brake GREAT WALL PEGASUS 2006 User Guide

SA-11
4. Take apart the front wheel hub oil seal, the inner race and
roller assembly of bearing 32007.
(a) Pry out the oil seal.
(b) Take out the bearing inner race and roller assembly.
Front Wheel Hub
Disassembly of Front Wheel Hub
1. Take apart the brake caliper.
2. Take apart the front wheel hub cap.
3. Take apart the front wheel hub and front brake disc:
(a) Take apart the split pin to take down the lock cover.
(b) Screw off the lock nuts of the hub bearing with spanner
and take down the stop washer.
(c) Take apart the front wheel hub and front brake disc with
the bearing 30205 together.
Disassembly the wheel hub and suspend it with tightwire.
Remark: Donít dismantle the brake hose and brake metal pipe
Takeapart the front wheel hub cap from the gap between the
front wheel hub cap and the front wheel hub.
5. Bearing outer race inspection and tear-down
(a) Inspect the bearings
Clean each bearing and check them to see whether there is wear
or damage.
(b) Take apart the bearing outer race
Tap out the bearing outer race with copper bar and hammer.
Notice: bind the disassembled inner and outer bearing
race together to avoid of mixing.
Suspension System and Automobile Axle (Dr/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-12
6. Inspection and replacement for front brake disc
(a) Check the wear situation of the front brake disc. (see Dr
the brake caliper).
(b) Use the spanner to tear down the bolts that connect the
front wheel hub and the front brake disc.
(c) Connect the front wheel hub and the front brake disc with
bolt and spring washer, and screw up the bolts with a
moment spanner to the specified torque in the diagonal
order.
Fastening torque
(60-79)N
m
(d) Conduct the equilibrium test on the dynamic balancer,
the amplitude value displayed should not be larger than
13.5g under the condition that the measuring rotating
velocity is 796 r/m and the locking rotating velocity is
786 r/m, when the amplitude value is larger than 13.5 g,
encase the counter balanced clip, which is 4 g each, at the
corresponding phase, the number of the clip encased
should not be more than four.
7. Bearing outer race change
Press in the new bearing outer space with the special service
tools.
Notice: the bearing inner and outer races should be changed at
one time.
Assembly of Front Wheel Hub
1. Mount on the Bearing 32007 inner race and roller assem-
bly as well as the front wheel hub oil seal.
Coat the lithium base grease of (4-5)mm on the inner surfaces
of bearing outer race and the front wheel hub, encase the
Bearing 32007 inner race and roller assembly, plaster the
lubricant again. Coat a little lubricant on the lips of front wheel
hub oil seal and then tap it in place.
Notice: do not make the lubricant contact the front brake
disc face.
2. Mount on the Bearing 32007 inner race.
After coating the bearing outer race with the lithium base
grease of 4-5 mm, encase the inner race and roller assembly of
Bearing 30205, and plaster the lubricant again.
Suspension System and Automobile Axle (Dr/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-13
3. Mount the front wheel hub on the steering knuckle.
Coat a little lubricant at the position of the steering knuckle
where the oil seal locates, mount the front wheel hub and front
brake disc on the steering knuckle, and then mount on the stop
washer.
4. Preload adjustment
(a) Mount on the lock nut and screw up according to the
specified torque.
Fastening torque
(130-150)N
m
(b) Run the front wheel hub about 1/4-1/3 of circle, and
combine it with the bearing seat.
(c) Loosen the locking nut to ensure the front brake disc run
freely, and then screw up the nuts to the specified torque.
Fastening torque
(25-35)N
m
(d) Hook the front wheel hub with the spring-tension meter
and pull the spring-tension meter slowly in the tangential
direction of this spot.
The reasonable range of tension force: (16-33)N.
Remark: if the tension force is larger or smaller of the reason-
