GREAT WALL FLORID 2008 Service Manual

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Rear Brake
Components
4. Remove the rear brake drum.
Remark: If it is difficult to remove the rear brake drum,
follow the steps below:
Method one:
(a) Remove the rubber plug of the adjuster's observation
port, and insert a slotted screwdriver into the brake's
back plate assembly hole, and pry off the adjusting
paddle from the adjusting clearance wheel.
(b) Use another slotted screwdriver to toggle the adjusting
clearance wheel and loosen the brake's leading and
trailing shoe assembly's tension on the rear brake drum.
Disposable parts
Dust cover
Brake leading shoe assembly
Pressure spring
Pressure spring cap
Brake shoe tension spring
Rear brake drum
Lever rotating shaft
Retainer spring
Locking cap
Split ring
Brake lever
Brake trailing shoe assembly
Brake back plate assembly
Pressure spring bar
Rubber plug of the adjuster's observation port
Rubber plug of the observation port gap
Washer
Bleed screw cap
Bleed screwPiston
Ring cup
Piston spring
Wheel cylinder
Adjusting clearance shaft head
Adjusting clearance wheel
Adjusting clearance screw rod
Return springAdjusting paddle
Pin
Side spring
Dust cover
Piston
Ring cup
Rubber grease
: Specified torqueN·m
7.8-11.8
High temperature resistant grease
Rear brake removal
1. Inspecting the brake's friction plate thickness.
Remove the rubber plug of the observation port gap and
examine the friction plate thickness via the observation port.
If it's smaller than the minimum value, the brake's leading
and trailing shoe assemblies should be replaced.
Minimum thickness: 1.0 mm
2. Remove the rear wheel.
3. Release the brake fluid.
Caution: Be sure not to spill the brake fluid onto the
paint's surface. Otherwise it must be immediately
cleaned.

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Method two:
(a) Find two M6×40 (the thread is longer than 25 mm)
phillip screws, and screw them into the rear brake
drum's two threaded holes.
(b) Use a screwdriver to tighten the phillip screw, and push
out the rear brake drum.
Caution: Alternately tighten the two screws.
5. Remove the brake leading and trailing shoe assembly
and adjusting paddle.
(a) Use SST (Special Service Tools) to separate and remove
the pressure spring cap of the brake leading and trail-
ing shoe assembly, and remove the pressure spring and
pressure spring bar.
(b) Take out the brake leading and trailing shoe assembly
from the brake back plate assembly, take down the
retainer spring, and remove the cable connector.
Remark: When taking out the brake leading and trailing
shoe assembly from the brake back plate assembly, screw
the adjusting clearance wheel thread completely into the
adjusting clearance screw rod, decrease the return spring's
tension on the brake leading and trailing shoe assembly.
(c) Use needle nose pliers to remove the brake shoe tension
spring, and take down the adjusting paddle.
(d) Use pliers to remove the return spring from the brake
leading and trailing shoe assembly, and separate the
brake leading and trailing shoe assembly.
SST
M6×40

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6. Remove the return spring and ratchet adjuster assem-
bly.
(a) Remove the adjusting clearance shaft head.
(b) Remove the adjusting clearance wheel.
(c) Remove the return spring.
7. Remove the parking brake lever.
(a) Remove the split ring with pliers.
(b) Remove the brake lever rotating shaft.
(c) Remove the brake lever.
Caution: If it is the riveted structure, there is no need to
remove the parking brake lever, instead of replace the
brake trailing shoe assembly.
8. Remove the brake wheel cylinder.
(a) Remove the brake line with a M10 open-end wrench,
and use a clean plug to clog it.
(b) Use a M8 open-end wrench to remove the two bolts, thus
removing the wheel cylinder assembly.
9. Remove the following parts from the wheel cylinder as-
sembly.
(a) Two dust covers.
(b) Two pistons.
(c) One piston spring.
(d) Bleed screw.
(e) Bleed screw cap.
Brake components inspection
and maintenance
1. Inspect the components after disassembly.
After disassembling the components, check them for wear
and tear, rust, and damage.
2. Measure the rear brake drum's internal diameter.
Standard internal diameter: Ф200 mm
Maximum internal diameter: Ф201 mm

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3. Measure friction plate thickness.
Standard thickness: 4.0 mm
Minimum thickness: 1.0 mm
If the friction plate thickness is smaller than the minimum
value or produces uneven wear and tear, the brake leading
and trailing shoe assemblies should be replaced.
Remark: If one of the brake shoe assembly needs to be
replaced, be sure to replace all the rear brake leading and
trailing shoe assemblies to ensure even braking ability.
4. Check to make sure the contacts of the friction plate
and rear brake drum are fine.
If the contacts of the friction plate and rear brake drum is not
good, the brake leading and trailing shoe assemblies should
be replaced.

