Great Wall V200. Service Manual — part 15
a. Make the assembly mark on the inner trumpet connector and
three-pin section assembly.
Caution: remove the grease in the connector before make the
mark and don’t make the mark by the hard object such as
punch.
b. Remove the inner trumpet connector.
4. Disassembly of three-pin section assembly
a. Use the circlip pliers to remove the circlip.
b. Use the adz and hand hammer to make the assembly mark on
the shaft and three-pin section assembly.
c. Use the cooper bar and hand hammer to remove the three-pin
section.
Caution: Remove the cooper chip on the shaft or three-pin
section assembly if has.
5. Remove the inner jacket
a. Use the pliers to disassemble the small clip of inner jacket.
b. Pull out the inner jacket.
Caution: Remove the grease in the jacket and maintain the
clean field.
6. Use the straight screwdriver to disassemble the
large and small clip of outer jacket.
assembly mark
assembly mark
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7. Remove the outer jacket
Caution: Clean the protective jacket and remove the grease on
the outer trumpet connector. Do not disassemble the outer
trumpet connector.
8. Use the screwdriver and hand hammer to remove
the dustproof cover.
Assembly of constant-speed drive shaft assembly
1. Use the hand hammer and screwdriver to install
the dustproof cover
Caution: The dustproof cover should be replaces when
itisdeformed heavily.
2. Install the large clip of outer jacket, outer jacket
and small clip of outer jacket.
Caution: The outer jacket should be replaced when it is
damaged or aged heavily and warp the end of the shaft with the
plastic band and coat with small grease before insert it.
3. Insert the small clip of inner jacket, inner jacket
and large clip of inner jacket.
Caution: The inner jacket should be replaced when it is
damaged or aged heavily.
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4. Install the three-pin section assembly on the front
drive shaft.
a.Let the end of three-pin section assembly with chamfer faces the
shaft inner direction.
Caution: The three-pin section assembly should be replaced if
its needle bearing position is damaged.
b.Align the assembly mark made before disassembly.
c. Use the hand hammer and copper bar to install the three-pin sec
tion assembly to the front drive shaft.
d.Use the circlip pliers to install the new circlip.
5 Install the outer jacket on the outertrump etconn
ector.
Fill the jacket with the grease supplied with the jacket before
install the jacket.
(Recommend used grease is CAPLEX or KY1)
Grease using amount: About 110g
with chamfer
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6
Install the inner trumpet connector on the front
drive shaft
a. Fill the inner trumpet connector and inner jacket with the
grease supplied with the jacket
(Recommend used grease is CAPLEX or KY1). Amount About140g
b. Align the assembly mark made during disassembly; covered
with inner trumpet connector.
c. Cover the inner jacket on the inner trumpet connector.
7
Use the inner and outer jacket clip pliers to
clamp the inner and outer jacket.
a. Use the special non-ear clip pliers to lock the large clip of
inner jacket.
b. Use the nutcracker to lock the small clip of inner jacket.
Caution: Ensure the large and small connecting place of jacket
is in the corresponding groove of trumpet connector and shaft.
assembly mark
outer jacket clip
inner jacket clip
non-ear clip pliers
nutcracker
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c.Use the special pneumatic pliers to lock the large and small clip of
outer jacket.
d.Ensure the jacket of both sides does not be prolonged or shortened
when the front drive shaft has the standard length.
Standard length: 400.5mm
If only need to replace the outer components of front drive
shaft assembly on car, it can remove the left and right steer-
ing knuckle of car, then disconnect the inner trumpet con-
nector of front drive shaft assembly, then take out the three-
pin section assembly and shaft from the inner trumpet con-
nector for replacement.
Installation of constant-speed drive shaft assem-
bly on front drive axle
1. Insert the hanger plank into the drive shaft, inserted
with oil seal; use the circlip pliers to install the inner
circlip.
Caution: It should replace the oil seal if damaged.
special tools
circlip pliers
support the lower end
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Use the special tools to knock bearing in slightly.
Caution: Support the lower end of the drive shaft assembly
when knock the bearing in. The lower end must not slide out.
3. Use the circlip pliers to install the outer circlip on
the front drive shaft assembly.
