plug GREAT WALL DEER 2006 Service Manual

IN-4
Overall Repairing Description
1. Keep the vehicle clean and prevent it from
damage with guard plate, seat and floor cover
cloth.
2. Put down the dismantled parts in order during
the dismantle process so as to facilitate the re-
assembly
3. Observe the following items:
a) Disconnect the cable cathode from the
accumulator terminal before the electric
operation;.
b) Disconnect the cable from the cathode
connected to the vehicle body when check-
ing or repairing the accumulator where
necessary.
c) In order to avoid the damage of terminal
post of accumulator, loose the bolts first,
then pull up the cable vertically when
dismantling, don
t wring it or prize it.
d) Clean the terminal posts of the accumula-
tor with dishcloth, and do not scrape them
with file or other similar tools to avoid
damage.e) Mount the cable terminal on the post with loosened nut, then
fasten the nut. donít tap the terminal onto the post with
hammer.
f) Be sure to check whether the cover of positive terminal (+) is
well located or not.
4. Check all hoses and wire plugs to verify whether they are
connected solidly and correctly.
5. Parts that cannot be reused after being used.
a) The following parts should be changed with new one regularly:
split pin, sealing washer, O-ring and oil seal, etc.
b) parts that cannot be reused after being used is marked with

 in the element figure.
6. Pre-coated parts
The pre-coated parts including the bolt and nut are coated with
locking seal glue in factory.
a) In case the pre-coated parts are moved due to its fastening,
loosening or other causes, they must be coated again with the
specified seal glue.
b) Coating procedure of pre-coated parts
1) Clear away the former seal glue from the screw thread of
the said parts.
2) Dry the parts with compressed air.
3) Coat the screw thread of the parts with the specified
locking seal glue.
c) The pre-coated parts are marked with the
 in element
figure.
7. When necessary, sealing agent or sealing ring to prevent the
leakage.
8. Each specification shall be followed strictly. And the torque
spanners should be used.
9. Determine the necessity of using the special service tools (SST)
or special service materials (SSM) according to the real situation.
SST and SSM must be used where necessary and the repairing
should be in accordance with the repairing approach. SST list
and SSM list are attached to this manual.
10. Be sure to check whether the rated current of the new fuse is
correct when changing the fuse. The fuse rated current should
not larger than that of securing fitting and the fuse of smaller
rated current must not be used.
11. Be careful to hang or support the vehicle on the suitable place
when propping up or raising it.
a) In case prop up the vehicle at the front or back part, the wheels
must be blocked to guarantee the safety work. Introduction
Overall Repairing Rescription
tighten seal glue

IN-5
Body lifting height and supporting position
wrong correct
Introduction
Body Lifting Height and Supporting Position
Jack lifting position
...........................................................................................................
Front......the front the beam center
Rear.....rear differential
Supporting position

safety bracket .............................................................................................
front
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b) The raised vehicle must be supported with the bracket; it is
dangerous to conduct the repairing work on the vehicle propped
up with one jack, even though such repairing can be finished in
short time.
12. The following items shall be taken notice to avoid the parts damage:
a) Do not open the covers of ECU and various computers where not
necessary absolutely. (if the IC terminal is touched, it be leaded
into static damage) .
b) Pull the hose at its ends when dismantling it, do not pull it at the
center section.
c) Pull the wire joint instead of the wire when pulling the joint
away.
d) Take notice to avoid of the drop of electric parts such as the
sensors or repeaters. In case those parts drop to the hard ground,
they must be changed instead of being reused.
e) Do not use the striking spanner to dismantle or mount the
thermostatic switch or thermostatic sensor.
f) Plug the needles of the multi-meter into the wire connector
carefully when checking its conductance and do not bend the
terminals.
g) Do not sheath the hose of the vacuum gauge into the very large
connector when using the gauge, instead, the stage joint shall be
used because once the hose expands, it is possible to lead into
the leakage.

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

MT-4Gearbox
Dismantle of Gear Box
3. Tear down the shifting ball of gear change lever
Loose the locking nuts by dextroroting the ball.
4. Tear down the glove box
Dismantle the four bolts of the glove box and put the glove box
into the suitable place.
5. Tear down the dust cover.
6. Tear down the gear change lever.
7. Raise the vehicle to discharge the oil in gearbox.
Warning: the reliability of vehicle shall be verified.
8. Tear down the drive shaft.
(See page PR-5)
9. Tear down the odometer sensor and the plugging
elements of backup switch
10. Tear down the vent pipe.
Tear down the heading exhaust pipe from branch exhaust pipe
Dismantle of gearbox
1. Disconnect the cathode wire from the cathode of storage
cell.
2. Tear down the setting bolts of fan cover.
Tear down 4

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-35Gearbox
Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism)
(c) Coat the sealing agent on the bolt thread.
(d) Propel the plug with the torque socket spanner.

MT-44
sealed material
Gearbox
Assembly of Gearbox
17. Mount the steel ball, locating spring and locating spring
plug
(a) Mount the steel ball and locating spring.
Remarks:
Mount the short spring at the bottom of the central link plate.
(b) Coat the sealing agent on the plug thread.
(c) Mount the plug and tighten them with the torque socket
spanner.
Tightening moment
(17
22)N
m
18. Tear down the central link plate from the table vice
(a) Tear down central link plate from the table vice.
(b) Dismantle the bolts, nuts and washers
19. Mount the gearbox frame
(a) Coat the sealing material on the coupling face of the
gearbox frame as shown in the drawing.
(b) Put down the central link plate straightly as shown in the
drawing.
(c) Mount the gearbox frame on the central link plate as
shown in the drawing.

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

TF-65D5D-Oil filling plug
5L-Oil drain plug5L2. Regular lubricant change
(a) The oil level of lubricant in transfer box shall be checked
when exchanging the engine lubricant or after the vehicle
covers 8000 kilometers, and the lubricant shall be added
as requirement.
(b) The lubricant shall be changed with the specified one
every year or after the vehicle covers 48000 kilometers.
3. Lubricant inspection approach
(a) Clean the oil filling plug and the around area.
(b) Open the oil-filling plug to check whether the lubricant
can flows out or not.
(c) if the lubricant can flow out, which means the real
lubricant volume is under the prescribed value, and the
specified lubricant shall be added into the transfer box
until the lubricant can flow from the oil filler hole.
(d) Propel the oil-filling plug tightly according to the given
Tightening moment.
Tightening moment
(19
30)N
m
Notice: The vehicle shall run for a certain time before
checking or exchanging the lubricant so that the
temperature of lubricant in transfer box may be a little
higher. Do not use hammer or other punching tools to
open or propel the oil drain plug or oil filling plug, otherwise,
the thread hole on the frame will be damaged
4. Lubricant change
(a) Clean the oil filling plug and oil drain plug and the around
area.
(b) Put down a oil container under the transfer box.
(c) Open the oil drain plug.
(d) Open the oil-filling plug.
(e) Drain the lubricant up.
(f) Mount the oil drain plug and screw it up according to the
given Tightening moment.
Tightening moment
(19
30)N
m
(g) Add the lubricant through the oil filler hole until the
lubricant overflows. Mount the oil-filling plug and tighten
it according to the Tightening moment.
Tightening moment : (19
30)N
m Transfer Box
lubricant grade: ATF--3Product Description and Simple Maintenance