Transfer box GREAT WALL SAFE 2006 Owner's Manual
[x] Cancel search | Manufacturer: GREAT WALL, Model Year: 2006, Model line: SAFE, Model: GREAT WALL SAFE 2006Pages: 484, PDF Size: 16.35 MB
Page 84 of 484
TF-18
1. deceleration gear
2. output shaft
3. insert face of toggle fork
4. deceleration toggle fork assembly
5. pin, contact roller and sleeve assembly
6. deceleration shift toggle fork
7. plastic sleeve
8. contact roller
9. pin
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Transfer BoxTransfer Box Assembly
7. Deceleration shift parts assembly
The mounting process is as follows:
(a) If the parts are taken apart for change, assemble the shift
toggle fork assembly with a new pin-contact roller
assembly. Press the pin-contact roller in the deceleration
fork hole until the detent passes the hole completely and
seizes the right location. Ensure that the contact roller can
run freely.
(b) Mount two inserted faces of toggle fork on the decelera-
tion toggle fork assembly.
(c) Engage the deceleration fork assembly and deceleration
gear sleeve and put them in the housing, and the decelera-
tion gear sleeve shall be put in the planetary mechanism
assembly that is assembled already. Mount the rear
output shaft and joint the bearings at the ends of output
shaft and input shaft as well as the spline of the gear
sleeve.
Remarks: the output shaft assembly can be delayed until the oil
pump is mounted on the output shaft. The oil pump may be
dipped into the lubricant through the oil pump screen, turn the
output shaft in clockwise from the output shaft direction to see
whether there is lubricant pumped out so as to check whether
the oil pump can work normally or not. The parts mounted
readily may be encased in the transfer box housing as an
assembly
8. Oil pump assembly
Ensure the parts of oil pump are completely lubricated when
assembling, and the oil can be pumped out from the conical
hole of the oil pump front cover. The mount of oil pump is as
follows:
(a) Mount the pin on the rear output shaft.
(b) Slide the oil pump assembly on the rear output shaft
along with the pin.
(c) Put the gripping hoop at the end of oil pipe that is
mounted on the oil nozzle of the pump housing, screw up
the gripping hoop.
1. filter
2. oil pump hose
3. gripping hoop
4. oil pump assembly
5. output shaft
6. pump pin
7. output shaft and pump assembly5
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TF-19
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Transfer BoxTransfer Box Assembly
9. Assembly of driving chain
The parts assembly process is as follows:
(a) Put the driving chain sprocket at the rear end of the output
shaft, and the driven chain sprocket is put at the rear end
of the front output shaft on the worktable after the transfer
box housing assembly mount.
(b) Mount the chain on the sprocket.
(c) Holding the two chain sprockets parallel with the transfer
box in the space that the chain on the two sprockets are
straightened, and encase the chain and sprocket assembly
through the output shaft, it is required to run the chain
sprocket slowly to ensure that they engage with the front
output shaft and the spline.
(d) Mount the gasket and snapping ring on the front output
shaft.
10. Shift locking element assembly
The parts mounting process is as follows (for the electric shift
transfer box):
(a) Mount the return spring and locking hub on the locking
sleeve and fasten them with snapping ring to finish the
2W-4W locking sleeve assembly.
(b) Encase the shift guide shaft in the blind hole of the
housing through the deceleration toggle fork assembly
that is already assembled.
(c) Mount the shift toggle fork on the 2W-4W locking sleeve
assembly, which will slide through the shift guide shaft
and rear output shaft.
(d) Joint the combined external gear sleeve spline and the
rear output shaft spline as well as the 2W-4W locking
sleeve.
1. output shaft
2. driving chain sprocket
3. driven chain sprocket
4. washer
5. snapping ring
6. transmission chain
7. front output shaft
1. output shaft
2. shift engagement
sleeve assembly
3. locking sleeve
4. return spring
5. engagement sleeve6. snapping ring
7. shift lock hub
8. clutch assembly
9. fastening snapping ring
10. shift guide shaft
11. toggle fork
Page 86 of 484
TF-20
1 convex plate
groove2
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1. electric shift convex plate
2. torsion spring
3. shift shaft
4. gear down shift fork assembly
5. shift fork
6. gear shifting shaft
Transfer BoxTransfer Box Assembly
1. clutch washer assembly
2. snapping ring
3. ball bearing
4. transfer box rear body
5. nut
6. oil seal
7. bearing
8. needle bearing
11. Rear cover Assembly
Mount the parts into the rear cover according to the following
process:
(a) Locate the rear cover on the suitable press machine, the
coupling face of the rear cover shall face upward and
parallel with the work face of the press machine.
