wheel GREAT WALL HOVER 2006 Service Service Manual

Disassembly of front reducer assembly
1. Remove the front drive axle and left and right
front drive shaft assembly.
(Refer to “Removal of Front Reducer Assembly”
and “Removal of Front Drive Shaft Assembly”)
2. Disconnect three interface positions of front drive
axle vent tube connector assembly.
3. Use the flat screwdriver to pry off the clip fixed
the vent tube connector assembly and take out
the vent tube connector assembly.
4. Screw off the bolt fixed the electric clutch and use
the brass bar to knock down the electric clutch.
5. Use the wrench to remove the oil filling plug;
remove the washer and pull out the vent tube.
6. Use the wrench to remove the bolt connected to
the electric clutch housing and front axle tubeflange;
take out the shift fork sleeve and mechanical wheel
of separator.
Caution: The leaked gear oil during disassembly
should be stored in the container to avoid the
pollution for environment.
disconnected in
this place
disconnected in this place
disconnected in this place

31.Use the special tools to install the needle bearing in
the major semiaxle.
32.Use the special tools to install the major semiaxle
bearing by press..
33. Use the circlip pliers to install the circlip to clamp
the bearing inner race of major semiaxle.
34.Insert the spline on small end of major semiaxle
into the spline of front reducer half axle gear; use
the brass rod and hand hammer to knock the major
semiaxle into the front reducer.
Caution: Does not damage the inside needle bearing.
On spline of large end of major semiaxle when
knock in the major semiaxle.
35.Use the circlip pliers to install the circlip in the
flange and clamp the major semiaxle bearing outer
race.
36. Push the mechanical wheel of separator into
theneedle bearing inner race in major semiaxle until
can not move.
special tools
special tools
special tools

Axle drving assembly
Removal of semiaxle
1. Remove the wheel.
2. Disconnect the manual brake pull-wire from the
carriage; loose the small bracket.
3. Remove the brake caliper; remove the brake disc .
4. Remove the rear halfaxle assembly from the rear
axle housing
a. Use the bolt to connect the special tools to the semiaxle flange
surface.
b. Use the hammer of special tools to remove the rear axle.
brake caliper assembly
brake disc
circlip
oil seal base
bearing
oil seal
oil seal pressing block
parking brake assembly
rear axle
N
m: Specified torque
Used component which can not be used any more.
pull-wire assembly
5. Remove the circlip from the halfaxle assembly.
Use the circlip pliers to remove the circlip.

8. Check the inner oil seal for wear or damage.
9. Remove the inner oil seal
Use the special tools to remove the inner oil seal.
10. Install the new inner oil seal
a. Coat the lip of oil seal with proper HP-R grease.
b. Use the special tools to knock in the new oil seal.
Installation of rear axle
1. Install the halfaxle assembly in the axle housing
a. Use the kerosene to clean the semiaxle and inner oil seal holder.
b. Assemble the halfaxle spline and halfaxle gear spline firstly,
then use the brass rod to beat knock the halfaxle assembly into
the axle housing.
Caution: Protect the lip of inner external oil seal and pull-wire
assembly during assembly; do not damage the oil sleeve
assembly; align the brake bolt with the flange bolt of rear axle.
Tightening force: 95-105N
m
2. Install the rear brake disc
3. Install the brake caliper
Tightening force: 95-105Nm
4. Connect the manual brake wire.
5. Install the wheel.
6. Discharge the air of brake system by test.
special tools
special tools
brake discaxle housing
flange
halfaxle
assembly

Brake-2
Troubleshooting
Cautions

Failure cause Inspection content



Pedal is low or soft brake pad is worn
brake block is worn
brake system is leaked
master pump has failure
Brake system has air
Brake pump has failure
Auto adjuster of rear brake has failure Replace the brake shoe
Replace the brake block
Repair the leakage
Repair or replace the master pump
Drain the air from brake system
Replace the brake pump
Repair or replace the adjuster




Lag of brake Parking brake is adjusted badly.
Pull wire of parking brake is locked
Assist push rod is adjust badly
Extension spring or return spring has fault
Pipeline is blocked
brake pad is broken or deformed
brake block is broken or deformed
Auto adjuster is damaged
Master pump has failure. Adjust the parking brake
Repair if necessary
Adjust the push rod
Repla ce the extension spring
Repair if necessary
Replace the brake shoe
Replace the brake block
Repla ce the a djuster
Repla ce the master pump





