GREAT WALL PEGASUS 2006 Owner's Guide

MT-12Gearbox
Disassembly of Gear Box
11. Grip the central link plate in the table vice,
(a) Use two clutch bolts, washers and suitable nuts as shown
in the drawing.
Remark: mount the washer in the reverse direction, increase
and decrease the washer quantity to flush the bolts terminal
with the external face of the washer.
(b) Grip the central link plate in the table vice.
12. Tear down the locating spring bolts, locating spring and
locking ball,
(a) Dismantle each locating spring bolts with the torque socket
spanner.
(b) Take out the toggle fork axles of the first, second, third,
fourth and reverse as well as the axial locating spring and
locking ball of the fifth-gear toggle fork.
13. Tear down the axial retainer ring of the gearshift fork
Tap the axial retainer ring of gearshift fork lightly with two
screwdrivers and one hammer.

MT-13Gearbox
Disassembly of Gear Box
14. Tear down the five-speed gearshift toggle fork,
(a) Punch out the spring pin with impact head and hammer.
(b) Tap the five-speed gearshift fork until take it out.
Notice: It must be the neutral location this time.
15. Tear down the guiding module of the five-speed gear-
shift and five-speed reverse shift fork axle.
(a) Take out the inter-locking steel ball from the guiding
module of the fifth reverse shift-shaft.
(b) Tear down the fifth reverse shift guiding module and fifth
reverse shift fork axle.
16. Take out the five-speed gearshift fork axle

MT-14Gearbox
Disassembly of Gear Box
17. Tear down the reverse shift fork axle, reverse rocker
arm, reverse toggle lever and toggle block
(a) Tap out the spring pin with the nail punch and hammer.
(b) Take out the interlocking ball and interlocking guidepost
between the reverse shift fork axle and the five-speed
gearshift fork axle.
(c) Tear down the reverse shift fork axle, and
(d) Tear down the reverse rocker arm and yoke block.
18. Tear down the first-second-speed gearshift fork axle.
(a) Take out the interlock pin and interlock guide post between
the reverse shift fork axle and the five-speed gearshift fork
axle.
(b) Dismantle the locating bolts of the toggle fork of the first-
second-speed gearshift toggle fork.
(c) Dismantle the fork axis of the first-second-speed gearshift.
(d) Take out the short interlock pin between the first-second-
speed gearshift fork axle and the third-fourth-speed gear-
shift fork axle

MT-15 Gearbox
Disassembly of Gear Box
19. Tear down the third-fourth-speed gearshift fork axle and
the toggle forks of first-second speed gear and third-
fourth speed gear.
(a) Tap out the spring pin with the nail punch and hammer.
(b) Tear down the toggle forks of the third-fourth and first-
second-speed gearshift.
20. Tear down the coupling gear, synchronizer, gear cluster,
thrust washer and needle bearing of the five-speed
gearshift
(a) Tap down the retainer ring of the rear countershaft with
two screwdrivers and one hammer.
(b) Tear down the synchronizer assembly, coupling gear and
gear cluster of the five-speed gearshift. And
(c) Dismantle the five-speed needle bearing.
21. Tear down the thrust washer and five-speed lock ball.
(a) Tear down the thrust washer of five-speed gear.
(b) Take out the lock ball with magnetic rod.

MT-16 Gearbox
Disassembly of Gear Box
22. Tear down the reverse rocker arm bracket
Dismantle the two bolts and the reverse rocker arm bracket.
23. Tear down the reverse idle gear and reverse idle gear
axle
(a) Dismantle the setting bolts of idle gear and the pressing
plate of reverse idle gear axle.
(b) Dismantle the reverse idle gear and the reverse idle gear
shaft.
24. Take down the bearing baffle of the output shaft.
(a) Dismantle the four bolts with torque socket spanner.
(b) Take down the bearing baffle of the output shaft.
25. Dismantle the intermediate-gear shaft.
(a) Pry out the split ring of the rear bearing of the intermediate-
gear shaft with the split-ring-type pliers.

