wheel GREAT WALL HOVER 2006 Service Owner's Manual

f. Make the installation of oil bottom shell is proper for transfer case and the tighten the safety valve according to the
specification and sequence (Refer to Figure 8.61). do not distort it.
16.Torque converter and support sleeve assembly
Install the hydraulic torque converter and housing assembly, the procedure is shown as follows:
a. Install the hydraulic torque converter housing on the main case.
Caution:
All hardware should be installed correctly and comply with the specification.
b. Use the Loctite243 or equivalent to fix the torque converter housing; install and tighten it to standard specification.
c. Install the torque converter; ensure the pump gear sealing is installed correctly.
17. Rear wheel drive mode of output ring flange assembly
Assemble the output shaft assembly, the procedure is shown as follows:
a. Place the paw of transmission operating rod on the parking position and lock the output shaft.
b. Wash the output shaft upper line; use the loctite243 or equivalent.
c. Install and tighten the ring flange, O-ring and nut.
Caution: In the heavy steel slide plate, place the ring flange on the upper nut; avoid the damage of bearing.
d. Tighten the nut on the output shaft
Torque type specification N.m Ft/lb
tra n s m iss io n as se m b ly

torque converter housing to
housing M12×32 4, 8or 9 54-68 40-50
rear end housing to housing
-C h a irm a n M12×32 4 54-68 40-50
C onnector housing to housing
-4 W D M8×25 10 35-40 26-30
rear end housing to housing
-2 W D M8×25 10 35-40 26-30
rear servo cover to housing
M8×25 6 30-35 22-26
O il pan to housing
M6×16 9 4-6 3-4.5
O il cooler pipe connection
2 40-45 29.5-33
V alve to housing
M6×26 7 8-13 6-9.5
V alve to housing
M6×45 5 8-13 6-9.5
B rake bar spring
M8×16 1 20-22 15-16
central support to housing
M10×34 2 20-27 15-20
C am disc to housing
M8×16 2 16-22 12-16
G ear-position sensor to
housing 10-24×13 2 4-6 3-4.5
O utput shaft lock nut
M24×1.5 1 100-110 74-81.5
oil filling plug M 20 1 30-35 22-26
Pump housing assembly


Pump to pump cover
M8×55 5 24-27 18-20
Pum p cover to housing
M8×40 6 24-34 18-25
Pum p cover to housing
M8×58 2 24-34 18-25
Pum p cover disc to pum p
cover M6×16 5 13-16 9.5-12
Pum p cover disc to crescent
M6×54 1 13-16 9.5-12
Valve assem bly


U p p e r v a lv e to lo w e r v a lv e
M6×30 24or 25 11-16 8-12
Line socket M 6 1 4-7 3-5
solenoid valve (on/off type
and VPS, including S7) M6×16 7 8-12 6-9
Table 8.1 Torque specification

Troubleshooting
Failure Cause Repair cont ent
Floating/pulling The t yre is worn or charged improperly.

The front wheel alignment is incorrect.

The wheel bearing is adjusted too tightened.
The front /rear suspension components is loose or
damaged
The steering linkage is loose or worn
The steering device is connect ed unsound or worn. Charge the t yre to the prop er pressur e or
repla ce the t yre.
Check the condition of front wheel
alignment.
Adjust the wheel bearing
Tighten or replace the suspension
partTighten or replace the steering
linkage
Adjust or replace the steering device
Subsidence of vehicle body Overload of vehicle
vibration damper is worn
spring is weak Check the load weight
Replace the vibration damper
Replace the spring
Left-right swing/up-down
bounce The t yre is charged improperly
The stabilizer bar is bend or damaged
The vibration damper is worn Charge the t yre to the prop er pressur e
Replace the stabilizer bar
Replace the vibration damper
Front wheel vibration The t yre is worn or is charged improperly

Unbalance of each wheel
The vibration damper is worn
The front wheel alignment is incorrect

