GREAT WALL PEGASUS 2006 Workshop Manual

MT-22Transmission
Output Shaft Assembly(Disassembly of Output Shaft Assembly)
7. Take down the 3rd and 4th gear synchronizer assembly,
3rd gear and needle bearing .
(a) Remove the snap ring with plier for snap ring.
(b) Take down the 3rd and 4th gear synchronizer assembly and
3rd gear with press machine.
(c) Remove the needle bearing .
8. Take off the meshing sleeve ,sliding block and spring
from 3rd and 4th synchronizer.
Remove the three sliding blocks and spring from the meshing
sleeve with one screwdriver.

MT-23
Inspection of output shaft assembly
1. Check the axial clearance of every gear:
For the transmission made by Shang Chi:(0.15
0.33)
mm(1st,2nd,and 3rd gear position)
For the transmission made by Tang Chi:(0.1
0.25)mm
(1st gear position)(0.09
0.26)mm,(2nd and 3rd gear
position)
2. Measure the idle clearance of every gear.
Check the radial clearance of every gear with micrometer.
Standard clearance:
For the transmission made by Shang Chi:0.05mm
(1st,2nd,and 3rd gear position)
For the transmission made by Tang Chi:
(0.009
0.033)mm(2nd and 3rd gear position)
(0.009
0.032)mm(1st gear position)
Max clearance

For the transmission made by Shang Chi:0.05mm
For the transmission made by Tang Chi:0.033mm
(2nd,and 3rd gear position);0.032(1st gear position)
If the clearance value exceeds the limit above , the gear,
needle bearing or shaft should be changed.
PKInspection for output shaft and 1st gear shaft sleeve
(a) Measure the thickness of output shaft flange with callipers
Min thickness

For the transmission made by Shang Chi:4.75mm
For the transmission made by Tang Chi:4.65mm
(b) Measure the thickness of flange of 1st gear shaft sleeve
with callipers
Min thickness

For the transmission made by Shang Chi:3.87mm
For the transmission made by Tang Chi:3.795mm
(c) Measure the outside diameter of the journal of output shaft
with micrometer.
Min diameter:19.216mm
Gear of 2nd gear:37.984mm
Gear of 3rd gear:34.984mm Transmission
Output Shaft Assembly(Inspection of Output Shaft Assembly)
1st gear position 2nd gear position3rd gear position

MT-24
(d) Measure the outside diameter of the gear sleeve of 1st gear
with micrometer.
Min diameter:38.984mm.
(e) Measure the radial run out torlerance of the shaft with
micrometer.
Max radial run out torlerance

For the transmission made by Shang Chi:0.015mm
For the transmission made by Tang Chi:0.05mm
4. Check the synchronized ring
(a) Turn the ring ,and put it into to check the brake action.
(b) Measure the gap between the rear of the synchronized ring
and gear end.
Standard clearance:
For the transmission made by Shang Chi:(1.5
1.8)mm
For the transmission made by Tang Chi:(1.2
0.4)mm
Limit clearance:0.8mm
5. Measure the clearance between the gear shifting fork
and meshing sleeve
Check the clearance between the gear sleeve and gear shifting
fork with feeler gauge.
Max clearance

For the transmission made by Shang Chi: 0.54mm
For the transmission made by Tang Chi: 0.7mm Transmission
Output Shaft Assembly(Inspection of Output Shaft Assembly)

MT-25Transmission
Output Shaft Assembly(Assembly of Output Shaft Assembly)
Assembly of output shaft assembly
1. Assembly of synchronizer
(a) Insert the synchronizer hub and sliding block into the gear
sleeve.
(b) Install the spring expansion ring under the sliding block.
Note:The openings of spring expansion ring should be
staggered during installation .
2. Install the gear components of 3rd gear and synchronizer
of 3rd and 4th gear on the output shaft.
(a) Smear the gear oil on the shaft and the needle bearing of
3rd gear.
(b) Put the synchronized ring on the components of gear of 3rd
gear, and align the notch of synchronized ring and sliding
block.
(c) Install the needle bearing into gear components of 3rd gear.
(d) Assembly the gear components of 3rd gear and synchro-
nizer of 3rd and 4th gear with pressing machine.
3. Assembly of snap ring for shaft
To choose one snap ring which make the axial clearance be
Min, and install it on the shaft.
3/4 gear posititon
1/2gear posititon
front
front side

MT-26Transmission
Output Shaft Assembly(Assembly of Output Shaft Assembly)
Standard clearance:
For the transmission made by Shang Chi
(0.15
0.33)mm
For the transmission made by Tang Chi:
(0.09
0.33)mm
5. Assembly for the gear components of 2nd and
synchronizer of 1st and 2nd gear
(a) Smear the gear oil on the needle bearing of gear of 2nd
gear.
(b) Put the synchronized ring on the gear,and align the notch
and shift key.
(c) Install the needle bearing into the gear components of 2nd
gear.
(d) Assembly the gear components of 2nd gear and meshing
sleeve of synchronzer of 1st and 2nd gear with pressing
machine.
6. Check the axial clearance of gear components of 2nd
gear
Measure the axial clearance of gear components of 2nd gear
with feeler gauge.
Standard clearance:
For the transmission made by Shang Chi:(0.15
0.33)mm
For the transmission made by Tang Chi:(0.09
0.33)mm
7. Assembly the locking ball and gear components of 1st
gear
(a) Install the locking ball into the shaft.