able range, screw up the nuts again until the tension force falls
within the reasonable range.
(e) Measure the bouncing value of the front brake disc,
which should not be larger than 0.11mm.
5. Mount on the lock cover and the split pin
Suspension System and Automobile Axle (Dr/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-14
6. Tap in the front wheel hub with a rubber hammer
7. Mount the brake caliper on the steering knuckle.
Fastening torque
(85-105)N
m
Steering Knuckle
Disassembly of Steering Knuckle
1. Take apart the brake caliper, the front wheel hub and the
front brake disc.
2. Take apart the front brake shell:
(a) Tear down the two bolts (M8X16).
(b) Tear down the two split pins, grooved nuts, washer and
bolts that connect the steering knuckle arm.
3. Tear down the steering knuckle
(a) Support the lower arm with jack;
(b) Tear down the two split pins and the grooved nuts
(c) Disconnect the steering knuckle from the upper and
lower ball studs and take apart it.
Inspection on Steering Knuckle
Check the steering knuckle
Check the steering knuckle with the dye penetration agent to
see whether the steering knuckle has a crack or not.
If the crack is found, the steering knuckle is required to be
changed.
Suspension System and Automobile Axle (Dr/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-15
Mount the steering knuckle
1. Mount the steering knuckle
(a) Support the lower arm of the steering knuckle with a jack.
(b) Mount the steering knuckle on the lower ball stud and
screw on the nuts.
(c) Press the upper arm to mount on the steering knuckle and
screw on the nuts.
(d) Screw up the nuts of the upper ball stud according to the
specified torque.
Fastening torque
(100-120)N
m
(e) Screw up the nuts of the lower ball stud according to the
specified torque.
Fastening torque
(98-118)N
m
(f) Mount on the split pin between the upper and lower ball
studs.
2. Mount the steering knuckle arm and the front brake shell;
(a) Screw up the two bolts of M8X16.
Fastening torque
(25-28)N
m
(b) Screw up the two bolts and groove nuts (M12X67) to the
specified torque.
Fastening torque
(98-118)N
m
(c) Mount on the two split pins.
In case the pin hole in the ball stud are not in alignment with
the groove nut, adjust the fastening torque and the rotating
angle under the condition that satisfying the minimum torque,
so as to ensure the torque falls within the specified range, if
cannot, mount the split pin with the minimum torque beyond
the range
3. Mount the front wheel hub and the front brake disc.
4. Check the Alignment of Front Wheel.
(See SA-3)
Suspension System and Automobile Axle (Dr/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-17
Ball stud
Inspection on Ball Stud
1. Check the lower ball stud to see whether it is excessively
loose or not.
(a) Prop up the front of the vehicle with jack and then support
it with the bracket.
(b) Tread down the brake pedal after verifying that the front
wheel are in straight line.
(c) Move the arm vertically to check the lower ball stud to see
whether the clearance is overlarge.
Max vertical clearance : 0.5mm
2. Check the upper ball stud to see whether it is over-loose.
Move the wheel vertically to check whether the clearance of
the ball stud is over large.
3. Check the rotating performance of ball stud
(a) Take apart the ball stud.
(b) Shake the ball stud several times forward and backward
before mounting on the nut, as shown in the drawing.
(c) Rotate the nut continuously with a torsion meter, which
rotates the nut round per 2 to 4 seconds, and read the
reading of the torsion meter after the fifth round.
Fastening torque (running)
Lower ball stud: (0.1-4)N
m
Upper ball stud: (0.1-4)N
m
Disassembly of Ball Stud
1. Tear down the steering knuckle.
(see the SA-14).
2. Take apart the lower ball stud from the lower arm; and
3. Take apart the upper ball stud from the upper arm. Suspension System and Automobile Axle (Dr/2WD)
Front Suspension (Ball Stud)

