GREAT WALL SO COOL 2006 Service Manual

PR-3
Drive Shaft
Element Drawing
2WD
two-joint type

snapping ring
bearing of cross shaft




universal joint flange fork


rear axle drive shaft
universal joint foke
cross shaft
three-joint type

snapping ring
bearing of cross shaft
universal
joint foke
cross shaftfront joint of rear
axle drive shaftcenter support
bearingflange
washer
washer
74
5
40
5
universal joint
flange fork
74
5
74
5universal joint
flange fork
rear section of
rear axle drive
shaft










N*m: specified torque

Parts that cannot be reused after being used
Drive Shaft
Drive Shaft

PR-4Drive Shaft
Drive Shaft
Element Drawing(continued)
4WD
front axle drive shaft
front axle drive shaft74
5
74
5
rear axle drive shaft
two-joint type

snapping ring
bearing of cross shaft
74
5
74
5

cross shaftuniversal joint yokerear axle drive shaft


universal joint flange fork
three-joint type









74
5
40
5
snapping ring
bearing of cross shaftcenter support
bearing
flange
front joint of rear
axle drive shaftwasher
universal joint flange fork
74
5
74
5
rear section of
rear axle drive
shaft
universal joint
flange fork

Parts that cannot be reused after being used
N*m
: specified torque

PR-5Drive Shaft
Drive Shaft
(4WD)
Rear axle drive shaft
1. Take apart the universal joint flange fork of rear axle drive
shaft from the differential flange.
(a) Label the two flanges with assembly marks.
(b) Take apart the four sets of bolt and nut.
Disassembly of Drive Shaft
(2WD)
1. Take apart the universal joint flange fork of the drive shaft
from the differential flange.
(a) Label the two flanges with assembly remarks.
(b) Take apart the four sets of bolt and nut.
assembly mark
2. Take apart the center support bearing from the frame
beam (for the three-joint type)
3. Take apart the drive shaft from the gearbox
(a) Pull out the universal joint yoke from the gearbox.
(b) Insert the SST in gearbox for oil leakage prevention.
2. Take apart the center support bearing from the frame
beam (three-joint type
SST
assembly mark

PR-6Drive Shaft
Drive Shaft
3. Take apart the drive shaft from the gearbox.
(a) Pull out the universal joint yoke from the gearbox.
(b) Insert the SST in gearbox to prevent the oil leakage
Front axle drive shaft
4. Tear down the front universal joint flange fork of the front
drive shaft.
(a) Hang he front end of the front axle drive shaft.
(b) Label the assembly mark on the flange
(c) Take apart the four sets of bolt and nut.
5. Disconnect the rear universal joint flange fork from the
front axel drive shaft along the transmission path.
(a) Label the assembly marks on each flange.
(b) Take apart the four sets of bolt and nut.
Drive shaft disassembly
1. Separation of the rear joint of the rear axle drive shaft
from the front joint of rear axle drive shaft
(a) Label the assembly marks on each flange.
(b) Take apart the four sets of bolt and nut.
2. Take apart the center support bearing from the front joint
of the rear axle drive shaft.
(a) Loosen the riveted nut by chiseling with a chisel and
hammer.
SST
assembly mark
assembly mark

PR-7Drive Shaft
Drive Shaft
(b) Lock the flange with SST tools to tear down the nuts.
(c) Label the assembly marks on flange and shaft.
SST
SST
assembly mark assembly mark
(d) Tear down the flange from the front joint of rear axle
drive shaft with SST tools.
3. Take apart the universal joint yoke from the rear joint of
rear axle drive shaft.
(a) Label the universal joint yoke and the shaft with assem-
bly marks.
(b) Pull out the universal joint yoke from the shaft.
Inspection on Drive Shaft Parts
1. Cross shaft bearing inspection
Check the wear or damage situation of the cross shaft bearing
and change the weary or damaged bearing where necessary.
2. Check the wear and damage situation of the central
bearing.
Check the bearing to see whether it can run freely.
In case that the bearing is damaged or wearied or cannot run
freely, change it in time.

PR-8Drive Shaft
Drive Shaft
3. Inspection for the front axle drive shaft
(a) Check the wear or damage situation of the shaft.
(b) Check the wear or damage situation of the two universal
joints
grease nozzle
rear axle drive shaft front axle drive shaft
assembly mark
assembly mark
SST
A4. Inspection for the drive shaft lubrication
If the drive shaft is not lubricated completely, add the Lithium
base lubricant grease with SST.
Cross bearing change
1. Label the shaft and universal joint yoke with assembly
marks.
2. Take apart the snapping ring.
(a) Tap in the outer bearing race lightly.
(b) Take apart the four snapping rings in the grooves with
two screwdrivers.
3. Take apart the cross shaft bearing
(a) Pull out the bearing from the drive shaft with SST tools.
Remarks: Pull up the part A in the drawing to a enough height
so that it cannot contact the bearing.

