clutch GREAT WALL FLORID 2008 User Guide

Downloaded from www.Manualslib.com manuals search engine 39Clutch Operational System
2. Remove the driven clutch discharge pipe with a M10
open-end wrench.
3. Remove the pedal lock pin.
4. Remove the return spring and the connecting pin.
5. Remove the lock nuts of the clutch pedal with a M13
sleeve and an extension bar.
6. Remove the clutch master cylinder.
Clutch discharge pipe
Pedal lock pin
Return springConnecting pin
Lock nut
Clutch master cylinder

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Clutch Master Cylinder Installation
Installation of clutch system is reverse to its removal, but
since the whole clutch system uses hydraulic assistance,
make sure to air bleed it after the installation is completed.
Detailed steps as follows:
(a) Plug one end of the long transparent connection hose
(about 0.5 m long) into the bottom of bleed screw, and
the other end into a fixed container.
(b) Loosen the bleed screw via the open end of the M8,
meanwhile ask the assistant to step on the clutch pedal
repeatedly until no air bubbles can be seen in the hose.
R e m a r k : R e s i d u a l a i r i n t h e c l u t c h s y s t e m h a s b e e n
completely exhausted.
(c) Lastly, lock the bleed screw.
Caution: Refilling the brake fluid reservoir should be
performed while air bleeding the clutch.
Clutch Pedal Removal
1. Remove the battery's negative cable.
2. Remove the glove box at the left of the dashboard.
3. Remove the cotter pin at the U-joint of the clutch
master cylinder, and separate the center pin and the
pedal lever.
4. Remove the clutch pedal bracket from the cowl.
5. Remove the clutch pedal.
(a) Move the clutch pedal to the maximum stroke position.
(b) Take down the return spring.
(c) Remove the bolts and nuts.
(d) Take the pedal lever down from the pedal bracket.
Clutch Pedal Installation
1. Install the clutch pedal.
(a) Install the return spring.
(b) Install the clutch pedal lever.
(c) Install the bolts and nuts.
Tightening torque: 30 N·m
(d) Put the pedal lever at the maximum stroke position and
connect it with the spring, in order to set the pedal to its
initial position.
2. Install the clutch pedal onto the 2 studs of the clutch
master cylinder.
Use a M13 wrench to tighten the clutch pedal brackets with
two M8 nuts.
Tightening torque: 23±3 N·m
3. Install the clutch master cylinder push rod with the U-
joint.
(a) Coat the contact areas between the center pin and the
U-joint pedal connector with multi-functional grease.
(b) In succession, join the U-joint (pedal connector) and
the clutch pedal lever with a cotter pin.
Caution: Insert the center pin into the pedal lever from
the left side of vehicle.
(c) Install the cotter pin onto the center pin.
4. Check and adjust the clutch pedal.
5. Connect the negative cable of the battery.
Bleed screw

Downloaded from www.Manualslib.com manuals search engine 41Clutch Operational System
Clutch Pedal Examination and Adjustment
1. Check if the pedal height is correct.
Height from the carpet: 100-110 mm
2. Adjust the pedal height.
Loosen the lock nut and adjust the clutch pedal limit adjust-
ing bolt until its height is correct, and then tighten the lock
nut.
Tightening torque: 20 N·m
3. Check if the pedal free play is correct.
Step on the pedal until one can feel the resistance.
Pedal free play: 13.7 mm
4. Adjust the free play.
(a) Loosen the lock nuts of the clutch master cylinder and
rotate the push rod until the pedal reaches the correct
free play.
(b) Tighten the lock nuts.
Tightening torque: 20 N·m
(c) Recheck the clutch pedal height.
Pedal height
Lock nut
Limit adjusting bolt
Lock nut
Free play

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Transmission
037A Transmission’s Overall External Schematics ............43
Main Technical Parameters ...............................................43
Transmission's Proper Use and Care .................................44
Technical Specifications for Transmission Installation
and Adjustment ...................................................................44
Areas of Importance ...........................................................45
Troubleshooting ..................................................................46
037A Transmission Structural Schematics .........................47
Clutch ........................................................................\
.........48
Gear Shift Fork and Fork Shaft...........................................49
Transmission Case .............................................................50
Disassembling the Input Shaft Subassembly .....................56
Disassembling the Output Shaft Subassembly ..................60
Disassembling the Shift Cover Subassembly .....................64
Disassembling the Differential Subassembly .....................68

