drive shaft GREAT WALL DEER 2006 User Guide

MT-22Transmission
Output Shaft Assembly(Disassembly of Output Shaft Assembly)
7. Take down the 3rd and 4th gear synchronizer assembly,
3rd gear and needle bearing .
(a) Remove the snap ring with plier for snap ring.
(b) Take down the 3rd and 4th gear synchronizer assembly and
3rd gear with press machine.
(c) Remove the needle bearing .
8. Take off the meshing sleeve ,sliding block and spring
from 3rd and 4th synchronizer.
Remove the three sliding blocks and spring from the meshing
sleeve with one screwdriver.

MT-27Transmissio
Output Shaft Assembly(Assembly of Output Shaft Assembly)
SST
SST
(b) Smear the gear oil on the needle bearing of gear of 1st gear.
(c) Assembly the gear components of 1st gear,synchronized
ring,needle bearing and sleeve of gear of 1st gear.
(d) Install the assembly on the output shaft,and align the notch
of synchronized ring and sliding block .
(e) Turn the sleeve of 1st gear shaft to align the it with the
locking ball.
8. Installation for rear bearing of output shaft
Fix the bearing of output shaft to the output shaft with SST and
pressing machine, make the notch of locking ring of output
shaft rear bearing expose to the tail.
Remark: Hold the sleeve of gear of 1st gear and don
t let it fall
off.
9. Install the gear of 5th gear
Fix the gear of 5th gear with SST and pressing machine.
10. Assembly the snap ring of shaft
(a) To choose one snap ring which make the axial clearance
be Min, and install it on the shaft.
Max clearance
0.1mm

(b) Knock the snap ring of shaft of 5th gear tightly with
screwdriver and hammer.
11. Measure the axial clearance of gear of 1st gear
Measure the axial clearance of gear of 1st gear with feeler
gauge
Standard clearance:

For the transmission made by Shang Chi:(0.15
0.33)mm
For the transmission made by Tang Chi:(0.09
0.33)mm

MT-28Transmission
Output Shaft Assembly(Installation of Output Shaft Assembly)
12. Fix the drive gear of speedometer
(a) Install the locking ball and drive gear.
(b) Install the drive gear of tachometer with plier for shaft
shield ring

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-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

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-5Transfer Box
Product Description and Simple Maintenance
Transfer Assembly NO. of Manufacturer
product assembly NO.
display
termnumber
displaythe last digit of the year
displaythe specific monthly
manufactuer data
displaythe month numnber
Example display:From January (A) to December (L)
Product instruction and simple maintenanceManufactuer data
Product instruction and simple mainte-
nance
1. Product Introduction
The transfer box adapted by our company is the transfer box
of 45-55 manufactured by Bogeguana, which is two-speed
and time driving, a set of planetary mechanism used is to
obtain the speed-reducing performance, while the driving
force is transmitted to the front driving gear by a highly precise
chain. The planetary gear train and rear output shaft element
of transfer box is lubricated initiatively through oil bath and oil
pump. This transfer box has four gears:

2H-stands for the two high gears
in which, only the two
rear wheel are driven, and the gear ratio of the transfer box
is 1:1


4H-stands for the four high gears, in which , all of the four
wheel are driven, and the gear ratio of the transfer box is
1:1


N- neutral location (this location only exists in the transfer
box of manual gearshift )
No driving force is transmitted
to the wheel when the input shaft and output shaft are
disconnected.

4L-stands for low gears, the four wheels are all driven, and
the gear ratio of transfer box is 2.48:1.
The gearshift of the mechanical gearshift transfer box is
obtained through the shifting-cam-type guide plate that is
operated by the shift rocker arm.
Sign board: which is fastened at the obvious external location
of transfer box, and on which the detailed data are marked.
borgwarner

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-11
5. Tear down the Chain drive system
Take apart the following parts from the transfer box housing
assembly.
(a) Take apart the snapping ring and washer from the front
output shaft.
(b) Take apart the driving chain sprocket, driven chain
sprocket and drive chain together from the two output
shafts.
(c) Separate the chain sprocket from the chain.
12
345
6 7
1. output shaft
2. driving chain sprocket
3. driven chain sprocket
4. washer
12 34
5
6 7
6. Oil pump assembly
Take apart the shaft and pump assembly, pipe clip, oil pipe and
filter from the remaining transfer box housing assembly.
1
2
7
6 3
4
5
8 1. deceleration gear hub
2. inserted face of Shift
toggle fork
3. plastic sleeve
4. contact roller
5. pin
6. pin, contact roller and sleeve assembly
7. deceleration shift toggle fork
8. deceleration shift toggle fork assembly7. Deceleration shifting element disassembly
Tear down the following parts from the remaining transfer box
housing assembly.
(a) Take apart the deceleration hub, and deceleration shift
fork assembly from the housing.
(b) Take apart two plastic inserted faces from the decelera-
tion shift fork assembly
(c) Disassembly the deceleration shift fork assembly only if
it were broken.Cut the plastic cover,and take out the pin
and truckle. Transfer Box
Disassembly of Transfer Box
1. output shaft
2. driving chain sprocket
3. driven chain sprocket
4. washer
5. snapping ring
6. transmission chain
7. front output shaft5. snapping ring
6. transmission chain
7. front output shaft