four wheel drive GREAT WALL DEER 2006 Service Manual

IN-3Introduction
How to Use This Manual
Introductionóhow to use this manual
The repairing approaches are described step by step:

The illustrations show you what to do and at which position.

The theme of repairing operation tell you what you need to do.

The detailed instruction show you how to accomplish the repairing and
introduce to you other related affairs, such as specification, warning etc.
Example:
Check and adjust the flange bounce
(a) Attach the dial indicator seat to the reducer housing, and touch the
flange face with the measuring head of dial indicator, run the flange
and observe the pendular range of the indicator carefully.
Full bounce tolerance of face : 0.10mm
Illustration:
what to do and at which positionSpecification
This formula can help the experienced technicians find out the failure
causes in short time. Overhauling staff can browse the operation theme
and refer to the detailed description thereunder where necessary; impor-
tant specifications and warnings are written out in boldface.
Specification
The corresponding specifications are given in boldface in each repairing
approach of this manual, which allows the overhauling staff to check the
specification while keeping on repairing work.
Warning, Notice and Remark

Warning written out in boldface means there is possibility of self-
injury or harm to others.

Notice written out in boldface means there is possibility of damage
to parts under repairing.

Remarks singled out independently, but not in boldface, serve as
supplementary descriptions to help you accomplish the work more
efficiently.
Vehicle Code
There are six vehicle models in this manual, the model codes are as follows:
Deer model
Dr
Sailor model
SL
SO COOL model
SK
Safe model
SF
Sing model
SY
PEGASUS model
SJ
Abbreviation used in this manual
A/C
air-conditioner
ECU
electronic controller unit
SST
special service tool
2WD
two-wheel drive
4WD
four-wheel drive
PMãã
Topic:what to do ?
Detailed introductionz;How to do?

TF-3Transfer 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 engagementDrive chain breakDisassemble 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 boxDamage 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 handleBreak 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 troubleDamage 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 shiftRefer 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-5Transfer Box
Product Description and Simple Maintenance
Transfer Assembly NO. of Manufacturer
product assembly NO.
display
termnumber
displaythe last digit of the year
displaythe specific monthly
manufactuer data
displaythe month numnber
Example display:From January (A) to December (L)
Product instruction and simple maintenanceManufactuer data
Product instruction and simple mainte-
nance
1. Product Introduction
The transfer box adapted by our company is the transfer box
of 45-55 manufactured by Bogeguana, which is two-speed
and time driving, a set of planetary mechanism used is to
obtain the speed-reducing performance, while the driving
force is transmitted to the front driving gear by a highly precise
chain. The planetary gear train and rear output shaft element
of transfer box is lubricated initiatively through oil bath and oil
pump. This transfer box has four gears:

2H-stands for the two high gears
in which, only the two
rear wheel are driven, and the gear ratio of the transfer box
is 1:1


4H-stands for the four high gears, in which , all of the four
wheel are driven, and the gear ratio of the transfer box is
1:1


N- neutral location (this location only exists in the transfer
box of manual gearshift )
No driving force is transmitted
to the wheel when the input shaft and output shaft are
disconnected.

4L-stands for low gears, the four wheels are all driven, and
the gear ratio of transfer box is 2.48:1.
The gearshift of the mechanical gearshift transfer box is
obtained through the shifting-cam-type guide plate that is
operated by the shift rocker arm.
Sign board: which is fastened at the obvious external location
of transfer box, and on which the detailed data are marked.
borgwarner

