GREAT WALL PEGASUS 2006 Service Manual

SA-70
4. Tear down the inner race and roller assembly of the two
bearings 50KB801 from the differential housing.
Tear down the inner race and roller assembly of bearing
50KB801 with SST.
5. Tear down the axle driven bevel gear:
Tear down the bolts and lock plate by tapping lightly the axle
driven bevel gear with the copper until tear them down. 3. Change the outer race of bearing 31306:
(a) Tap down the outer race of bearing 31306 with copper bar
and hammer.
(b) Press in the new outer race of bearing 31306 with SST.
Remark: the inner race of the bearing should be changed with
the outer race together.
6. Differential disassembly
(a) Tap out the pin with SST.
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-71
(b) Tear down the planetary gear shaft to take out the planetary
gear, planetary gear stop gasket, half-axle gear and the
half axle gear thrust gasket
7. Differential assembly mount
(a) Clean the differential housing.
(b) Encase the half-axle thrust gasket in the differential
housing after covering on the half-shaft gear.
(c) Run the half-axle gear to encase the planetary gear and
planetary gear stop gasket, and put on the planetary gear
shaft.
Remark: The half-axle gear and the planetary gear should run
freely without stagnant.
(d) Measure the clearance between the half axle gear thrust
gasket and differential housing.
Push the planetary gear to the inside and then measure
the clearance between half-axle gear thrust gasket and
the differential housing with the dial-indicating lamp.
Suitable clearance range: (0.4-0.75)mm
Remark:If the clearance fails to fall within the above-
mentioned range, change the half-axle gear thrust gasket,
and ensure that the thrust gaskets on the both sides are
same thick.
(e) Tap the pin in the pinhole of differential housing and the
planetary gear shaft with SST, and rivet the hole port so
as to prevent the pin from missing.
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-72
(f) Clean the differential housing surface, mount the axle
driven bevel gear on the differential housing with copper
bar.
Notice: align the assembly marks made when
disassembling when mounting the axle driven bevel
gear, and tap in the driven bevel gear evenly alongside
the direction of circumference.
(g) Mount on the lock plate and screw on the bolts, then lock
the lock plate with the drift pinch and hammer.
Fastening torque
(70-90)N
m
Notice: the bolts should be screwed up in the diagonal
order in such manner that tighten a little at first, and then
screw up evenly to the specified torque, the lock plate
claw should contact closely the side face of bolt head.
(h) Press the inner race and roller assembly of bearing
50KB801 in the bearing position at the both sides of
differential housing.
(i) Put the adjusting gasket in the outer position of the side
bearing of front speed reducer shell.
(j) Encase another adjusting gasket with the outer race of
bearing 50KB801 in the front speed reducer shell to-
gether with the differential.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)
(k) Mount on the right and left cap-differential bearing, and
screw up the bolts with spanner according to the specified
torque.
Fastening torque
78N
m

SA-73
(l) Run the flange to check the swing difference of axle
driven bevel gear.
Max swing difference
0.07mm
Remark: if the requirement is not satisfied, tear down the axle
driven bevel gear from the differential, and then screw up the
bolts again.
8. Change the bearing of the long semi-axis:
(a) Take down the retainer ring with the calipers.
(b) Tear down the grooved ball bearing from the long semi-
axis.
(c) Mount on the new grooved ball bearing on the long semi-
axis
(d) Mount on the retainer ring with calipers.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-74
4. Select the adjusting washer ñdriving bevel gear accord-
ing to the experience, and cover it on the driving bevel
gear; and mount the inner race and roller assembly of
bearing 32307 on the driving bevel gear by pressing.
5. Mount the adjusting washer and sleeve on the driving
bevel gear, and encase it in the front speed reducer cell
through the flange along with the spline, and screw on
the nuts.
6. Screw up the main-tooth nuts to the specified torque with
the SST.
Fastening torque
(175
35)N
m
7. Measure the preload on the driving bevel gear bearing
with torque tester :
New bearing
(1.2-1.7)N
m
Old bearing
(0.9-1.3)N
m
Assembly of Front Speed Reducer
1. Clean the front speed reducer shell; press the outer
races of bearing 31306 and bearing 32307 to mount
them in the speed reducer shell.
2. Mount he inner race and roller assembly of bearing
31306 as well as the oil-guard tray in the front speed
reducer shell, then press on the driving bevel gear oil
seal with SST.
Notice: coat a little lubricant on the lip open of the oil seal
before encasing it, and the oil seal that is encase in the
front speed reducer shell should be 1.5 mm away from
housing faces.
3. Encase the flange and dust cover in the front speed
reducer through the lip open of oil seal and press it by
hand.
Suspension System and Automobile Axle (SF/4WD) Front Speed Reducer (Assembly of Front Speed Reducer)

