wheel GREAT WALL SAFE 2006 Repair Manual

SA-57
1. Support up the front of vehicle to tear down the front
wheel and the steering knuckle.
2. Drain off lubricant in the front speed reducer.
3. Disconnect the front speed reducer flange and the drive
shaft.
Notice: Mark the assembly marks on the speed reducer
and the drive shaft before disconnecting them.
4. Tear down the front speed reducer.
5. Tear down the flange and dust cover:
(a) Loosen the riveted position on main-tooth nut with the
hammer and chisel.
Front Speed Reducer
Change of driving bevel gear oil seal of front speed reducer
front speed reducer and
differential assembly
oil-guard tray

driving bevel gear oil seal
flange and dust cover
140-210


Parts that cannot be reused after being used
specified torque
N
M
main-tooth nut
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Change of Driving Bevel Gear Oil Seal of Front Speed Reducer)

SA-79
Rear Axle Shaft
Element figure
rear axle housing
O rubber O-ring sealrear brake
brake drum
inner oil seal seat of
rear wheel bearingbearing seat
oil seal of rear
wheel bearinglinerhalf-shaft
grooved ball
bearing
rear brakeoil-guard tray

Parts that cannot be reused after being used
Suspension System and Automobile Axle (rear)
Rear Axle Shaft

flat steel retainer ring for shaft

SA-80
Dismantle of Rear half Axle Shaft
1. Tear down the wheels.
2. Tear down the rear brake drum.
3. Tear down the grab end of the bracing wire of hand brake
from the rear brake.
4. Tear down the half-shaft and the rear brake assembly
from the rear axle housing.
5. Tear down the flat steel retainer ring for shaft from the
half-shaft;
Tear down the flat steel retainer ring for shaft with the ring
calipers.
6. Tear down the half-shaft:
Put down a wooden plate on the flat ground, and thrust the end
of spline of half-shaft and rear brake assembly toward the
wooden plate to separate the shaft and the rear brake assembly.
Inspection on and repairing of half-shaft parts
1. Check the wear, damage and swing difference half-shaft
and the flange.
Max shaft run-out: 2 mm
Max flange run-out: 0.2 mm
In case the half-shaft is damaged, or wearied or the measuring
value of the swing difference is excessive, change the half-
shaft.
2. Check he oil seal of rear wheel bearing:
Check to see whether there is wear or damage, and change the
oil seal if necessary.
3. The disassembly of the outer oil seal of rear wheel
bearing;
Tear down the outer oil seal of rear wheel bearing with SST. Suspension System and Automobile Axle (rear)
Rear Half Axle Shaft

SA-81
4. Check the grooved ball bearing
Check the grooved bearing to see whether there is damage or
wear.
5. Change the bearing where necessary:
(a) Press out the grooved ball bearing with SST.
(b) Press in the new grooved ball bearing with SST.
6. Mount the new oil seal of rear wheel bearing.
Press in the new oil seal of rear wheel bearing with SST
Coat moderate lithium base grease on the lip open of oil seal.
7. Check the bearing seat.
Check the wear or damage situation.
8. Change the bearing seat where necessary:
(a) Tear down the oil seal of rear wheel bearing and the
grooved ball bearing with SST.
(b) Tap the bolts with copper bar to tear down the bearing seat.
(c) Mount the new grooved ball bearing and the oil seal of
rear wheel bearing on the bearing seat
(d) Press the rear brake, which is put on with bolts, in the
bearing seat.
9. Check the wear or damage of the inner oil seal of the rear
wheel bearing.
10. Change the rear wheel bearing where necessary:
(a) Tear down the oil seal of rear wheel bearing with SST. Suspension System and Automobile Axle (rear)
Rear half Axle Shaft

SA-82
11. Mount the new inner oil seal of rear wheel bearing.
Coat the hyperbolic gear oil on the axle housing where matches
with the oil seal; and plaster the moderate lithium base grease
on the lip open of the oil seal, then put them on the pressure
head and press them in.
Mount of Rear Axle Shaft
1. Press the rear brake and the bearing seat assembly on
the haft shaft.
2. Press the heated inner oil seal seat of rear wheel bearing
on he half shaft;
Notice: the face at the chamfering end of inner oil seal of
rear bearing should contact the oil seal closely, do not
mount it at the incorrect position.
Requirement for heat mount: heat the inner oil seal seat into the
22# oil (GB443-1989) to 100
, after the part is heated
completely, take it out for mount.
3. Mount on the flat steel retaining ring with the ring calipers.
4. Encase the half-shaft rear brake in the axle housing,
screw on the self-locking nut.
Tightening moment
(63-79)N
m
Notice: protect the oil seal lip open, bracing wire assembly
and the oil-guard sleeve.
5. Mount on the hand brake wire and the brake pipe.
6. Mount on the liner and rear brake drum;
7. Make a trial gas exhaust on the braking system, and
8. Mount on the rear wheels.
Suspension System and Automobile Axle (rear)
Rear Half Axle Shaft

