brake GREAT WALL HOVER 2006 Service Workshop Manual

Steering knuckle
Disassembly of steering knuckle
1. Remove the disc brake and front hub
(Refer to section “Front Hub”)
2. Remove the brake cover
special tools
special tools
special tools
3. Disconnect the steering cross rod from the steering
knuckle arm
a. Remove the split pin and nut on the ball pin.
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 steering knuckle from the
upper ball pin.
c. Remove the split pin and nut on the lower ball pin.
d. Use the special tools to disconnect the steering knuckle from
the upper ball pin.
e. Remove the steering knuckle.

3. Connect the steering cross rod to the steering
knuckle arm.
a. Tighten the slotted nut according to the specified torque.
Tightening force: 170
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
loosedduring the alignment.
Tightening force: 233Nm
5. Install the front hub and disc brake
(see section of front hub)

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.

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.

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)

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

special tools
diagram of
special tools
Front hub
Disassembly of front hub
1. Remove the disc brake
Remove the brake caliper and hang it by steel cable.
Remarks: Do not remove the brake pipe and brake hose.
2. Remove the hub cap and flange
a. Use the inner hexagon spanner to screw off the fastening blot
and remove the hub cap.
b. Use the pliers to remove the circlip and remove the adjusting
washer.
c. Remove the flange.
3. Remove the hub and brake disc
a. Use the Philips screwdriver to screw off the tight screw;
remove the lock washer.
b. Use the special tools to remove the lock nut.
c. Remove the hub and brake disc with the outer bearing.

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.