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Rear Brake Installation
1. Install the brake wheel cylinder.
(a) Apply a small amount of lithium grease onto two piston
assemblies.
(b) Install the wheel cylinder assembly.
• Install two dust covers onto the two piston assemblies.
• Install a piston spring and two piston components in the
wheel cylinder body.
R e m a r k : R e f e r t o t h e d i a g r a m f o r p r e c i s e i n s t a l l a t i o n
directions.
2. Install the wheel cylinder assembly.
(a) Use two bolts to install the wheel cylinder assembly
onto the brake back plate assembly.
Tightening torque: 7.8-11.8 N·m
(b) Connect the brake line to the wheel cylinder assembly.
Tightening torque: 16 N·m
3. Apply an appropriate amount of grease to the following
parts.
(a) Apply a small amount of high temperature resistant
grease on the brake back plate assembly and the brake
shoe connection's six convex plate surface.
Caution: Refer to the diagram for installation directions.
ForewardForeward
Left wheelRight wheel

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(b) Apply a small amount of lithium grease on the brake
leading shoe assembly and brake trailing shoe assembly
(refer to the arrows in the diagram for indicated areas).
Remark: Do not contaminate the friction plate.
(c) Insert the return spring into the adjusting clearance
screw rod and apply an appropriate amount of lithium
grease on the adjusting clearance wheel's thread and
screw, adjusting clearance screw rod's shaft head,
and adjusting clearance shaft's shaft head (refer to the
arrows in the diagram for locations).
4. Install the brake lever on the brake trailing shoe as-
sembly.
(a) Install the parking brake lever and insert the lever rotat-
ing shaft.
(b) Use pliers to install a new split ring in the lever rotating
shaft.
5. Install the return spring and ratchet adjuster assembly
on the brake leading shoe assembly and brake trailing
shoe with brake lever assembly.
Hang one side of the return spring on the brake leading shoe
assembly, and use pliers to hang the other side of the return
spring on the brake trailing shoe with brake lever assembly.
6. Install the adjusting paddle on the brake leading shoe
assembly.
(a) Install the adjusting paddle on the brake leading shoe
assembly.
(b) Use needle nose pliers to install the brake shoe tension
spring on the adjusting paddle and brake leading shoe
assembly.

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7. Install the brake cable connector on the brake trailing
shoe with brake lever assembly.
(a) Install the brake cable connector on the brake trailing
shoe with brake lever assembly.
(b) Insert the brake trailing shoe with brake lever assembly
and the shoe end of the brake leading shoe assembly
into the wheel cylinder assembly.
Remark: Do not let oil or grease drip on the brake shoe's
lining.
8. Install the retainer spring.
9. Install the brake leading and trailing shoe assemblies
onto the brake back plate assembly.
(a) Insert the pressure spring bar into the brake back plate
assembly and brake leading and trailing shoe assemblies.
(b) Put the pressure spring on the pressure spring bar,
put in the pressure spring cap, and use SST (Special
Service Tools) to lock the pressure spring cap onto the
pressure spring bar.
10. Inspect the operating procedures of the automatic ad-
juster.
(a) Refer to the diagram for directions, step on and off the
brake pedal, and make sure the self-adjusting screws
can rotate. If they are unable to rotate, inspect the rear
brake to try to determine the source of the problem.
(b) Adjust the adjusting mechanisms length and make it as
short as possible.
(c) Install the rear brake drum.
(d) Press the brake pedal towards the floor until a clicking
noise cannot be heard.
11. Inspect the space between the brake's friction plate
and rear brake drum.
(a) Remove the rear brake drum.
(b) Measure the rear brake drum's internal diameter and
the brake shoe friction plate's external diameter, and
inspect if the difference between the two diameters is
within the regulated clearance range.
Single sided clearance: 0.25 mm
If not correct, inspect the braking system.
12. Install the rear wheel.
Tightening torque: 100 N·m
13. Fill the brake fluid reservoir up with brake fluid and
exhaust the air out of the brake system.
14. Check for leaking brake fluid
SST