4. Repeat the previous method to install the hanger
plank, oil seal, circlip, bearing and circlip on another
end.
5. Insert the spline of connecting end of drive shaft
and reducer into the differential halfaxle gear spline
hole of electric clutch and reducer slowly.
6. Drip 1-2 drop of screw lock agent on the middle of
screw of connecting bolt of hanger plank andreducer.
7. Use the wrench to tighten the connecting bolt of
hanger plank and drive axle to specified torque.
specified torque : 90-110N
m
Caution: It should screw on all bolts before tighten
them, then tighten them in diagonal direction.
Check the hanger plank for levelness after tightened
the bolt to the specified torque. Remove the hanger
plank and reinstall it if is not planished.
8. Install the vent tube connector assembly; connect
all ports to front drive axle.
(Refer to “Assembly of Front Reducer Assembly”)
special tools
support the lower end
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Specified torque : 200-220N
m
Caution: Drip 1-2 drop of screw lock agent on the middle front
part of the lifting bolt
10 Use the bolt to connect the front drive axle flange
and drive shaft according to the mark mage before
disassembly and tighten it to the specified torque.
specified torque: 73-83N.m
11. Install the beam under the front drive axle.
Tighten the beam connecting bolt to the specified
torque.
specified torque: 73-83N.m
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Replacement of drive gear oil seal of front reducer assembly
1. Support the front of car; remove the left and right
front wheel and the beam under the reducer.
2. Drain the lubricant oil in the front reducer; remove
the left and right steering knuckle
3. Disconnect the front reducer assembly flange from
the drive shaft and use the jack to remove the front
drive axle
Caution: Make the assembly mark on the reducer and
drive shaft before separate them.
4. Remove the front differential assembly
(Caution: Drain the oil in front differential before the
disassembly)
front reducer
assembly
washer
spacer
drive
bevel gear
bearing
oil seal
front reducer drive gear flange,
main gear flange and dustproof
cover assembly
Used component which can not be used
any more.
N
m:
specified torque
assembly mark
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5. Remove the drive gear flange and dustproof cover
assembly
a. Use the hand hammer and chisel to loose the riveted part on
nut.
b. Use the special tools to clamp the drive gear flangeandremove
the drive gear nut.
c. Use the cooper bar to knock down the drive gear flange and
dustproof cover assembly.
6. Remove the drive gear oil seal
Use the special tools to remove the oil seal; do not
damage the inner wall of reducer housing.
7. Install the new drive gear oil seal
a. Use the special tools to knock into the new oil seal.
b. The top of the oil seal is level to the top of reducer housing.
Caution: Coat the oil seal lip with the lithium base grease and
the oil seal should be in correct position.
special
rotate the wrench in clockwise.
special
special
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8
Install the drive gear flange and dustproof cover
assembly
a. Match the drive gear flange and dustproof cover assembly on
the front drive gear.
b. Coat the new nut with the lithium base grease.
c. Use the special tools to clamp the flange and tighten the nut
to the specified torque.
Tighten torque:140-160N.m
a. Use the torque meter to measure the pre-applied load of the
gap between the drive bevel gear and driven bevel gear.
pre-applied load: 1.2-1.7N.m
b. Is should be replaced by the thicker washer if the pre-ap
plied load is more than specified value
(The step of thickness of washer is 0.03mm)
c. Is should be replaced by the thinner washer if the pre-applied
load is less than specified value. Repeat the previous
operation until meet the requirement.
Caution: Do not reduce the load by loosing the nut.
10. Check the axial and radial run-out tolerance
offlange.
a. Use the dial indicator to measure the axial runout of flange.
Max. axial runout: 0.1mm
b. The max. radial run-out tolerance is 0.1mm
It should check the bearing if the radial run-out tolerance is large.
9
Adjust the pre-applied load of the drive
bevelgear bearing
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11
Rivet the drive gear nut after meet the previ-
ous requirements.
12
Install the reducer assembly on the front drive
axle assembly and assemble the front drive shaft
assembly (refer to Assembly of Front Reducer Assembly
and Assembly of Front Drive Shaft Assembly)
13
Install the oil drain plug; screw off the oil
filling plug and filled with the hypoid gear oil.
