GREAT WALL HOVER 2006 Service Repair Manual

15. Use the wrench to remove the bolt fixed the
clump weight bracket welded assembly.
16. Use the wrench to remove the bolt and nut used
to fix the front reducer assembly and front axle
housing.
17. Use the brass rod or hand hammer to knock the
front reducer housing to separate it from the front
drive axle housing.
18. Check the run-out of driven bevel gear.
Rotate the flange; use the dial indicator to measure
the run-out of driven bel gear.
Max. Runout: 0.07mm
It should replace the drive and driven bevel gear totally if the run-
out is more than 0.07mm.
19Check the running clearance of drive and
driven bevel gear.
a. Install the dial indicator and ensure the side axis is vertical to
contact tooth surface.
b. Hold the drive gear flange and rotate the driven bevel gear in
clockwise and anticlockwise to measure the clearance.
Specified range of clearance: 0.15-0.25mm
Remarks: Check three average points on circumference of driven
bevel gear at least.

20. Check the engaging mark of drive and driven
bevel gear.
(Refer to “Assembly of Front Reducer Assembly”)
21. Measure the pre-applied load of drive bevel gear
bearing.
Use the torque measuring meter to measure the preapplied
load on the gap between the drive and drivenbevel gear.
Range of pre-applied load: 1.2-1.7N.m
22. Measure the total pre-applied load of drive bevel
gear.
23 Remove the drive gear flange and dustproof cover
assembly.
a. Use the hand hammer and chisel to loose the riveted part of
drive gear nut.
b. Use the special tools to clamp the drive gear flange and
remove the drive gear nut.
c. Use the brass rod to knock down the drive gear flange and
dustproof cover assembly.

25. Use the special tools to remove the small
bearing inner race, and then reverse the reducer
to slide out the spacer.
Remarks: The bearing should be replaced by new
one if damaged.
26. Use the wrench to remove two bearing glands.
Remarks: It should distinguish the left and right of
the bearing gland when remove it to avoid the
confusion.
Remove the side bearing outer race and marked
with L and R.
29. Remove the left and right adjusting washer; mea-
sure its thickness; marked with left and right. 27. Use the brass rod to vibrate the differential
assembly upwardly, then take out the differential
assembly.
holding
pliers
special tools
rotate the wrench in clockwise
24. Use the special tools to remove the drive gear oil
seal.

30. Remove the drive bevel gear, then take out the
adjusting washer under spacer.
Check and replacement of reducer
1. Replace the big bearing of drive bevel gear .
a. Use the special tools to press out the big bearing of drive
bevel gear.
Caution: It should replace the drive and driven bevel gear in
pair before replace the big bearing if the drive bevel gear is
damaged.
special
special
specialb. Install the washer on the drive bevel gear, Use the special
tools to install the new big bearing .
2. Replace the big bearing outer race of drive bevel
gear.
a. Use the brass bar and hand hammer to knock down the big
bearing outer race.
b. Use the special tools to press in the new big bearingouter race.
Special tools

3. Replace the small bearing of drive bevel gear.
a. Use the brass rod and hand hammer to knock down the small
bearing outer race of drive bevel gear.
b. Use the special tools to press in the new bearing outer race.
c. Replace it by the new bearing inner race when installs the
small bearing..
4Remove two side bearing inner races from the
differential housing.
a Use the special tools to remove the side bearing inner race on
the side of differential assembly with bolt.
b. It should pay attention to does not damage the driven bevel
gear when use the vice for clamping to remove the bearing
inner race on another side.
5. Use the wrench to remove the bolt fastened the
driven bevel gear
Caution: It should make the assembly mark on the
driven bevel gear and differential housing before
disassembly.
6
Disassembly of differential assembly
a. Use the hand hammer and special tools to knock out the pin
after remove the driven bevel gear.
special tools
rubber pad
assembly mark
rubber pad
special tools

b. Knock out the planetary gear shaft, rotate the half axle gear to
take out the planetary gear, then take out the half axle gear
and thrust plate.
7. Assembly of differential assembly.
a. Wash the differential housing.
b. Cover the half axle gear thrust plate with the half axle gear,
then installs it in the differential housing.
c. Rotate the half axle gear; install the planetary gear in rolling
and insert the planetary gear shaft.
d. Use the special tools to hit the pin to fix the planetary gear
shaft, and rivet the inserted hole to prevent the loose of pin.
Remarks: The rotation of half axle gear and planetary gear
should be smooth and without block; push the planetary gear
to inside, then use the dial indicator to measure the clearance
between the half axle gear thrust plate and differential
housing.
Rational clearance range: 0.4-0.75mm
It is necessary to replace the half axle gear thrust plate if the
clearance is beyond the previous range, at the same time ensure the
thrust plate in left and right side has the same thickness.
e. Check the clearance between the half axle gear thrust plate and
differential housing.
special tools