SA-28Suspension System and Automobile Axle(SF/2WD)
Front Suspension
locking ring
cushion block nut
locking ringcushion blockupper arm
transverse stabilizer rod
bolt
transverse stabilizer rod gasket

rubber
snubber washer
restrictor tube
Brake
caliper
steering knuckle
brake oil pipe bracket
steering
knuckle arm
brake shell
dust cover

oil seal -front hub
front wheel
bearing(inner)
front wheel hub and
front brake discstop washer
lock plate
front hub bearing
(outer)
steering knuckle nut

liner
lower
ball stud






Parts that cannot be reused after being used:specified torque
N
m
135-155
23
2925
29 70-90
132-152
20-26
180 127-147132
152123
shock absorber


steering knuckle
outer flange cap
Front wheel hub and steering knuckle
Element figures
SF2WD
stabilizer rod gasket

stabilizer rod gasket

rubber snubber
washer
stabilizer rod gasket

stabilizer rod gasket

SA-29
Front Wheel Hub
Disassembly of Front Wheel Hub
1. Tear down the brake caliper.
(a) Tear down the brake Bundy tube from the brake caliper,
and block the Bundy tube line with a cork.
(b) Tear down the brake caliper from the steering knuckle.
2. Tear down the steering knuckle outer flange cap.
3. Tear down the front wheel hub and brake disc.
(a) Open the lock plate with a screwdriver.
(b) Tear down the steering knuckle nut with the SST tools to
take out the. lock plate
(c) Tear down the other steering knuckle nut with SST tools
to take out the stop washer and the steering knuckle outer
bearing.
(d) Tear down the front wheel hub and the brake disc
assembly.
4. Tear down the front hub, oil seal, front hub bearing
(inner) inner race and roller assembly.
(a) Pry out the oil seal.
Notice: the deformed oil seal should not be reused.
(b) Take out the front hub bearing (inner) inner race and
roller assembly.
Suspension System and Automobile Axle (SF/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-30
5. Front hub bearing outer race inspection and change
(a) Check each bearing
Wash the inner and outer races of each bearing, and check
them whether they are wearied or damaged.
(b) Tear down the outer race of each bearing.
Tap out the bearing outer race with copper bar and
hammer.
Notice: bind the dismantled inner and outer races of
bearing together to prevent from mixing.
6. Front brake disc inspection and change
(a) Check the wear situation of front brake disc.
(b) Tear down the bolts that connect the front wheel hub and
front brake disc.
(c) Connect the front wheel hub and front brake disc and
screw up the bolts with moment spanner to the specified
torque diagonally
Fastening torque
(70-80)N
m
(d) Conduct the dynamic balance test on the dynamic balancer,
the amplitude value displayed should not be above 13.5g
under the condition that the measuring rotating velocity
is 796 r/m and the locking rotating velocity 786 r/m,
otherwise, tap in the counter balanced clip, which is 4g
each, at the corresponding location, the number of the
clip should not be more than 4.
(e) Tap in the new bearing outer race with the special service
tool.
Notice: the inner and outer races of bearing should be
changed in set.
Assembly of Front Wheel Hub
1.Mount on the inner race and roller assembly of front hub
bearing (inner) as well as the front hub oil seal.
Coat the lithium base grease of 4 to 5 mm on the inside surface of
the bearing outer race and front wheel hub, and plaster the
lubricant in the front hub bearing (inner) and the roller assembly.
Coat a little lubricant on the lips of oil seal of front wheel hub, and
then tap the oil seal of front hub in place with special service tool.
Notice: do not coat the lubricant on the front brake disc face.
Suspension System and Automobile Axle (SF/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-31
2. Mount on the inner race and roller assembly of front hub
bearing (outer).
After coating 4 to 5 mm lithium base grease on the outer race
of bearing, put in the inner race and roller assembly of front hub
bearing (outer), and then plaster the lubricant.
3. Mount the front wheel hub and front brake disc on the
steering knuckle.
Coat a little lubricant on the steering knuckle where the oil seal
locates, and mount the front wheel hub and front brake disc on
the steering knuckle, then mount on the stop washer.
4. Adjust the preload
(a) Mount on the steering knuckle nut and screw up them
according to the specified torque.
Tighten torque: (100-120)N
m
(b) Run the front wheel hub about 1/4-1/3 round, and seat the
bearing.
(c) Loosen the steering knuckle nut to ensure the front brake
disc can run freely. Screw up the steering knuckle nut
again according to the specified torque.
Fastening torque
25N
m
(d) Mount on the lock plate and another steering knuckle nut.
Tighten torque
60N
m
(e) Hold the front wheel hub bolts with a spring-tension
meter and drag the meter slowly in the direction of the
tangent line of this spot.
Suitable tension range: (29-54)N
The nuts should be retightened until falls within the suitable
range if the tension force is overlarge or over small.
(f) Check the bearing and ensure that the clearance, which is
not larger than 0.05 mm, is not excessive.
(g) Measure the bouncing value of the front brake disc face.
Bouncing value should not be above o.11mm.
Suspension System and Automobile Axle (SF/2WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)