Great Wall service chassis and body Manual — part 2

CL-6

Clutch

Clutch Brake-Wheel Cylinder

Clutch brake-wheel cylinder

Element drawing

clutch brake-wheel cylinder

spring

piston

dust cover

push-rod

air-exhausting plug

N*m

specified torque

Disassembly of brake-wheel cylinder

1.

Tear down the clutch pipeline.

Remove the pipeline with SST

2.

Tear down the two bolts to take down the clutch

brake-wheel cylinder

mount of brake-wheel cylinder

1.

Mount the brake-wheel cylinder with two bolts;

2.

Connect the clutch pipeline;

Connect the pipeline with SST;

3.

Exhaust the air in clutch system.

18

2

19

1

CL-7

Clutch

Clutch Cluster

Clutch cluster

Element drawing

flywheel

clutch rib

clutch pressure plate

separation

bearing

clamp

separation fork

dust cover

30

specified torque

N*m

Disassembly of clutch cluster

1.

Tear down the gear box;

Remark: do not leave the gear oil in drying

2.

Tear down the clutch pressure plate and the clutch rib

a) Make aligning marks on the clutch pressure plate and the

flywheel.

b) Loosen the fixing bolts gradually until the spring tension

is released;

c) Tear down the fixing bolts to pull out the clutch pressure

plate and clutch rib.

3.

Tear down the bearing and separation fork from the gear

box;

a) Tear down the clamp to pull out the bearing;

b) Tear down the separation fork and dust cover.

CL-8

Clutch

Clutch Cluster

Inspection on clutch parts

1.

Check whether there is abrasion or damage of clutch rib;

Measure the depth of the rivet head with calipers.

Min depth of rivet head: 0.3mm

If the depth of rivet head exceeds the limit value, change the

clutch rib.

2.

Check the radial pendulum difference of the clutch

Check the radial pendulum difference of the clutch rib with

multi-meter.

Max radial pendulum difference: 0.8mm

If the radial pendulum difference exceeds the max value,

change the clutch rib.

3.

measure the rdial pendulum difference of the flywheel;

Check the radial pendulum difference of flywheel with multi-

meter;

Max radial pendulum difference: 0.2mm

If the radial pendulum difference exceeds the max value,

change the flywheel.

4.

Check the guide bearing

Exert the force in radial direction to rotate the bearing by hand.

If the guide bearing doesn

t run or if there is great resistance,

change the guide bearing.

Remark: as this bearing is lubricated permanently, it needs not

to be cleaned or lubricated.

5.

Change the guide bearing where necessary.

a) Tear down the guide bearing with SST;

SST

CL-9

Clutch

Clutch cluster

b) Mount the guide bearing with SST.

Remark: the bearing shall be verified in good running after it

is encased in the flywheel hub.

2.

Check whether there is abrasion on the diaphragm spring.

Check the abrasion depth and width of diaphragm spring with

calipers.

Limit value: Max depth: 0.6mm

Max width: 5mm

If the abrasion depth or width of the diaphragm spring exceeds

the limit value, change the diaphragm spring .

3.

Check the separation bearing

Exert force in radial direction by hand to rotate the bearing.

If it cannot be rotated or if the resistance is too large, change

the separation bearing.

Remark:

Remark: as this bearing is lubricated permanently, it doesnít

need to be cleaned or lubricated.

Mount of clutch cluster

1.

Mount the clutch rib on flywheel;

Mount the clutch rib on flywheel with SST.

2.

Mount the clutch pressure plate

a) Align the marks on clutch pressure plate and that on flywheel;

b) Screw up the bolts in even manner around the clutch pressure

plate until pressure plate and the flywheel contact closely,

then tighten the bolts.

Tightening moment: 30 N

m

Remark: tighten the uppermost bolt of the three that is near to

the locating pin.

SST

flywheel side

SST

alignment

mark