f. Clean the surface of differential housing; use the brass rod to
install the driven bevel gear on the differential housing.
Caution: It should align the marked assembly mark when
install the driven bevel gear and knock it in uniformly in
circumference ; it should remove the cooper chip in time if it
is adhered on the driven bevel gear.
g. Coat the fastening bolt of driven bevel gear with the screw
lock agent, then tighten it to the specified torque.
Specified tightening force: 80-95N
m
Caution: It should be in the diagonal sequence to tighten the
bolt and tighten it for little, then tighten it to the specified
torque uniformly.
h. On press machine, use the special tools to press the inner
race of bearing into the bearing position on both sides of
differential housing.
i. Place an adjusting shim in the position of front reducer
housing side bearing near exterior.
j. Install another adjusting shim and the other side bearing outer
race in the front reducer housing with thedifferentialassembly
k. Install two bearing glands, left and right and use the wrench
to tighten the bolt to the specified torque.
Specified torque : 90-115N.m
special tools
special tools
bearingbearing
adjusting shimadjusting
shim

1.Rotate the driven bevel gear, check the runout of
driven bevel gear.
Max. Runout: 0.07mm
Assembly of front reducer assembly
1.Install the adjusting washer in the drive bevel gear,
install the big bearing inner race of drive bevel gear
by press.
2. Clean the front reducer housing, install the outer
race of big and small bearing on the reducer housing
by press..
3. Install the drive bevel gear into the front reducer
housing, then install the washer, spacer and small
bearing inner race.
4.Use the special tools to install the drive bevel gear
oil seal.
Caution: It should coat the lip with the oil seal
lithium base grease before install it and the rear
surface of rear oil seal should flush with the top of
front reducer housing after knocked in.
5. Install the drive gear flange and dustproof cover
assembly.
(Refer to “Replacement of Drive Bevel Gear Oil Seal”)
6.Use the special tools to tighten the drive gear nut
to the specified torque; the nut should be precoated
with the lithium base grease.
specified torque : 140-200N
m
7. Use the torque measuring meter to measure the
pre-applied load of big and small bearing of drive
bevel gear.
Range of pre-applied load: 1.2-1.7N
m
special tools

8. Place the differential assembly on the corresponding
position of front reducer housing.
9.Select an adjusting shim and insert it in a side of
side bearing outer race; push the differential assem-
bly to the side with adjusting shim.
10. Use the dial indicator to measure the gear side
clearance of driven bevel gear and drive bevel gear;
select out the adjusting shim in the side which meets
the rational clearance of 0.15mm.
11.Measure the thickness of the adjusting shim.
12. After select out one side adjusting shim, then
select theadjusting of another side according to that
the theoreticthickness of the adjusting shimofanother
side equals to subtracting the thickness of selected
shim and oppositiondistance L2 between outer race of
two side bearings of differential assembly from the
opposition distance L1 between two side bearings of
front reducer housing.

13. Place an adjusting shim in the position of front
reducer housing side bearing and close to exterior.
14. Install the other adjusting shim and the bearing
outer race of another side with the differential
assembly into the front reducer housing.
Remarks: Ensure the selected adjusting shim has
not gap with front reducer housing.
15. Rotate the driven bevel gear to make the differ-
ential assembly closed to the front reducer housing.
16. Use the dial indicator to measure the tooth side
gap between the drive and driven bevel gear.
The rational range of gap is: 0.15-0.25mm.
If the measured gap is beyond the range, then adjust it by
adding or reducing the thickness of shim. ( When add in
one side, the other side should be reduced with same
thickness)
Caution: Ensure the selected adjusting shim is
without clearance form front reducer housing.
17. Adjust the pre-applled axial load of side bearing.
a. Remove two adjusting shim, remeasure the thickness of two
adjusting shims.
b. Install the new adjusting shim with thickness 0.06-0.09mm
more than that of removed adjusting shim, then install it with
the differential in the reducer housing.
c. Remeasure the tooth side clearance between the drive bevel
gear and driven bevel gear.
Rational range of clearance: 0.15-0.25mm
Remarks: If the measured gap is beyond the range, then adjust
it by adding or reducing the thickness of shim. ( When add in
one side, the other side should be reduced with same
thickness)
Caution: Ensure the selected adjusting shim has not the
clearance with the front reducer housing.
18. Install the bearing gland of both sides and use
the wrench to tighten it to the specified torque.
specified torque : 90-115Nm
Remarks: Distinguish the left and right during assembly.