PR-9Drive Shaft
Drive Shaft
SST
(c) Mount the two outer bearing races that are taken apart on
the cross shaft.
(d) Pull out the bearing on the universal joint yoke with SST
tool, and (b) Grip the outer bearing race with a vice to tap out the drive
shaft lightly with a hammer.
Remarks: Take apart another bearing with the same approach.
4. Cross shaft bearing mount
(a) Coat the lithium base grease on the cross shaft and the
bearing.
Remarks: do not over coat the lubricant.
(b) Align the assembly marks on the universal yoke and on
the shaft. (e) Grip the outer bearing race in the vice and tap lightly out
the universal joint yoke with a hammer.
Remarks: the bearing at the other end may be taken apart with
the same approach.

PR-10Drive Shaft
Drive Shaft
5. Snapping ring mount
(a) Mount two snapping rings with the same thickness.
Remarks: Do not use the used snapping ring.
(b) Tap the universal joint yoke lightly with a hammer until
there is no clearance between the outer bearing race and
the snapping ring.
6. Cross shaft bearing inspection
Check the cross shaft bearing to see whether it can run freely
Remarks: the approach for mounting the cross shaft bearing at
the bearing end is the same.
(c) Encase the new cross shaft in the universal joint yoke.
(d) Mount the new bearing on the cross shaft with SST tool,
andSST
(e) Adjust the two bearings with SST tool so that the widths
of two snapping ring grooves are equal and maximum.

PR-11Drive Shaft
Drive Shaft
Drive shaft assembly
1. Mount the center support bearing on the front joint of rear
axle drive shaft.
Remarks: The notch of the center support bearing shall face
backward when mounting it.
2. Mount the flange joint on the front joint of rear axle drive
shaft.
(a) Coat the spline of front joint of rear axle drive shaft with
lithium base grease.
(b)
Mount flange joint on the shaft and align the assembly marks.
Remarks: if the central flange joint or the front joint of the rear
axle drive shaft is required to change, the front and back
universal joint yokes of the rear axle drive shaft shall face in the
same direction when re-assembling.
(c) Lock the flange joint with SST and screw up the newly-
changed nut to press the bearing in place.
(d) Loosen the nuts.
(e) Tighten the nuts again, and
(f) Rivet the nuts with hammer and punch.
3. Drive shaft mount
(a) Align the assembly marks on flanges, and connect the
two flanges with four sets of bolt and nut.
Remarks: if the central flange or the front joint of the rear axle
drive shaft is required to be changed, the front and back
universal joint yokes of the front joint of rear axle drive shaft
shall face in the same direction when reassembling them.
(b) Screw up the sets of bolt and nut according to the
specified torque.
Fastening torque: (74
5)N
m
4. Insert the universal joint yoke in the universal joint yoke
(4WD).
(a) Coat the lithium base grease on the sliding surfaces of the
drive shaft spline and the universal joint yoke.
(b) Align the assembly marks on universal joint yoke and
drive shaft.
(c) Insert the universal joint yoke in drive shaft.
assembly mark
2WD 4WD
forward
assembly mark
SST
assembly mark

PR-12Drive Shaft
Drive Shaft
Mount of Drive Shaft
(2WD)
1. Insert the universal joint yoke in the gearbox.
(a) Tear down the SST tools.
(b) Push the universal joint yoke into the gearbox.
2. Connect the universal joint flange of the rear joint of rear
axle drive shaft and the relative the differential flange.
(a) Align the assembly marks on the two flanges and connect
the flanges with four sets of bolt and nut.
(b) Screw up the sets of bolt and nut according to the
specified torque.
Fastening torque
(74
5)N
m
3. Mount the center support bearing on the frame beam
(three-joint type)
(a) Use two bolts to mount the center support bearing on the
frame beam and tighten them manually.
(b) Check the bearing seat, which shall be vertical with the
drive shaft, and change it where necessary.
(c) Check the central line of the central bearing and ensure
that the central lines of the central bearing and the bear-
ing seat shall be the same when the vehicle is in the non-
loaded stage. And adjust the bearing seat only it is
necessary.
(d) Screw up the mounting bolts according to the specified
torque.
Fastening torque
(40
5)N
m
(4WD)
1. Connect the universal joint flange fork of the front axle
drive shaft with the flange that matches with the transfer
box.
Align the assembly marks and use four sets of bolt and nut to
connect the flange fork with the flange, screw up the sets of bolt
and nut according to the specified torque.
Fastening torque
(74
5)N
m
forward
SST
assembly mark
assembly mark