clutch GREAT WALL SAFE 2006 User Guide

CL-9Clutch
Clutch cluster
b) Mount the guide bearing with SST.
Remark: the bearing shall be verified in good running after it
is encased in the flywheel hub.
2. Check whether there is abrasion on the diaphragm spring.
Check the abrasion depth and width of diaphragm spring with
calipers.
Limit value: Max depth: 0.6mm
Max width: 5mm
If the abrasion depth or width of the diaphragm spring exceeds
the limit value, change the diaphragm spring .
3. Check the separation bearing
Exert force in radial direction by hand to rotate the bearing.
If it cannot be rotated or if the resistance is too large, change
the separation bearing.
Remark:
Remark: as this bearing is lubricated permanently, it doesnít
need to be cleaned or lubricated.
Mount of clutch cluster
1. Mount the clutch rib on flywheel;
Mount the clutch rib on flywheel with SST.
2. Mount the clutch pressure plate
a) Align the marks on clutch pressure plate and that on flywheel;
b) Screw up the bolts in even manner around the clutch pressure
plate until pressure plate and the flywheel contact closely,
then tighten the bolts.
Tightening moment: 30 N
m
Remark: tighten the uppermost bolt of the three that is near to
the locating pin.
SST
flywheel sideSST
alignment
mark

CL-10Clutch
Clutch Cluster
3. Check the alignment of the diaphragm spring end.
Check the alignment of diaphragm spring end with SST.
Max dislocation: 0.5mm
if the difference is more than the specified value, adjust the
alignment of diaphragm spring end with SST.
4. Coat the lithium base grease;
Coat the lithium base grease on the following parts:

Contact spot of separation fork and bearing

Contact spot of separation fork and push-rod;

Support spots of separation fork

Spline of clutch rib
5. Encase the dust cover, separation fork, separation bearing
seat and bearing into the gearbox;
6. Mount the gearbox.
SST

MT-3
Troubleshooting
Gear Box
Troubleshooting
Non-use of clutch
Non-full separation of clutch
Severely warned tooth rings of synchronizing
fittings
Over-hard locating springUse the right driving approach
Checking for adjustment
Change
Change Difficulty in gear engagement
Over-low oil level
Lubricating oil of inferior quality
Non-timely oil change
Unsuitable axial location or clearance of gears
Bearing damage
Burr or collision on gearAdd oil to the specified level
Change it with the specified oil
Change the oil and damaged parts
Check for adjustment
Change
Repair or change the gear
Oil leakage, oil penetration Oil added above the specified level
Loss or missing of bolts
Vent plug trouble
Sealing element damageAdjust oil to the given level
Reassembling or fasten the bolt according to
the specified torque
Change
Change
Damage of synchronizer Overexert in gear shift
Non-use of clutch
Damage on spring collar of synchronizer
Incorrect mounting of drive shaftChange
Use the right driving approach
Change
Check for adjustment
Non-engagement of gear Trouble in controlling mechanism
Incorrect assembling the locating spring or
steel ball
Invalidation of locating spring
Severely worn gear sleeve or fork groove
Seriously worn toggle forkCheck for adjustment
Reassembly
Change
Change
Change
Burning bearing, burning gear Over-low oil level
Inferior lubricating grease
Non-timely oil change, over-dirty oil
Inter-use of differential oil or usage of
additiveChange damaged parts and add oil
Change the damaged parts and lubricating oil
Change damaged parts and lubricating oil
Change damaged parts and lubricating oil
Difficult in gear disengagement Spring invalidation of synchronizer
Warn inner groove of tooth ring of synchronizer
Tooth ring of synchronizer choked on conical
face
Toggle fork deformation or toggle fork axle
deformation
Severely worn toggle forkChange
Change
Change
Change
Change
Methods for troubleshooting
Over-loud or abnormal noise
Common Failures Causes

MT-5Gearbox
Dismantle of Gear Box
4WD
11. Tear down the wheel-brake cylinder of clutch.
(a) Dismantle the setting bolts of the wheel-brake cylinder of
clutch with spanner.
(b) Hang the wheel-brake cylinder with a thread on the side
of engine without oscillation.
Remark: Do not disconnect the pipeline of the wheel-brake
cylinder.
12. Tear down the pawl washer and bracket of the rear part
of gearbox:
Two-wheel driving:
(a) Dismantle the four bracket bolts (skip over this process
for the wielding structure).
(b) Lift the engine with jack to raise the gearbox a little.
(c) Dismantle the pawl washer from the rear part of gearbox.
Four-wheel driving:
Dismantle the bolts from the pawl washer and bracket of the
rear part of gearbox to tear down the pawl washer and bracket.
13. Insert the wooden plate between the bottom frame and
the beam.

