Great Wall service chassis and body Manual — part 15

TF-1

page

Notice . . . . . . . . . . . . . . . . . . ... TF-2

Troubleshooting . . . . . . . . . . . . . . ... TF-3

Product Description and Simple Maintenance . . . . TF-5

Dismantle and Mount of Transfer Box . . . . . . .. TF-7

Disassembly of Transfer Box . . . . . . . . . ... TF-9

Assembly of Transfer Box . . . . . . . . . . . TF-14

Washing, Inspection, Maintenance and Change . . .. TF-24

Washing . . . . . . . . . . . . . . . . ... TF-24

Inspection . . . . . . . . . . . . . . . . TF-25

Maintenance and Change of Gear and Chain gear .. TF-28

Attachment for Inspection, Maintenance and

Change of Parts. . . . . . . . . . . . . ... TF-30

Transfer Box

TF

TF-2

Transfer Box

Notice

Notice

Notice on transfer box disassembly and assembly

Notice shall be taken on the soft handling of the parts (coupling face in particular) during the process of

transfer box disassembly to avoid the collision; each parts shall put down in order so as to avoid of missing

or mistaking.

Notice shall, during assembly process, not only on the aforesaid items, but also on the following items:

1.

Wash all parts and fittings before assembly (rubber element and washer excluded).

2.

Oil seal, clip for shaft and spring pin of various kinds shall not be reused.

3.

Lubricating oil is required to coat on the various friction surface and lubricant on lips of various oil seal.

4.

Rolling body is not allowed to use for pressure transmission when mounting various bearings.

5.

Lip-type oil seal is not allowed to mount slantwise.

6.

The openness on the two sides of spring collar shall not be coupled face-to-face when assembling the

component elements of synchronizer. And

7.

No parts is allowed the lubricant leakage and penetration when the transfer box locates at the working

location.

TF-3

Transfer Box

Troubleshooting

Common troubles

Causes

Resolving approaches

Change the lubricant or supplement the
lubricant volume.
Guarantee the torque of all connecting
elements stand at the specified value.
Open the transfer case to check the
bearing and othe parts whether is weared
or daamaged,if this happened,change
the parts.

Difficulty in mechanic gearshift or
outplace gear engagement

Troubleshooting

Incorrect lubricant or insufficient
lubricant volume.
Looseness of connecting bolt or other
connecting element.
Noise from the transfer box bearing

Noise, which is spreader by the transfer
box instead of clutch, engine, drive shaft
and other parts, occurs in each speed.

No driving of front wheel in the four-
gear engagement

Drive chain break

Disassemble and check the damage of
inner parts, and change the chain.

Adjust or repair shift lever.Open the
transfer box to check the toggle fork and
guide shaft, and change the parts as
requirement.Open the transfer box to
check whether the parts is wearied or not,
and, if any, change the weary parts.Open
the transfer box to check whether the
parts is wearied or not, and, if any, change
the weary parts.Open the transfer box to
check whether the parts is wearied or not,
and, if any, change the weary parts.

Overlarge loose fit clearance of the
shift toggle fork on the shift guide
shaft.
Wear of the shift toggle fork
assembly including pin and contact
roller.
Wear of the shift cam hub and the
liner.
Attainment of coupling gear

Mechanic gearshift seizing at a certain
location

Engagement failure of the mechanically
shift transfer box

Damage or unsuitable adjustment of
the shifting mechanism.
Damage or serious wear of the inner
shifting parts, or looseness or
attainment of the shift toggle fork
assembly on the guide shaft.
Unsuitable adjustment of shift lever.

Adjust or repair the shift lever mechanism.

Change the seriously wearied parts.

Change the loose or weary parts.

Refer to the vehicle manual for correct
operation.
Add the specified oil of given volume.

Open the rear cover of transfer box to check
and changer the damaged parts.
Open the rear cover of the transfer box to
check whether the sliding parts can slide
freely along the axle, if not, dismantle it and
change the damaged parts.

Incorrect operation.

Lubricant of inferior quality or
insufficient volume.
Adhesive bonding of shift toggle fork.

Adhesive bonding of the sliding joint
cover, locking sleeve or gear.

Mechanic gearshift failure under the
movement of shifting handle

Break or damage of the shift rocker
arm or shift lever.
Damage of the guide plate of shifting
cam;

Change the damaged element.

Open the rear cover of the transfer box to
check the damaged element and change
it.

Electric gearshift trouble

Damage or failure of electrically
controlled element, electric module,
speed sensor, electric motor, electric
clutch, or built-in wire harness.
Damage or worn of shifting cam,
joint cover, locking sleeve, toggle
fork or shift guide axle.Adhesive
bonding shift

Refer to the vehicle usage manual to
diagnose the failure element and change
it as requirement.
Dismantle the weary or damaged parts
and change it as requirement.
Dismantle and check the free movement
of sliding element, and change it as
requirement

TF-4

Transfer Box

Troubleshooting

Common troubles

Causes

Resolving approaches

Unsuitable tire pressure.

Noise, which is spread by the transfer
box instead of the clutch, engine or other
parts, occurs at each speed.

Gear noise.
Damage or wear of chain gear or
chain.

Open to check whether there is weary
element or damaged element (including
the odometer gear) and, if any, change
them

Noise occurs in the high-speed or low-
speed four-gear driving.

Open to check whether there is wear or
damage, and if any, adjust the tire pressure
to suitable value.

Oil leakage in transfer box.

Frame Break of transfer box.
Oil leakage of other element.
Ventilation pipe block

Over-added lubricant or lubricant of
unsuitable brand
Looseness of the bolts on sealing
face.
Sealing glue of different brand or
unused sealing glue.
Oil seal wear or damage.

Change the frame.
Check the leakage by wiping dry.
Open and clean it and, if necessary,
change it.
Use the specified lubricant and adjust the
lubricant to suitable volume.
Propel the bolts tightly as requirement.

Use the specified sealing glue and propel
the bolts tightly as required.