Great Wall Pegasus (2006 year). Service Manual — part 4
MT-35
Gearbox
Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism)
(c) Coat the sealing agent on the bolt thread.
(d) Propel the plug with the torque socket spanner.
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MT-36
Gearbox
Bearing Front Cover Assembly (Element Drawing, Change of Oil Seal)
Bearing Front Cover Assembly
element drawing
bearing front cover
assembly
washer
front cover oil seal
assembly
Change of oil seal
The oil seal of the bearing front cover shall be changed where
necessary
(a)
Pry out the oil seal with screwdriver
(b)
Press in the new oil seal with SST.
Depth of oil seal:
Upper tooth
9.5mm
Tang tooth
(12.4 0.4)mm
SST
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MT-37
Assembly of Gearbox
1.
Mount the output shaft in the central link plate
(a)
Tap the output shaft in the central link plate while pulling
it, until mounting it in the central link plate.
(b)
Mount the stop ring of the rear bearing of output shaft in
with the split-ring-type pliers.
Remarks: The stop ring shall flush with the surface of central
link plate.
2.
Mount the input shaft in output shaft
(a)
Coat the MP lubricant on the bearing with 13 needle
rollers, and mount the needle rollers in input shaft.
(b)
Propel the input shaft in the output shaft and flush the
groove of synchronizing ring with the sliding block.
3.
Mount the countershaft in the central link plate
(a)
Mount the stop ring on the rear bearing of countershaft
with split-ring-type pliers.
alignment
Gearbox
Assembly of Gearbox
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MT-38
Gearbox
Assembly of Gearbox
(b)
Mount the intermediate-gear shaft in the central link
plate, and mount the backup rear bearing with SST while
holding the intermediate-gear shaft.
4.
Mount the baffle of rear bearing of output shaft
Mount and propel the bolts with torque socket spanner.
Tightening moment
Tang tooth
(1722)Nm
Upper tooth
(1217)Nm
5.
Mount the reverse idle gear and shaft
(a)
Mount the reverse idle gear and shaft.
(b)
Mount the axial pressing plate of the reverse idle gear,
and then propel the bolts tightly.
Tightening moment
(1520)Nm
6.
Mount the bracket cluster of reverse rocker arm
Mount the reverse rocker arm bracket and propel the two bolts
tightly.
SST
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MT-39
locking ball
socket spanner
Gearbox
Assembly of Gearbox
7.
Mount the steel ball and the five-speed thrust washer.
8.
Mount the five-speed gear cluster
(a)
Coat the gear oil on the needle bearing.
(b)
Mount the five-speed gear cluster.
9.
Mount the synchronizing ring and the fifth coupling gear
(a)
Mount in the synchronizing ring and the fifth coupling
gear.
(b)
Dismantle the old central link plate from the table vice.
(c)
Put the gearbox straightly as shown in the drawing.
(d)
Flush the groove of synchronizing ring with the sliding
block and mount the fifth coupling gear with pressure
machine.
(e)
Mount the new central link plate in the table vice.
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MT-40
Gearbox
Assembly of Gearbox
10. Mount the split ring
(a)
Select the retainer for shaft that leaves the minimum
radial clearance, which is not larger than 0.1mm.
(b)
Mount in the retainer for shaft with copper bar and
hammer.
(c)
Mount the spring cylindrical pin of third-fourth-speed
gearshift fork.
Notice: The pin port should align with the direction of the
shaft.(Same sa below)
11. Measure the radial clearance of the five-speed gear
cluster.
Measure the radial clearance of the five-speed gear cluster
with the measuring gauge.
Standard clearance
Shang chi
(0.1350.325)mm
Tang chi
(0.10.3)mm
12. Mount the third-fourth-speed gearshift fork axle and the
first-second-speed gearshift toggle fork as well as the
third-fourth-speed gearshift toggle fork
(a)
Mount the first-second speed and third-fourth speed
gearshift toggle forks.
(b)
Mount the third-fourth-speed gearshift fork axle in the
central link plate and the gearshift toggle fork.
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MT-41
Gearbox
Assembly of Gearbox
13. Mount the first gearshift fork axle and first gearshift fork
(a)
Coat the MP lubricating on the interlocking guidepost
and mount the interlocking guidepost on the first-second-
speed gearshift fork axle.
(b)
Mount the interlocking pin in the central link plate with
the magnetic bar.
(c)
Mount first-second gearshift fork axle in the first gear-
shift toggle fork and central link plate.
d) Mount the setting bolts of the first toggle fork and tighten
them.
Tightening moment
Upper tooth
(1520)Nm
Tang tooth
(1317)Nm
14. Mount the reverse yoke rod, reverse rocker arm and
reverse yoke block
(a)
Mount the reverse yoke rod, reverse rocker arm and
reverse yoke block together.
(b)
Mount the reverse rocker arm on the reverse rocker arm
bracket.
