roof GREAT WALL HOVER 2006 Service User Guide

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

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.
specialspecial

8Install 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.
9Adjust the pre-applied load of the drive
bevelgear bearing

Disassembly and assembly of front reducer assembly and electric clutch
adjusting shim
bearing gland
differential housing
driven bevel gear
front drive axle housing
washer
oil filling plug
vent tube
clip
front axle vents tube
connector assembly
major semiaxle
needle bearingelectric clutch
location pin
vent tube
mechanical wheel of separator
declutch shift sleeve
electric clutch housing
oil filling plug
circlip
major semiaxle oil seal
half axle gear thrust plate
half axle gear
planetary gear shaft
planetary gear
bolt clump
weight bracketclump weight and bush
assembly
clump weight bracket
welded assembly
front reducer
housing
adjusting washerspacer
drive bevel gear
small bearingoil sealfront drive gear flange and
dustproof cover assembly
drive bevel gearadjusting washer
Pregummed component
N m: Specified torque
Used component which
can not be used any more.bearing
circlip
big bearing

20. Check the engaging mark of drive and driven
bevel gear.
(Refer to “Assembly of Front Reducer Assembly”)
21. Measure the pre-applied load of drive bevel gear
bearing.
Use the torque measuring meter to measure the preapplied
load on the gap between the drive and drivenbevel gear.
Range of pre-applied load: 1.2-1.7N.m
22. Measure the total pre-applied load of drive bevel
gear.
23 Remove the drive gear flange and dustproof cover
assembly.
a. Use the hand hammer and chisel to loose the riveted part of
drive gear nut.
b. Use the special tools to clamp the drive gear flange and
remove the drive gear nut.
c. Use the brass rod to knock down the drive gear flange and
dustproof cover assembly.

1.Rotate the driven bevel gear, check the runout of
driven bevel gear.
Max. Runout: 0.07mm
Assembly of front reducer assembly
1.Install the adjusting washer in the drive bevel gear,
install the big bearing inner race of drive bevel gear
by press.
2. Clean the front reducer housing, install the outer
race of big and small bearing on the reducer housing
by press..
3. Install the drive bevel gear into the front reducer
housing, then install the washer, spacer and small
bearing inner race.
4.Use the special tools to install the drive bevel gear
oil seal.
Caution: It should coat the lip with the oil seal
lithium base grease before install it and the rear
surface of rear oil seal should flush with the top of
front reducer housing after knocked in.
5. Install the drive gear flange and dustproof cover
assembly.
(Refer to “Replacement of Drive Bevel Gear Oil Seal”)
6.Use the special tools to tighten the drive gear nut
to the specified torque; the nut should be precoated
with the lithium base grease.
specified torque : 140-200N
m
7. Use the torque measuring meter to measure the
pre-applied load of big and small bearing of drive
bevel gear.
Range of pre-applied load: 1.2-1.7N
m
special tools

Reducer
Replace the oil seal on the car
1. Disconnect the reducer from the drive shaft.
a. Make the assembly mark on two flanges.
b. Remove four bolts and nuts.
2. Remove the flange and dustproof cover assembly
3. Remove the oil seal
Use the special tools to remove the oil seal.
bearing spacer
adjusting washer
rear bearing
drive bevel gear
adjusting ring
side bearingdriven bevel gear
differential housing
locking plate
plain washer
flange
dustproof cover
oil seal
oil baffle disc
front bearingbearing glandstop plate
lock washer with
double ears
N m: Specified torque
Used component which can not be used any more.
assembly mark

4. Install the new oil seal
a. Coat the lip of oil seal with the HP-R grease.
b. Use the special tools to knock in the new oil seal.
Insertion depth of oil seal: 1.0mm
5. Install the flange and dustproof cover assembly
6. Rivet the drive bevel gear nut.
7. Connect the drive shaft flange to the reducer
flange Align the assembly mark ; then connect them
by bolt.
Tightening force: 785Nm
8. Check the oil level of reducerReplace the hyperbolic
gear oil if necessary.
Oil number : GL-5 hyperbolic gear
Viscosity : SAE80W/90
Amount: Filled with oil until the oil flows out form oil filling
port.
Removal of reducer
1.Remove the oil drain plug; drain the oil from the
reducer
2. Remove the rear axle
(Refer to Step 2 in “Disassembly of Rear Axle”)
3. Disconnect the drive shaft from the reducer
(Refer to step 1 in “Replace the Oil Seal on Car”)
4Remove the assembly of reducer.
special tools
insertion depth: 1mm
assembly mark
assembly mark

Remarks: Mark the label on the removed components to indi-
cate the position of reassembly.
7. Remove the flange and dustproof cover assembly
a.Use the hammer and chisel to loose the riveted part of nut.
b.Use the special tools to clamps the flange; then remove the nut.
Caution: The used nut can not be used any more.
c.Remove the flange and dustproof cover assembly.
8. Remove the oil seal
Use the tools to pry out the oil seal.
9. Remove the drive bevel gear and spacer
Remove the drive bevel gear, bearing and spacer from the reducer
housing.
10. Remove the oil baffle disc and front bearing inner
race
11. Replace the rear bearing of drive bevel gear
a. Use the press machine and special tools to pull out the rear
bearing from the drive bevel gear.
special tools
special tools

2. Install the rear bearing of drive bevel gear and ad
justing washer
a. Select the proper adjusting washer according to “Meshing Condi
tion of Drive Bevel Gear and Driven Bevel Gear”.
b. Install the rear bearing and selected adjusting washer by press
machine.
3. Install the spacer.
a.Select the adjusting washer between the rear bearing and spacer
based on the experience.
b.Install the spacer.
4. Install the front bearing inner race, oil baffle disc
and oil seal of drive bevel gear
a. Place the front bearing inner race in the reducer housing; place the
oil baffle disc.
b. Coat the position of reducer housing oil seal and lip of oilseal
with grease uniformly; place the oil seal in position. Start the
press machine for installation.
5. Install the drive bevel gear, flange and dustproof
cover assembly
a. Install the flange and dustproof cover assembly in the reducer
housing, Press it to level by hand.
b. Insert the drive bevel gear installed with the spacer, rear bearing
and adjusting washer into the flange through the spline; screw on
the nut.
c. Use the nut to tighten the flange, plain washer and drive gear.
special tools
level
special tools