Great Wall Deer (2006 year). Service Manual — part 30
B0-87
Body
Size of Chasis
Unit
mm
size in 2D
Safe
front
Axial spacing
2630
assuming standard
line
Mark
A,a
B,b
C,c
D,d
Name
Cab mounting hole
Cab mounting hole
Cab mounting hole
Cab mounting hole
Bore diameter
Mark
Name
Bore diameter
Cab mounting hole
E,e
central line of front wheel
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B0-88
Body
Size of Chasis
Unit
mm
size in 2D
Sing
Axial spacing
3025
front
Mark
A,a
B,b
C,c
D,d
Name
Cab mounting hole
Cab mounting hole
Cab mounting hole
Cab mounting hole
Bore diameter
Mark
Name
Bore diameter
Cab mounting hole
E,e
Cab mounting hole
F,f
central line of front wheel
assuming
standard line
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B0-89
Body
Size of Chasis
Unit
mm
size in 2D
Pegasus
Axial spacing
2760
assuming
standard line
front
central line of front wheel
Mark
A,a
B,b
C,c
D,d
Name
Cab mounting hole
Cab mounting hole
Cab mounting hole
Cab mounting hole
Bore diameter
Mark
Name
Bore diameter
Cab mounting hole
E,e
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A-1
Specifications of Maintenance
and Up-keeping
page
Clutch . . . . . . . . . . . . . . . . . . .. A-2
Gear box . . . . . . . . . . . . . . . . . . A-2
Transfer box . . . . . . . . . . . . . . . . A-3
Drive shaft . . . . . . . . . . . . . . . . ... A-4
Suspension system and automobile axle . . . . . A-4
Braking system . . . . . . . . . . . . . . . A-5
Steering system . . . . . . . . . . . . . . .. A-6
A
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A-2
Clutch
Specification
Item
Specification
Fastening torque for clutch tube on master cylinder
Fastening torque for clutch tube on wheel-brake cylinder
Fastening torque for clutch pressure plate
160
190-200
5-15
0.3
0.8
0.2
0.6
5
Max misplacement
0.5
Pedal height (calculated from front wall
Pedal free stroke
Min depth of clutch-facing rivet
Max radial swing difference of clutch rib
Max radial swing difference of flywheel
Max width of wear of diaphragm spring
Max width of wear of diaphragm spring
Alignment degree of diaphragm spring end
Applicable vehicle model
Dr SF
SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Torsion moment
Fastening location
(N*m)
15-17
15-17
30
Applicable Vehicle model
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Gearbox
Three-grade maintenance for gearbox
1.
Grade I maintenance for gear box
Grade I maintenance: Check the lubricant level to see whether the lubricant level is in alignment with the lower edge of oil
filler; if the lubricant is lower than the oil filler lower edge, add the lubricant; or the insufficient lubricant will lead to the poor
lubrication or burn-out of bearing and teeth; while the over-high lubricant will cause the overheating and oil leakage.
2.
Grade II maintenance for gear box
Grade II maintenance: The gear box of a new vehicle should be maintained by exchanging the lubricant during the
first grade II maintenance and should be washed with kerosene; and the lubricant quality should be checked in the
grade II maintenance in later time, if the lubricant is diluted, gumming or over-dirty, it should be changed.
3.
Grade III maintenance
The gearbox should be disassembled for inspection, washing and oil change.
Notice: As the new vehicle is in the running-in status, the gearbox should be maintained by exchanging lubricant
after the vehicle covers 1500 km,
Lubricant Type
GL-5 SAE80W/90
Torsion moment of relative connecting elements
Tung Teeth: Tang tooth(5DYA4TWD
5DYA8FWD)
Unit
ãã
Specification of Maintenance and Up-Keeping
Clutch and Gearbox
Locating screw of fork axle at first and second gear
Locating screw of yoke block
Screw on baffle of rear bearing of output shaft
Screw of reverse idler shaft
Bolt of gearshift cover
Bolt of front cover
Bolt of rear body
Bolt of clutch shell
Bolt of locating spring
13
17
15
20
17
22
17
20
15
20
15
20
30
45
30
45
17
22
Fastening location
N*m
-------------------------------------------------------------------------------------------------------------------------------------------------------------
A-3
Fastening location
N*m
Upper tooth(JK72TWD)
Fastening location
N*m
Specification of Maintenance and Up-Keeping
Transfer Box
Maintenance and Up-keeping of Transfer Box
1.
The oil level of transfer box should be checked when exchanging the engine lubricant or the vehicle
covers more than 8000 km
and add the lubricant where necessary.
2.
Change with the appointed lubricant each year or after the vehicle covers more than 48000 km.
Notice: lubricant brand: 85W/90 GL-5.
