four wheel drive GREAT WALL DEER 2006 Service Manual
[x] Cancel search | Manufacturer: GREAT WALL, Model Year: 2006, Model line: DEER, Model: GREAT WALL DEER 2006Pages: 484, PDF Size: 16.35 MB
Page 7 of 484
IN-3IntroductionHow 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 modelDr
Sailor modelSL
SO COOL modelSK
Safe modelSF
Sing modelSY
PEGASUS modelSJ
Abbreviation used in this manual
A/Cair-conditioner
ECUelectronic controller unit
SSTspecial service tool
2WDtwo-wheel drive
4WDfour-wheel drive
PMãã
Topic:what to do ?
Detailed introductionz;How to do?
Page 69 of 484
TF-3Transfer BoxTroubleshooting
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
Page 71 of 484
TF-5Transfer Box Product Description and Simple Maintenance
Transfer Assembly NO. of Manufacturer
product assembly NO.
displaytermnumber
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 gearsin 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
Page 117 of 484
SA-6Suspension System and Automobile AxleAlignment of Front WheelAlignment of Front Wheel (SF)
Alignment of Front Wheel
(SF)
1. The following items should be checked to remove the
troubles.
(a) Check the tire abrasion and the air inflation to see it is
suitable or not.
Tire inflation pressure: (2500)kPa
(b) Check the front wheel bearing to see whether it is loose.
(c) Check the front suspension to see whether it is loose.
(d) Check the steering driving device to see whether it is
loose, and
(e) Check the front vibration through elastic force test to see
whether it is normal in performance.
2. Height adjustment of vehicle
Adjust the vehicle height to the standard value so as to make
the Alignment of Front Wheel inspection.
A-B-58 5mm
A: The height of steering knuckle shaft center.
B: The center height of the adjusting cam bolt at front end
The standard value for the unloaded height is: the
difference of the center height of drive shaft climax and
the front adjusting cam bolt is 58.5mm.
3. Mount on the four wheel locating device
This approach should be conducted according to the detailed
instruction of the equipment manufacturer.
4. Adjust the outer tilt angle of front wheel and the back tilt
angle of kingpin
The outer tilt angle of front wheel: 05'0'
The back tilt angle of kingpin: 20'0'
Outer inclination of front wheel:
BA
the outer tilt angle of
front wheelthe back tilt angle
of kingpin
front
Page 234 of 484
BR-23
Wheel-brake cylinder disassembly:
1. Tear down the dust cover steel gripping hoop and the
dust cover.
Tear down the dust cover steel gripping hoops and piston dust
covers of the four wheel-brake cylinders with the screwdriver.
2. Tear down the piston from the wheel-brake cylinder:
(a) Prepare a wooden block with the dimensions as shown in
the drawing (which is used to support the piston)
(b) Put the wooden block between the pistons and insert one
brake pad on one side of the wooden block.
(c) Tear down the four pistons from the wheel-brake cylin-
der by using the compressed air.
Warning: do not put your fingers in front of the piston
when using the compressed air.
3. Tear down the piston sealing ring.
Tear down the four piston sealing ring from the wheel-brake
cylinder with the screwdriver.
Check the front brake parts
1. Measure the thickness of brake pad liner;
Standard thickness9.0mm
Min thickness2.0mm
In case the liner is less than the min thickness or the liner is
worn unevenly, change the brake pad. Braking SystemFront Brake(SF)
mm
mm
mm