lock GREAT WALL HOVER 2006 Service Owner's Manual

e. Remove the gear 3/4 declutch shift shaft assembly
f. Remove the reverse gear 5 shift fork
18. Remove the lock nut of intermediate shaft
Caution: When install the lock nut of intermediate shaft , the
tightening torque is 160-190N·m
19.Remove the Gear 1/2 declutch shift shaft assembly, intermediate
shaft rear ball bearing, 5th-Gear drive gear
20. Remove the Gear 1/2 shift fork

21.Use the special tools to remove the second shaft lock nut
Caution: When install the second shaft lock nut, the tightening
torque is : 250-270N·m
22.Remove the thrust plate
23.Use the magnetic rod to remove the steel ball.
24.Remove the 5th-Gear driven gear assembly
Caution: When install the 5th-Gear driven gear assembly, it should
use the plug gage to test the 5th-Gear driven gear assembly axial
clearance, ensure the axial clearance is within 0.170-0.284mm
25.Remove the 5th-Gear driven gear needle bearing

27. Use the pliers to remove the split pin on the reverse shaft lock
nut.
28. Use the special tools to remove the reverse lock nut
Caution: when install the reverse lock nut, the tightening torque
i s within 20-60N·m
29. Remove the thrust plate
30. Remove the 5th/reverse -Gear synchronizer assembly
a. Use the special tools to remove the 5th/reverse -Gear synchronizer
assembly 26. Remove the synchronizer gear ring
Caution: When install the synchronizer gear, it should use the
plug gage to test the synchronizer gear ring axial clearance, en-
sure the axial clearance is within 1.25-1.65mm

35. Remove the reverse drive gear
36. Remove the intermediate shaft spacing ring
37. Remove 8 countersunk screws
Caution: when install the countersunk screw, the tightening torque
is within 15-22N·m
38. Remove the support axial lock plate
39. Remove the air duct grease baffle

Disassembly of clutch housing assembly /bearing
housing assembly
40. Use the special tools to remove the reverse shaft
Use the magnetic rod to take out 2 interlocking pins
Remove the first bearing block assembly
a. Use the special tools to install 6 M8 bolts.
Caution: When install 6 M8 bolts, the tightening torque is 10-
13N·m
Clutch housing assembly / Bearing housing assembly
bush
oil seal
Used component which can not be used any more.
throwout bearing
assembly washer 8
¦ non-standard spring
first bearing
first shaft assembly
needle bearingsecond shaft assembly
¦circles for shaft
¦adjusting shim
leather cup
separation rocker arm assembly separation rocker arm ball supportclutch cylinder assembly
front space ring of intermediate shaft
intermediate shaft assembly aluminum waher
Specified torque

b. Remove the first bearing blocks assembly ; take out the adjusting
shim
Caution: It should select the adjusting shim when install the
adjusting shim
43. Remove the bearing snap ring
44
Remove the intermediate shaft assembly
45. Remove the first shaft assembly
46. Remove the needle bearing
Mark

Transmission-27
Manipulator cover assembly
Rear housing assembly
nut
reverse lock
assembly
manipulator
cover assembly
ball head
rubber cover
auxiliary steering
column stop platebush
ball head basewasher
pin
auxiliary steering
column assembly
handle of transfer case
ball head
hood
ball head
rubber cover
stop plate of
main bar
bush
ball head base
pin
washer
master control lever assembly
handle of
gearlever
N m: specified torque
Used component which can not be used any more.
odometer driven gear
assembly
odometer seating lock plate
14-19
14-19
oil seal
dustproof seal
guide bushing
rear housing
adjusting shim
24-33
26-36
aluminum gasket
mushroom lock spring
aluminum gasket
24-33
mushroom lock spring
26-3630-42
N m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special tools
steel ball 7.938 (3)

Disassembly of rear housing assembly
1.Remove the M8
18 hexagon bolt and the lock plate
Caution: When install the M8
18 hexagon bolt, the tightening
torque is 14-19N
m
2.Remove the odometer driven gear assembly
Use the special tools to remove the odometer driven gear assembly
3.Remove the rear cover assembly
Caution: When install 6 M10
1.2530 hexagon bolts, the tightening
torque is 14-19N
m
b.Use the plastic hammer to knock the rear cover slightly and take out
the rear cover
c.Take out the adjusting shim
Caution: It should select the adjusting shim as follows when
install it.
mark

Transmission-29
Transfer case assembly (one)
Transfer case assembly
transfer case
housing assembly
rear output
shaft assembly
transfer case cover
26-36
30-35
aluminum gasket 18
30-35
waved springhigh speed gear chain
front output shaft assembly
15-20
side cover plate
bush
thrust washer
needle bearing
needle bearing
spacing ring
O-RING
rear intermediate shaft
high/low gear
duplicate gear
thrust washerlock plate
14-19
high/low gear
declutch shift shaft high/low gear shift fork assembly
2nd/4th drive
declutch shift shaft
pin 526
2nd/4th drive
shifting blockinterlocking
cylinder pin
spacing ring2nd/4th drive
shift fork
cylindrical compression spring
spring base
split retainer
aluminum
gasket 18
N
m: specified torque
Used component which can not be used any more.
Pregummed component
transfer case housing assembly
N
m: specified torque
Used component which can not be used any more.

dustproof seal
guide bushingoil seal
transfer case housingball bearingfront output shaft
ball bearing
bowel patch
circlips for hole
rear input shaft
auxiliary gear
disk spring
circlips for shaft
spacing ring
duplicate ball bearing
circlips for
shaft oil seal
back plate
Transfer case assembly (three)
Disassembly of transfer case assembly
4.Remove the shouldered lock screw plug
Use the wrench to remove the shouldered lock screw plug M16
1.512
Caution: The tightening torque is 26-36N
m when install the
shouldered lock screw plug M16
1.512.
5.Remove the upper and lower drive switch M12
1.25
Caution: When install the upper and lower drive switch M12
1.
25, the tightening torque is within 26-36N
m
6.Remove the 2nd/4th drive switch M14
1.25
Caution: When install the 2nd/4th drive switch M14
1.25, the
tightening torque is with in 26-36N
m
N m: specified torque
Used component which can not be used any more.