manual transmission GREAT WALL FLORID 2008 Service Manual

Downloaded from www.Manualslib.com manuals search engine Chapter Five: Transmission ........................................................................\
................................42
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
Chapter Six: Suspension System ........................................................................\
.......................71
Suspension System Technical Parameters ...............................................................72
Front Suspension ...................................................................................\
....................73
Subframe and Front Stabilizer Bar ............................................................................77
Lower Swing Arm ...................................................................................\
....................80
Drive Shaft ..................................................................................\
...............................84
Rear Suspension ..................................................................................\
.....................86
Wheel and Tire ...................................................................................\
........................89
Chapter Seven: Brake System ........................................................................\
...........................94
Brake System Components Arrangement Schematics ..............................................95
Brake System Maintenance ...................................................................................\
....96
Brake Pedal ..................................................................................\
.............................98
Parking Brake Control Mechanism Assembly ..........................................................102
Vacuum Booster with Brake Cylinder Assembly ......................................................103
Anti-lock Brake System ...................................................................................\
.........107
ABS General Problem Maintenance and Areas of Importance ................................109
Steering Knuckle and Hub Brake Assembly ............................................................112
Front Brake Caliper ...................................................................................\
...............118
Rear Brake ...................................................................................\
............................124
Rear Support Axle ...................................................................................\
.................131
Chapter Eight: Steering System ........................................................................\
.......................134
Troubleshooting ..................................................................................\
.....................135
Steering System Maintenance .................................................................................137
Power Steering Fluid Instructions ............................................................................141

Downloaded from www.Manualslib.com manuals search engine 13Overall Parameters
Chassis' Main Assembly Technical Parameters
ItemSpecifications
Model numberGW413EFGW4G15YC4W75-31
ClutchClutch type
Single chip, dry type, diaphragm springSingle chip, dry type,
diaphragm spring
Driven disc diameter:
200 mm
Clutch disc diameter:
213 mm
Driven disc diameter:
212 mm
Maximum stroke: 9 mm, separating stroke: 7.5 mmSeparating stroke:
7.5 mm
Clutch hydraulic pressure
control systemClutch pedal total stroke: 116.5mm
Transmission
Transmission
model number037ACC0011AZM007QZM007W
Transmission typeMechanical 5-gear manual transmission
Main speed
reduction ratio3.9444.31254.2673.937
Gear
transmission
ratio
1st gear3.5453.5453.3643.182
2nd gear1.9131.9051.8951.895
3rd gear1.3101.3101.2861.25
4th gear0.9730.9700.9690.91
5th gear0.8040.8160.8000.703
Reverse
gear3.2143.2503.2143.08
Maximum bearing
torque (N·m)130160153153
Maximum input speed
(r/min)6000
Propeller shaft
The input end of the propeller shaft adopts a widely used, near constant
velocity, retractable spherical roller wheel joint. The output end adopts a
Rzeppa joint.
Air intake systemDry air filter, paper filtering element.
Exhaust system
Equipped with GW413EF engine, two grade muffler with two grade three-
way catalytic converter. Front/rear oxygen sensors.
Equipped with YC4W75-31 engine, two grade muffler with one grade three-
way catalytic converter and oxygen sensor.
Fuel supply system
Equipped with GW413EF engine. The 45L metal fuel tank includes an
electronic fuel pump and a charcoal canister. An electronic accelerator pedal
controls the fuel supply. The fuel evaporation control system controls the
charcoal canister through a solenoid valve
Equipped with the YC4W75-31 engine. High pressure electronic common-
rail fuel injection and dual fuel pipeline. The 45L metal fuel tank includes an
electronic fuel pump and a charcoal canister, electronic accelerator pedal, a
fuel line is connected with the fuel-water separator and diesel fuel filter.
Cooling system
The cooling system uses the enclosed forced water circulation cooling
system, the heat dissipating electronic fan uses a two level speed controller.
The electronic fan and overflow tank are combined in one. The radiator is
equipped with upper and lower water chamber aluminum pipe. The system
pressure is 90 kPa.

