Transfer box GREAT WALL SAFE 2006 Owner's Guide

TF-28Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear)
Maintenance or Change of Gear or Chain
Sprocket Gear
1. Maintenance principle
(a) Conduct the maintenance for the partial, small peel off
with the suitable manual high-speed grinding tool.
(b) Do not clear away the metal as can as possible when
grinding the matrix metal.
(c) All pointed angles and sides must be repaired as the slip-
pery contour line. Because the pointed angle or edges
may be peeled off again or developed into crack.
(d) Clear away the burr with the suitable grinding stone. Take
notice not to damage the matrix when clearing away the
projecting materials, and
(e) When substituting the non-repaired parts (such as
bearing), if the part is doubted in its re-application
capability, it must be changed.
2. Cases for gear or chain sprocket maintenance or substi-
tuting
(a) The gear, being peeled off at the two sides of tooth top in
contact face, may be repaired for reuse.
(b) The gear, being peeled off at the central tooth top of
contact face, may be repaired for reuse.
(c) The gear, being peeled off at one side of the non-contact
face, may be repaired for reuse.

TF-29Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear)
(d) The gear, being peeled off at the center of one side of
contact face, may be repaired for reuse
(e) The gear, being peeled off in the center of contact area,
shall be changed.
(f) The gear, being peeled off at two sides of tooth top, shall
be changed.

TF-30Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts)
Change the parts and fittings as requirement
Attachment for Inspection Maintenance or Change of Parts
Checking items
Acceptance/Refusal
Parts (items)
All parts (including
all springs)Crack inspection, distortion inspection and ero-
sion inspectionAll parts with crack, all parts that are bended,
distorted or poor in round bouncing are refused.
All threaded partsThread inspection for buckle missing or other
damageThose parts cannot be threaded or bottomed in
overlap manner shall be refused.
Flange and fork
flangePlease refer to the paragraph of
inspection
to
check the spline.Please refer to the
inspection paragraph
for
spline inspection.
Velocity sensor, mo-
tor assembly
Parts of electric clutch
systemPlease refer to the part of electric appliance
Sliding bearing Inside surface inspection for the sliding bearing In the case that the bearing has pitting corrosion
or other damage, refuse it.
Ball bearingCheck visually the ball and track of the ball
bearing to see whether there is damage such as
adhesive bonding, pitting corrosion, etc.
Ensure that the bearing are all lubricated, run the
outer race of the bearing while holding the inner
one to feel whether there is poor running or
corrosion, the bearing shall be run smoothly
without excessive clearance.Refuse to use the damaged bearing;
Refuse to use the damaged or loose bearing; or
Check the axial clearance to see whether it
exceeds 0.23mm.
Needle bearing Check the bearing needle roller and track to see
whether there is damage such as adhesive
bonding, pitting corrosion, etc.Refuse to use the damaged bearing.
The rear cover, front
body and front hous-
ing of transfer boxCheck to see whether there is burr on the cou-
pling face or other damage that impedes assem-
bling or sealing.Clear away the burr according to the paragraph
of
inspection
, otherwise, change the dam-
aged element
Rear cover of trans-
fer boxCheck the bearing holeRefuse to use the assembly that has pitting
corrosion
Odometer gear Check the gear teeth referring to the Inspection
ParagraphRefer to the gear or chain sprocket inspection in

inspection paragraph
.
Clutch shell, joint
outer gear sleeve and
joint coverCheck the spline according to the Inspection
paragraphRefer to the spline inspection of
inspection
paragraph

Locking sleeveCheck the wear or damage of the toggle fork
grooveRefuse the parts with step slipping or damage.
Shift guide shaft Check the deformation situation
Check the burr or other damage on outer race
Check the wear of outer raceRefuse to use the bend shaft; clear away the burr
according to the
inspection
paragraph, oth-
erwise refuse to use.
Refuse to use the shaft with step slipping or
other damage.
Shift toggle forkCheck whether there is wear or damage at the
location where the toggle fork combines with
the shifting cam and gear sleeve.If any step slipping or damage is found, refuse
to use it.

TF-31Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts)
Attachment for Inspection Maintenance or Change of Parts
Parts (items) Checking items Acceptance/Refusal
Shift toggle fork as-
semblyCheck the wear and damage of the inserted face
that is combined with gear sleeve;
Check to see whether the contact roller can
rotate freely or is damaged or notIf any step wear or damage is found, the inserted
face shall be refused to use.
If the contact runs difficultly or is damaged, a
new pin-contact roller and new cage assembly
shall be used.
Driving and driven
chain sprocketCheck the sprocket teeth according to
the
inspection
paragraphRefer to the sprocket teeth inspection of

inspection
paragraph
Shift toggle fork as-
semblyCheck the inner diameter that matches with the
output shaftIf any pitting corrosion or damage is found,
refuse to use it.
Driving chain Check the step sliding, looseness or damage of
pin or connecting elementRefuse to use the weary or damaged driving
chain
Filtering screenCheck to see the filtering screen is clean or with
small hole or damageClean it where necessary, and abandon the dam-
aged one.

