torque GREAT WALL HOVER 2006 Service Manual PDF

transmission
drive shaft assemblyrear axle assembly
front axle drive shaft assembly
transmissionrear axle drive
shaft assembly
transfer case
rear axle assembly
Disassembly of drive shaft:
Remove the intermediate support bolt of drive shaft firstly (CC6460KY
is without intermediate support connecting bolt ), then remove the
connecting bolt between the drive shaft and rear axle , lastly, pull out
the drive shaft assembly from the transmission output spline shaft and
remove it in integral.
Installation of drive shaft:
1. Firstly, check the drive shaft for damage, spline for corrosion
and connecting surface for deficiency of damage or sand hole by
itself.
2
Install the connecting spline bushing of drive shaft on the
transmission output spline shaft carefully; then install the drive
shaft intermediate support on the intermediate support bracket
of carriage.
3. Use the special drive shaft bolt, nut and spring shim to connect
the drive shaft to the vehicle axle ring flange and tighten it. The
tightening torque is 78
5Nm
4. Tighten the drive shaft intermediate support nut, the tightening
torque is 63
5Nm (the front and rear drive shaft in
CC6460KY model are the integral and has the installation
content)

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 hub and steering knuckle (2WD)
stabilizer bar
connecting rod
of stabilizer bar
flat shim
disk shim
fill block
shim
fill block
disk shim
absorber
bearing
hub cap
brake cover
spring shim
split pin
lower suspension arm
split pin
upper suspension arm
spring shimbrake caliper assembly
steering knuckle
tight nut
lock washer
screw
oil seal
bearing
hub and brake disc flat shim
N
m: specified torque
Used component which can not be used any more
precoated component

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.
4. Install the hub on the steering knuckle
a. Install the hub on the steering knuckle.
b. Install the external bearing.
diagram of spe-
cial tools
special tools
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
diagram of spe-
cial tools
special tools

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 hub cap
a. Coat the silicon rubber surface sealant on the matching surface of
hub and hub cap.
b. Coat the screw of the inner hexagon bolt with the screw lock sealant.
c. 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: 45
5Nm
9. Install the disc brake
Install the disc brake on the steering knuckle and tighten the bolt to the
specified torque.
Tightening force: 140
10Nm

Check and replacement of steering knuckle
Use the dye penetrant to check the steering knuckle for
crack.It should replace the steering knuckle if has crack.
Installation of steering knuckle
1. Install the steering knuckle
a. Install the lower ball pin on the steering knuckle and install the
slotted nut temporarily.
b. Press down the upper arm and connect the upper ball pin to the
steering knuckle. Install and tighten the nut to the specified torque.
Tightening force: 145
15Nm
c. 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.
Tightening force: 23020Nm
e. 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.
Tightening force: 635Nm

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)

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).