MT-17 Gearbox
Disassembly of Gear Box
SST
push down
to close
(b) Taker apart the rear bearing of intermediate shaft with
SST tool and wrench.
(c) Take down the intermediate shaft.
26. Tear down the input shaft
Tear down the bearing with 13 needles and synchronizing ring
from the input shaft.
27. Tear down the output shaft
(a) Dismantle the stop ring from the output bearing with split-
ring-type pliers.
(b) Tap lightly the central link plate with rubber hammer while
pulling the output shaft manually to tear down the output
shaft.
28. Check the back-up lamp switch
Check the terminal connection, when the switch is pressed
down, as shown in the drawing, it is connected, otherwise is
disconnected, in case the switch is not in conformity with this,
it shall be changed.

MT-18Gearbox
Input Shaft Assembly (Element Drawing, Inspection On Synchronizing Ring, and BearingChange)
Input Shaft Assembly
Inspection on Synchronizing Ring
1. Run the synchronizing ring and put it into the assembly
to check its stopping performance
2. Check the clearance between the rear face of
synchronizing ring and the gear.
Standard clearance:
Tung tooth
(1
1.6)mm
Upper tooth
(1.5
1.8)mm
Limit clearance
0.8mm
Bearing Change
1. Tear down the input shaft bearing with the pressure
machine.
retainer ringbearing stop ringbearinginput shaftneedle bearing
synchronizing ring
element drawing

MT-19Gearbox
Input Shaft Assembly (Bearing Change)
ppq
2. Mount the new bearing with pressure machine and SST.
3. Select the retainer ring to obtain the minimum axial clearance
4. Mount the retainer ring with the split-ring-type pliers.
5. Mount the retainer ring with the split-ring-type pliers.

MT-20Transmission
Output Shaft Assembly (Components Figure)
Output shaft assembly
Components figure
synchronizer spring
expansion ring
snap ringsynchronizer
slide block3th,4th gear synchronizer
meshing sleeve3th gear needle bearing
synchronizer hub of 3rd
and 4th geartoothed ring of
synchronizergear components of 3rd gear
steel ball
synchronizer sliding blocksynchronizer meshing sleeve
of 1st and 2nd gear
gear components
of 1st gear1st gear shaft sleeve
locking ring of output
shaft rear bearing
spring expansion ring
needle bearing of
2nd gear
gear components
of 2th geartoothed ring of synchronizer
for 1st and 2nd geartoothed ring of synchro-
nizer for 1st and 2nd gearneedle bearing of 1st gearrear bearing of
output shaft
gear of 5th gearodometer drive geardrive gear snap ring of odometer output shaft
snap ring of 5th gear
steel ball

MT-21Transmission
Output Shaft Assembly(Disassembly of Output Shaft Assembly)
Disassembly of output shaft assembly
1. Remove the drive gear of speedometer
(a) Pry down the two shield rings with open end ring plier
(b) Dismantle the drive gear of tachometer.
(c) Take out the steel ball with magnetic stick.
2. Remove the 5th gear,rear bearing of output shaft,1st
gear assembly,1st gear shaft sleeve and needle bearing
of 1st gear
(a) Take down the circlip of 5th gear with two screwdrivers
and one hammer.
(b) Dismantle the rear bearing of output shaft,1st gear assem-
bly and 1st gear sleeve with press machine.
(c) Remove the needle bearing of 1st gear.
3. Remove the synchronized ring
4. Take down the steel ball
Take out the steel ball with magnetic rod.
5. Take down the 1st and 2nd gear synchronizer assembly,
2nd gear assembly,and 2nd gear needle bearing.
(a) Remove the 1st and 2nd synchronizer assembly and 2nd
gear components.
(b) Take off the needle bearing of the 2nd gear.
6. Take down the meshing sleeve ,sliding block and spring.
Remove the three sliding blocks and two springs from the
synchronizer assembly with one screwdriver.