(b) Locate the needle bearing, of which the marked end
facing upward, and press it in the rear cover until the
upper end of needle bearing is 40.4740.97 lower than
the coupling face of the rear cover that matches with the
front housing.
(c) Press the ball bearing in the rear cover and mount the
snapping ring well.
(d) As for the electric shift transfer box, the parts shall be
encased according to the following process:
(1) Confirm the four O-rings are set on the clutch
washer assembly (one O-ring is located on the coil,
the other three on studs).
Mount on the clutch coil assembly, of which the
wire and stud shall protrude out the rear cover, take
notice not to damage the wire when screwing up the
nuts.
Fastening torque(811)Nm
(2) Encase the motor bearing and oil seal in the rear
cover. (e) As for the electric shift transfer box, encase the as-
sembled electric shifting cam group and clutch shell in
the process as follows:
(1) Put down the electric shifting cam group as shown in
the drawing.
(2) Hold the shift guide shaft downward and raise lightly
the toggle fork assembly. Run the electric shifting
cam group in place, so that the contact roller on
deceleration toggle fork assembly enters in the groove
of shifting cam, and the projecting part of lock
toggle fork is at the rear end of the shifting cam, and
then take reduce the component elements in the
transfer box housing, meanwhile, joint the shift
shaft on the pin in transfer box housing.
(3) Locate the clutch shell well through the shift exter-
nal gear sleeve and mount on the snapping ring.
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TF-21
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(d) All of the following aligning conditions shall be satisfied
when the rear cover assembly is mounted on the transfer
box front housing:
a) Align the pin hole in the rear cover to the pin on the
housing.
b) Align the rear output shaft to the inner bearing in
cover rear hole.
c) Align the blind hole in the rear cover and the shift
guide shaft; ensure the return spring is not tilted.
Check the hole in velocity sensor of the rear cover
with a pen.
d) Align the shift shaft and the inner bearing in rear
cover.
(e) Screw up the nine bolts after locating the sign bolts
correctly.
(f) Encase the gear of odometer in the rear cover assembly
through the spline of the rear output shaft.
(g) Press the new oil seal in the cover assembly
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Transfer BoxTransfer Box Assembly
1. bolt
2. wire harness
3. magnet
4. return spring
5. shift guide shaft
6. transfer box rear
body assembly
7. sign board
8. driving gear of Odometer
9. oil seal
10. transfer box front housing
1. locating pin
2. output shaft
3. shift shaft4. return spring
5. shift guide shaft
6. output shaft.12. Assembly of Rear Cover
Mount the aforesaid accomplished cover assembly on the
transfer box housing according to the following process:
(a) Mount the return spring on the shift guide shaft of the
transfer box.
(b) Mount the magnet in the groove of the housing.
(c) Coat the Letai glue 598 of 1.6mm on the coupling face of
housing, steer clear of the screwed hole when coating
continuously.
Notice: try to button the rear cover on the transfer box front
housing with the moderate force during the following process.
Not too much force is required when mounting the rear cover
on the front housing when all aligning conditions are satisfied,
in case the rear cover cannot be mounted on the front housing,
take down the rear cover assembly to check the aligning
condition
1. wire harness clip
2. motor assembly
3. bolt
4. sign board
Page 88 of 484
TF-22
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Transfer BoxTransfer Box Assembly
1. motor assembly
2. shift shaft
1. fixed sensor bracket
2. bolt
3. sensor assembly
4. velocity sensor
5. o-ring6. motor assembly
7. bolt
8. gasket
9. transfer box rear body
12. Mount the external electric shifting element (for the elec-
tric shift transfer box)
(a) Locate the motor assembly by aligning the triangle
groove on motor to the shift shaft.
(b) Move the motor to combine the shift shaft and keep it
close to the rear cover. Then run the motor clockwise
until the motor locates the correct place and the mooting
holes are aligned.
(c) Mount the O-ring on the velocity sensor and encase the
velocity sensor assembly in rear cover. A clip and three
bolts shall be mounted on the velocity sensor.