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual18
Torque Specifications for Key Operational Bolts
Any part that has a tightening torque requirement for fastening piece connections should be fastened according
to specifications, the tightening torque of fastening pieces that have no tightening torque specification should
satisfy the QC/T 518—1999 regulations.
Tightening torque for key operational bolts are shown in the table below.
No.Important fastening piece locationsFastening piece name
and model numberQuantity
Tightening
torque
(N·m)
1Chassis
1.01Left mount & left side memberHexagon bolt for flange face1112±10
Left mount & left mounting bracketHexagon bolt for flange face264±5
1.02Left mounting bracket & transmissionHexagon bolt for flange face364±5
Right mount & engineHexagon nut for flange face141±4
1.03Right mount & engineHexagon bolt for flange face264±5
Right mount & vehicle bodyHexagon bolt for flange face 264±5
Grade Specification and Filled Quantity of Each Individual Functioning
Component's Working Agent
No.Functioning
component
QuantitySpecificationsGW413EFGW4G15
1Engine fuel45L
#93 and above high quality unleaded gasoline (GW413EF,
GW4G15 engine)
#-10 light diesel fuel (YC4W75-31 engine)
2Engine
lubricant3.25±0.25 L3.5L
GW413EF
SJ 15W-40/SJ 10W-30
(For China domestic model)
SL 5W-30 (For alpine region model)
GW4G15
SJ 20W-40/SJ 10W-30 (For domestic &
exported high-temperature region model)
SL 10W-30 (For alpine region model)
3Coolant5.5±0.5 L5.4±0.5 L
Ethylene-Glycol-35oC antifreeze fluid
(For China domestic model)
Ethylene-Glycol-45oC antifreeze fluid
(For alpine region model)
4Clutch fluid0.49±0.02 L0.72±0.02 LDOT4 synthetic brake fluid
5Transmission
lubricant1.9±0.1 L1.8L
GL-4 80W-90 (For China domestic model)
GL-4 75W-90 (For alpine region model)
GL-5 140 (For high-temperature region model)
6Power steering
fluid0.65±0.02 L0.75±0.02 LATF DEXRONⅢ Mobil fluid
7Brake fluid0.49±0.02 LDOT4 synthetic brake fluid
8Battery
terminal1.0 gIndustrial vaseline
9Windshield
washer fluid2.8±0.1 L
Room temperature: use clean water with a hardness less
than 205g/1000 kg.
Low temperature (-18oC±3oC): use methanol-water
solution concentration of 50%.
10Air conditioner
refrigerant510±10 gR134a

Downloaded from www.Manualslib.com manuals search engine 19Overall Parameters
No.Important fastening piece locationsFastening piece name
and model numberQuantity
Tightening
torque
(N·m)
1.04Right mount & vehicle bodyHexagon bolt for flange face164±5
Right mount & transmissionHexagon bolt for flange face 164±5
1.05Right mount & transmissionHexagon bolt for flange face 264±5
Rear mount & rear mounting bracketHexagon bolt for flange face 164±5
1.06Rear mount & subframeHexagon bolt for flange face
(M10 × 1.25 × 70)164±5
1.07Rear mount & subframeHexagon nut for flange face (M10 × 1.25)264±5
1.08Fuel tank & railHexagon head bolt and flat washer
subassembly435±3
1.09Fuel filler pipe & vehicle bodyHexagon head bolt, spring washer and flat
washer subassembly147±3
1.10Accelerator pedal & vehicle bodyHexagon nut for flange face39±2
1.11Fuel filter bracket & tankHexagon head bolt and flat washer
subassembly39±2
1.12Fuel pump install panel & tankHexagon head bolt and flat washer
subassembly84±1
1.13Fuel filler pipe assembly & vehicle
body
H e x a g o n h e a d b o l t a n d s p r i n g w a s h e r
subassembly19±2
1.14Air filter bracket & vehicle bodyH e x a g o n h e a d b o l t a n d s p r i n g w a s h e r
subassembly29±2
1.15Air filter & air filter bracketHexagon head bolt and flat washer
subassembly39±2
1.16Exhaust pipe rear protection supportHexagon bolt for flange face223±3
1.17Between the front muffler and catalytic
convertorHexagon bolt for flange face264±5
1.18
Connections between the front exhaust
pipe and catalytic convertor, front &
rear muffler flanges
Bolt (M10 × 1.25)464±5
1.19Connections between the front exhaust
pipe & engine exhaust manifoldAir intake and exhaust nut components264±5
1.20Front, central, and rear heat shieldHexagon head bolt, spring washer and flat
washer subassembly59±2
1.21Front heat shieldHexagon nut for flange face19±2
1.22Fan with overflow tank assemblyHexagon head bolt and flat washer
subassembly39±2
1.23Clutch pedal & clutch master cylinderNut (M8)221±5
1.24Clutch pedal & beamHexagon bolt for flange face123±3
1.25
Mounting bolts on the bracket connected
the rigid pipe of the clutch master cylinder
and hose
Hexagon head bolt and flat washer
subassembly19±2
1.26Connected the rigid pipe bracket of
clutch slave cylinders & boltsHexagon head bolt323±3
1.27Transmission control mechanism
assembly & floor
Hexagon head bolt and flat washer
subassembly420±2
1.28Transmission control cable assembly
bracket mounting bolt
Hexagon head bolt and flat washer
subassembly19±2
1.29Transmission control cable fixed plate
mounting bolt
Hexagon head bolt and flat washer
subassembly29±2
1.30Transmission control cable assembly
bracket & vehicle bodyHexagon nut for flange face19±2

