Great Wall service chassis and body Manual — part 19
TF-17
1.25-1.75mm
2
3
1
12.70mm
1
3
2
4
4
2
1
5
6
7
8
3
(e)
In the case that the input shaft is taken apart, what need
to do is to fill the needle bearing as shown in the drawing
and press it in the input shaft, meanwhile, press the new
sliding bearing to complete the whole input shaft assembly.
(f)
Raise the planetary mechanism assembly to mount it into
the input shaft assembly; encase the thrust gasket and
press in the bearing through the input shaft end. Encase
the fixed bearing in the snapping ring groove of the input
shaft with a snapping ring.
(g)
If the transfer box front body is taken apart, press the new
located pin in the front body, and the pressing dimensions
are shown in the drawing.
(h)
Put down the oil seal as the drawing shows, and press it
in the front body according to the dimensions shown in
the drawing.
(i)
Put down the front body assembly on two wooden blocks
in the way that the coupling face of the front body and the
housing faces upward, so that there is clearance left
between the input shaft assembly and the worktable. Put
down the input shaft and planetary mechanism assembly
in the front body, in which the input shaft shall be
downward. Open the long ends of the snapping ring to
encase input shaft and planetary mechanism assembly
until the snapping ring enters into the external snapping
ring groove of the bearing.
(j)
Coat the sealing glue of 1.6mm on the coupling locations
of the front end cover and transfer box assembly, The
glue shall be coated continuously without break and steer
clear of the screwed hole.
(k)
Screw up the six bolts.
Fastening torque
(2746)Nm
6.
Assembly of front output shaft
Mount the following parts:
(a)
If the dust cover is taken apart, mount it by pressing.
(b)
Encase the input shaft, sealing ring, gasket and nuts in the
transfer front housing.
(c)
Insert the torque arm of T-13-54-002 in the flange hole to
screw up the nuts.
Fastening torque
(203244)Nm
Transfer Box
Transfer Box Assembly
1. needle bearing
2. bearing roller
3. input shaft
1. locating pin
2. oil seal
3. front body of transfer box
4. snapping ring
1. fork-type flange
2. dust cover
3. fork-type flange assembly
4. transfer box housing
5. output shaft
6. oil seal
7. washer
8. nut
TF-18
1. deceleration gear
2. output shaft
3. insert face of toggle fork
4. deceleration toggle fork assembly
5. pin, contact roller and sleeve assembly
6. deceleration shift toggle fork
7. plastic sleeve
8. contact roller
9. pin
1
2
6
7
8
9
3
N
O
P
Q
R
S
T
Transfer Box
Transfer Box Assembly
7.
Deceleration shift parts assembly
The mounting process is as follows:
(a)
If the parts are taken apart for change, assemble the shift
toggle fork assembly with a new pin-contact roller
assembly. Press the pin-contact roller in the deceleration
fork hole until the detent passes the hole completely and
seizes the right location. Ensure that the contact roller can
run freely.
(b)
Mount two inserted faces of toggle fork on the decelera-
tion toggle fork assembly.
(c)
Engage the deceleration fork assembly and deceleration
gear sleeve and put them in the housing, and the decelera-
tion gear sleeve shall be put in the planetary mechanism
assembly that is assembled already. Mount the rear
output shaft and joint the bearings at the ends of output
shaft and input shaft as well as the spline of the gear
sleeve.
Remarks: the output shaft assembly can be delayed until the oil
pump is mounted on the output shaft. The oil pump may be
dipped into the lubricant through the oil pump screen, turn the
output shaft in clockwise from the output shaft direction to see
whether there is lubricant pumped out so as to check whether
the oil pump can work normally or not. The parts mounted
readily may be encased in the transfer box housing as an
assembly
8.
Oil pump assembly
Ensure the parts of oil pump are completely lubricated when
assembling, and the oil can be pumped out from the conical
hole of the oil pump front cover. The mount of oil pump is as
follows:
(a)
Mount the pin on the rear output shaft.
(b)
Slide the oil pump assembly on the rear output shaft
along with the pin.
(c)
Put the gripping hoop at the end of oil pipe that is
mounted on the oil nozzle of the pump housing, screw up
the gripping hoop.
