plug GREAT WALL SAFE 2006 User Guide

TF-7Transfer Box
Disassembly and Mount of Transfer Box
Disassembly and Mount of Transfer Box
1. Transfer Box Disassembly
(a) Drive the vehicle on the lifting jack.
(b) Locate the gear of transfer box at the neutral
position, shift the transfer box to the 2H and
extinguish the engine.
(c) Disconnect the cell cathode.
(d) Lift the vehicle.
(e) Put down an oil disc under the transfer box, tear
down the oil drain plug and oil filling plug of the
transfer to drain all the lubricant up, then re-
mount the two plugs.
(f) Disconnect all wires and wire harnesses that
connected with the transfer box.
(g) Take apart the hose on the venting valve of
transfer shaft.
(h) Disconnect the linkage of the front drive shaft
with the front flange of the transfer box.
(i) Disconnect the linkage of the rear drive shaft
with the rear flange of the transfer box.
(j) Raise the transfer box up with the jack.Notice: The transfer box shall be guaranteed to
support by the lifting jack before tearing down
the sets of bolt and nut that connected with the
transfer box and gearbox. The transfer box is
not allowed to hang directly on the gearbox
through spline because such operation will
damage the transfer box parts.
(l) Tear down the connecting nuts between the
transfer box and gearbox and take down the
transfer box.
(m) Move the transfer box backward directly until
the linkage between the input shaft of transfer
box and the gearbox spline.
(n) Put down the lifting jack of the transfer box, and
(o) Tear down the gasket between the transfer box
and gearbox. Clean the gasket or glue on the
coupling face of front body of transfer box with
rear body of the gearbox. Take notice not to
damage the coupling face.
1234
5 6 7
8
9
1. input shaft
2. front frame of transfer box
3. rear cover of transfer box
4. flange
5. front output fork flange
6. venting valve
7. gasket
8. rear body of gearbox
9. bolt

TF-8Transfer Box
Disassembly and Mount of Transfer Box
2. Transfer box mount
a) Coat the lubricant grease on the output axial
spline of the gearbox with a thin sleeve contain-
ing lubricant grease.
b) Mount a new gasket on the mounting face of the
transfer box.
c) Lift the lifting bracket of transfer box and align
it to the same axle with the gearbox.
Notice: The transfer shall be guaranteed to flush
with the gearbox before connecting the spline.
Do not handle it forcefully to press the transfer
box spline into the gearbox. Otherwise, damage
will be caused, run the rear output shaft where
necessary to aim at the spline.
(d) Move the transfer box forward slowly so that
the spline and pin of the input shaft of gearbox
reach the front body of the transfer box, and the
gasket attaches on the gearbox completely.
(e) Ensure that the mounting holes of the front
body of transfer box, gasket, and gearbox are in
alignment and then mount the sets of bolt and
nut.
Fastening torque
(35-48)N
m
(f) Connect the rear drive shaft and the rear output
flange of the transfer box.
(g) Connect the front drive shaft and the front
output fork flange of the transfer box.(h) Connect the venting valve and the soft ventila-
tion pipe.
(i) Connect the cables of odometer that locates
nearby the transfer box.
(j) Connect all wire harnesses that connected with
the transfer box, and
(k) Add the lubricant of right brand.
Notice: when starting the engine, if the lubricant
is added incorrectly or in unsuitable volume,
which may lead the transfer box to damage.
Notice: as for the transfer box mounted on
vehicle, oil pump shall be used when adding oil
for it.
Notice: In case the transfer box is taken apart for
maintenance or inspection, there will be no
lubricant supplied by oil pump in the oil passage
on the top of transfer box. Therefore, it is not
accurate to control the oil volume by opening the
oil filling plug, in such condition, the oil passage
will be filled with oil once the oil pump runs. If the
wheel can run, such operation can be conducted
on the lifting jack. The oil level shall be rechecked
once the oil pump runs.
(l) Put down the vehicle after finishing the lubri-
cant inspection, and connect the cell cathode.