Fastening torque of relative connecting elements
15
20
10
15
12
17
15
20
15
20
15
20
15
20
30
40
60
70
30
40
30
40
17
22
30
50
20
40
30
40
90
125
Toggle fork at first, second and fifth gears and the screw of
toggle fork
Bolt on odometer pressure plate
Screw on baffle of rear bearing of output shaft
Screw on baffle of reverse idler shaft
Locating screw of gearshift yoke block
Bolt of front cover
Bolt of gearshift cover
Pillar of clutch toggle fork
Bolt of clutch cover
Bolt of rear body (M10X1.25X130)
Bolt of rear body (M10X1.25X80)
Plug of locating spring
Oil filling/draining plug
Reverse gear switch assembly
Location mechanism cluster
Locking nut at rear end of countershaft
Fastening location
N*m
Flange nut
Oil drain plug
Bolt of motor clip
Fixing bolt of motor
Clutch coil nut
Housing bolt
Oil pump bolt
Venting valve
Bolt of front connecting body
203
244
19
30
8
11
8
11
8
11
27
46
4.0
8.5
8
19
27
46
Oil filling/draining plug
Location mechanism cluster
Pillar of clutch toggle fork
Bolt on odometer pressure plate
Reverse gear switch assembly
30
50
30
50
30
50
10
15
30
50
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A-4
Drive Shaft
Torsion moment
Fastening location
Applicable vehicle model
N*m
Connecting bolt
Fixing bolt of central supporter
74
5
40
5
Dr SF SL SK SY SJ
Dr SL SK SY SJ
Inflation pressure of tire
Ground clearance of chassis
Steering angle of inner wheel
Kingpin inner inclination
Outer inclination of front wheel
Mechanical steering
Power steering
Kingpin rear inclination (inclination)
Mechanical steering
Power steering
Toe-in
Error in length between left and right
drag rod
Side slip value
Front:220
0kPa
Back:240
0kPa
Front:250
0kPa
Back:250
0kPa
295mm
255
mm
58.5mm(difference in height between
shaft center of lower arm and wheel
center)
310
mm
295
mm
36
40
32
32
34
9
30' 5'
14
52'
0
30' 0'
0
10' 0'
0
20' 0'
0
20' 5'
1
50'
-20'
2
5' 5'
2
0' 0'
0-2mm
=2mm
=5m/km
.5m/km
Suspension System and Automobile Axle
Specification
Item
Applicable vehicle model
Specification
Dr SL SK SY SJ
SF
Dr
SL SK
SF
SY
SJ
Dr SL SK SY
SF
SJ
Dr SL SK SY
SJ
Dr SL SK SY
Dr
SL SK SY
SJ
Dr SL SK SY
Dr SL SK SY
SJ
Dr SL SK SF SY SJ
Dr SL SK SF SY SJ
Dr SF
SL SK SY SJ
HPM
Specification of Maintenance and Up-Keeping
Drive shaft, Suspension System and Automobile Axle
-------------------------------------------------------------------------------------------------------------------------------------------------------------
A-5
Torsion moment
Fastening location
Applicable vehicle model
N*m
Limit bolt of steering knuckle
U-type fixing bolt
Bolt of spring pin of rear plate and shackle
Central bolt of rear steel plate spring
Connecting bolt of rear vibration damper and rear axle
Connecting bolt of front vibration damper and lower swing arm
Connecting bolt of rear vibration damper and frame
Connecting bolt of rear vibration damper and lower swing arm
Fixing bolt of pedestal arm of torsion rod spring
Locking nut of torsion rod spring
Fixing bolt at two ends of transverse stabilizer rod
Fixing bolt of transverse stabilizer rod bracket
Connection bolt of guide lever and lower arm
Fixing nut at front end of guide lever
Axial fixing nut of front suspension and lower arm
Axial fixing nut of lower arm of front suspension
Connecting nut of steering knuckle and upper ball stud
Connecting bolt of steering knuckle and lower ball stud
90
10
110
10
90
10
50
5
64
5
25
5
25
5
137
10
83
5
83
5
23
3
29
5
23
3
25
5
96
10
150
10
96
10
178
15
226
25
196
10
226
0
25
210
0
25
110
10
142
10
142
10
SJ
Dr SL SK SY SJ
Dr SL SK SY SJ
SL SK SY SJ
SF
SL SK SY SJ
SL SK SY SJ
SF
SL SK SY SJ
SL SK SY SJ
Dr
SL SK SY SJ
Dr SF
SL SK SY SJ
Dr SF SL SK SY
Dr
Dr SL SK SY SJ
SF
Dr
SF
SL SK SY
SJ
Dr SL SK SY SJ
SF
Dr SF SL SK SY SJ
Braking system
specification
Item
Applicable vehicle model
specification
Pedal height
Free stroke of pedal
Stroke of operating lever of parking brake
160mm
190-200mm
3-6mm
9-10
7-9
Dr SF
SL SK SY SJ
Dr SL SK SF SY SJ
Dr
SL SK SY
torsion moment
Fastening location
Applicable vehicle model
N*m
Brake oil pipe
Dr SF
SL SK SY SJ
18
2
19
1
Specification of Maintenance and Up-Keeping
Braking System
-------------------------------------------------------------------------------------------------------------------------------------------------------------
A-6
Torsion moment
Fastening location
Applicable vehicle model
N*m
Fixing nut of steering wheel
Connecting nut of steering ger and swing arm
Fixing bolt of steering driven arm
Fixing bolt of steering gear
Connecting nut of steering drag rod and swing arm of
steering gear
Connecting nut of steering drag rod and steering driven