SA-6Suspension System and Automobile Axle
Alignment of Front Wheel
Alignment of Front Wheel (SF)
Alignment of Front Wheel
(SF)
1. The following items should be checked to remove the
troubles.
(a) Check the tire abrasion and the air inflation to see it is
suitable or not.
Tire inflation pressure: (250
0)kPa
(b) Check the front wheel bearing to see whether it is loose.
(c) Check the front suspension to see whether it is loose.
(d) Check the steering driving device to see whether it is
loose, and
(e) Check the front vibration through elastic force test to see
whether it is normal in performance.
2. Height adjustment of vehicle
Adjust the vehicle height to the standard value so as to make
the Alignment of Front Wheel inspection.
A-B-58 5mm
A: The height of steering knuckle shaft center.
B: The center height of the adjusting cam bolt at front end
The standard value for the unloaded height is: the
difference of the center height of drive shaft climax and
the front adjusting cam bolt is 58.5mm.
3. Mount on the four wheel locating device
This approach should be conducted according to the detailed
instruction of the equipment manufacturer.
4. Adjust the outer tilt angle of front wheel and the back tilt
angle of kingpin
The outer tilt angle of front wheel: 0
5'
0'
The back tilt angle of kingpin: 2
0'
0'
Outer inclination of front wheel:
BA
the outer tilt angle of
front wheelthe back tilt angle
of kingpin
front

BR-23
Wheel-brake cylinder disassembly:
1. Tear down the dust cover steel gripping hoop and the
dust cover.
Tear down the dust cover steel gripping hoops and piston dust
covers of the four wheel-brake cylinders with the screwdriver.
2. Tear down the piston from the wheel-brake cylinder:
(a) Prepare a wooden block with the dimensions as shown in
the drawing (which is used to support the piston)
(b) Put the wooden block between the pistons and insert one
brake pad on one side of the wooden block.
(c) Tear down the four pistons from the wheel-brake cylin-
der by using the compressed air.
Warning: do not put your fingers in front of the piston
when using the compressed air.
3. Tear down the piston sealing ring.
Tear down the four piston sealing ring from the wheel-brake
cylinder with the screwdriver.
Check the front brake parts
1. Measure the thickness of brake pad liner;
Standard thickness
9.0mm
Min thickness
2.0mm
In case the liner is less than the min thickness or the liner is
worn unevenly, change the brake pad. Braking System
Front Brake(SF)
mm
mm
mm

BE-32Body Electric System
Combination Instrument
Combination instrument
Electric circuit diagram

  



^N ^NS _N _ N P
DraêaáÉëÉärear fog lamp indicating lamp
rear window/defroster indicating lamp
upper beam indicating lamp
front fog-lamp indicating lamp
A13
B3

connected
with
negative
pole
A10
connected
with
positive
pole
A2
connected
with
negative
polewater
thermometer
tachometer
speedometerconnected with sensor
connected with revolution signal
connected with sensor anode
connected with sensor
fuel gauge
connected with sensor
braking liquid level indicating lamp
parking brake indicating lamp
safety airbag indicating lamp
low oil pressure indicating lamp
engine failure indicating lamp
four wheel drive indicating lamp
generator preheating indicating lamp
fuel alarming indicating lamp
accumulator charging indicating lamp
ABS failure indicating lamp
left turn indicating lamp
right turn indicating lamp
instrument interior
lighting lamp
liquid crystal back-light lamp
A1A16 B1 A5 A6A7 A8 A9 B6 B8 B9B10 B11A12 B4
A15
A14
A10
connected
with
positive
pole
A3
A4
B12
B13
B5
A13
B3

connected
with
negative
pole
A10
connected
with
positive
pole
A2
connected
with
negative
pole
liquid crystal back-light lampinstrument interior
lighting lamp
rear fog lamp indicating lamp
upper beam indicating lamp
front fog-lamp indicating lamp
water
thermometer
tachometer
speedometer
fuel gaugeconnection with sensor
connected with revolution signal
connected with sensor anode
connected with sensor
connected with sensor
oil-water separation indicating lamp
safety belt indicating lamp
parking brake indicating lamp
braking liquid level indicating lamp
low oil pressure indicating lamp
engine failure indicating lamp
four wheel drive indicating lamp
generator preheating indicating lamp
fuel alarming indicating lamp
accumulator charging indicating lamp
ABS failure indicating lamp
left turn indicating lamp
right turn indicating lamp
A1 A16 B1
A5 A6 A7A8
A9 B6 B8
B9 B10
B11 A4A12 A14 A15B4
A10
connected
with
positive
pole
A3
B12
B13
B5

