GREAT WALL HOVER 2006 Service Repair Manual

Front axle propeller shaft (4WD) assembly
Rear axle propeller shaft (4WD) assembly
N m: Specified torque
universal-joint forkfront section of
rear axle propeller
shaft
intermediate sup-
port assembly
universal-
joint fork
shimnut
circlip
cross-axle assembly
rear section assembly of
rear axle propeller shaft
flange forkcirclip
cross-axle assembly
axle tube assembly
front axle drive shaft assembly
N
m: Specified torque
universal-joint fork
circlip
cross-axle
assembly
drive shaft axle
pipe assembly
N
m: Specified torqueflange fork

transmission
drive shaft assemblyrear axle assembly
front axle drive shaft assembly
transmissionrear axle drive
shaft assembly
transfer case
rear axle assembly
Disassembly of drive shaft:
Remove the intermediate support bolt of drive shaft firstly (CC6460KY
is without intermediate support connecting bolt ), then remove the
connecting bolt between the drive shaft and rear axle , lastly, pull out
the drive shaft assembly from the transmission output spline shaft and
remove it in integral.
Installation of drive shaft:
1. Firstly, check the drive shaft for damage, spline for corrosion
and connecting surface for deficiency of damage or sand hole by
itself.
2
Install the connecting spline bushing of drive shaft on the
transmission output spline shaft carefully; then install the drive
shaft intermediate support on the intermediate support bracket
of carriage.
3. Use the special drive shaft bolt, nut and spring shim to connect
the drive shaft to the vehicle axle ring flange and tighten it. The
tightening torque is 78
5Nm
4. Tighten the drive shaft intermediate support nut, the tightening
torque is 63
5Nm (the front and rear drive shaft in
CC6460KY model are the integral and has the installation
content)

Chapter 7
Suspension and vehicle axle
Rear suspension …………………………………112

Troubleshooting
Failure Cause Repair cont ent
Floating/pulling The t yre is worn or charged improperly.

The front wheel alignment is incorrect.

The wheel bearing is adjusted too tightened.
The front /rear suspension components is loose or
damaged
The steering linkage is loose or worn
The steering device is connect ed unsound or worn. Charge the t yre to the prop er pressur e or
repla ce the t yre.
Check the condition of front wheel
alignment.
Adjust the wheel bearing
Tighten or replace the suspension
partTighten or replace the steering
linkage
Adjust or replace the steering device
Subsidence of vehicle body Overload of vehicle
vibration damper is worn
spring is weak Check the load weight
Replace the vibration damper
Replace the spring
Left-right swing/up-down
bounce The t yre is charged improperly
The stabilizer bar is bend or damaged
The vibration damper is worn Charge the t yre to the prop er pressur e
Replace the stabilizer bar
Replace the vibration damper
Front wheel vibration The t yre is worn or is charged improperly

Unbalance of each wheel
The vibration damper is worn
The front wheel alignment is incorrect

The wheel bearing is worn or adjusted badly
The ball joint or bushing is worn
The steering system is loose or worn
The steering mechanism is adjusted badly or damaged Repla ce the t yr e or char ge it to the prop er
pressure.
Balance all wheels
Replace the vibration damper
Check the condition of front wheel
alignment
Replace or adjust the wheel bearing
Check the ball joint or bushing
Tighten or replace the steering linkage
Adjust or repair the steering device
Abnormal abrasion of tyre The t yre is charged improperly
The vibration damper is worn
The front wheel alignment is badly

The suspension part is worn Charge the t yre to the prop er pressur e
Replace the vibration damper
Check the condition of front wheel
alignment
Replace the suspension part
Oil leakage of differential High oil level or incorrect oil grade

The oil seal is worn or damaged
The matching flange is loose or damaged Drain the oil to the specified level or
repla ce the oil
Replace the oil seal
Tighten or replace the flange
The axle has the nois e The oil grade is low or incorrect

The clearance of the pinion, ring gear or side gear is
large.
The ring, pinion gear or side gear is worn or broken
The pinion gear bearing is worn
The b earing of rear axle half shaft is worn.
The differential b earing is loos e or worn Fill with the lubrication oil or replace the
oil according to the specification
Check the clearance

Check each gear
Replace the bearing
Replace the bearing
Tighten or replace the bearing

Front wheel alignment
1. Process the following inspection and eliminate
all problems
a. Check the wear condition of tyre and proper inflation.
Tyre inflation pressure: 230kPa
b. Check the wheel bearing of front wheel for loose.
c. Check the front suspension for loose.
d. Check the steering drive device for loose.
e. Process the standard elastic test; check thefrontvibration damper
for normal operation.
3. Install the 4-Wheel alignment instrument
Processed according to the detailed description of equipment
manufacturer.
4. Adjust the wheel angle
Remove the cover of spacing bolt of steering knuckle; check the internal
wheel’s steering angle A.
Internal wheel’s steering angle:
32
Caution: The wheel should not touch the brake hose of car body
when the steering wheel is rotated to limit.
2. Adjust the height of car
A:Adjust the height of car to the standard value for theconvenience of
processing the front wheel alignmentinspection.
B: Front fixed bolt of lower suspension arm
The standard no-load height is: the center of front fixed boltof lower
suspension arm is 295
1mm away form theground.

6. Adjust the wheel toe
Adjust the wheel toe according to the following method
a. Shake the car upwardly and downwardly to make the suspension
reach the stable status.
b. Push the car forwardly for 5m in flat ground when the front
wheel is in the straight forward position.
c. Mark the center of each rear wheel; measure the distance “B”
between the marks of left and right tyre.
d. Push the car forwardly to move the mark on the back of tyre to
the position of front instrument.
Remarks: if the tyre moves too far, repeat the procedure (b).
e. Measure the distance “A” ‘between the marks on front of tyre.
f. Measure the toe of wheel.
toe =B-A
Inspection standard: 0-2mm
If the toe does not consist with the specified value, it can be
adjusted by the left and right draw-bar.
Move the vehicle forwardly
g. Adjustment of toe: the standard value is 02mm. The toe is
adjusted by rotating the cross draw-bar. When adjust the toe, it
should rotate the cross draw-bar on left and right side uniformly.
After the adjustment, tighten the lock nut, the tightening torque
is 55
65Nm.

h. Check the sideslip
Sideslip: Within
5m/km

Front hub and steering knuckle (2WD)
stabilizer bar
connecting rod
of stabilizer bar
flat shim
disk shim
fill block
shim
fill block
disk shim
absorber
bearing
hub cap
brake cover
spring shim
split pin
lower suspension arm
split pin
upper suspension arm
spring shimbrake caliper assembly
steering knuckle
tight nut
lock washer
screw
oil seal
bearing
hub and brake disc flat shim
N
m: specified torque
Used component which can not be used any more
precoated component

Front hub
Disassembly of front hub
1. Remove the disc brake
Remove the brake caliper and hang it by steel cable.
Remarks: Do not remove the brake pipe and brake hose.
2. Remove the hub cap
Use the inner hexagon spanner to screw off the fastening blot and
remove the hub cap.
3. Remove the hub and brake disc
a. Use the Philips screwdriver to screw off the lock screw and
remove the lock washer.
b. Use the special tools to remove the lock nut.
c. Remove the hub and brake disc with the external bearing.
special tools