Fastening torque(811)Nm
(d) Mount the bolts and gaskets on the end of motor clip.
Fastening torque(811)Nm
Page 89 of 484
TF-23
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Transfer BoxTransfer Box Assembly
1. transfer box rear body
2. flange
3. oil seal
4. gasket
5. nut
6. oil plug
13. Flange assembly
The parts mount process is as follows:
(a) Encase the two oil plugs in the rear cover.
(b) Encase the flange, sealing ring and gasket, and then
screw up the nuts.
Fastening torque(203244)Nm
Page 90 of 484
TF-24Transfer Box Washing, Checking, Up-Keeping and Exchanging (Washing)
1. Washing
Notice: check the metal rag around the magnet first before washing, large granule or irregular metal
granule shows the disintegratation or similar damage. Small or fine metal granule shows the uneven
or serious wear. If the metal rag is founded, notice shall be taken on damage and wear inspection
during checking the rotating parts and the element matched with the rotating parts.
(a) Common washing
Wash the parts in cleaning agent to clean away the old lubricant and deposit. Clean away the deposit in oil hole
with brush. Take notice not to scrape the metal coupling face when washing the parts cannot be cleaned with
brush.
(b) Dry the washed parts by blowing
Dry the washed parts by blowing the low-pressure compressed air (max pressure is 137.9kPa), because cloth
thread may be left during cleaning the parts with cloth. The bearing shall be held by hand to prevent it from
rotating when blowing it.
(c) Bearing lubrication
The ball bearing and needle bearing shall be lubricated with the lubricant for transfer box after washing. As
the non-lubricated bearing may cause damage when be dry. Cover the lubricated bearing to prevent dust
entering in.
Washing, Inspection, Maintenance or Change
Page 91 of 484
TF-25
(b) Normal gear grinding trace.
Transfer BoxWashing, Checking, Up-Keeping and Exchanging (Checking)
Checking
1. Common Checking process
Check all parts by visual check to see whether there is damage
or serious or uneven wear (parts needed be substituted by new
parts such as O-ring, oil seal and etc. shall be excluded).
Abandon the damaged or weary parts that will affect on their
performance. The check items are as follows:
Burr: tips protruded from the material regionally
Rag: broken small blocks or particles
Crack: surface thread showing the material is partly or
completely separated.
Excessive abrasionRefer to the serious or obvious abra-
sion beyond of application limit.
Reduction changeMaterial slip caused by the heavy
pressure on part of it.
adhesive bondingGranules of the soft metal are dis-
persed and bonded on the hard metal surface.
Ditch trance: partial crack or trough that means the material
transfer instead of material loss.
Pitting corrosionDamages to the metal surface caused by
pressure, which are displayed due to color change caused
by heat generated by metal friction.
Step weara weary step may be seen or felled between the
neighboring interface or between the non-touching face
due to the excessive wear.
Uneven wear: Partially, unevenly distributed wear, which
includes holes, bright spots, uneven polishing or other
visual drawbacks.
2. Gear or Chain sprocket tooth inspection
Check the gear and chain sprocket tooth according to the
following process:
(a) Normal gear shaving trace.
normal gear shaving trace
normal gear grinding trace
Page 92 of 484
TF-26Transfer BoxWashing, Checking, Up-Keeping and Exchanging (Checking)
(e) Unacceptable side deflective contact area that must be
changed.
(f) Acceptable side-deflective contact area
(g) Unacceptable side deflective contact area that must be
changed. (c) Ideal engagement contact area
(d) Acceptable side-deflective contact area
Page 93 of 484
TF-27Transfer BoxWashing, Checking, Up-Keeping and Exchanging (Checking)
(h) Acceptable contact area deflecting to the tooth top.
(i) Unacceptable contact area deflecting to the tooth top,
which must be changed.
(j) Acceptable contact area deflecting to tooth root.
(k) Unacceptable contact area deflecting to tooth root, which
must be changed.
4. Key tooth inspection
Check the broken or peeled spline teeth. The spline teeth may,
if only small part is peeled off, be repaired in the same way as
that for the gear teeth, and can be reused. In case the spline
tooth is broken, the spline must be abandoned. The contact
type of spline is not the same as that for gear; however, spline
that shows step sliding must be abandoned.