GREAT WALL HOVER 2006 Service Repair Manual

6Install the inner trumpet connector on the front
drive shaft
a. Fill the inner trumpet connector and inner jacket with the
grease supplied with the jacket
(Recommend used grease is CAPLEX or KY1). Amount About140g
b. Align the assembly mark made during disassembly; covered
with inner trumpet connector.
c. Cover the inner jacket on the inner trumpet connector.
7Use the inner and outer jacket clip pliers to
clamp the inner and outer jacket.
a. Use the special non-ear clip pliers to lock the large clip of
inner jacket.
b. Use the nutcracker to lock the small clip of inner jacket.
Caution: Ensure the large and small connecting place of jacket
is in the corresponding groove of trumpet connector and shaft.
assembly mark
outer jacket clip
inner jacket clip
non-ear clip pliers
nutcracker

c.Use the special pneumatic pliers to lock the large and small clip of
outer jacket.
d.Ensure the jacket of both sides does not be prolonged or shortened
when the front drive shaft has the standard length.
Standard length: 400.5mm
If only need to replace the outer components of front drive
shaft assembly on car, it can remove the left and right steer-
ing knuckle of car, then disconnect the inner trumpet con-
nector of front drive shaft assembly, then take out the three-
pin section assembly and shaft from the inner trumpet con-
nector for replacement.
Installation of constant-speed drive shaft assem-
bly on front drive axle
1. Insert the hanger plank into the drive shaft, inserted
with oil seal; use the circlip pliers to install the inner
circlip.
Caution: It should replace the oil seal if damaged.
special tools
circlip pliers
support the lower end

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

5. Remove the drive gear flange and dustproof cover
assembly
a. Use the hand hammer and chisel to loose the riveted part on
nut.
b. Use the special tools to clamp the drive gear flangeandremove
the drive gear nut.
c. Use the cooper bar to knock down the drive gear flange and
dustproof cover assembly.
6. Remove the drive gear oil seal
Use the special tools to remove the oil seal; do not
damage the inner wall of reducer housing.
7. Install the new drive gear oil seal
a. Use the special tools to knock into the new oil seal.
b. The top of the oil seal is level to the top of reducer housing.
Caution: Coat the oil seal lip with the lithium base grease and
the oil seal should be in correct position.
special
rotate the wrench in clockwise.
specialspecial

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.

Front reducer assembly
front drive shaft assembly
hanger plank R
oil seal front vibration damper
bearing front vibration damper
front reducer electric clutch assembly
Power plug of electric clutch
circlip
bearing front vibration damper
oil seal front vibration damper
hanger plank L
front drive shaft assembly
front drive axle vent tube connector assembly
circlip
circlip
Pregummed component N
m: specified trque
circlip

6. Use the wrench to screw off the bolt on the vent tube
bracket, which is used to fix the vent tube connector.
7. Disconnect the connection between the front drive
shaft assembly and steering knuckle front hub
assembly.
a. Screw off the connecting bolt which is used to fix the front
hub cover; remove the front hub cover.
b. Use the circlip pliers to remove the circlip from the front drive
shaft and remove the adjusting washer.
c. Remove the steering knuckle of both sides and separate it
form the front drive shaft assembly.
1. Support the front of the car; remove two front
wheels and the beam under the front reducer
assembly.
2. Drain the lubrication oil in the front reducer
assembly.
3. Remove the flange of front reducer assembly from
the drive shaft
Caution: Make the assembly mark on the flange of
front reducer assembly and drive shaft before discon-
nect them.
4. Disconnect the connector of power wire of electric
clutch
5. Disconnect three rubber connectors on the front
drive axle vent tube connector assembly.
assembly mark
disconnect three connectors in this place