air GREAT WALL DEER 2006 User Guide

CL-5Clutch
Clutch Master Cylinder
Disassembly of oil cup of master cylinder
1. Tear down the oil cup
a) Use the pinch and hammer to tap out the spring pin with
groove;
b) Tear down the oil cup and ring pipe.
Assembly of master cylinder
1. Mount the oil cup
a) Mount the oil cup and the new ring pipe.
b) Use the pinch and hammer to tap in the spring pin with
groove.
Mount of master cylinder
1. Mount the master cylinder
Mount the fixing nuts and screw them up.
2. Connect the clutch pipes;
Connect the clutch pipes with SST
3. Connect the push-rod and mount the pin;
Encase the pin of push-rod with clamping pliers.
4. Exhaust the air in clutch system and adjust the clutch
pedal.

CL-6Clutch
Clutch Brake-Wheel Cylinder
Clutch brake-wheel cylinder
Element drawing
clutch brake-wheel cylinder
springpistondust coverpush-rod air-exhausting plug
N*m
specified torque
Disassembly of brake-wheel cylinder
1. Tear down the clutch pipeline.
Remove the pipeline with SST
2. Tear down the two bolts to take down the clutch
brake-wheel cylinder
mount of brake-wheel cylinder
1. Mount the brake-wheel cylinder with two bolts;
2. Connect the clutch pipeline;
Connect the pipeline with SST;
3. Exhaust the air in clutch system.
18
2
19
1

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

TF-3Transfer Box
Troubleshooting
Common troubles Causes Resolving approaches
Change the lubricant or supplement the
lubricant volume.
Guarantee the torque of all connecting
elements stand at the specified value.
Open the transfer case to check the
bearing and othe parts whether is weared
or daamaged,if this happened,change
the parts.
Difficulty in mechanic gearshift or
outplace gear engagement
Troubleshooting
Incorrect lubricant or insufficient
lubricant volume.
Looseness of connecting bolt or other
connecting element.
Noise from the transfer box bearing Noise, which is spreader by the transfer
box instead of clutch, engine, drive shaft
and other parts, occurs in each speed. No driving of front wheel in the four-
gear engagementDrive chain breakDisassemble and check the damage of
inner parts, and change the chain. Adjust or repair shift lever.Open the
transfer box to check the toggle fork and
guide shaft, and change the parts as
requirement.Open the transfer box to
check whether the parts is wearied or not,
and, if any, change the weary parts.Open
the transfer box to check whether the
parts is wearied or not, and, if any, change
the weary parts.Open the transfer box to
check whether the parts is wearied or not,
and, if any, change the weary parts. Overlarge loose fit clearance of the
shift toggle fork on the shift guide
shaft.
Wear of the shift toggle fork
assembly including pin and contact
roller.
Wear of the shift cam hub and the
liner.
Attainment of coupling gear Mechanic gearshift seizing at a certain
location Engagement failure of the mechanically
shift transfer boxDamage or unsuitable adjustment of
the shifting mechanism.
Damage or serious wear of the inner
shifting parts, or looseness or
attainment of the shift toggle fork
assembly on the guide shaft.
Unsuitable adjustment of shift lever.Adjust or repair the shift lever mechanism.
Change the seriously wearied parts.
Change the loose or weary parts. Refer to the vehicle manual for correct
operation.
Add the specified oil of given volume.
Open the rear cover of transfer box to check
and changer the damaged parts.
Open the rear cover of the transfer box to
check whether the sliding parts can slide
freely along the axle, if not, dismantle it and
change the damaged parts. Incorrect operation.
Lubricant of inferior quality or
insufficient volume.
Adhesive bonding of shift toggle fork.
Adhesive bonding of the sliding joint
cover, locking sleeve or gear. Mechanic gearshift failure under the
movement of shifting handleBreak or damage of the shift rocker
arm or shift lever.
Damage of the guide plate of shifting
cam;Change the damaged element.
Open the rear cover of the transfer box to
check the damaged element and change
it. Electric gearshift troubleDamage or failure of electrically
controlled element, electric module,
speed sensor, electric motor, electric
clutch, or built-in wire harness.
Damage or worn of shifting cam,
joint cover, locking sleeve, toggle
fork or shift guide axle.Adhesive
bonding shiftRefer to the vehicle usage manual to
diagnose the failure element and change
it as requirement.
Dismantle the weary or damaged parts
and change it as requirement.
Dismantle and check the free movement
of sliding element, and change it as
requirement

