oil GREAT WALL HOVER 2006 Service Repair Manual

17. Check and adjust the run-out of flange.
a.Adhere the dial indicator base on the reducer housing; make the
probe of dial indicator contact with the end surface of flange;
rotate the flange and watch the rotation range of the dial.
Full run-out tolerance of end surface: 0.10mm
b.Adhere the dial indicator base on the reducer housing; make the
probe of the dial indicator contact with the inner diameter of
flange; rotate the flange by hand , and watch the rotation range of
the dial.Radial full run-out tolerance: 0.10mm
18. Rivet the nut of drive bevel gear
Installation of reducer and differential assembly
1.Install the new stiffening ring
2.Install the reducer and differential assembly
Install the reducer and differential assembly in the rear axle housing;
place the washer and nut. Tighten the nut to the specified torque.
Tightening force: 18-25N
m
3.Install the reducer and differential assembly flange
on the drive shaft flange and align the assembly
mark; use four bolts and nuts to connect them.
Tighten the bolt and nut to the specified torque.
Tightening force: 78
5Nm
4.Install the oil drain plug; fill the differential with the
gear oil
oil number : GL-5 hyperbolic gear oil
Viscosity: SAE80W/90
Amount: Filled with oil until the oil flow out from the oil filling
port.
Tighten the oil filling plug.
Tightening force: 140-150N
m
assembly mark

Rear suspension
N m: specified torque
bush clip
bush
rear stabilizer barrear connecting rod of stabilizer bar assembly
plain washer
short longitudinal
pull-rod fixed bolt
rubber padshort longitudinal
pull-rod fixed bolt
long longitudinal
pull-rod assembly
long longitudinal
pull-rod fixed bolt
long longitudinal
pull-rodassembly
short longitudinal
pull-rod assembly
rear axle
assembly
coil spring
upper support pad
of coil spring
short longitudinal pull-rod assembly
long longitudinal
pull-rod assembly
rear vibration damper
cross pull-rod assembly
cross pull-rod
connecting bolt

Removal of vibration damper
1. Use the lifter to raise the car firstly, then support
the rear axle by bracket.
2. Remove the upper and lower fixing nut which is used
to fix the vibration damper; compress the vibration
damper by hand.
Remove the upper end firstly, then the
lower end; take out the vibration damper .
Installation of vibration damper:
1. Lower tightening force of vibration damper:
170
5Nm.
Upper tightening torque : Compress the rubber block to 2/3 of
total height.
Caution: If the fixing nut of vibration damper is the lock nut, it
should be replaced by the new lock nut after replace the vibra-
tion damper.
Removal of coil spring:
1
. Remove the vibration damper (As previous )
2. Use the special tools to clamp the coil spring.
3. Place the car in the bounce status, take out the
coilspring
4. Remove the special tools from the coil spring.
Installation of coil spring:
1. Firstly, use the special tools to clamp the coil spring
to certain height (height when car is in bounce
status).
2. Cautions for installation: Adjust the rubber gasket on
the spring to ensure the spring in flat status.
3. Remove the special tools.special tools

Brake-2
Troubleshooting
Cautions

Failure cause Inspection content



Pedal is low or soft brake pad is worn
brake block is worn
brake system is leaked
master pump has failure
Brake system has air
Brake pump has failure
Auto adjuster of rear brake has failure Replace the brake shoe
Replace the brake block
Repair the leakage
Repair or replace the master pump
Drain the air from brake system
Replace the brake pump
Repair or replace the adjuster




Lag of brake Parking brake is adjusted badly.
Pull wire of parking brake is locked
Assist push rod is adjust badly
Extension spring or return spring has fault
Pipeline is blocked
brake pad is broken or deformed
brake block is broken or deformed
Auto adjuster is damaged
Master pump has failure. Adjust the parking brake
Repair if necessary
Adjust the push rod
Repla ce the extension spring
Repair if necessary
Replace the brake shoe
Replace the brake block
Repla ce the a djuster
Repla ce the master pump