TF-9
5 4
3
1
6 2
1. rear body of transfer box
2. flange
3. oil seal
1. sensor bracket
2. bolt
3. speed sensor
4. o-ring
5. sensor assembly
6. bolt
7. gasket
8. rear body of transfer box2 1
5 3
4
4
6
7
8
Transfer Box
Disassembly of Transfer Box
4. gasket
5. nut
6. oil plug
Disassembly of Transfer Box
1. Brief instruction
In case the transfer box is required to be repaired for the
damaged specific element, it shall be taken apart to the degree
on which the damaged element is taken out. And the parts
taken apart from the transfer box, if it doesnít include the
damage element, can exist in the form of sub-assembly or
group instead the individual form, otherwise, the parts will be
taken apart individually.
2. Transfer Box Disassembly
Put the transfer box on the worktable and ensure the rear part
or the rear cover faces upward. Put the wooden block under the
front part of transfer box to keep the transfer box stands
horizontally. The disassembly process is as follows:
(a) Fasten the flange with the torque arm typed T-13-54-
002, screw off the nut to take down the gasket, then take
apart the flange and oil seal.
(b) Take down the two oil plugs from the transfer box body.
As for the electric gearshift transfer box, tear down the
electric shifting element according to the following
disassembly approach:
(a) Tear down the three bolts, gaskets, sensor and clip for
wire harness.
(b) Tear down the sensor assembly and take apart the O-
ring.
(c) Tear down the motor assembly.

TF-23
5 4
3
1
6 2
Transfer Box
Transfer Box Assembly
1. transfer box rear body
2. flange
3. oil seal
4. gasket
5. nut
6. oil plug
13. Flange assembly
The parts mount process is as follows:
(a) Encase the two oil plugs in the rear cover.
(b) Encase the flange, sealing ring and gasket, and then
screw up the nuts.
Fastening torque
(203
244)N
m

SA-85
Dismantle of Rear Speed Reducer
1. Take out the oil drain plug to drain the oil in the speed
reducer up.
2. Tear down the rear axle shaft.
3. Disconnect the drive shaft from the speed reducer.
4. Tear down the nuts on the bolts that connect the rear axle
housing and the speed reducer.
5. Tear down the rear speed reducer.
Disassembly of Rear Speed Reducer
Remark: in case the noise is over loud, the following item
should be checked before taking apart it to find out the causes.
If the speed reducer has serious drawback, take it apart for
repairing where necessary.
1. Check the play between the axle driven bevel gear;
In case the play value fails to be within the specified range,
adjust the preload of bearing 200719E or repair it where
necessary.
(see page SA-91)
Standard play: (0.13-0.25)mm
2. Check the teeth engagement of the driving bevel gear
with the axle driven bevel gear.
(See Page SA-92)
Record the teeth engagement positions.
3. Check the clearance between the half-shaft gear thrust
gasket and the differential housing.
Check the clearance between the half-shaft gear thrust gasket
and the differential housing with the feeler.
Standard clearance
(0.45-0.75)mm
Remark: in case the clearance value fails to fall within the
above range, change the half-shaft gear stop gasket, and
ensure the half-shaft gear stop gaskets on the left and right
sides are same in thickness.
(See Page SA-95)
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)

SA-94
Mount of Rear Speed Reducer and
Differential Assembly
1. Mount the speed reducer and differential assembly on
the rear axle housing.
Tightening moment
(18-26)N
m
Remark: in case the sealing gasket is mounted, it should be
checked to see whether it is damaged before mounting, if
damaged, change with the new sealing gasket, and the dam-
aged sealing gasket should be clear away; if no sealing gasket
is mounted, no mount is required to mount. Clean the contact
face of the mounted axle housing and coat it with silicon-
rubber plain sealing agent.
2. Connect the drive shaft and flange well and be careful to
align the assembly marks marked when disassembling.
Tightening moment
(69-79)N
m
Screw up the oil drain plug with the Tightening moment
of (140-150)N
m
Mount on the half-shaft and the brake assembly to adjust the
brake oil path so that the wheel brake pump is filled with brake
liquid.
3. Inject in the heavy-duty oil.
Oil brand: heavy-duty oil graded GL-5;
Viscosity: SAE 85W/90
Oil volume: add the oil until it overflows from the oil filler
outlets.
Screw up the oil-filling plug.
Tightening moment
(140-150)N
m
Suspension System and Automobile and Axle (Rear)
Rear speed reducer (Mount of Rear Speed Reducer and Differential Assembly)