arm
Connecting nut of steering drag rod and front brake
Steering limit bolt
Dr SF
SL SK SY SJ
Dr SF
Dr
SF
SL SK SY
SJ
Dr
SF
SL SK SY
SJ
Dr SF
Dr
SF
Dr SF
SJ
50
5
30
2
245
25
80
10
142
10
83
10
78
10
96
10
145
10
96
10
78
10
91
10
91
10
59
5
91
10
90
10
Steering system
Specification
Item
Applicable vehicle model
Specification
Max play of steering wheel
Tension degree of driving belt:
When f=98N
New belt
Old belt
Dr SF
Dr SL SK SF SY SJ
Dr SL SK SF SY SJ
6
5-7mm
7-9mm
Specification of Maintenance and Up-Keeping
Steering System
-------------------------------------------------------------------------------------------------------------------------------------------------------------
B-1
SST Special tool
page
Special tool . . . . . . . . . . . . . . . . ... B-2
B
-------------------------------------------------------------------------------------------------------------------------------------------------------------
B-2
Disassembling and as-
sembling tools for lock-
i n g n u t o f s t e e r i n g
knuckle
3916001
Press fitting tool for in-
ner bearing of front wheel
hub
3916002
3916003
3916004
3916005
3916006
3916007
3916008
3916009
3916010
Press fitting tool for outer
bearing of front wheel
hub
Disassembling tool of
ball stud
Fixing tool of main teeth
flange of needle bearing
Press fitting tool for steer-
ing knuckle oil seal
Disassembling tool of
shorter liner of lower arm
Mounting tool of shorter
liner of lower arm
Mounting and disassem-
bling tool of long liner of
lower arm
Disassembling tool of
upper arm liner
SST Special Service tool
Diagram
Tool name
tool number
Remark
SST Special Tool
Special Service Tool
Application position
Front axle
Rear axle
2WD
4WD
-------------------------------------------------------------------------------------------------------------------------------------------------------------
B-3
Application position
Front axle
Rear axle
2WD
4WD
3916011
3916012
3916013
3916014
3916015
3916016
3916017
3916018
3916019
3916020
Press fitting tool of up-
per arm liner
Disassembling and as-
sembling tools of wheel
brake cylinder of front
brake caliper
Disassembling tool of
front drive shaft bearing
Pneumatic caliper of
outer sleeve of front drive
shaft
Press fitting casing of
front drive shaft bearing
Disassembling tool of
main teeth oil seal
Press fitting tool of main
teeth oil seal
Disassembling tool of
long semi-axis
Electric cutch tester
Disassembling tool of oil
seal and needle bearing
Oil seal of long semi-
axis of front axle
Inner oil seal of rear axle
shaft
Needle bearing of long
semi-axis
SST Special tool
Diagram
Tool Name
tool number
Remark
SST Special Tool
Special Service Tool
-------------------------------------------------------------------------------------------------------------------------------------------------------------
B-4
3916021
Press fitting tool of oil
seal of long semi-axis
3916022
Disassembling bracket of
long semi-axis bearing
3916023
Disassembling tool of
inner race of small bear-
ing of main teeth
3916024
Disassembling bracket of
inner race of large bear-
ing of main teeth
3916025
Press fitting casing of
inner race of large bear-
ing of main teeth
3916026
Press fitting casing of
outer race of large bear-
ing of main teeth
3916027
Press fitting casing of
outer race of small bear-
ing of main teeth
3916028
Disassembling tool of
differential side bearing
3916029
Press fitting tool of dif-
ferential side bearing
3916030
Mounting tool of needle
bearing of long semi-axis
SSTSpecial Service tool
Diagram
Tool name
tool number
SST Special Tool
Special Service Tool
Application position
Front axle
Rear axle
2WD
4WD
Remark
-------------------------------------------------------------------------------------------------------------------------------------------------------------
B-5
3916031
Press fitting tool of long
semi-axis bearing
3916032
Electric cutch tester
3916033
Disassembling tool of
half-shaft bearing
3916034
Press fitting casing of
half-shaft bearing and oil
seal
3916035
Mounting tool of rear
axle oil seal
3916036
Mounting tool of main
teeth oil seal
3916037
Change oil seal of rear
axle main teeth on
vehicle
3916038
Mounting tool of main
teeth oil seal
3916039
Mounting tool of main
teeth oil seal
3916040
Spanners of adjusting
ring of side bearing of
differential
Use with torsion
spanner together
Change oil seal of
rear axle main teeth
on vehicle
SSTSpecial Service tool
Diagram
Tool name
tool number
SST Special Tool
Special Service Tool
Application position
Front axle
Rear axle
2WD
4WD
Remark
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