torque GREAT WALL HOVER 2006 Service Repair Manual

1. Place the car in the middle of repair platform or
trench, support the front of the car steadily(support
on the carriage) then remove the left and right
front wheel. (make the car in 2WD status before
the disassembly)
2. Remove the beam on the lower of front drive axle
assembly.
3. Disconnect the connection of front drive axle
flange and drive shaft and make the assembly
mark
4. Drain the lubrication oil in reducer.
bolt
front hub cover
circlip
adjusting washer set
flange
disconnect three ports in this position
N m: specified torque

Use the special tools to knock bearing in slightly.
Caution: Support the lower end of the drive shaft assembly
when knock the bearing in. The lower end must not slide out.
3. Use the circlip pliers to install the outer circlip on
the front drive shaft assembly.
4. Repeat the previous method to install the hanger
plank, oil seal, circlip, bearing and circlip on another
end.
5. Insert the spline of connecting end of drive shaft
and reducer into the differential halfaxle gear spline
hole of electric clutch and reducer slowly.
6. Drip 1-2 drop of screw lock agent on the middle of
screw of connecting bolt of hanger plank andreducer.
7. Use the wrench to tighten the connecting bolt of
hanger plank and drive axle to specified torque.
specified torque : 90-110N
m
Caution: It should screw on all bolts before tighten
them, then tighten them in diagonal direction.
Check the hanger plank for levelness after tightened
the bolt to the specified torque. Remove the hanger
plank and reinstall it if is not planished.
8. Install the vent tube connector assembly; connect
all ports to front drive axle.
(Refer to “Assembly of Front Reducer Assembly”)
special tools
support the lower end

Specified torque : 200-220Nm
Caution: Drip 1-2 drop of screw lock agent on the middle front
part of the lifting bolt
10Use the bolt to connect the front drive axle flange
and drive shaft according to the mark mage before
disassembly and tighten it to the specified torque.
specified torque: 73-83N.m
11. Install the beam under the front drive axle.
Tighten the beam connecting bolt to the specified
torque.
specified torque: 73-83N.m

Replacement of drive gear oil seal of front reducer assembly
1. Support the front of car; remove the left and right
front wheel and the beam under the reducer.
2. Drain the lubricant oil in the front reducer; remove
the left and right steering knuckle
3. Disconnect the front reducer assembly flange from
the drive shaft and use the jack to remove the front
drive axle
Caution: Make the assembly mark on the reducer and
drive shaft before separate them.
4. Remove the front differential assembly
(Caution: Drain the oil in front differential before the
disassembly)
front reducer
assembly
washer
spacer drive
bevel gear
bearing
oil seal
front reducer drive gear flange,
main gear flange and dustproof
cover assembly
Used component which can not be used
any more.
N m: specified torque
assembly mark

8Install the drive gear flange and dustproof cover
assembly
a. Match the drive gear flange and dustproof cover assembly on
the front drive gear.
b. Coat the new nut with the lithium base grease.
c. Use the special tools to clamp the flange and tighten the nut
to the specified torque.
Tighten torque:140-160N.m
a. Use the torque meter to measure the pre-applied load of the
gap between the drive bevel gear and driven bevel gear.
pre-applied load: 1.2-1.7N.m
b. Is should be replaced by the thicker washer if the pre-ap
plied load is more than specified value
(The step of thickness of washer is 0.03mm)
c. Is should be replaced by the thinner washer if the pre-applied
load is less than specified value. Repeat the previous
operation until meet the requirement.
Caution: Do not reduce the load by loosing the nut.
10. Check the axial and radial run-out tolerance
offlange.
a. Use the dial indicator to measure the axial runout of flange.
Max. axial runout: 0.1mm
b. The max. radial run-out tolerance is 0.1mm
It should check the bearing if the radial run-out tolerance is large.
9Adjust the pre-applied load of the drive
bevelgear bearing