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)

SA-100Suspension System and Vehicle Axle
Rear Suspension (Leaf Spring Type)
Remark: Tightening U-shaped bolt to the degree that the
protruding lengths of all U-shaped bolts under the spring seat
are the same.
3. Mount the rear vibration damper
(a) Connect the vibration damper to the vehicle frame with
bolts and then tighten the bolts.
Tightening moment: (25
)N
m
(b) Connect the vibration damper to the sprint seat with bolts
and tighten these bolts.
Tightening moment: (25
)N
m
4. Keep the suspension frame in stable status;
(a) Mount on the wheel;
(b) Remove the bracket, and make the vehicle bounce verti-
cally for several times so as conduce it in stable status.
5. Tighten the front ear pin and rear ear pin;
Tighten the nuts of front ear pin;
Tightening moment: (90
0)N
m
Tighten the nuts of rear ear pin;
Tightening moment: (90
0)N
m
all lengths of bolts protruding are same

BR-2Braking System
Notice and Troubleshooting
Notice:
1. Carefully change each part where necessary because any
mistake will affect the brake system properties, and will lead
accidents during driving. And the parts to be changed must
be the same in part number or equal in quality.
2. Keep the parts and each position clean when repairing the
braking system.
Troubleshooting
Trouble Causes Inspection items
Lower or soft pedal Abrasion of brake shoe
Abrasion of brake pad
Oil leakage of braking system
Master cylinder failure
Air in braking system
Wheel-brake cylinder failure
Failure in the automatic regulator of rear brake.Change the brake shoe; Change the brake
pad;
Repair the oil leakage;
Change the master cylinder;
Drain out the air from braking system;
Change the wheel-brake cylinder;
Repair or change the regulator
Brake stagnantPoor adjustment of parking brake;
The bracing wire of parking brake is seized;
Poor adjustment of vacuum booster pushrod)
Failure of the drag spring or the return spring
Pipe line blockage
Brake shoe breakage or deformation
Brake pad breakage or deformation
Seizing of the wheel-brake cylinder or the brake
caliper piston
Automatic regulator breakage
Master cylinder failureAdjust the parking brake;
Make repairing according to real situation;
Adjust the drag rod;
Change the drag spring or the return spring
Make repairing according to real situation;
Change the brake shoe
Change the brake pad
Make repairing according to real situation;
Change the regulator
Change the master cylinder
Over large braking
distanceUnsuitable tire inflation
There is oil stain or lubricant on the brake shoe or
brake pad;
Brake shoe deforms, the brake liner is worn or polished;
Brake pad deforms or is worn or polished;
Brake drum or brake disc deforms
Drag spring or return spring has trouble
The wheel-brake cylinder has trouble
The inner piston of wheel-brake cylinder is seized;
The brake pad is seized;Inflate the air to suitable pressure;
Change the brake shoe or the brake pad;
Change the brake shoe;
Change brake pad
Change the brake drum or the brake disc;
Change the spring;
Change the wheel-brake cylinder;
Change the wheel-brake cylinder
Change the brake pad
The brake pedal is hard
but doesn
t work;There is oil stain or lubricant on the brake shoe or
brake pad;
The brake shoe deforms, brake liner is worn or
polished, or the brake wheel is worn;
The brake pad deforms, or is worn or polished;
The piston of wheel brake pump is seized;
The vacuum booster has trouble
The vacuum degree is unsuitable
The brake pipe line is blockedChange the brake shoe brake pad;
Change the brake shoe
Change the brake pad;
Change the wheel-brake cylinder;
Change the vacuum booster;
Make repairing according to real situation;
Make repairing according to real situation;