Downloaded from www.Manualslib.com manuals search engine 45Transmission
Areas of Importance
Removal
During removal, all components should be gently handled to avoid knocking, especially the joint surface.
All components should be placed in the proper order to avoid misplacing \
and mistaking.
Installation
1. Clean all parts before installation (except rubber pieces and gaskets)\
.
2. All oil seals, shaft retainers, and elastic pins should not be reused.
3. All rubbing surfaces should be coated with lubricant, and the lips of all oil seals should be coated with
grease.
4. During installation of the bearings, do not use any kind of rolling element to transmit pressure, and
make sure not to tilt it.
5. During the installation of synchronizer components, the two sides of the spring piston's openings
should alternate.
6. When the transmission is operating under normal working conditions, there should be no lubricant
leakage from any of the parts.
Transportation and storage
1. When transporting a transmission, make sure the conditions are dustproof and rainproof, as well as
take proper care not to damage it due to jolting, shaking, removal, or i\
nstallation.
2. Transmission assembly should be stored in a ventilated, dustproof, and dr\
y place.
3. Users with special transportation or storage requirements should have another discussion to reach an
agreement on this matter in the supply contract.
Use partsBolt codeSpecificationsQuantity
Tighten-
ing torque
(N·m)
Differential case × differential ring gear037-2303309M12 × 1.06123.6
C l u t c h h o u s i n g × r e v e r s e g e a r a r m
bracket subassembly037-1702073M8 × 1.25217.2
No. 1 gear shift fork shaft × No. 1 gear
shift fork037-1702056M6 × 0.75115.7
No. 2 gear shift fork shaft × No. 2 gear
shift fork037-1702056M6 × 0.75115.7
Transmission case × clutch housing037-1701012M8 × 1.251329.4
Transmission case × manipulation lid
subassembly037-1702051M8 × 1.25412.0
Transmission case × position mechanism
component037-1702042M18 × 1.5136.8
Transmission case × reverse gear idler
shaft × sealing ring037-1701404M8 × 1.25129.4
Transmission case × hexagon head plug037-1701016M18 × 1.5239.2
Transmission case × reverse gear switch
subassembly037-1701022M18 × 1.5140.2
Transmission case × cable bracket037-1701019M8 × 1.25411.3
Clutch housing × clutch slave cylinder
subassembly037-1601019M8 × 1.25211.3
Select lever assembly × gear shifting
block037-1702027M8 × 1.25138.0
Clutch housing × release fork support
nail037-1601011M10 × 1.25136.8
Counterweight component × shift lever
component037-1702030M8 × 1.25220.0
Release fork support nail129.4
Thread fastening piece tightening torque table

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Troubleshooting
Common problemsPossible causesSolving methods
Difficult gear
engagement
Not applying clutchUse correct driving methods
Insufficient clutch separation Inspection & adjustment
Serious abrasion of the synchronizer ringReplace component
Positioning spring is too hardReplace component
Noise is too loud or
abnormal
Oil level is too lowFill oil to the specified level
Lubricant is of poor qualityReplace the specified oil
Untimely oil changesReplace oil and damaged part
Improper gear axial position and clearanceInspect and adjust
Damaged bearingReplace component
Gear has a burr or has been knockedRepair or replace gear
Oil leakageToo much oil is added, oil level too high.Fill the oil level to the specified position.
Bolt loose or missingReassemble and screw in according to regu-
lations.
Breather plug failsReplace
Damaged sealReplace
Synchronizer is damagedExcessive gear shifting force Replace synchronizer
Not applying clutchUse correct driving methods
Synchronizer's spring expan-
sion ring is damagedReplace
Gear disengagementControl mechanism malfunctionInspect and adjust
Retaining spring or steel ball missingAdditional assembly
Retaining spring malfunctionReplace
Fork groove of the gear sleeve is worn outReplace
Shifting fork is worn out.Replace
Bearing and gear are burntOil level is too lowReplace part and fill oil
Lubricant is of poor quality.Replace part and lubricant
Untimely oil replacement causes
the oil to be too dirtyReplace part and lubricant
Mixed use of different oils
or use of additivesReplace part and lubricant
Difficulty shifting gearsSynchronizer spring malfunctionReplace
The internal groove of the syn-
chronizer ring is worn outReplace
The synchronizer ring is seized
into the conical surfaceReplace
Deformed shifting fork or
shifting fork shaftReplace
Shifting fork is worn outReplace