(c)
Coat the MP lubricant on the interlocking guidepost and
mount the guidepost on the reverse gearshift fork axle.
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MT-42
Gearbox
Assembly of Gearbox
(d)
Mount the interlocking pin in the central link plate with
the magnetic bar.
(e)
Mount the reverse gearshift fork axle in the reverse yoke
rod and central link plate.
(f)
Mount the spring cylindrical pin with the drift punch and
hammer.
15. Mount the five-speed reverse gearshift guide block and
five-speed reverse gearshift fork axis.
(a)
Mount the five-speed reverse gearshift guide block in the
five-speed reverse gearshift guide shaft.
(b)
Mount the reverse gearshift fork axle in the next step.
(c)
Mount the steel ball in the five-speed gearshift guide
block with the magnetic bar.
(d)
Mount the five-speed gearshift fork axle as shown in the
drawing.
(e)
Mount the steel ball in the central link plate with mag-
netic bar.
(f)
Mount the five-speed gearshift fork axle in the central
link plate.
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MT-43
Gearbox
Assembly of Gearbox
(g)
Tap the pin in the five-speed gearshift toggle fork with
the drift punch and hammer.
(h)
Mount the five reverse gearshift guide shaft in the five-
speed reverse guide block and central link plate, and
(i)
Tap the spring cylindrical pin in the five-speed reverse
guide block with drift punch and hammer.
16. Mount the retainer ring gripped by the gearshift fork axle.
Mount the clamp retainer ring with the steel bar and hammer
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MT-44
sealed material
Gearbox
Assembly of Gearbox
17. Mount the steel ball, locating spring and locating spring
plug
(a)
Mount the steel ball and locating spring.
Remarks:
Mount the short spring at the bottom of the central link plate.
(b)
Coat the sealing agent on the plug thread.
(c)
Mount the plug and tighten them with the torque socket
spanner.
Tightening moment
(1722)Nm
18. Tear down the central link plate from the table vice
(a)
Tear down central link plate from the table vice.
(b)
Dismantle the bolts, nuts and washers
19. Mount the gearbox frame
(a)
Coat the sealing material on the coupling face of the
gearbox frame as shown in the drawing.
(b)
Put down the central link plate straightly as shown in the
drawing.
(c)
Mount the gearbox frame on the central link plate as
shown in the drawing.
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MT-45
sealed material
Gearbox
Assembly of Gearbox
20. Mount the stop ring of the front bearing
(a)
Mount the two stop rings in the input shaft bearing and
countershaft front bearing with the split-ring-type pliers.
(b)
Mount the coated component elements of front cover.
(c)
Coat the sealing agent on the bolt thread, and
(d)
Mount and propel tightly the bolts.
Tightening moment
(1520)Nm
21. Mount the rear body, gear-change bar and selection bar
and their housings
(a)
Coat the sealing materials on the rear body as shown in
the drawing.
(b)
Mount the gearshift shaft and gearshift yoke block in the
rear body.
(c)
Mount the gearshift catching head in the groove of guide
block, and
(d)
Mount the catching head with the rear body together.
(e)
Mount and propel tightly the bolts.
Tightening moment
Shang chi
(3040)Nm
Tang chi
(3045)Nm
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MT-46
4WD
Gearbox
Assembly of Gearbox
(f)
Fasten the rear cover bolts of the four-gear driving
gearbox
Tightening moment:(30
45)Nm(Tang tooth)
(g)
Mount and propel tightly the setting bolts of the gearshift
yoke block.
Tightening moment
(1722)Nm
22. Mount the steel ball spring and plug
(a)
Coat the sealing agent on the plug thread.
(b)
Mount the steel ball, setting spring and setting spring
plug.
Tightening moment
(1722)Nm
23. Check the following items after mounting the rear body
or gearbox
(a)
Check the stability of the running input shaft and output
shaft.
(b)
Check the gearshift stability of each speed
24. Mount the component elements of the locating mecha-
nism
(a)
Mount the black component elements of the locating
mechanism on the side of the five-speed reverse gear.
(b)
Mount another component element of locating mecha-
nism and propel it tightly.
Tightening moment
(3040)Nm
25. Mount the gearshift cover of the gearbox.
(a)
Mount the gearshift cover coated with sealing agent.
(b)
Mount six bolts and then tighten them.
Tightening moment
(1520)Nm
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MT-47
Gearbox
Assembly of Gearbox
26. Mount the clutch frame
(a)
Mount the clutch frame.
(b)
Coat the sealing agent on the bolt thread.
(c)
Mount the nine bolts and then tighten them.
Tightening moment
Upper tooth
(6070)Nm
Tang tooth
(3045)Nm
27. Mount the back-up lamp switch.
Tightening moment
(2040)Nm
28. Mount the driven gear of odometer
(a)
Mount the driven gear of odometer.
(b)
Mount the bolts and tighten them.
Tightening moment
(1015)Nm
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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
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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.
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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
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