Brake is stagnant Improper inflation of tyre
There is grease spot or lubricant oil on the
brake shoe or brake block.
The brake shoe is deformed ; the brake pad
is worn or smoothed
The brake block is deformed, worn or
smoothed
The brake drum or brake disc is deformed
Extension spring or return spring has failure
Wheel pump has failure
Pump has failure
Brake block is blocked Charge the tyre to the proper pressure.
Find out the cause. Replace the brake shoe or block.
Replace the brake shoe
Replace the brake block
Replace the brake drum or brake disc
Repla ce the spring
Repair the wheel pump
Replace
Replace the brake block





brake pedal is hard There is the grease spot or lubrication oil on
the brake disc or brake block.
The brake shoe is deformed; the brake pad is
worn or s moothed
The brake block is deformed, worn or
smoothed
Brake pump has failure.
Brake assist has failure
Improper vacuum degree
The brake pipeline is blocked. Find out the caus e .
Replace the brake shoe or brake block
Replace the brake block
Replace
Replace the assist
Repair if necessary
Repair if necessary

Brake-3
Troubleshooting (continued)

failure caus e Inspection content


The brake generates the
crack clatter during
operation. (drum brake)
The brake shoe is blocked in the rear apron flange
The rear apron flange is worn
The brake shoe pull-out piece spring is loose or lost
The fixed bolt of rear apron is loose (disc brake )
Brake block support plate is loose or lost
Installation bolt is loose
Filled with lubricated oil
Replace the lubricant flange
Replace
tighten
replace
tighten



It has the rustle or rattler
when use the brake The brake shoe gasket or brake block is worn
The brake caliper and wheel or rotor are disturbed
mutually
The dustproof cover and rotor, rear apron and brake
drum are disturbed mutually
Failure of other brake system component
Tyre generates the abrasion with the tyre and chassis Replace, if the scratch is heavy,
then fine machine the brake drum or
rotor again
Replace it according to requirement
Correct or replace
Repair or replace it according to
requirement
Check or maintain
It has the squeak, continuous
scream, rattler or vibration
noise when use the brake .
Caution: The abrasion
material in the brake will
generate the inherent noise
and heat during the
abrasion, then emit the
heat. So it is normal that
generate the squeak by
accident. The condition
will be serious in extreme
environment, such as cold,
hot, high humidity,
snowing, saliferous and
mud. The accident squeak
will not cause the fatal
failure of the brake, and
will not reduce the effective
performance of the brake. The brake drum and brake shoe gasket, rotor and
brake block is worn or scratched.
The brake pad or block is dirty, with oil or smoothed.
The brake pedal or assistor push bar is adjusted
incorrectly
(dis c brake )
The brake block silencing plate is lost or damaged.
The abrasion of the brake block makes the brake
block abrasion indication plate contacts the rotor
The brake ca lip er has burr or is corrosive
(drum brake)
The pull-out piece spring of brake shoe is soft,
damaged or improper. The pull-out piece spring pin
and spring of brake shoe is loose or damaged; and
rear apron flange has crack Check, repair or replace
clean or replace
check, replace
check and adjust
replace
replace
clean or remove the flash
check, repair or replace

Brake-4
failure caus e Inspection content











It has the continuous
scream and squeak
when does not us e the
brake The brake pedal or assist push bar is adjusted
incorrectly
The return of brake assist or master pump or wheel
pump is bad
(dis c brake )
T he piston is corr osive or blocked
T he brake block in brake calip er is in improp er
position
Shell abrasion of rotor and brake caliper
The brake block support plate in disc brake is
installed improperly
The brake block abrasion indication plate contacts
the rotor for the abrasion of brake block
(drum brake)
The press spring of brake shoe is soft, damaged or
improper.
The flange of rear back rear apron is cracked
T he rear apron interfer e with the brake drum
mutually after bent or warp
Improper machining of brake drum , caus e the mutual
interference of rear apron and brake shoe
components of other brake s ystem :
Brake system has loose or redundant components
T he brake pad is smoothed for the rear brake drum is
adjusted too tight
The wheel bearing is worn damaged or under
lubricated Check and adjust