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual42
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 43Transmission
Main Technical Parameters
Basic parameters of the 037A transmission
Max. input torque115 N·m/4400-5200 rpm
Speed ratio for each gear3.5451.9131.3100.9730.8043.214
Main deceleration ratio3.944
Odometer speed ratio31/35 (currently no driven gear)
Center distance (mm)65
Lubricant capacity (L)1.8
Control methodRemote cable control
Netweight (kg)28
Match engineGW413EF
037A Transmission’s Overall External Schematics
The 037A transmission is a step mechanical transmission with differential, two-shaft front wheel drive
application. The forward gear has adopted the inertia synchronizer gear-shifting mechanism, which offers
smooth and easy gear shifting, reduces noise dramatically, and improves the service life of the gear - important
in achieving the overall economical efficiency. Regarding its control mechanism, the set steel ball and spring
allow the shifting gear to be quick, accurate with solid handling. The 5th gear transmission is equipped with an
interlocking mechanism to prevent accidental switching to reverse, to im\
prove driving comfort and reliability.

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual44
Transmission's Proper Use and Care
1. Transmission's proper operation
1.1 Shift the gear gently, not excessively.
1.2 Do not start with high speed.
1.3 To avoid premature abrasion of the gear shift fork, do not rest your hand on the \
gear lever while driving.
2. Model number of the lubricant to be used:
GL-4 80W-90 (For China domestic model)
GL-4 75W-90 (For alpine region model)
GL-5 140 (For high-temperature region model)
Caution: Please only use the lubricant with model numbers specified by t\
he Great Wall Motor Co., Ltd.
Do not mix lubricants with different model numbers. Only fill with clean lubricant.
3. Areas of importance for new vehicle usage:
3.1 Before using a new vehicle, be sure to check the transmission and all exposed connectors and fastening
pieces, so as to avoid failure due to faulty installation or loose conne\
ctions.
3.2 Since the new vehicle is still in the run-in period, the transmission's lubricant should be replaced after 5000 km
distance.
4. Transmission three-level maintenance:
4.1 Transmission level-one maintenance: During the first level of maintenance, the liquid level of the lubricant
should be checked to ensure that it is up to the oil-filling mouth. Add more if insufficient. Excessive low
oil level can lead to ineffective lubrication, as well as burning of the bearings and gears. Excessive high oil
level, however, can overheat the transmission or cause oil to leak. In addition, during the first level of main-
tenance, the breather plug should be checked and cleaned. If the breather plug is clogged, internal pressure
will build up and oil will leak from the transmission.
4.2 Transmission level-two maintenance: The transmission's lubricant should be replaced the first time that the
vehicle undergoes the second level of maintenance. Clean the transmission with kerosene. The quality of the
lubricant should be inspected during the future second level of maintenance practises. The lubricant should
be replaced if diluted, gummy, or dirty.
4.3 Transmission level-three maintenance: During the third level of maintenance, it should be removed for in-
spection, cleaning, and oil changing.
Technical Specifications for Transmission Installation and Adjustment
Inspect the axial play (δ) between the synchronizer ring and the gear shaft
Gear (δ1) (δ2) (δ3) (δ4) (δ5)
Standard axial play (mm)0.7-1.70.7-1.70.7-1.70.7-1.70.7-1.7
Gear (δ1) (δ2) (δ3) (δ4) (δ5)
Standard axial play (mm)0.1-0.40.1-0.60.1-0.40.1-0.60.1-0.55
Check the axial play (δ) between each gear

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

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 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