11Rivet the drive gear nut after meet the previ-
ous requirements.
12
Install the reducer assembly on the front drive
axle assembly and assemble the front drive shaft
assembly (refer to Assembly of Front Reducer Assembly
and Assembly of Front Drive Shaft Assembly)
13
Install the oil drain plug; screw off the oil
filling plug and filled with the hypoid gear oil.
Tightening force of oil drain plug: 30-35Nm
Model of lubrication oil: GL-5
Filling amount: Flush to the lower edge of oil filling open
14Insert the oil filling plug washer and tighten
the oil filling plug to the specified torque.
Specified torque : 140-150Nm
15Install the front drive axle assembly on the
carriage.
16
Connect the drive shaft to the flange
a. Align the assembly mark; use four bolts and nuts to connect
the flange of drive shaft and front drive axle.
b.Tighten the nut to the specified torque.
specified torque:
Remarks: Keep the clean of the field during the maintenance.

8. Use the jack to support the front reducer assembly
9. Remove the lifting bolt of front drive axle hanger
plank and carriage.
10. Remove the front drive axle assembly
Caution: Do not damage the drive shaft and front drive
shaft jacket
11. Remove the front drive shaft assembly of both sides
from the front drive axle assembly.
12. Use the wrench to remove the bolt and nut which is
used to fix the front reducer housing.
13. Remove the clump weight assembly and clump
weight bracket welded assembly
(Refer to “Disassembly of Front Reducer Assembly”)
electric clutch connector
N
m: specified torque

Replacement of front reducer assembly oil seal
1. Remove the front drive axle assembly
(Refer to “Removal of Front Reducer Assembly”)
2. Remove the left and right front drive shaft assem-
bly from the front drive axle assembly.
3. Remove and replace the lower oil seal according to
the removal and installation procedure of front drive
shaft assembly and install the new side oil seal on
the front drive shaft, then install them in the front
reducer assembly.
(Refer to “Removal and Installation of Front Drive Shaft
Assembly”)
Replacement of oil seal and major semiaxle oil seal of front reducer assembly
major semiaxle oil seal
major semiaxle pressing assembly
circlip
mechanical wheel of separator
Pregummed component N
m: Specified torque

14. Align the spline of mechanical wheel of separator
with the spline in front drive shaft and separator
shift fork sleeve, and install it in the front drive
shaft and separator shift fork sleeve.
15. Coat the flange matching surface with the 1596
silicon rubber plane sealant uniformly and level it by
plate.
Caution: Ensure the continuity of sealant and avoid
the sealant enter into the screw hole.
16. Align the shift fork bush with the spline on the
major semiaxle to make the mechanical wheel of
separator enters into the major semiaxle, then use
the bolt to connect the electric clutch housing and
front axle pipe flange and tighten it to the specified
torque. In which the bolt should be precoated with
the screw locking agent (drip one or two drops on the
middle of screw).
specified torque : 90-110Nm
Caution: Prevent the foreign material from entering into the
front drive axle during assembly.
17. Use the wrench to tighten the bolt of vent tube
bracket to tightening torque.
Tightening force: 23-26Nm
18. Screw off the oil filling plug on the electric clutch
housing, remove the washer and fill it with the gear
lubrication oil until flush with the bottom of oil
filling port.
Number of lubrication oil: GL-5
19. Place the washer of oil filling plug, tighten the oil
filling plug to specified torque.
Specified torque: 140-150N.m

Disassembly and assembly of front reducer assembly and electric clutch
adjusting shim
bearing gland
differential housing
driven bevel gear
front drive axle housing
washer
oil filling plug
vent tube
clip
front axle vents tube
connector assembly
major semiaxle
needle bearingelectric clutch
location pin
vent tube
mechanical wheel of separator
declutch shift sleeve
electric clutch housing
oil filling plug
circlip
major semiaxle oil seal
half axle gear thrust plate
half axle gear
planetary gear shaft
planetary gear
bolt clump
weight bracketclump weight and bush
assembly
clump weight bracket
welded assembly
front reducer
housing
adjusting washerspacer
drive bevel gear
small bearingoil sealfront drive gear flange and
dustproof cover assembly
drive bevel gearadjusting washer
Pregummed component
N m: Specified torque
Used component which
can not be used any more.bearing
circlip
big bearing