Check, repair or replace


Check and fill with lubrication oil if
necessary.
Repair or replacement
Repair or replacement
Repair or replacement

Repair


Repair

Repair or replacement
Repair or replacement

Replace the brake drum


Check, maintain and replace if
necessary.
It still has the rattler,
click or cackle noise
when does not us e the
brake. The stone or foreign enters into the inside of wheel
protecting hood
The hub nut is loose


The brake pedal or assistor push bar is adjusted
improperly
The wheel bearing is worn, damaged or lubricated
insufficiently
(dis c brake )
T he muffler spring is soft or lost; the brake block
support plate or external end of brake block is coiled
silencing plate is unsound
T he slide bush is worn
T he installation bolt is loos e
Piston returns unsoundly
(drum brake)
Have loose or redundant component Remove the foreign materials such as
the stone
Tighten it to the specified torque, it
should be replaced if the bolt hole is
enlarged
Check and adjust

Check, lubricate or replace


Repair or replacement


Check and replace if necessary
Check and replace if necessary
Check and tighten if necessary
Check , repair or replace
Check, take out or repair

Brake-7
Air discharge of brake system
Remarks:
It should discharge the air if operate on the brake system or as-
sume the brake system pipeline has the air.
Caution:
Must not keep the brake fluid on the paint surface, wipe off it if
has.
1. Fill the liquid reservoir up with the brake fluid.
Check the liquid level in liquid reservoir after discharge the air of each
wheel pump. Filled with the brake fluid if necessary.
2. Connect the polyethylene resin pipe to the overflow hole plug of
wheel pump;insert the other end of pipe into the container with
half of brake fluid.
Remarks:
When discharge the air of wheel brake pump, it should begin
from the longest pipeline.
3. Air discharge of brake system pipe
a. Step down the brake pedal slowly for several times.
b. Let the assistant presses down the pedal, at the same time screw
off the overflow hole plug until the brake fluid flows out. Then
switch off the overflow hole plug.
c. Repeat the procedure until the liquid is without air bubble.
Tightening torque of overflow hole plug: 11N
m
4. Process the same procedure for each wheel pump.
hexagon flange nut
brake bracket
welded assembly
support sleevereturn spring
bush
screw bar
pin shaft
pedal cover block
rocker arm
welded assembly
Brake pedal

Brake-9
Front brake
front brake oil pipe
cliper bracket
outer silencing plate combination
lower circlip of
brake block
brake block assembly
lower circlip of brake block
wear limitation alarm plate of brake block
lnner silencing plate combination
Inner brake block
silencing plate
upper circlip of brake block (I)upper circlip of brake block (II)
piston
dustproof cover
guide pin dustproof cover
guide pin rubber covercooper washer
tong
air-bleed
bolt cover
location pin
guide pin dustproof coversquare seal ring
N
m: Specified torque
Piston
Replacement of brake block
Remarks:
When brake during the travel process, if the front wheel has the
continuous screams noise, then it should check the wear limitation
alarm plate of brake block. If the alarm plate has the abrasion
mark with brake disc, then it should replace the brake block .
1. Remove the front wheel
2. Check the thickness of abrasion material of brake block.
Check the thickness of abrasion material of brake block by the watch
hole on the tong.
Replace it if is not within specified range.
Min. thickness : 2.0mm

Brake-11
8. Install the new brake block
a. Install a wear limitation alarm plate of brake block on the inner
brake block.
b. Install a silencing plate and a silencing plate combination on the
inner brake block.
c. Install a silencing plate combination on the on the outer brake
block.
d. Install two brake blocks; let the wear limitation alarm plate is in
the inside of brake caliper.
Caution: It is unallowable that the operating surface of brake
block andbrake disc is polluted by the grease and paint.
e. Suck a few of brake fluid form the liquid reservoir (prevent the
brake fluid from overflowing from liquid reservoir).
f. Use the special tools to press the piston .
9. Install the brake pump
Install and tighten the hexagon flange bolt.
Tightening force: 25
35Nm
Remarks: Only can replace the brake block on a wheel in one
time to avoid the piston on another wheel is pushed out.
10. Install the front wheel
Tightening force of the wheel fixing nut is 120N
m
11. Check whether the brake fluid level is in the specified position.