MT-27Transmissio
Output Shaft Assembly(Assembly of Output Shaft Assembly)
SST
SST
(b) Smear the gear oil on the needle bearing of gear of 1st gear.
(c) Assembly the gear components of 1st gear,synchronized
ring,needle bearing and sleeve of gear of 1st gear.
(d) Install the assembly on the output shaft,and align the notch
of synchronized ring and sliding block .
(e) Turn the sleeve of 1st gear shaft to align the it with the
locking ball.
8. Installation for rear bearing of output shaft
Fix the bearing of output shaft to the output shaft with SST and
pressing machine, make the notch of locking ring of output
shaft rear bearing expose to the tail.
Remark: Hold the sleeve of gear of 1st gear and don
t let it fall
off.
9. Install the gear of 5th gear
Fix the gear of 5th gear with SST and pressing machine.
10. Assembly the snap ring of shaft
(a) To choose one snap ring which make the axial clearance
be Min, and install it on the shaft.
Max clearance
0.1mm

(b) Knock the snap ring of shaft of 5th gear tightly with
screwdriver and hammer.
11. Measure the axial clearance of gear of 1st gear
Measure the axial clearance of gear of 1st gear with feeler
gauge
Standard clearance:

For the transmission made by Shang Chi:(0.15
0.33)mm
For the transmission made by Tang Chi:(0.09
0.33)mm

MT-28Transmission
Output Shaft Assembly(Installation of Output Shaft Assembly)
12. Fix the drive gear of speedometer
(a) Install the locking ball and drive gear.
(b) Install the drive gear of tachometer with plier for shaft
shield ring

MT-29Gear Box
Countershaft Assembly and Reverse Idle Gear Assembly (Element Drawing, Countershaft Assembly Disassembly, Testing and Assembly)
Countershaft Assembly and Reverse Idle Gear Assembly
Element drawing
Disassembly, Testing and Assembly of
Countershaft
1. Tear down the coupling gear, sliding block and the five-
speed spring collar.
Tear down the coupling collar, three sliding blocks and the two
five-speed spring collars with screwdriver.
2. Measure the radial clearance of the reverse idle gear
with dial gauge
Standard clearance:
Shang chi:0.05mm
Tang chi:(0.10~0.30)mm (Tang chi is the close Spline
match, which belongs to radial clearance)
Max clearanle:
Shang chi:0.05mm
Tang chi:(0.10~0.30)mm (Tang chi is the close spline
match, which belongs to radial clearance)
front bearing of
countershaftintermediate-gear shaft
steel ballrear bearing of
countershaftstop ring of the rear bearing
of countershaft
five-speed thrust washerfive-speed needle
bearingsliding block of
synchronize
five-speed clusterengagement sleeve of the
five-speed synchronizer
spring collarsynchronizer tooth
of spring collaraxial pressing plate
for reverse idle gearreverse idle
gear shaft
reverse idle gear
cluster
coupling gear around
the five-speed gear
retainer ring for front
countershaft stop ring for front bearing
of countershaft

MT-30 Gear Box
Countershaft Assembly and Reverse Idle Gear Assembly ( Countershaft Assembly Disassembly, Testing and Assembly)
3. Reverse gear inspection
Measure the diameter of needle bearing with micrometer.
Standard diameter

Shang Chi
26.000mm
Tang Chi
(25.98
26.00)
Limit Diameter

Shang Chi
25.984mm
Tang Chi
25.86mm
4. Check the synchronizing ring
(a) Run the retainer ring for shaft and put it onto the shaft to
check itsstopping performance
(b) Measure the clearance between the rear section of the
synchronizing ring and the spline.
Standard clearance:
Shang Chi
(1.5
1.8)mm
Tang Chi
(1
2)mm
Limit clearance: 0.8mm
5. Measure the clearance of the shift fork and gear sleeve.
Test the clearance of the shift fork and gear sleeve with the
feeler gauge.
Max clearance:
Shang Chi: 0.54mm
Tang Chi:1.0mm
6. Change the bearing
The front bearing of the reverse gear shall be changed when
necessary
(a) Pry down the retainer ring for shaft with a split-ring-type
pliers.

MT-31Gear Box
Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly)
SST
sleeve wrench
front
(b) Press out the bearing with SST.
(c) Press in the bearing, side race and inner race with the
socket spanner.
(d) Select the split ring that leave the radial clearance to
minimum level, and mount it on the shaft.
7. Mount the engagement sleeve of synchronizer, sliding
block and the five-speed spring collar.
Remark: the opens of the spring collar shall be in non-
alignment
Encase the sliding pad into the gear hub and then cover the
gear sleeve.
Mount the spring retainer under the sliding pad.
Notice, the opening direction of the spring retainer shall
not face-to-face.
Mount of Reverse Gear Assembly
1. Check the reverse idle gear
Measure the radial clearance of the reverse idle gear with dial
gauge.
Standard clearance:
Shang Chi
0.05mm; Tang Chi
(0.04
0.08)mm
Max clearance

Shang Chi
0.05mm; Tang Chi
0.13mm