The wheel bearing is worn or adjusted badly
The ball joint or bushing is worn
The steering system is loose or worn
The steering mechanism is adjusted badly or damaged Repla ce the t yr e or char ge it to the prop er
pressure.
Balance all wheels
Replace the vibration damper
Check the condition of front wheel
alignment
Replace or adjust the wheel bearing
Check the ball joint or bushing
Tighten or replace the steering linkage
Adjust or repair the steering device
Abnormal abrasion of tyre The t yre is charged improperly
The vibration damper is worn
The front wheel alignment is badly

The suspension part is worn Charge the t yre to the prop er pressur e
Replace the vibration damper
Check the condition of front wheel
alignment
Replace the suspension part
Oil leakage of differential High oil level or incorrect oil grade

The oil seal is worn or damaged
The matching flange is loose or damaged Drain the oil to the specified level or
repla ce the oil
Replace the oil seal
Tighten or replace the flange
The axle has the nois e The oil grade is low or incorrect

The clearance of the pinion, ring gear or side gear is
large.
The ring, pinion gear or side gear is worn or broken
The pinion gear bearing is worn
The b earing of rear axle half shaft is worn.
The differential b earing is loos e or worn Fill with the lubrication oil or replace the
oil according to the specification
Check the clearance

Check each gear
Replace the bearing
Replace the bearing
Tighten or replace the bearing

Front wheel alignment
1. Process the following inspection and eliminate
all problems
a. Check the wear condition of tyre and proper inflation.
Tyre inflation pressure: 230kPa
b. Check the wheel bearing of front wheel for loose.
c. Check the front suspension for loose.
d. Check the steering drive device for loose.
e. Process the standard elastic test; check thefrontvibration damper
for normal operation.
3. Install the 4-Wheel alignment instrument
Processed according to the detailed description of equipment
manufacturer.
4. Adjust the wheel angle
Remove the cover of spacing bolt of steering knuckle; check the internal
wheel’s steering angle A.
Internal wheel’s steering angle:
32
Caution: The wheel should not touch the brake hose of car body
when the steering wheel is rotated to limit.
2. Adjust the height of car
A:Adjust the height of car to the standard value for theconvenience of
processing the front wheel alignmentinspection.
B: Front fixed bolt of lower suspension arm
The standard no-load height is: the center of front fixed boltof lower
suspension arm is 295
1mm away form theground.

6. Adjust the wheel toe
Adjust the wheel toe according to the following method
a. Shake the car upwardly and downwardly to make the suspension
reach the stable status.
b. Push the car forwardly for 5m in flat ground when the front
wheel is in the straight forward position.
c. Mark the center of each rear wheel; measure the distance “B”
between the marks of left and right tyre.
d. Push the car forwardly to move the mark on the back of tyre to
the position of front instrument.
Remarks: if the tyre moves too far, repeat the procedure (b).
e. Measure the distance “A” ‘between the marks on front of tyre.
f. Measure the toe of wheel.
toe =B-A
Inspection standard: 0-2mm
If the toe does not consist with the specified value, it can be
adjusted by the left and right draw-bar.
Move the vehicle forwardly
g. Adjustment of toe: the standard value is 02mm. The toe is
adjusted by rotating the cross draw-bar. When adjust the toe, it
should rotate the cross draw-bar on left and right side uniformly.
After the adjustment, tighten the lock nut, the tightening torque
is 55
65Nm.