Downloaded from www.Manualslib.com manuals search engine 47Transmission
1. No. 2 gear sleeve 2. Shaft retainer 3. No. 2 Slider (3) 4. Spring expansion ring (2) 5. No. 2 gear hub 6. 3rd gear synchronizer ring 7. 3rd gear gear assembly 8. Needle bearing 9. With washer bolt 10. Clutch slave cylinder subassembly 11. Release fork protective cover 12. Release fork spring 13. Bolt for flange face (3) 14. Release fork 15. Clutch housing 16. Release fork support nail 17. Ball bearing 18. 2nd gear synchronizer ring 19. T oil seal 20. No. 1 gear sleeve 21. No. 1 Slider 22. 1st gear synchronizer ring 23. 1st gear gear components 24. Needle bearing 25. Release bearing subassembly 26. Tapered roller bearing 27. Guide nozzle 28. 2nd gear gear
assembly 29. No. 1 gear hub 30. Spring expansion ring (2) 31. Bolt for flange face (6) 32. Straight pin 33. Odometer driver 34. T oil seal 35. Tapered roller bearing 36. Adjusting shim (2) 37. Axle shaft gear (2) 38. Planetary gear (2) 39. Gasket (2) 40. Differential case 41. Planetary gear shaft 42. Differential ring gear 43. Bolt for flange face (8) 44. Tapered roller bearing 45. Adjusting shim 46. T oil seal 47. Shaft retainer 48. Retaining ring 49. Needle bearing 50. 3rd driven gear 51. Spacer 52. 4th driven gear 53. 5th driven gear 54. Shaft retainers 55. Tapered roller bearing 56. Adjusting shim 57. Output shaft 58. 5th gear gear assembly 59. Shaft retainer 60. Retaining ring 61. Spring expansion ring (2) 62. Needle bearing 63. Input shaft 64. Adjusting shim 65. Ball bearing 66. 3rd gear gear hub 67. 3rd gear Slider (3) 68. 3rd gear gear sleeve 69. 5th gear synchronizer ring 70. Steel ball 71. 5th gear thrust washer 72. Needle bearing 73. 4th gear components 74. Retaining ring 75. 4th gear synchronizer ring 76. Transmission case
037A Transmission Structural Schematics
1
2
34
567
9
8
10
111213
1415
1617181920
21
222324
25
26
27
2829
3031
32
33
343536
37
3839
4041
42
43
44
45
4647
48
49
50
51
52
53
54
55
59
56
57
58
60
61
62
63646566
6768
69
70
71
72
73
74
75
76

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual48
Clutch
Components
Release bearing
Release fork
Cable bracket
Bolts with washer
Bolts with washer
Magnetic bodyDifferential assembly
Output shaft assembly
Input shaft assembly
T oil seal
Tapered roller bearings
Guide nozzle
Clutch housing
Release fork dust cover
Cable bracket
×5
Release fork support nail
29.4
11.3
11.3
: Specified torqueN·m

Downloaded from www.Manualslib.com manuals search engine 49Transmission
Gear Shift Fork and Fork Shaft
Components
Clutch housing
No. 1 gear shift fork shaft
Shaft retainers
Set bolt
Elastic cylindrical pin
No. 1 gear shift fork
Elastic cylindrical pin
No. 1 guide block
Lock pin
Pressure spring
Shaft retainers
Lock pin
No. 3 gear shift fork shaft
No. 2 gear shift fork shaft
No. 3 guide block
No. 3 gear shift fork
Set bolt
Output shaft assembly
Input shaft assembly
Gasket
Reverse gear idler shaft
Reverse gear idler assembly
No. 2 gear shift fork
Bracket bolt
Reverse gear arm bracket assembly
Reverse gear gear shift fork
Shaft retainers
Shaft retainers
15.7
15.7
Bolt for flange face
29.4
17.2
: Specified torqueN·m

Downloaded from www.Manualslib.com manuals search engine 51Transmission
Shift System Removal
1. Remove 4 bolts for flange face from the manipulation
lid.
2. Remove the set bolts from the sides of the transmis-
sion case.
3. Separate the clutch housing and the transmission
case.
(a) Remove 8 bolts for flange face from the transmission
case and clutch housing.
(b) Remove 5 bolts for flange face from the clutch housing
and transmission case.
(c) Pound the housing's protruding parts with a soft ham-
mer to remove the transmission case.
4. Remove the reverse gear idler shaft and the reverse
gear idler assembly.