4WD GREAT WALL DEER 2006 Service Manual

IN-3Introduction
How to Use This Manual
Introductionóhow to use this manual
The repairing approaches are described step by step:

The illustrations show you what to do and at which position.

The theme of repairing operation tell you what you need to do.

The detailed instruction show you how to accomplish the repairing and
introduce to you other related affairs, such as specification, warning etc.
Example:
Check and adjust the flange bounce
(a) Attach the dial indicator seat to the reducer housing, and touch the
flange face with the measuring head of dial indicator, run the flange
and observe the pendular range of the indicator carefully.
Full bounce tolerance of face : 0.10mm
Illustration:
what to do and at which positionSpecification
This formula can help the experienced technicians find out the failure
causes in short time. Overhauling staff can browse the operation theme
and refer to the detailed description thereunder where necessary; impor-
tant specifications and warnings are written out in boldface.
Specification
The corresponding specifications are given in boldface in each repairing
approach of this manual, which allows the overhauling staff to check the
specification while keeping on repairing work.
Warning, Notice and Remark

Warning written out in boldface means there is possibility of self-
injury or harm to others.

Notice written out in boldface means there is possibility of damage
to parts under repairing.

Remarks singled out independently, but not in boldface, serve as
supplementary descriptions to help you accomplish the work more
efficiently.
Vehicle Code
There are six vehicle models in this manual, the model codes are as follows:
Deer model
Dr
Sailor model
SL
SO COOL model
SK
Safe model
SF
Sing model
SY
PEGASUS model
SJ
Abbreviation used in this manual
A/C
air-conditioner
ECU
electronic controller unit
SST
special service tool
2WD
two-wheel drive
4WD
four-wheel drive
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Topic:what to do ?
Detailed introductionz;How to do?

MT-5Gearbox
Dismantle of Gear Box
4WD
11. Tear down the wheel-brake cylinder of clutch.
(a) Dismantle the setting bolts of the wheel-brake cylinder of
clutch with spanner.
(b) Hang the wheel-brake cylinder with a thread on the side
of engine without oscillation.
Remark: Do not disconnect the pipeline of the wheel-brake
cylinder.
12. Tear down the pawl washer and bracket of the rear part
of gearbox:
Two-wheel driving:
(a) Dismantle the four bracket bolts (skip over this process
for the wielding structure).
(b) Lift the engine with jack to raise the gearbox a little.
(c) Dismantle the pawl washer from the rear part of gearbox.
Four-wheel driving:
Dismantle the bolts from the pawl washer and bracket of the
rear part of gearbox to tear down the pawl washer and bracket.
13. Insert the wooden plate between the bottom frame and
the beam.

MT-6Gearbox
Dismantle of Gear Box
4WD14. Dismantle the eight bolts that fasten the beam of gearbox.
15. Tear down the starter
Put the starter on the side of engine.
16. Dismantle the bolts of clutch frame and bracket (wrapping
angle).
17. Tear down the remaining bolts of gear box
18. Tear down the gear box
(a) Pull out the gear box in backward direction;
(b) Put down the engine at the front and tear down the
gearbox from the vehicle.
Notice: be careful not to damage the dust cover of
expansion shell.

MT-8Gear Box
Mount of Gear Box
4WD:
(a) Mount the bracket and supporter of leg washers of rear
engine in 4WD vehicle;(SF)
(b) Mount and tighten the third beam of 4WD vehicle. (SF)
4. Remove the wooden spill.
5. Mount exhaust pipe.
Mount the exhaust pipe on the branch exhaust pipe.
Tightening moment
(62
3)N
m
6. Mount the wheel-brake cylinder of clutch.
Tightening moment
(18
2)N
m
7. Mount odometer sensor and plugging elements of backup
switch.
8. Connect the drive shaft.
(See page PR-12)
9. Add oil into the gearbox.
Lubricating oil grade: GL-5 85W/90
Volume: 2.4L(dry)
Remark: the Tightening moment of oil filling/draining
plug: (30
50)N
m
4WD
4WD

MT-11Gearbox
Disassembly of Gear Box
(c) Dismantle the nuts of the four-gear driven extension fram.
(d) Tap the extension frame lightly with rubber hammer to tear
down the selective gearshift shaft and selective rocker
arm.
8. Tear down front cover.
Dismantle the eight bolts and front cover and axial oil seal.
9. Tear down the input shaft, axial/bearing open ring and
countershaft bearing open ring.
10. Dismantle the gearbox frame from the central link plate,
(a) Put the gearbox straightly as shown in the drawing.
(b) Tap out the gearbox frame out carefully with the rubber
hammer. And
(c) Pull out the gearbox frame out from the central link plate
as the drawing shows
4WD

MT-46
4WD
Gearbox
Assembly of Gearbox
(f) Fasten the rear cover bolts of the four-gear driving
gearbox
Tightening moment:(30
45)N
m(Tang tooth)
(g) Mount and propel tightly the setting bolts of the gearshift
yoke block.
Tightening moment
(17
22)N
m
22. Mount the steel ball spring and plug
(a) Coat the sealing agent on the plug thread.
(b) Mount the steel ball, setting spring and setting spring
plug.
Tightening moment
(17
22)N
m
23. Check the following items after mounting the rear body
or gearbox
(a) Check the stability of the running input shaft and output
shaft.
(b) Check the gearshift stability of each speed
24. Mount the component elements of the locating mecha-
nism
(a) Mount the black component elements of the locating
mechanism on the side of the five-speed reverse gear.
(b) Mount another component element of locating mecha-
nism and propel it tightly.
Tightening moment
(30
40)N
m
25. Mount the gearshift cover of the gearbox.
(a) Mount the gearshift cover coated with sealing agent.
(b) Mount six bolts and then tighten them.
Tightening moment
(15
20)N
m

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-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