SA-75
8. Encase in the differential:
(a) Put the adjusting gasket in the outer position of bearing
at the side of the front speed reducer shell, and then
Encase the differential in the front speed reducer shell, be
sure there is a play between the driving gear and the
driven gear.
(b) Tap the axle driven bevel gear with the rubber hammer,
so that the bearing 50KB801 on the differential, together
with the adjusting gasket, contact the mounting part of
the side face of speed reducer closely.
9. Measure the clearance between the axle driven bevel
gear and the driving bevel gear with the dial indicator to
select the adjusting gasket that satisfy the reasonable
play of (0.15-0.25)mm.
10. Select the adjusting washer for the other side:
The thickness of adjusting gasket should eliminate the clear-
ance between the bearing 50KB801 and the front speed re-
ducer shell, on the other side, the adjusting gasket should not
be over thick because the over-thick gasket will lead in too
large pre-tightening force on the bearing 50KB801 of
differential.
11. Tear down the adjusting gasket and differential, and
encase the new adjusting gasket in the front speed
reducer shell, and another adjusting gasket, together
with the differential housing, should be encased in the
front speed reducer shell correctly.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Assembly of Front Speed Reducer)

SA-76
12. Measure the clearance between the axle driven bevel
gear and the driving bevel gear with dial indicating lamp.
Clearance: 0.15-0.25mm
Remark: if the play fails to fall within the specified range,
change with the adjusting gasket of other thickness to satisfy
the requirement under the precondition there is no clearance
between the adjusting gasket and the differential.
14. Measure the total preload of the front speed reducer with
torque tester;
Fastening torque
(1.8-2.4)N
m 13. Mount on the left and the right cap-differential bearing:
Screw up the bolts with spanner to the specified torque;
Fastening torque
78N
m
15. Check the teeth engagement between the axle driven
bevel gears:
(a) Coat three or four teeth at three different positions of the
axle driven bevel gear in red
(b) Hold the flange tightly while rotating the axle driven
bevel gear.
(c) Check the teeth engagement situation.
Remark: the trace of the teeth of axle driven bevel gear should
satisfy this requirement. Otherwise, select the suitable adjust-
ing washer for correcting according to the situation of poor
teeth engagement;
Select the adjusting gasket that makes the main teeth apart
from the axle driven bevel gear.
convex surface of gear
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Assembly of Front Speed Reducer)
concave surface of gear

SA-77
heel end engagement tooth top engagement
Select the adjusting gasket that make the main teeth contact
closer with the axle driven bevel gear.
toe end engagement tooth top engagement
Select the adjusting gasket that make the main teeth contact farther with the axle driven bevel gear.
(d) Tear down the bearing 32307 from the driving bevel gear
and change the adjusting washer.
(e) Re-measure the total preload of the front speed reducer
and the situation of teeth engagement until they satisfy
the requirement.
16. Rivet the main-tooth nut;
17. Mount on the new oil seal ó front half-shaft;
Press in the new oil seal with the SST until it flush with the
outer face of the oil seal, coat the moderate lubricant on the
position of oil seal and on the lip open of oil seal.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Assembly of Front Speed Reducer)

SA-78
18. Mount on the front drive axle shaft sleeve;
Notice: Thread locking agent should be coated on the
bolt thread.
Fastening torque
88N
m
19. Mount on the front long semi-axis and the front minor
half-shaft.
(a) Mount the new snapping ring on half-shaft.
(b) Mont on the front semi-axis and the front minor half-
shaft.
20. Mount the front speed reducer shell assembly:
(a) Clear the front speed reducer shell and the contact face of
front speed reducer shell;
(b) Coat the glue line with diameter of 2-3 mm, and the glue
line should be even and without fracture.
Remark: The front speed reducer shell should be mounted
ready within 15 min after coating the glue.
(c) The bolts, before screwed up, should be coated with
thread locking sealing agent and screwed up to the
specified torque.
Fastening torque
47N
m
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Assembly of Front Speed Reducer)

SA-79
Rear Axle Shaft
Element figure
rear axle housing
O rubber O-ring sealrear brake
brake drum
inner oil seal seat of
rear wheel bearingbearing seat
oil seal of rear
wheel bearinglinerhalf-shaft
grooved ball
bearing
rear brakeoil-guard tray

Parts that cannot be reused after being used
Suspension System and Automobile Axle (rear)
Rear Axle Shaft

flat steel retainer ring for shaft