BR-3
Troubleshooting (continued)
Braking System
Notice and Troubleshooting
Trouble Causes Inspection items
There is clatter noise when using
the brake(Drum-type brake)
The brake shoe is seized on the flange of rear baffle;
The flange of rear baffle is worn;
The pressure spring of brake shoe is loose or missing;
The fixed bolts of brake bottom plate is loose;
(disc type brake)
The brake pad support plate is loose or missing
The mounting bolts are loose;Add lubricant
Change the lubricating flange
Change
Tightening it
Change
Tightening it
There is hoarse noise or quack-
quack when using the brakeThe brake shoe or brake pad is worn;
The brake caliper, the wheel or the rotator interferes each
other.
There is friction between the dust cover and brake disc,
the brake bottom plate and the brake drum;
The other braking part has trouble
There is friction between the tire and bodyChange the part, and re-process
precisely the brake drum or
rotator if the abrasion is serious;
Make change according to real
situation;
repair or change
Make repairing according to
real situation;
Change
Check or maintain the part
There is such noise as
continuous screaming, quack-
quack, oscillating sound, etc.
Notice: the braking materials
may generate the natural noise
and heat during friction, and
thus emit the energy. Therefore,
it is normal to have the
screaming noise. These
phenomena will be more serious
under the condition of frigidity,
torridity, and over humidity,
snowing and mud. the
screaming noise occurring
occasionally will not lead the
fatal brake trouble nor reduce
the effective properties of the
brake.The brake drum, brake liner, liner or brake pad is worn
or scraped
The brake liner or brake pad is dirty or with oil stain or
polished.
The brake liner or brake pad is improperly used.
The brake pedal or vacuum booster drag rod is unsuitably
adjusted.
(disc type brake)
The brake pad silent pad is loss or damaged;
The brake pad is worn to the degree that the abrasion-
indicating lamp of brake pad has friction with the rotator.
There is burr or rust on the brake caliper.
(Drum type brake)
The pressure spring of brake shoe is soft in rigidity, or is
damaged or unsuitable.
The pressure spring pin or spring of brake shoe is loose
or damaged;
There is crack on the brake bottom plate flangeCheck, repair or change
Clean or change
Check or change
Check for adjustment
Change
Change
Clean or polish the burr
Check, repair or change
Check, repair or change
Check, repair or change

BR-4Braking System
Notice and Troubleshooting
Troubleshooting (continued)
Trouble Causes Inspection items
There are quack-
quack noises
without using the
brake.Alien materials such as stone is reeled inside the wheel shell
Nuts on hub is loose;
The brake pedal or vacuum booster pushrod is adjusted
improperly;
The wheel bearing is worn or damaged or lubricated
insufficiently;
(disc type brake)
The outer end edge of brake pad support plate or brake pad
is dog-eared;
The silent pad is poor in properties;
The sliding liner is worn;
The mounting bolt is loose
The piston returns incompletely
(drum type brake)
There is loose or redundant part.Clear away the alien materials
Tighten the nut to the specified torque; and
change it in case the bolt hole is enlarged;
Check and adjust
Check, lubricate or change
Check repair or change
Check and make change according to real
situation
Check and make change according to real
situation
Check and tighten according to the necessity.
Check, repair or change
Check, take out or repair.
There is continuous
screaming noise
without using brakeThe brake pedal or vacuum booster pushrod is adjusted
improperly
The vacuum booster, master cylinder or wheel-brake cylinder
returns incompletely.
(Disc type brake)
The piston is rusted or seized;
The brake pad in brake caliper locates improperly;
There is friction between the brake disc and brake caliper
shell;
The brake pad support plate is mounted improperly;
There is interference between the abrasion indicating lamp
of brake pad and the brake disc due to the brake pad
abrasion;
(Drum type brake)
The pressure spring of brake shoe is soft rigidity, damaged
or unsuitable;
There is crack on the brake bottom plate flange;
There is interference of brake bottom plate with the brake
drum after it is bending or warping.
The brake drum interferes with the brake bottom plate or
with brake shoe due to it is processed improperly;
Other brake parts

There is loose or redundant part in braking system;
The brake liner is polished due to it is adjusted over-tightly;
The wheel bearing is worn, damaged or lubricated
insufficiently.Check and adjust
Check, repair or change
Check and add the lubricant according to
the necessity;
Repair or change
Repair or change
Repair or change
Change
Change
Repair or change
Repair or change
Change the brake drum
Check, maintain and change according to
the necessity;
Check, maintain and change according to
the necessity;
Check, maintain and change according to
the necessity;