maintenance GREAT WALL FLORID 2008 Owner's Guide

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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

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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

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Transmission Case
Components
Clip
Shift lever assembly
Pressure torsion spring
Reverse gear switch subassembly
Washer
Bush
Oil drain slot
Tapered roller bearings
Adjusting shim
Transmission case
Clip
Clip
Adjusting shim
×8
WasherWasher
Hexagon head plug
39.2
Bolt for flange face12.0
: Specified torqueN·m
Hexagon head plug
39.2
Bolt for flange face
29.4
Position mechanism assembly
36.8

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5. Remove the reverse gear arm bracket assembly.
6. Remove the No. 1 gear shift fork shaft and the set
bolts.
7. Remove the elastic cylindrical pin from the No. 1 guide
block.
8. Remove the No. 1 gear shift fork, No. 1 gear shift fork
shaft, and No. 1 guide block.

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13. Remove the No. 2 gear shift fork shaft, No. 2 gear shift
fork, and No. 2 guide block.
14. Remove the input and output shaft subassembly.
15. Remove the differential subassembly.
16. Remove the magnetic body from the inside of the
clutch housing.

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Disassembling the Input Shaft Subassembly
Components
Input shaft
Rear ball bearing
No. 3 gear sleeve/
No. 3 gear hub
No. 3 Slider
Spring expansion ring
5th gear synchronizer ring
5th gear gear subassemblyNeedle bearing
Retaining ring
Shaft retainer
Steel ball
5th gear thrust washer
Needle bearing4th gear subassembly
4th gear synchronizer ring
Retaining ring
Shaft retainer
No. 2 gear sleeve/No. 2 gear hub
No. 2 Slider
Spring expansion ring
3rd gear synchronizer ring
Needle bearing
Front ball bearing
3rd gear gear subassembly
Spring expansion ring
Spring expansion ring
1. Remove the input shaft's ball bearing.

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6. Remove the input shaft's 5th gear thrust washer.
7. Remove the steel balls from the 5th gear thrust washer
of the input shaft.
8. Remove the 4th gear subassembly, 4th gear needle
bearing, 4th gear synchronizer ring, and the 4th gear
bearing washer (4 types of part).
9. Remove the shaft retainer from the input shaft's No. 2
synchronizer gear hub.

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Disassembling the Output Shaft Subassembly
Components
Front tapered roller bearing
Output shaft
Needle bearing
1st gear gear subassembly
1st gear synchronizer ring
No. 1 gear sleeve/No. 1 gear hub
No. 1 Slider
Spring expansion ring
Shaft retainer
Retaining ring
Needle bearing
2nd gear synchronizer ring
2nd gear gear subassembly
3rd driven gear
Spacer
4th driven gear
5th driven gear
Shaft retainer
Rear tapered roller bearing
1. Remove the output shaft's rear tapered roller bearing.

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6. Remove the output shaft's 2nd gear synchronizer ring,
2nd gear needle bearing, and the 2nd gear subassem-
bly retaining ring.
7. Remove the shaft retainer from the No. 1 synchronizer
gear hub of the output shaft.
8. Remove the output shaft's No. 1 synchronizer compo-
nents and the 1st driven gear.
9. Remove the needle bearing from the output shaft's 1st
driven gear subassembly.

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Disassembling the Shift Cover Subassembly
Components
Shift lever assembly
Dust cover
T oil seal
Gear shifting block
No. 2 spring seat
Pressure spring
Shaft retainer
Gasket
Lock plateShaft retainerElastic cylindrical pin
Shift guide block
Select lever subassembly
Manipulation lid
T oil seal
1. Remove the shift lever's elastic cylindrical pin.
Set bolt38.0
: Specified torqueN·m