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-24Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Washing)
1. Washing
Notice: check the metal rag around the magnet first before washing, large granule or irregular metal
granule shows the disintegratation or similar damage. Small or fine metal granule shows the uneven
or serious wear. If the metal rag is founded, notice shall be taken on damage and wear inspection
during checking the rotating parts and the element matched with the rotating parts.
(a) Common washing
Wash the parts in cleaning agent to clean away the old lubricant and deposit. Clean away the deposit in oil hole
with brush. Take notice not to scrape the metal coupling face when washing the parts cannot be cleaned with
brush.
(b) Dry the washed parts by blowing
Dry the washed parts by blowing the low-pressure compressed air (max pressure is 137.9kPa), because cloth
thread may be left during cleaning the parts with cloth. The bearing shall be held by hand to prevent it from
rotating when blowing it.
(c) Bearing lubrication
The ball bearing and needle bearing shall be lubricated with the lubricant for transfer box after washing. As
the non-lubricated bearing may cause damage when be dry. Cover the lubricated bearing to prevent dust
entering in.
Washing, Inspection, Maintenance or Change

TF-27Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Checking)
(h) Acceptable contact area deflecting to the tooth top.
(i) Unacceptable contact area deflecting to the tooth top,
which must be changed.
(j) Acceptable contact area deflecting to tooth root.
(k) Unacceptable contact area deflecting to tooth root, which
must be changed.
4. Key tooth inspection
Check the broken or peeled spline teeth. The spline teeth may,
if only small part is peeled off, be repaired in the same way as
that for the gear teeth, and can be reused. In case the spline
tooth is broken, the spline must be abandoned. The contact
type of spline is not the same as that for gear; however, spline
that shows step sliding must be abandoned.

TF-28Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear)
Maintenance or Change of Gear or Chain
Sprocket Gear
1. Maintenance principle
(a) Conduct the maintenance for the partial, small peel off
with the suitable manual high-speed grinding tool.
(b) Do not clear away the metal as can as possible when
grinding the matrix metal.
(c) All pointed angles and sides must be repaired as the slip-
pery contour line. Because the pointed angle or edges
may be peeled off again or developed into crack.
(d) Clear away the burr with the suitable grinding stone. Take
notice not to damage the matrix when clearing away the
projecting materials, and
(e) When substituting the non-repaired parts (such as
bearing), if the part is doubted in its re-application
capability, it must be changed.
2. Cases for gear or chain sprocket maintenance or substi-
tuting
(a) The gear, being peeled off at the two sides of tooth top in
contact face, may be repaired for reuse.
(b) The gear, being peeled off at the central tooth top of
contact face, may be repaired for reuse.
(c) The gear, being peeled off at one side of the non-contact
face, may be repaired for reuse.

TF-29Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear)
(d) The gear, being peeled off at the center of one side of
contact face, may be repaired for reuse
(e) The gear, being peeled off in the center of contact area,
shall be changed.
(f) The gear, being peeled off at two sides of tooth top, shall
be changed.

SA-2
Troubleshooting
Suspension System and Automobile Axle
Troubleshooting
Change the tire or inflate to the proper pressure
Balance the wheels
Change vibration damper
Check Alignment of Front Wheel
Change or adjust the wheel bearing
Check ball joint) or liner
Tighten or change steering linkage
Adjust or repair the steering device
Discharge the oil and change with new one
Check the wandering clearance
Check the gears
Change the bearing
Change the bearing
Tighten or change the bearing Trouble Causes
Inspection items
Body wandering/body
draggingTire wear or improper air inflation
Incorrect alignment of front wheel
Over-tightened wheel bearing
Part looseness or damage of front/rear sus-
pension
Wear or looseness of steering rod system
Poor connection or damage of steering de-
viceInflate the tire to the proper pressure or change
the tire.
Check the situation of alignment of front wheel
Adjust the wheel bearing
Tighten or change the suspension element
Tighten or change the steering rod system
Adjust or repair the steering device
Body sink Overloaded vehicle
Wear of vibration damper
Poor spring performanceCheck the loading mass
Change vibration damper
Change spring
Left-right vibration/up-
down bouncingImproper air inflation
Bending or damaged lateral stabilizer
Vibration damper wearInflate the tire to suitable pressure
Change stabilizer
Change vibration damper
Front wheel vibration Tire wear or improper air inflation
Imbalance of wheels
Vibration damper wear)
Improper Alignment of Front Wheel
Wheel bearing wear or improper adjustment
Ball joint or liner wear
Steering linkage looseness or wear
Poor adjustment or damage of steering mecha-
nism
Abnormal tire wear Improper air inflation
Vibration damper wear
Poor Alignment of Front Wheel
Suspension system wearInflate the tire to the proper pressure
Change vibration damper
Check the Alignment of Front Wheel
Change suspension element
Speed reducer leakage Over-high oil level or improper oil quality
Oil seal wear or damage
Flange looseness or damageDischarge the oil for change
Change oil seal
Tighten or change the flange
Noise inside the
axleNoise inside the axleOver-low oil level or inferior oil quality
Over-large wandering clearance between
driving bevel gear and driven bevel gear
Wear and disintegration of driving bevel
gear and driven bevel gear
Bearing wear of driving bevel gear
Bearing wear of rear axle shaft
Bearing looseness or wear of speed reducer