Brake is stagnant Improper inflation of tyre
There is grease spot or lubricant oil on the
brake shoe or brake block.
The brake shoe is deformed ; the brake pad
is worn or smoothed
The brake block is deformed, worn or
smoothed
The brake drum or brake disc is deformed
Extension spring or return spring has failure
Wheel pump has failure
Pump has failure
Brake block is blocked Charge the tyre to the proper pressure.
Find out the cause. Replace the brake shoe or block.
Replace the brake shoe
Replace the brake block
Replace the brake drum or brake disc
Repla ce the spring
Repair the wheel pump
Replace
Replace the brake block





brake pedal is hard There is the grease spot or lubrication oil on
the brake disc or brake block.
The brake shoe is deformed; the brake pad is
worn or s moothed
The brake block is deformed, worn or
smoothed
Brake pump has failure.
Brake assist has failure
Improper vacuum degree
The brake pipeline is blocked. Find out the caus e .
Replace the brake shoe or brake block
Replace the brake block
Replace
Replace the assist
Repair if necessary
Repair if necessary

Brake-3
Troubleshooting (continued)

failure caus e Inspection content


The brake generates the
crack clatter during
operation. (drum brake)
The brake shoe is blocked in the rear apron flange
The rear apron flange is worn
The brake shoe pull-out piece spring is loose or lost
The fixed bolt of rear apron is loose (disc brake )
Brake block support plate is loose or lost
Installation bolt is loose
Filled with lubricated oil
Replace the lubricant flange
Replace
tighten
replace
tighten



It has the rustle or rattler
when use the brake The brake shoe gasket or brake block is worn
The brake caliper and wheel or rotor are disturbed
mutually
The dustproof cover and rotor, rear apron and brake
drum are disturbed mutually
Failure of other brake system component
Tyre generates the abrasion with the tyre and chassis Replace, if the scratch is heavy,
then fine machine the brake drum or
rotor again
Replace it according to requirement
Correct or replace
Repair or replace it according to
requirement
Check or maintain
It has the squeak, continuous
scream, rattler or vibration
noise when use the brake .
Caution: The abrasion
material in the brake will
generate the inherent noise
and heat during the
abrasion, then emit the
heat. So it is normal that
generate the squeak by
accident. The condition
will be serious in extreme
environment, such as cold,
hot, high humidity,
snowing, saliferous and
mud. The accident squeak
will not cause the fatal
failure of the brake, and
will not reduce the effective
performance of the brake. The brake drum and brake shoe gasket, rotor and
brake block is worn or scratched.
The brake pad or block is dirty, with oil or smoothed.
The brake pedal or assistor push bar is adjusted
incorrectly
(dis c brake )
The brake block silencing plate is lost or damaged.
The abrasion of the brake block makes the brake
block abrasion indication plate contacts the rotor
The brake ca lip er has burr or is corrosive
(drum brake)
The pull-out piece spring of brake shoe is soft,
damaged or improper. The pull-out piece spring pin
and spring of brake shoe is loose or damaged; and
rear apron flange has crack Check, repair or replace
clean or replace
check, replace
check and adjust
replace
replace
clean or remove the flash
check, repair or replace

Brake-4
failure caus e Inspection content











It has the continuous
scream and squeak
when does not us e the
brake The brake pedal or assist push bar is adjusted
incorrectly
The return of brake assist or master pump or wheel
pump is bad
(dis c brake )
T he piston is corr osive or blocked
T he brake block in brake calip er is in improp er
position
Shell abrasion of rotor and brake caliper
The brake block support plate in disc brake is
installed improperly
The brake block abrasion indication plate contacts
the rotor for the abrasion of brake block
(drum brake)
The press spring of brake shoe is soft, damaged or
improper.
The flange of rear back rear apron is cracked
T he rear apron interfer e with the brake drum
mutually after bent or warp
Improper machining of brake drum , caus e the mutual
interference of rear apron and brake shoe
components of other brake s ystem :
Brake system has loose or redundant components
T he brake pad is smoothed for the rear brake drum is
adjusted too tight
The wheel bearing is worn damaged or under
lubricated Check and adjust

Check, repair or replace


Check and fill with lubrication oil if
necessary.
Repair or replacement
Repair or replacement
Repair or replacement

