steering GREAT WALL HOVER 2006 Service Owner's Manual

Installation of ball pin
1. Install the upper ball pin on the upper arm
Tightening force: 785Nm
2. Install the lower ball pin on the lower arm
Tightening force: 14010Nm
3. Install the steering knuckle and front hub assembly
(Refer to section Front Hub and Steering Knuckle)
Disassembly of ball pin
(Refer to section “Front Hub and Steering Knuckle”)
2. Remove the lower ball pin form the lower arm
3. Remove the upper ball pin from the upper arm.

4. Installation of longbushoflowersuspensionarmUse
the special tools to install the new bush.
Remarks: Do not coat the bush with the grease.
Installation of lower suspension arm
1. Installation of lower suspension arm
a. Install the rear shaft of lower arm and tighten the nut to the
specified torque.
Tightening force: 290
25Nm
b. Install the front shaft of lower arm and screw on the nut
temporarily.
2. Installation of front hub and steering knuckle
assem bly
(Refer to section “Front Hub and Steering Knuckle”)
3. Install the vibration damper on the lower suspension
arm.
Install the vibration damper on the lowersuspensionarmbracket.
Tightening force: 90
10Nm
4. Connect the stabi lizerbar to the lower suspension
arm
Tightening force: 635Nm
special tools

special toolsUpper suspension arm
Disassembly of upper suspension arm
1. Disconnect the upper ball pin from the steering
knuckle
Remove the split pin and nut; use the special tools to disconnect
the upper ball pin from the steering knuckle.
2. Remove the brake oil pipe on the upper arm shaft
a. Use the open-end wrench to screw off the oil pipe tight nut.
b. Pull out the brake oil pipe and plug it by the rubber plug.
Remarks: There are two two-way valves for rear brake oil pipe
beside the right upper arm shaft ; when remove the right
upper suspension arm, it must remove four oil pipe tight nuts
in the place and plug it by the rubber plug to prevent the brake
fluid from overflowing.
3. Disconnect the brake hose form the brake caliper
Remove the hollow bolt and disconnect the brake hose form the
brake caliper
Remarks: Must not lose the copper gasket seal.
4. Disconnect the brake hose from the upper arm oil
pipe bracket.
Use the pliers to pull out the sheet steel spring clip and discon-
nect the brake hose from the upper arm oil pipe bracket.
5. Remove the upper suspension arm
Remove two bolts and remove the upper suspension from the
arm carriage.
Remarks: Keep the adjusting shim and don’t lose it. Record
the thickness of front and rear adjusting shim for convenience
of reinstalling them in the original position.

b. Tighten the upper arm shaft nut to specified torque.
Tightening force: 210
10Nm
Installation of upper suspension arm
1. Install the upper suspension arm on the carriage
a. Install the upper suspension arm and camber adjusting shim.
b. Tighten all bolts to the specified torque.
Tightening force: 200
10Nm
Remarks: Install the shim with same quantity and thickness to
the original position.
2. Connect the brake oil pipe of upper arm shaft
Tighten the oil pipe compression nut to specified torque.
Tightening force: 15-17N
m
Remarks: It should tighten four connector of two two-way
valves to the specified torque if disassemble the right upper
arm.
3. Connect thebrakehosetotheupperarmoilpipebracket
a. Thread the brake hose from the hole on upper arm oil pipe
bracket.
b. Use the hand hammer to knock in the sheet steel spring clip to
fix the brake hose.
4. Connect the upper ball pin to the steering knuckle
a. Tighten the slotted nut according to the specified torque.
Tightening force: 145
15Nm
b. Install the new split pin.
Remarks: It should align the notch of nut with the pinhole
when install the split pin; the nut can be tightened but not
loosed during the alignment.