Front suspension (2WD)
front stabilizer bar
rubber cover
clip
connecting rod of
stabilizer bar
flat shim
front shaft of
lower arm
split pin
adjusting bolt
lower adjusting block
fixed arm
upper adjusting block
lower arm
rear shaft of lower arm
torsion bar base
torsion bar
lower arm long bushsplit pin
upper ball pin
upper arm shaft
upper arm bush
flat shim
lower arm
short bush
eccentric shim
disk shim
fill block
fill block
disk shim shim
shock absorbershimshim
upper arm bush
upper arm shaft
lower ball arm
front wheel hub
and steering
knuckle assy
N m: specified torque
Used component which can not be used any more.
Pregummed component N m: specified torque

Ball pin
Inspection of ball pin
1. Check the lower ball pin for loose
a. Raise the front of the car by jack and support it by the frame.
b. Ensure the front wheel is in straight advancing position and
step down the brake pedal.
c. Move the arm upwardly and downwardly; check the
clearance of lower ball pin.
Max. vertical clearance: 0mm
2. Check the upper ball pin for loose;
move the wheel upwardly and downwardly and check the gap of
upper ball pin.
Max. vertical clearance: 0mm
3. Check the rotation of ball pin
a. Remove the ball pin.
b. Shown as figure, shake the ball pin stud forwardly and
backwardly for several times before install the nut.
c. Rotate the nut continuously by torsion meter and 2-4s for a
cycle; record the readout of torsion meter in the fifth cycle.
tightening torque (for rotary):
lower ball pin 0.1
4Nm
upper ball pin 0.1
4Nm
Disassembly of ball pin
1.Take down the steering knuckle and front wheel hub assy.

d. Tighten the adjusting bolt to make the extension length of the bolt
equal to the length before remove.
2. For new torsion bar spring
a. Remove the wheel.
b. Coat thin grease on the spline of the torsion bar spring.
c. Install the torsion bar spring on the torsion bar base.
d. Lower the lower arm to the lower limitation position; install the
adjusting arm in the torsion bar spring with the angle that the
adjusting bolt just can be screwed on the upper adjusting block.
e. Tighten the adjusting bolt to the specified torque.
Nut tightening limitation: A is about 30-35mm; if A>
35mm, then it is adjusted through height of adjusting arm.
f. Install the wheel; remove the bracket; bounce the vehicle for
several times to make the suspension enters into the stable
status.
g. Rotate the adjusting bolt and adjust the ground clearance of
chassis (Refer to 4-Wheel Alignment).

5. Install the torsion bar spring
(Refer to “Torsion Bar Spring”)
6. Tighten the nut of front shaft of lower arm to
specified torque
a. Install the wheel, remove the bracket and bounce the vehicle for
several times to make the vibration damper enters into the
stable status.
b. Align the assembly mark and tighten the nut to specified torque.
Tightening force: 240
20Nm
7. Check the wheel alignment parameter
(Refer to 4-Wheel Alignment)

Connect the copper gasket seal and tighten the hollowbolttospecified
torque.
Tightening force: 50
5Nm
6. Discharge the air in front brake system
(refer to relevant chapter)
Remarks: It must discharge the air in the rear brake system if
disassemble the right upper arm.
7. Check the brake fluid for leakage
8. Tighten the upper arm front shaft nut to the specified
torque
Install the wheel, remove the bracket and bounce the vehicle for
several times to make the vibration damper enters into the stable
status.
9. Check the wheel alignment parameter
(Refer to 4-Wheel Alignment)

Ball pin
Check of ball pin
1. Check the lower ball pin for loose
a. Raise the front of the car by jack and support it by the frame.
b. Ensure the front wheel is in straight advancing position and step
down the brake pedal.
c. Move the arm upwardly and downwardly; check
the clearance of lower ball pin.
Max. vertical clearance: 0mm
2. Check the upper ball pin for loose move the wheel
upwardly and downwardly and check the gap of
upper ball pin.
Max. vertical clearance: 0mm
3. Check the rotation of ball pin
a. Remove the ball pin.
b. Shown as figure, shake the ball pin stud forwardly and backwardly
for several times before install the nut
c. Rotate the nut continuously by torsion meter and 2-4s for a
cycle; record the readout of torsion meter in the fifth cycle.
Tightening torque (for rotary):
Lower ball pin 0.1
4Nm
Upper ball pin 0.1
4Nm
Disassembly of ball pin
1. Remove the steering knuckle and front hub assembly
(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