Gear box GREAT WALL SAILOR 2006 Owner's Manual

MT-16 Gearbox
Disassembly of Gear Box
22. Tear down the reverse rocker arm bracket
Dismantle the two bolts and the reverse rocker arm bracket.
23. Tear down the reverse idle gear and reverse idle gear
axle
(a) Dismantle the setting bolts of idle gear and the pressing
plate of reverse idle gear axle.
(b) Dismantle the reverse idle gear and the reverse idle gear
shaft.
24. Take down the bearing baffle of the output shaft.
(a) Dismantle the four bolts with torque socket spanner.
(b) Take down the bearing baffle of the output shaft.
25. Dismantle the intermediate-gear shaft.
(a) Pry out the split ring of the rear bearing of the intermediate-
gear shaft with the split-ring-type pliers.

MT-17 Gearbox
Disassembly of Gear Box
SST
push down
to close
(b) Taker apart the rear bearing of intermediate shaft with
SST tool and wrench.
(c) Take down the intermediate shaft.
26. Tear down the input shaft
Tear down the bearing with 13 needles and synchronizing ring
from the input shaft.
27. Tear down the output shaft
(a) Dismantle the stop ring from the output bearing with split-
ring-type pliers.
(b) Tap lightly the central link plate with rubber hammer while
pulling the output shaft manually to tear down the output
shaft.
28. Check the back-up lamp switch
Check the terminal connection, when the switch is pressed
down, as shown in the drawing, it is connected, otherwise is
disconnected, in case the switch is not in conformity with this,
it shall be changed.

MT-18Gearbox
Input Shaft Assembly (Element Drawing, Inspection On Synchronizing Ring, and BearingChange)
Input Shaft Assembly
Inspection on Synchronizing Ring
1. Run the synchronizing ring and put it into the assembly
to check its stopping performance
2. Check the clearance between the rear face of
synchronizing ring and the gear.
Standard clearance:
Tung tooth
(1
1.6)mm
Upper tooth
(1.5
1.8)mm
Limit clearance
0.8mm
Bearing Change
1. Tear down the input shaft bearing with the pressure
machine.
retainer ringbearing stop ringbearinginput shaftneedle bearing
synchronizing ring
element drawing

MT-19Gearbox
Input Shaft Assembly (Bearing Change)
ppq
2. Mount the new bearing with pressure machine and SST.
3. Select the retainer ring to obtain the minimum axial clearance
4. Mount the retainer ring with the split-ring-type pliers.
5. Mount the retainer ring with the split-ring-type pliers.

MT-29Gear Box
Countershaft Assembly and Reverse Idle Gear Assembly (Element Drawing, Countershaft Assembly Disassembly, Testing and Assembly)
Countershaft Assembly and Reverse Idle Gear Assembly
Element drawing
Disassembly, Testing and Assembly of
Countershaft
1. Tear down the coupling gear, sliding block and the five-
speed spring collar.
Tear down the coupling collar, three sliding blocks and the two
five-speed spring collars with screwdriver.
2. Measure the radial clearance of the reverse idle gear
with dial gauge
Standard clearance:
Shang chi:0.05mm
Tang chi:(0.10~0.30)mm (Tang chi is the close Spline
match, which belongs to radial clearance)
Max clearanle:
Shang chi:0.05mm
Tang chi:(0.10~0.30)mm (Tang chi is the close spline
match, which belongs to radial clearance)
front bearing of
countershaftintermediate-gear shaft
steel ballrear bearing of
countershaftstop ring of the rear bearing
of countershaft
five-speed thrust washerfive-speed needle
bearingsliding block of
synchronize
five-speed clusterengagement sleeve of the
five-speed synchronizer
spring collarsynchronizer tooth
of spring collaraxial pressing plate
for reverse idle gearreverse idle
gear shaft
reverse idle gear
cluster
coupling gear around
the five-speed gear
retainer ring for front
countershaft stop ring for front bearing
of countershaft