Tightening force of oil drain plug: 30-35N
m
Model of lubrication oil: GL-5
Filling amount: Flush to the lower edge of oil filling open
14
Insert the oil filling plug washer and tighten
the oil filling plug to the specified torque.
Specified torque : 140-150N
m
15
Install the front drive axle assembly on the
carriage.
16
Connect the drive shaft to the flange
a. Align the assembly mark; use four bolts and nuts to connect
the flange of drive shaft and front drive axle.
b.Tighten the nut to the specified torque.
specified torque:
Remarks: Keep the clean of the field during the maintenance.
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Front reducer assembly
front drive shaft assembly
hanger plank
R
oil seal
front vibration damper
bearing
front vibration damper
front reducer
electric clutch assembly
Power plug of electric clutch
circlip
bearing
front vibration damper
oil seal
front vibration damper
hanger plank
L
front drive shaft assembly
front drive axle vent tube connector assembly
circlip
circlip
Pregummed component
N
m: specified trque
circlip
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6. Use the wrench to screw off the bolt on the vent tube
bracket, which is used to fix the vent tube connector.
7. Disconnect the connection between the front drive
shaft assembly and steering knuckle front hub
assembly.
a.
Screw off the connecting bolt which is used to fix the front
hub cover; remove the front hub cover.
b.
Use the circlip pliers to remove the circlip from the front drive
shaft and remove the adjusting washer.
c.
Remove the steering knuckle of both sides and separate it
form the front drive shaft assembly.
1. Support the front of the car; remove two front
wheels and the beam under the front reducer
assembly.
2. Drain the lubrication oil in the front reducer
assembly.
3. Remove the flange of front reducer assembly from
the drive shaft
Caution: Make the assembly mark on the flange of
front reducer assembly and drive shaft before discon-
nect them.
4. Disconnect the connector of power wire of electric
clutch
5. Disconnect three rubber connectors on the front
drive axle vent tube connector assembly.
assembly mark
disconnect three connectors in this place
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8. Use the jack to support the front reducer assembly
9. Remove the lifting bolt of front drive axle hanger
plank and carriage.
10. Remove the front drive axle assembly
Caution: Do not damage the drive shaft and front drive
shaft jacket
11. Remove the front drive shaft assembly of both sides
from the front drive axle assembly.
12. Use the wrench to remove the bolt and nut which is
used to fix the front reducer housing.
13. Remove the clump weight assembly and clump
weight bracket welded assembly
(Refer to “Disassembly of Front Reducer Assembly”)
electric clutch connector
N
m: specified torque
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Replacement of front reducer assembly oil seal
1. Remove the front drive axle assembly
(Refer to “Removal of Front Reducer Assembly”)
2. Remove the left and right front drive shaft assem-
bly from the front drive axle assembly.
3. Remove and replace the lower oil seal according to
the removal and installation procedure of front drive
shaft assembly and install the new side oil seal on
the front drive shaft, then install them in the front
reducer assembly.
(Refer to “Removal and Installation of Front Drive Shaft
Assembly”)
Replacement of oil seal and major semiaxle oil seal of front reducer assembly
major semiaxle oil seal
major semiaxle pressing assembly
circlip
mechanical wheel of separator
Pregummed component
N
m: Specified torque
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Replacement of major semiaxle oil seal
1. Make the electric clutch is in the 4WD status,
them stop the engine and remove the front drive
axle assembly (see the disassembly of front reducer
assembly)
2. Use the wrench to screw off the bolt which fix the
front axle vent tube connectorassemblyonventtubeb
racket bolt
3. Disconnect the connector between vent tube of
electric clutch housing and front drive axle vent tube
connector assembly
4. Disconnect the connector between the vent tubes
on the electric clutch and vent tube connector
assembly.
5. Remove the bolt which is used to fix the electric
clutch housing and front axle tube flange; use the
brass bar to open the electric clutch housing and take
out the mechanical wheel of separator.
Caution: The lubrication oil will flow out when sepa-
rate the electric clutch housing from the front axle
flange. It should use the container to hold it.
mechanical wheel of separator
disconnect the place
disconnect the place
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