Repair


Repair

Repair or replacement
Repair or replacement

Replace the brake drum


Check, maintain and replace if
necessary.
It still has the rattler,
click or cackle noise
when does not us e the
brake. The stone or foreign enters into the inside of wheel
protecting hood
The hub nut is loose


The brake pedal or assistor push bar is adjusted
improperly
The wheel bearing is worn, damaged or lubricated
insufficiently
(dis c brake )
T he muffler spring is soft or lost; the brake block
support plate or external end of brake block is coiled
silencing plate is unsound
T he slide bush is worn
T he installation bolt is loos e
Piston returns unsoundly
(drum brake)
Have loose or redundant component Remove the foreign materials such as
the stone
Tighten it to the specified torque, it
should be replaced if the bolt hole is
enlarged
Check and adjust

Check, lubricate or replace


Repair or replacement


Check and replace if necessary
Check and replace if necessary
Check and tighten if necessary
Check , repair or replace
Check, take out or repair

Brake-9
Front brake
front brake oil pipe
cliper bracket
outer silencing plate combination
lower circlip of
brake block
brake block assembly
lower circlip of brake block
wear limitation alarm plate of brake block
lnner silencing plate combination
Inner brake block
silencing plate
upper circlip of brake block (I)upper circlip of brake block (II)
piston
dustproof cover
guide pin dustproof cover
guide pin rubber covercooper washer
tong
air-bleed
bolt cover
location pin
guide pin dustproof coversquare seal ring
N
m: Specified torque
Piston
Replacement of brake block
Remarks:
When brake during the travel process, if the front wheel has the
continuous screams noise, then it should check the wear limitation
alarm plate of brake block. If the alarm plate has the abrasion
mark with brake disc, then it should replace the brake block .
1. Remove the front wheel
2. Check the thickness of abrasion material of brake block.
Check the thickness of abrasion material of brake block by the watch
hole on the tong.
Replace it if is not within specified range.
Min. thickness : 2.0mm

Brake-10
3Lift the main body of brake caliper.
a. Remove the hexagon flange bolt.
b. Lift the brake pump and hang it by rope to protect the brake oil
pipe.
Remarks: Do not screw off the brake oil pipe and bleed plug.
4. Remove the following components
a. Two pieces of brake block
b. One piece of silencing plate
c. Two piece of silencing plate combination
d. One wear limitation alarm plate of brake block
e. Four brake block circlip plates
5. Measure the thickness of brake disc
(Refer to step 2 of “ Inspection of component of front brake” )
6. Measure the circular runout of brake disc.
(Refer to step 3 of “Inspection of component of front brake”)
7. Install the brake block circlip plate

Brake-12
Removal of brake pump
1. Remove the brake pipeline
Remove the brake pipeline. Use a container to contain the brake fluid.
2. Remove the brake pump from the clamp bracket
a. Remove the hexagon flange bolt, location pin and guide pin.
b. Remove the brake pump.
3. Remove the brake block
a. Two brake blocks
b. One silencing plate
c. Two silencing plate combinations
d. One wear limitation alarm plate of brake block
e. Four brake block circlips
Disassembly of brake pump
1. Remove the piston form the tong
a. Place the wood block between the tong bracket and tong body .
b. Use the air gun or air pipe to aim at the brake oil pipe hole; remove
the piston form the tong.
c. Use the clean rag or soft cloth to take out the piston.
Warning: It must not place the finger in front of the piston when
use the compressed air.
2. Remove the piston gasket from the tong body.
Use the paper clip to remove the piston gasket.
Caution: The used tools must not be sharp to prevent from scratching
the piston gasket.

Brake-15
Installation of brake caliper
1. Install the brake block
2. Install the brake pump
a. Install the brake pump.
b. Install and tighten the hexagon flange bolt.
Tightening force: 25
35Nm
3. Connect the brake pipeline
Connect the brake oil pipe to the tong body.
Tightening force: 50
5Nm
4. Fill up the brake liquid reservoir with the brake fluid and dis
charge the air in brake system.
5. Check for the leakage of brake fluid.
Caution: Discharge the air after the completion of replacement.