BE-33Body Electric System
Combination Instrument
Electric circuit diagram (continued)
SF
A3 connected
with negative pole
A1 connected
with positive pole
B8 connected
with negative
pole
B7connected
with positive
pole
A4 connecting
with lighting
switch
A6 connected
with negative
pole
pressure-regulating
potential deviceirect-current
power supply
5-9Vdrive power
supply
110VEL
luminous
plate
left turn indicating lamp
right turn indicating lamp
upper beam indicating lamp
rear fog lamp indicating lamp
rear window/defroster indicating lamp
front fog-lamp indicating lamp
water
thermometer
tachometer
connected with sensor
connected with revolution signal
speedometer
digital clock
fuel gaugeconnect to the cathode of sensor
connected with sensor anode
connected with sensor
connected with sensor
back door indicating lamp
parking brake indicating lamp
safety airbag indicating lamp
low oil pressure indicating lamp
engine failure indicating lamp
four wheel drive indicating lamp
generator preheating indicating lamp
fuel alarming indicating lamp
accumulator charging indicating lamp
ABS failure indicating lamp75
B9
B2 A15 B1 A9 B11 B10
A14 B4 B6 A12
B14 connected
with positive
pole
B7 connected
with positive
pole
A11 A5A7 B12B5 B13 A16A13 B16 B15
A2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
In this drawing, A stands for the white plugging
elements, B for black plugging elements, they
use the same numerical order.
instrument
plugging element

BE-34Body Electric System
Combination Instrument
Electric circuit diagram (continued)
A16 A1 B16 B1
SL SK
B1
B16
A1
A16
speed and mileage meter
4P
G
VA9vehicle speed signal
A11odometer sensorA10odometer sensor anode
B11sensor signalelectronic tachometer
water thermometer
fuel gaugecoolant temperature sensor
B5
A12
fuel gauge sensor
B14
A2
B3
upper beam
_NPdifferential latch-in
safety belt
preheating
sediment water alarmingelectricity charging/
discharging
fuel level alarming
brake failure alarming lamp
oil pressure alarming lamp
rear fog lamp
engine failure
four wheel drive indicating lamp
A1 Aturn indicating lamp
B16 left turn indicating lamp
A8
B4 +B7 - B8 A16 B15 B2B1 A15 A14B6 A13 B10B9
SY SJaccumulator plus four door-closing indicating lampA3turn on when the door is opened.
A11odometer sensor_NO
electronic odometer
electronic tachometerA10
B11
engine ignition coil
water thermometer
fuel gauge
B5
A12
neutral gear indicating lampA9
_NP
upper beamB14
differential latch-in
vacuum alarming
preheating
sediment water alarming
electricity charging/
discharging
fuel level alarming
brake failure alarming lamp
oil pressure alarming lamp
rear fog lamp
engine failure
four wheel drive indicating lamp
A1 left turn indicating lamp
B16 right turn indicating lamp
A8
B4 +
instrument lighting
system
B8
B7 - A16 B15 B2
B1 A15A14 B6 A13 B9 B3 B10A2
instrument lighting
system

B0-53Vehicle Body
Instrument Panel
Dismantle of instrument panel
(Dr SF)
1. Disconnect the cable of accumulator from the negative
polar;
2. Tear down the steering wheel;
3. Tear down the combined switch shell cluster;
4. Tear down the bonnet lock switch;
Tear down the two screws and the sliding fastener of bonnet
lock.
5. Tear down the central bottom-wall (Dr)
Tear down the decorative cover of gearbox (SF)
6. Tear down the instrument cover (SF).
Tear down the two screws and the cover.
7. Tear down the lower instrument cover;
(a) Tear down the ignition lock;
(b) Tear down the five screws and the cover;
Tear down the four screws and the cover;
(c) Disconnect the plugging elements.
8. Tear down the air-conditioner controlling panel;
(a) Pull out the air-conditioner controlling button;
(b) Prize out the A/C switch;
(c) Prize out the air-conditioner panel as shown in the
drawing with screwdriver and take it down.
Notice: the screwdriver should be wrapped with adhesive
strap at its head before using.
(d) Disconnect the plugging elements.
9. Tear down the decorative cover of instrument (Dr)
(a) Tear down the two screws to pull out the decorative cover
of instrument;
(b) Disconnect the plugging elements.E
F