N m: specified torque
Used component which can not be used any more.
precoated component
Front hub and steering knuckle (4WD)
stabilizer bar
flat shim
connecting rod
of stabilizer bar
hub and brake disc
flange
adjusting washer
circlip
hub cap
spring shimdisc brake
split pin
lower suspen-
sion arm
split pin
upper suspension arm
drive shaft
oil seal
needle
bearing
lock washer
steering knuckle
lock nut
lock washer
screw
brake cover
spring shim
flat shim
disk shimShim
fill blockfill block disk shim
oil seal
bearingbearing shock absorber

2. Place in the bearing inner race; use the fill the gap
between the inner and outer race of the bearing up
with the HP-R grease.grease
grease
3. Install the inner bearing and oil seal
a. Place the inner bearing in the hub
b. Use the special tools to knock the new oil seal into the hub.
c. Coat the oil seal lip with HP-R grease.diagram of
special tools
special tools
4. Install the hub on the steering knuckle
a. Install the hub on the steering knuckle
b. Install the outer bearing.
5. Adjust the pre-applied load
a. Use the special tools to screw on the locknut to specified
torque.
Tightening force: 80-100N
m
b. Rotate the hub to right and left 1/3
1/4 round respectively.
c. Screw off the nut until the nut can be loosed by hand.
d. Use the special tools to retighten the lock nut.
Tightening force: 28N
m
e. Use the spring tension meter to check the pre-applied load.
Pre-applied load (for starting): 28-56N
special
tools
diagram of
special tools

6. Install the lock washer
Install the lock washer with the surface with counterbore outwardly
and fix it on the lock nut by screw.
Remarks: If the screw installation hole on the lock washer can not
align with the screw hole on the lock nut, then it can remove the
lock washer and adjust he lock nut slightly (rotate in the direction
of Min. adjusting range ); then install the lock washer.
7. Recheck the pre-applied load
Use the spring tension meter to recheck the pre-applied load
Pre-applied load (for starting): 28-56N
If the pre-applied load does not meet the specified value, it must
remove the lock washer and adjust it by the adjusting nut.
8. Install the ring flange
a. Install the ring flange on the hub.
b. Install the adjusting washer.
c. Install the circlip.
9. Install the hub cap
a. Coat the screw of the inner hexagon bolt with the screw lock
sealant.
b. Use the inner hexagon bolt to fix the hub cap and ring flange on
the hub; tighten the bolt to the specified torque.
Tightening force: 78
5Nm
10. Install the disc brake
Install the disc brake on the steering knuckle; tighten the bolt to the
specified torque.
Tightening force: 140
10Nm

special
tools
special
tools
special
tools
Steering knuckle
Disassembly of steering knuckle
1. Remove the disc brake and front hub
(Refer to section “Front Hub”)
2. Remove the brake cover
3. Disconnect the steering cross rod from the steer-
ing knuckle arm
a. Remove the split pin and nut on the ball pin.
b. Use the special tools to disconnect the steering cross rod
from the steering knuckle arm.
4. Disconnect the connecting rod of stabilizer bar
from lower arm
Use the inner hexagon spanner to fix the ball pin; remove the
self-locking nut.
5. Remove the steering knuckle
a. Remove the split pin and nut on the upper ball pin
b. Use the special tools to disconnect the upper ball pin from
the steering knuckle.
c. Remove the split pin and nut on the lower ball pin.
d. Use the special tools to disconnect the upper ball pin from
the steering knuckle.

e. Use the jack to raise the lower arm; remove the steering knuckle.
Check and replacement of steering knuckle
1. Check of steering knuckle
Use the dye penetrant to check the steering knuckle for crack.
It should replace the steering knuckle if has crack.
2. Remove the steering knuckle oil seal
Use the screwdriver to pry out the oil seal from the steering knuckle.
3. Take out the thrust plate
4. Remove the needle bearing
Use the copper bar and hand hammer to knock out the needle
bearing.

5. Installation of needle bearing
Use the special tools and hand hammer to knock in the new
needle bearing slightly.
Remarks: The thicker end of needle bearing should be
upwardly when knock in. with thicker end.
chamfer
steering
knuckle
6. Installation of thrust plate
Coat the installation position of thrust plate of steering knuckle
with the HP-R grease; place the thrust plate with the surface
with chamfer facing the steering knuckle.
Remarks: It must measure the thickness of the thrust plate
before the installation; it should install the new thrust plate if
the thickness is less than 1.5mm. The nominal thickness of
the new thrust plate is 2mm.
7. Installation of steering knuckle oil seal
Use the special tools and hand hammer to knock in the new
steering knuckle oil seal slightly.
Installation of steering knuckle
1. Install the steering knuckle
a. Coat the drive shaft and inner of drive shaft dustproof cove
with the lithium base grease.
b. Insert the drive shaft into the steering knuckle, meanwhile
connect the lower ball pin to the steering knuckle and install the
slotted nut temporarily.
special
tools
special
tools