MT-6Gearbox
Dismantle of Gear Box
4WD14. Dismantle the eight bolts that fasten the beam of gearbox.
15. Tear down the starter
Put the starter on the side of engine.
16. Dismantle the bolts of clutch frame and bracket (wrapping
angle).
17. Tear down the remaining bolts of gear box
18. Tear down the gear box
(a) Pull out the gear box in backward direction;
(b) Put down the engine at the front and tear down the
gearbox from the vehicle.
Notice: be careful not to damage the dust cover of
expansion shell.

MT-7Gear Box
Mount of Gear Box
Mount of gear box
1. Put down the gearbox at the mounting place.
2. Mount the bolts of gearbox, clutch bracket and starter.
Tightening moment:
(a) Setting bolt of gear box (82
10)N
m
(b) Enforcement plate bolt (37
5)N
m
(c) starter bolt (39
5)N
m
Notice: the bolts of gear box and clutch shall be mounted
with the clutch pipe clip together.
3. Mount the pawl washer and bracket of gearbox
Two-gear driving:
(a) Mount the gearbox pawl washer and fasten the relative
bolts.
Tightening moment: 23
3)N
m
(b) Lift the rear part of engine with jack and wooden block so
that the gearbox is raised a little.
(c) Mount the bracket of gear box on beam and fasten the
relevant bolts (this process may skip over in wielding
structure)
Tightening moment
(23
3)N
m
(d) Connect the gearbox bracket and supporter with bolts,
then tighten the bolts.
Tightening moment: (23
3)N
m

MT-8Gear Box
Mount of Gear Box
4WD:
(a) Mount the bracket and supporter of leg washers of rear
engine in 4WD vehicle;(SF)
(b) Mount and tighten the third beam of 4WD vehicle. (SF)
4. Remove the wooden spill.
5. Mount exhaust pipe.
Mount the exhaust pipe on the branch exhaust pipe.
Tightening moment
(62
3)N
m
6. Mount the wheel-brake cylinder of clutch.
Tightening moment
(18
2)N
m
7. Mount odometer sensor and plugging elements of backup
switch.
8. Connect the drive shaft.
(See page PR-12)
9. Add oil into the gearbox.
Lubricating oil grade: GL-5 85W/90
Volume: 2.4L(dry)
Remark: the Tightening moment of oil filling/draining
plug: (30
50)N
m
4WD
4WD

MT-10Gearbox
Disassembly of Gear Box
Disassembly of Gear Box
1. Tear down the separation toggle fork and separation
bearing.
2. Tear down the backup switch, the driven gear of
speedometer.
3. Tear down the clutch from the gearbox frame.
Take apart the nine boits.
4. Tear down bolts of locating spring of the five-speed
toggle fork, locating spring and locking ball.
(a) Dismantle the bolts from the rear cover with the torque
socket spanner.
(b) Take out the spring and locking ball with magnetic rod.
5. Tear down the operating seat of gear change lever.
(a) Dismantle the setting bolts of the operating seat of gear
change lever.
(b) Take away the operating seat lightly and put it at the
suitable place.
6. Tear down axial locating pin assembly of shifting gear.
7. Tear down the fastening nuts of extension frame.
(a) Tear down the fixing bolts of gearshift shaft.
(b) Tear down the fastening nuts of expansion shell.

MT-12Gearbox
Disassembly of Gear Box
11. Grip the central link plate in the table vice,
(a) Use two clutch bolts, washers and suitable nuts as shown
in the drawing.
Remark: mount the washer in the reverse direction, increase
and decrease the washer quantity to flush the bolts terminal
with the external face of the washer.
(b) Grip the central link plate in the table vice.
12. Tear down the locating spring bolts, locating spring and
locking ball,
(a) Dismantle each locating spring bolts with the torque socket
spanner.
(b) Take out the toggle fork axles of the first, second, third,
fourth and reverse as well as the axial locating spring and
locking ball of the fifth-gear toggle fork.
13. Tear down the axial retainer ring of the gearshift fork
Tap the axial retainer ring of gearshift fork lightly with two
screwdrivers and one hammer.

MT-47Gearbox
Assembly of Gearbox
26. Mount the clutch frame
(a) Mount the clutch frame.
(b) Coat the sealing agent on the bolt thread.
(c) Mount the nine bolts and then tighten them.
Tightening moment

Upper tooth
(60
70)N
m
Tang tooth
(30
45)N
m
27. Mount the back-up lamp switch.
Tightening moment
(20
40)N
m
28. Mount the driven gear of odometer
(a) Mount the driven gear of odometer.
(b) Mount the bolts and tighten them.
Tightening moment
(10
15)N
m