GREAT WALL PEGASUS 2006 Service Manual

SA-60
13. Mount the front speed reducer assembly on the frame.
14. Connect the drive shaft to the flange:
(a) Align the assembly mark and then connect the drive
shaft and the front drive axle flange with four sets of
bolt and nut.
(b) Screw up the nuts according to the specified torque.
Specified torque
(69-79)N
m
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Change of Driving Bevel Gear Oil Seal of Front Speed Reducer)

SA-61
Dismantle of Front Speed Reducer
constant speed drive shaft
front drive axle shaft
sleeve assembly
front drive axle hanger
front speed reducer and
differential assembly
front speed reducer shell hanger

rubber jacket and
shaft tube
constant speed
drive shaft

Parts that cannot be reused after being used
N
M
cpecified torque
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (DisassEmbly of Front Speed Reducer)

SA-62
1. Disconnect the front speed reducer flange and the drive
shaft.
2. Screw off the nuts that connect the constant speed drive
shaft.
3. Screw off the bolts connecting the rubber jacket and
shaft tube of the front speed reducer cover and the
frame.
4. Screw off the bolts connecting the front drive axle hanger
assembly and the front speed reducer shell hanger, and
tear down the front speed reducer.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (DisassEmbly of Front Speed Reducer)

SA-63
1. Tear down the front long semi-axis and the front minor
half-shaft
Pull out the front long and minor semi-axis from the front
speed reducer with tool.
2. Tear down the front drive axle shaft sleeve and screw off
the bolts connecting the half-shaft sleeve.
3. Tear down the oil seal - front half-shaft:
Tear down the oil seal-front half-shaft with the special service
tool.
Change of Axle Shaft Oil Seal

snapping ring
front minor half-shaft
front speed reducer and differential

oil seal-front half-shaft
front long
semi-axis

snapping ring
88
N
M
specified torque

Parts that cannot be reused after being used)
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Change of Axle Shaft Oil Seal)

SA-64
5. Mount on the upper front drive axle shaft sleeve,
Coat the bolt thread with thread locking agent.
Fastening torque
88N
m 4. Mount on the new oil seal-front half-shaft:
Press in the new oil seal with the special service tool until it
flush with the outer ending of the oil seal, coat moderate
lubricant on the lips of the oil seal.
6. Mount on the front long semi-axis and the front minor
half-shaft.
(a) Mount the new snapping ring on the half-shaft.
(b) Mount on the long semi-axis and the minor half-shaft
with the special service tool.
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Change of Axle Shaft Oil Seal)

SA-65
Disassembly and Assembly of Front Speed Reducer
Element figure
front minor half-shaft

snapping ringbearing 31306 front speed
reducer shell
oil-guard trayflange and dust cover
driving bevel gear oil seal
jacketoil seal-front half-shaft

Parts that cannot be reused after being used

s pecified torqueN
M
140-210 bearing 32307
driving bevel gear oil seal
speed reducer coveradjusting washer
bearing 50KB801
47
cap-differential
bearing
78

lock plate adjusting washer
half axle gear thrust
gasket
planetary gear shaft
half-axle gearplanetary gear stop gasket
planetary gearaxle driven bevel gear front differential housing
adjusting gasket
pin
70-90 retainer ring
front long semi-axisbearing B36Z-10







oil seal-front half-shaft
adjusting washer
snapping ring
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-66
Disassembly of Front Speed Reducer
1. Tear down the speed reducer cover:
Screw off the eight bolts connecting the speed reducer cover.
2. Tear down the front long semi-axis and the front minor
half-shaft:
Tear down the front long semi-axis and the front minor half-
shaft from the speed reducer assembly with the special service
tool.
3. Tear down the front drive axle shaft sleeve
Screw off the four bolts connecting the front drive axle shaft
sleeve.
4. Tear down the oil seal ó front half-shaft;
Tear down the oil seal ófront half shaft with the special service
tool.
5. Check the swing difference of the axle driven bevel gear;
Run the flange to measure the axle driven bevel gear with the
dial-indicating lamp.
Swing difference)
0.07mm
Max swing difference: 0.07 mm
In case the swing difference is more than 0.07 mm, change the
compete package of driven bevel gear.
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-67
6. Check the teeth-clearance of the driving bevel gear and
the axle driven bevel gear:
(a) Install the dial-indicating lamp and ensure the axial line
of measuring head is vertical with the contact teeth face.
(b) Run the flanges, and record the clearance values of
driving bevel gear and the axle driven bevel gear.
Specified clearance range
(0.15-0.25)mm
Remark: the inspection should be conducted at no less than
three equally divided spots on the circumference of the axle
driven bevel gear.
7. Check the engagement trace of the axle driven bevel
gear.
(See page SA-76)
8. Tear down the flange and dust cover:
(a) Loosen the riveted position of main-tooth nut with the
hammer and chisel.
(b) Lock the main-tooth flange with SST to tear down the
main-tooth nut.
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)
(c) Tap down the driving bevel gear flange and dust cover
with copper bar.

SA-68
10. Tear down the inner race of bearing 31306 with SST;
If the bearing is damaged, change with a new bearing.
11. Tear down the cap-differential bearing.
12. Take out the differential.
13. Take down the outer race of bearing 50KB801 and mark
clearly the left and right parts to avoid of confusion during
reassembling. 9. Tear down the driving bevel gear oil seal and the oil-
guard tray:
(a) Tear down the oil seal from the driving bevel gear with
SST.
(b) Take out the oil-guard tray.
right
left
left
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)
14. Tear down the adjusting gaskets and clearly mark the left
and right to avoid of confusion during re-assembling.
right

SA-69
15. Tear down the driving bevel gear.
Inspection on and Change of Front Speed
Reducer
1. Change the bearing 32307 on driving bevel gear
(a) Press out the inner race and roller assembly of bearing
32307 with the special service tool.
(b) Press in the new inner race and roller assembly of bearing
32307 with SST.
2. Change the outer race of bearing 32307:
(a) Tap down the outer race of bearing 32307 with the copper
bar and hammer.
(b) Press in the new outer race of bearing 32307 with the
SST.
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)
.