Great Wall service chassis and body Manual — part 3
CL-10
Clutch
Clutch Cluster
3.
Check the alignment of the diaphragm spring end.
Check the alignment of diaphragm spring end with SST.
Max dislocation: 0.5mm
if the difference is more than the specified value, adjust the
alignment of diaphragm spring end with SST.
4.
Coat the lithium base grease;
Coat the lithium base grease on the following parts:
Contact spot of separation fork and bearing
Contact spot of separation fork and push-rod;
Support spots of separation fork
Spline of clutch rib
5.
Encase the dust cover, separation fork, separation bearing
seat and bearing into the gearbox;
6.
Mount the gearbox.
SST
MT-1
Gear box
page
Notice . . . . . . . . . . . . . . . . . . ... MT-2
Troubleshooting . . . . . . . . . . . . . . ... MT-3
Dismantle of Gear Box . . . . . . . . . . . . . MT-4
Mount of Gear Box . . . . . . . . . . . . . ... MT-7
Disassembly of Gear Box . . . . . . . . . . . . MT-10
Input Shaft Assembly . . . . . . . . . . . . ... MT-18
Element Drawing . . . . . . . . . . . . . .. MT-18
Inspection on Synchronizing Ring . . . . . . . MT-18
Bearing Change . . . . . . . . . . . . . ... MT-18
Output Shaft Assembly . . . . . . . . . . . . . MT-20
Element Drawing . . . . . . . . . . . . . .. MT-20
Disassembly of Output Shaft Assembly. . . . . MT-21
Inspection on Output Shaft Assembly . . . . . .. MT-23
assembly of Output Shaft Assembly . . . . . . . MT-25
Countershaft Assembly And Reverse Idle Gear
Assembly . . . . . . . . . . . . . . . . . .. MT-29
Element Drawing . . . . . . . . . . . . . .. MT-29
Disassembly Inspection and Assembly of
Countershaft Assembly . . . . . . . . . . . . MT-29
Assembly of Reverse Gear . . . . . . . . . .. MT-31
Rear Housing assembly . . . . . . . . . . . ... MT-33
Element Drawing . . . . . . . . . . . . . .. MT-33
Change of Oil Seal . . . . . . . . . . . . ... MT-33
Change of Shaft Bush . . . . . . . . . . . .. MT-33
Inspection on and change of Position-Limit
Mechanism Cluster . . . . . . . . . . . . ... MT-34
Front Cover of Bearing . . . . . . . . . . . . . MT-36
Element Drawing . . . . . . . . . . . . . .. MT-36
Change of Oil Seal . . . . . . . . . . . . ... MT-36
Assembly of Gear Box . . . . . . . . . . . . . MT-37
MT
MT-2
Gear Box
Notice
Notice
Notice for disassembly and assembly of gearbox
Notice shall be taken during the gear disassembly and assembly on the soft handle for the parts, especially
for the coupling faces so as to avoid the collision; each part shall be put down in order to avoid the missing
or mistaking.
Notice shall not only be taken in the aforesaid aspects, but also in the following items
1.
Wash all parts before assembly (rubber fittings and washers excluded).
2.
Various oil seals, retainer rings for shafts, spring-type pins shall not be reused.
3.
Lubricating oil shall be coated on the friction surfaces, and lubricating grease shall be coated on the lips
of oil seals.
4.
Rolling elements shall not be used to transfer the pressure during the various bearing assembly.
5.
Lip-type oil seal must not be sloping when assembling it.
6.
The openness at the two ends of the spring collar shall be misfit when assembling the component
elements of the synchronizing instrument, and
7.
No part is allowed to leak the lubricating oil when the gearbox locating at its working place.
MT-3
Troubleshooting
Gear Box
Troubleshooting
Non-use of clutch
Non-full separation of clutch
Severely warned tooth rings of synchronizing
fittings
Over-hard locating spring
Use the right driving approach
Checking for adjustment
Change
Change
Difficulty in gear engagement
Over-low oil level
Lubricating oil of inferior quality
Non-timely oil change
Unsuitable axial location or clearance of gears
Bearing damage
Burr or collision on gear
Add oil to the specified level
Change it with the specified oil
Change the oil and damaged parts
Check for adjustment
Change
Repair or change the gear
Oil leakage, oil penetration
Oil added above the specified level
Loss or missing of bolts
Vent plug trouble
Sealing element damage
Adjust oil to the given level
Reassembling or fasten the bolt according to
the specified torque
Change
Change
Damage of synchronizer
Overexert in gear shift
Non-use of clutch
Damage on spring collar of synchronizer
Incorrect mounting of drive shaft
Change
Use the right driving approach
Change
Check for adjustment
Non-engagement of gear
Trouble in controlling mechanism
Incorrect assembling the locating spring or
steel ball
Invalidation of locating spring
Severely worn gear sleeve or fork groove
Seriously worn toggle fork
Check for adjustment
Reassembly
Change
Change
Change
Burning bearing, burning gear
Over-low oil level
Inferior lubricating grease
Non-timely oil change, over-dirty oil
Inter-use of differential oil or usage of
additive
Change damaged parts and add oil
Change the damaged parts and lubricating oil
Change damaged parts and lubricating oil
Change damaged parts and lubricating oil
Difficult in gear disengagement
Spring invalidation of synchronizer
Warn inner groove of tooth ring of synchronizer
Tooth ring of synchronizer choked on conical
face
Toggle fork deformation or toggle fork axle
deformation
Severely worn toggle fork
Change
Change
Change
Change
Change
Methods for troubleshooting
Over-loud or abnormal noise
Common Failures
Causes
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