1. filter
2. oil pump hose
3. gripping hoop
4. oil pump assembly
5. output shaft
6. pump pin
7. output shaft and pump assembly
5
4
TF-19
1
9
8
7
6
5
4
3
2
10
11
1
2
3
4
5
6
7
Transfer Box
Transfer Box Assembly
9.
Assembly of driving chain
The parts assembly process is as follows:
(a)
Put the driving chain sprocket at the rear end of the output
shaft, and the driven chain sprocket is put at the rear end
of the front output shaft on the worktable after the transfer
box housing assembly mount.
(b)
Mount the chain on the sprocket.
(c)
Holding the two chain sprockets parallel with the transfer
box in the space that the chain on the two sprockets are
straightened, and encase the chain and sprocket assembly
through the output shaft, it is required to run the chain
sprocket slowly to ensure that they engage with the front
output shaft and the spline.
(d)
Mount the gasket and snapping ring on the front output
shaft.
10. Shift locking element assembly
The parts mounting process is as follows (for the electric shift
transfer box):
(a)
Mount the return spring and locking hub on the locking
sleeve and fasten them with snapping ring to finish the
2W-4W locking sleeve assembly.
(b)
Encase the shift guide shaft in the blind hole of the
housing through the deceleration toggle fork assembly
that is already assembled.
(c)
Mount the shift toggle fork on the 2W-4W locking sleeve
assembly, which will slide through the shift guide shaft
and rear output shaft.
(d)
Joint the combined external gear sleeve spline and the
rear output shaft spline as well as the 2W-4W locking
sleeve.
1. output shaft
2. driving chain sprocket
3. driven chain sprocket
4. washer
5. snapping ring
6. transmission chain
7. front output shaft
1. output shaft
2. shift engagement
sleeve assembly
3. locking sleeve
4. return spring
5. engagement sleeve
6. snapping ring
7. shift lock hub
8. clutch assembly
9. fastening snapping ring
10. shift guide shaft
11. toggle fork
TF-20
1
convex plate
groove
2
3
4
5
6
1
2
3
4
5
6
7
1. electric shift convex plate
2. torsion spring
3. shift shaft
4. gear down shift fork assembly
5. shift fork
6. gear shifting shaft
Transfer Box
Transfer Box Assembly
1. clutch washer assembly
2. snapping ring
3. ball bearing
4. transfer box rear body
5. nut
6. oil seal
7. bearing
8. needle bearing
11. Rear cover Assembly
Mount the parts into the rear cover according to the following
process:
(a)
Locate the rear cover on the suitable press machine, the
coupling face of the rear cover shall face upward and
parallel with the work face of the press machine.
(b)
Locate the needle bearing, of which the marked end
facing upward, and press it in the rear cover until the
upper end of needle bearing is 40.47
40.97 lower than
the coupling face of the rear cover that matches with the
front housing.
(c)
Press the ball bearing in the rear cover and mount the
snapping ring well.
(d)
As for the electric shift transfer box, the parts shall be
encased according to the following process:
(1)
Confirm the four O-rings are set on the clutch
washer assembly (one O-ring is located on the coil,
the other three on studs).
Mount on the clutch coil assembly, of which the
wire and stud shall protrude out the rear cover, take
notice not to damage the wire when screwing up the
nuts.
Fastening torque
(811)Nm
(2)
Encase the motor bearing and oil seal in the rear
cover.
(e)
As for the electric shift transfer box, encase the as-
sembled electric shifting cam group and clutch shell in
the process as follows:
(1) Put down the electric shifting cam group as shown in
the drawing.
(2) Hold the shift guide shaft downward and raise lightly
the toggle fork assembly. Run the electric shifting
cam group in place, so that the contact roller on
deceleration toggle fork assembly enters in the groove
of shifting cam, and the projecting part of lock
toggle fork is at the rear end of the shifting cam, and
then take reduce the component elements in the
transfer box housing, meanwhile, joint the shift
shaft on the pin in transfer box housing.
(3) Locate the clutch shell well through the shift exter-
nal gear sleeve and mount on the snapping ring.
8
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