MT-30 Gear Box
Countershaft Assembly and Reverse Idle Gear Assembly ( Countershaft Assembly Disassembly, Testing and Assembly)
3. Reverse gear inspection
Measure the diameter of needle bearing with micrometer.
Standard diameter

Shang Chi
26.000mm
Tang Chi
(25.98
26.00)
Limit Diameter

Shang Chi
25.984mm
Tang Chi
25.86mm
4. Check the synchronizing ring
(a) Run the retainer ring for shaft and put it onto the shaft to
check itsstopping performance
(b) Measure the clearance between the rear section of the
synchronizing ring and the spline.
Standard clearance:
Shang Chi
(1.5
1.8)mm
Tang Chi
(1
2)mm
Limit clearance: 0.8mm
5. Measure the clearance of the shift fork and gear sleeve.
Test the clearance of the shift fork and gear sleeve with the
feeler gauge.
Max clearance:
Shang Chi: 0.54mm
Tang Chi:1.0mm
6. Change the bearing
The front bearing of the reverse gear shall be changed when
necessary
(a) Pry down the retainer ring for shaft with a split-ring-type
pliers.

MT-31Gear Box
Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly)
SST
sleeve wrench
front
(b) Press out the bearing with SST.
(c) Press in the bearing, side race and inner race with the
socket spanner.
(d) Select the split ring that leave the radial clearance to
minimum level, and mount it on the shaft.
7. Mount the engagement sleeve of synchronizer, sliding
block and the five-speed spring collar.
Remark: the opens of the spring collar shall be in non-
alignment
Encase the sliding pad into the gear hub and then cover the
gear sleeve.
Mount the spring retainer under the sliding pad.
Notice, the opening direction of the spring retainer shall
not face-to-face.
Mount of Reverse Gear Assembly
1. Check the reverse idle gear
Measure the radial clearance of the reverse idle gear with dial
gauge.
Standard clearance:
Shang Chi
0.05mm; Tang Chi
(0.04
0.08)mm
Max clearance

Shang Chi
0.05mm; Tang Chi
0.13mm

MT-32Gear Box
Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly)
2. Measure the clearance between the reverse idle gear
and gearshift yoke block
Measure the clearance between the reverse idle gear and the
gearshift yoke block with feeler.
Standard clearance:
Shang Chi
0.2mm
Tang Chi
(0.05
0.27)mm
Max clearance

Shang Chi
0.35mm
Tang Chi
0.5mm

MT-33Gearbox
Rear Housing Assembly (Element Drawing, Change of Oil Seal, Change of Shaft Bush)
Rear Housing Assembly
Element drawing
Change of Oil Seal
1. The rear housing oil seal shall be changed where necessary.
(a) Dismantle the oil seal with SST.
(b) Press in the new oil seal with SST
2. The driven oil seal of speedometer shall be changed
where necessary
(a) Pry out the oil seal with SST.
(b) Tap the new oil seal into the shaft bracket with SST.
Change of Shaft Bush
The shaft bush shall be changed where necessary
(a) Tear down the oil seal and dust bush.
(b) Heat the ending parts of extension frame to 80
-100
in
the oil groove.
(c) Tear down the shaft bush with SST and mount on the new
shaft bush.
SST
SST
SST
SST
SST
oil reservoirlocating spring bolts and
spring cylindrical pinrear housing oil seal
assemblyrear housing dust
cover
oil groove
component element
of position-limit
mechanismrear housing
cluster

MT-34Gearbox
Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism)
Inspection on and change of the component
elements of position-limit mechanism
1. Tear down the component elements of position-limit
mechanism
(a) Dismantle the bolts with the torque socket spanner.
(b) Punch out the spring cylindrical pin with the drift punch
and hammer.
(c) Tear the component elements of position-limit mechanism
down.
2. Check the component element of position-limit mechanism.
Run and propel the limit stop and the limit stop can return
to the original location automatically, otherwise, change the
limit stop.
3.
Mount the component element of position-limit mechanism
(a) Mount the component elements of position-limit mecha-
nism in the rear housing.
(b) Tap the spring cylindrical pins in with drift punch and
hammer as shown in the drawing.