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Rear Support Axle
Components
Rear hub unit inspection and removal
1. Manually rotate the wheel according to the diagram,
and check the bearing of the rear hub unit for abnormal
noises and stiff rotation. If these flaws exist, please
replace the rear hub unit.
2. Remove the wheel.
3. Manually screw the two wheel nut's opposite angles on the
wheel bolt and fixed rear brake drum.
Remark: Alternately tighten the two nuts, and manually
screw it down as much as possible.
Rear brake drum
Rear brake assembly RH
R i g h t p a r k i n g b r a k e cable assembly
Rear hub unit
Trailing arm spindle sleeve with nylon bushing assembly
Rear twist beam assembly
Rear brake assembly LH
Rear brake drum
Rear hub unit
Left parking brake cable assembly
Disposable parts
Spring
Spring
9±1
: Specified torqueN·m
78-98
9±1
100
100

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4. Measure the rear brake drum's outer end surface
runout.
S t i c k a d i a l i n d i c a t o r m a g n e t t o t h e r e a r w h e e l h u b ' s
mounting bracket. Point the dial indicator to the rear brake
drum's outer end surface diameter at about a Φ136 mm
circumference (refer to diagrams dotted line area). Rotate the
rear brake drum, measure its runout, and maximum runout
0.11 mm is approval.
Caution: When the runout exceeds the maximum limit
of 0.11 mm, the rear hub unit should be replaced.
5. Remove the rear brake drum (See rear brake removal
step 4).
6. Examine the rear hub unit's starting torque.
(a) M a n u a l l y r o t a t e t h e r e a r h u b u n i t a n d c h e c k f o r
abnormal sounds or looseness. If the above problems
exist, it should be replaced with a new rear hub unit.
(b) Use a spring dynamometer to inspect the load applica-
tion.
Load application (when start the engine): 1 N·m
Caution: If the load application is greater than 1 N·m,
the rear wheel hub unit must be replaced.
7. Use calipers to measure the rear brake drum's internal
diameter.
If the measured result exceeds 201 mm, the drum brake must
be replaced.
Trailing arm spindle sleeve assembly removal
1. Examine the trailing arm spindle sleeve.
(a) Inspect the trailing arm spindle sleeve for deformities,
shifting, partial or serious cracks, and the gaskets for
loosening.
(b) If it's not easy to see clearly any existing damage of
the trailing arm spindle sleeve, take the following
steps: Use clean water to wash the trailing arm spindle
sleeve's rubber areas. At the same time rub it clean with
cotton. Check and make sure the rubber surface has
none of the previously mentioned flaws. If the above
flaws exist, replace with a the new trailing arm spindle
sleeve assembly.Cotton

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2. Remove the trailing arm spindle sleeve.
(a) M a r k w i t h a w h i t e p a i n t p e n , a n d r e m e m b e r t h e
direction of the trailing arm spindle sleeve assembly .
(b) The trailing arm spindle sleeve is a disposable part. If
it is damaged, first use a pry bar to lift up the edge of
the trailing arm spindle sleeve's outer tube in order to
install SST.
(c) Use SST (Special Service Tools) to clog the spindle
sleeve's installation tube. Tighten the two bolts, twist
them with a wrench and push out the spindle sleeve.
Caution: When performing the pressing out process,
be certain to ensure the trailing arm spindle sleeve is
vertically forced out.
3. Install the new trailing arm spindle sleeve with nylon
bushing assembly.
(a) Before installing the new trailing arm spindle sleeve
with nylon bushing assembly, first distinguish the
installation direction for the trailing arm spindle
sleeve's nylon bushing assembly, whereas the direction
of the nylon lining's four holes face one end of the
trailing arm.
Caution: Do not install the trailing arm spindle sleeve
with nylon bushing assembly in the opposite direction.
(b) Use SST to position the trailing arm spindle sleeve with
nylon bushing assembly, and slowly press it in.
Caution: When performing the pressing process, be
certain to ensure the trailing arm spindle sleeve is
vertically forced in.
SST
Steering alignment
SST