oil volume by opening the
oil filling plug, in such condition, the oil passage
will be filled with oil once the oil pump runs. If the
wheel can run, such operation can be conducted
on the lifting jack. The oil level shall be rechecked
once the oil pump runs.
(l)
Put down the vehicle after finishing the lubri-
cant inspection, and connect the cell cathode.
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