BR-14
Brake pad change
Remark: Check the thickness of the friction material of brake
pad through the observation hole on caliper body after the
vehicle covers thirty thousand; if the thickness fails to fall
within the specified range, change is required. (If the brake is
used often, the thickness of friction materials of brake
pad is required to check whether it is within the specified
range after the vehicle covers more than ten thousand,
if not, change it.
1. Tear down the front wheel;
2. Check the thickness of friction material of brake pad:
Check the thickness of friction material of brake pad through
the observation hole on caliper body, if it fails to be within the
specified range, change it.
Min thickness: 2.0mm
3. Raise the wheel-brake cylinder:
(a) Tear down the short bolts of sliding sleeve;
(b) Uplift the wheel brake pump and hang it with rope to
protect the brake oil pipe.
Remark: Do not loosen the brake oil pipe and the bleeding plug.
4. Tear down the following parts:
(a) Two braking pads;
(b) Two silent pad clusters;
(c) Four braking pad lock plates.
Braking System
Front Brake (Dr)

SR-14Steering System
Power Steering (On-Vehicle Inspection)
Change of power steering liquid
1. Tear down the oil-returning hose from the oil cup to
drain the liquid into the container;
2. Run the engine in the idle status, and rotate the
steering wheel toward the max rotating angle for
several times in right or left direction while draining the
liquid, until the oil in steering liquid is drained up.
3. Turn off the engine.
4. Connect the oil-returning pipe and inject the new
power steering liquid in the liquid tank;
Hydraulic oil type: No.8 Liquid drive oil (Q/SH003.01.012-88)
5. Start the engine, and make it running in the idle status.
Rotate the steering wheel to the max rotating angle repeatedly
several times, meanwhile, supplement new power steering
liquid in the liquid tank until there is no foam or turbidities in
the liquid tank, and the oil indicating lamp reaches the marked
range when the engine is turned off.
6. Tighten the liquid tank cover
7. Exhaust the air in the power steering system;
Ai-r bleeding in power steering system
1. Check the liquid level height in the liquid tank
Check the liquid level and, if needed, supplement the liquid.
2. Start the engine in the idle status and rotate the
steering wheel repeatedly to the max rotating angle
several times.
3. Turn off the engine and connect the ethane pipe and
bleeding plug.
4. Start the engine and rotate the steering wheel
repeatedly to the max rotating angle several times.
5. Locate the steering wheel at the intermediate position.

SR-15Steering System
Power Steering (On-Vehicle Inspection)
6. Exhaust the air in steering system:
(a) Loosen the bleeding plug;
(b) Screw up the bleeding plug when there is no air bubble
exhausted from the pipeline.
Notice: take care not let the ethane pipe slide from the
bleeding plug, because the liquid is high in temperature
and pressure.
7. Check to see whether there is air bubble or turbidities
in the oil cup, and ensure the liquid level will not
exceed the max value when the engine stops,
Measure the liquid height under the condition of engine running,
then turn off the engine and measure the liquid height again.
In case any problem is found, repeat the approaches of (5) and
(6) in Power Steering Liquid Change. If the problem still
exists, repair the power steering oil pump.
RPM RPM

BE-2
Brief Introduction
1. Power supply system
The power supply system includes accumulator, generator and its adjustor. Generator is the main power supply; the
accumulator is the auxiliary power supply. The generator, parallel with the accumulator, is equipped with the
adjustor, which is used to maintain the voltage of generator stable when the rotating velocity and the load varies.
2. Starting System
Which includes the direct current motor, drive mechanism and control device, etc. its performance is to start the
engine.
3. Lighting system
Which includes various lighting lamps inside and outside of the body and their control device; they are used mainly
to guarantee safety driving in night.
4. Alarming System
Which includes the electric horn, flasher and various service signal indicating lamps, etc. they are mainly used to
guarantee the physical and driving safe when driving.
5. Auxiliary Electric Appliance System
It includes the electric wiper, air-conditioner, recorder and cigarette lighter, etc.
R
red
R/G
redgreen
socket plugging element plug plugging elementN
2 3
4 5 6 123
4
5
S
socket plugging
elementplug plugging element
1. The codes of sockets of socket plugging element are
complied from left to right.
2. The codes of sockets of socket plugging element are
compiled from right to left.
Remark: all of plugging elements are watched from the in-
wiring direction.
3. Comparison between plug and socket plugging elements
The plug and socket plugging elements are classified accord-
ing to their in-built socket shape.
(a) All of plugging element are marked according to the
opening end and are locked at their tops.
(b) When pulling the plugging element, pull the plugging
element itself instead of wire.
Remark: before pulling the plugging element, check the
plugging element that you want to disconnect first to verify
their classifications.
English letters for wiring colors code:
B =black Bl =blue R =red Br =brown
Lg =reseda V =purple G =green O =orange
W =white Gr =gray P =pink Y =yellow
First letter stands for the basic color, while the second for the
stripe color.
Body Electric System
Brief Introduction