TF-32Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection
Maintenance or Change of Parts
Pump shell Check to see whether there is pitting corrosion
or step slippingAbandon it in case it is seriously damaged or
worn
Output shaftCheck the spline, check the surface that matches
with bearing and check the distortion according
to
inspection
paragraphRefer to the spline inspection of
inspection

paragraph;
Refuse to use the one with pitting corrosion or
damage;
Refuse to use the one that is bending or poor in
round bouncing.
Deceleration hubCheck the spline of chain sprocket and check the
wear or damage of the location where matches
with the toggle fork according to the

inspection
paragraphRefer to the spline inspection of
inspection

paragraph; refuse to use the one with step slid-
ing or damage.
Front output shaftCheck the surface where matches with the
bearing;
Check the spline according to the
inspection
:
paragraphRefuse to use the one with pitting corrosion or
damage
Input shaft Check the spline according to the
inspection

paragraph
Check the distortionRefer to the spline inspection of
inspection

paragraph;
Refuse the one that is bending or poor in round
bouncing.
Thrust washer and
thrust discCheck the pitting corrosionRefuse to use the one with pitting corrosion or
damage
Sun wheelCheck the gear teeth and spline according to the

inspection
paragraphRefer to the gear teeth inspection and spline
inspection of
inspection
paragraph.
Planetary mechanism
assemblyCheck the gear teeth according to the

inspection
paragraph;
Check the wear and looseness of the planetary
gear pin; check the wear of thrust gasketRefer to the gear teeth inspection of

inspection
paragraph;
If any step sliding or pitting corrosion is found,
refuse to use it
Electric shifting camCheck to see whether there is step slipping or
pitting corrosionIf any step sliding or pitting corrosion is found,
refuse to use it
Shift guide shaftCheck to see whether there is step slipping or
pitting corrosion
Check the distortion situationIf any step sliding or pitting corrosion is found,
refuse to use it
Refuse to use the bending one
Planetary gear ringCheck the match performance of it with the
transfer box housing
Check the gear teeth according to the

inspection
paragraphCheck the transfer box housing assembly to see
whether the gear ring is loose or not in the
housing
Refer to the gear teeth inspection of

inspection

paragraph
Transfer box housingCheck the holes matches with the bearingAbandon the one with pitting corrosion or
damage.

PR-12Drive Shaft
Drive Shaft
Mount of Drive Shaft
(2WD)
1. Insert the universal joint yoke in the gearbox.
(a) Tear down the SST tools.
(b) Push the universal joint yoke into the gearbox.
2. Connect the universal joint flange of the rear joint of rear
axle drive shaft and the relative the differential flange.
(a) Align the assembly marks on the two flanges and connect
the flanges with four sets of bolt and nut.
(b) Screw up the sets of bolt and nut according to the
specified torque.
Fastening torque
(74
5)N
m
3. Mount the center support bearing on the frame beam
(three-joint type)
(a) Use two bolts to mount the center support bearing on the
frame beam and tighten them manually.
(b) Check the bearing seat, which shall be vertical with the
drive shaft, and change it where necessary.
(c) Check the central line of the central bearing and ensure
that the central lines of the central bearing and the bear-
ing seat shall be the same when the vehicle is in the non-
loaded stage. And adjust the bearing seat only it is
necessary.
(d) Screw up the mounting bolts according to the specified
torque.
Fastening torque
(40
5)N
m
(4WD)
1. Connect the universal joint flange fork of the front axle
drive shaft with the flange that matches with the transfer
box.
Align the assembly marks and use four sets of bolt and nut to
connect the flange fork with the flange, screw up the sets of bolt
and nut according to the specified torque.
Fastening torque
(74
5)N
m
forward
SST
assembly mark
assembly mark

A-1
Specifications of Maintenance
and Up-keeping
page
Clutch .......................................................................... A-2
Gear box ..................................................................... A-2
Transfer box ................................................................ A-3
Drive shaft ................................................................... A-4
Suspension system and automobile axle .................... A-4
Braking system ............................................................ A-5
Steering system .......................................................... A-6
A

A-3
Fastening location N*m
Upper tooth(JK72TWD)
Fastening location N*m
Specification of Maintenance and Up-Keeping
Transfer Box
Maintenance and Up-keeping of Transfer Box
1. The oil level of transfer box should be checked when exchanging the engine lubricant or the vehicle
covers more than 8000 km
and add the lubricant where necessary.
2. Change with the appointed lubricant each year or after the vehicle covers more than 48000 km.
Notice: lubricant brand: 85W/90 GL-5.
Fastening torque of relative connecting elements
15
20
10
15
12
17
15
20
15
20
15
20
15
20
30
40
60
70
30
40
30
40
17
22
30
50
20
40
30
40
90
125 Toggle fork at first, second and fifth gears and the screw of
toggle fork
Bolt on odometer pressure plate
Screw on baffle of rear bearing of output shaft
Screw on baffle of reverse idler shaft
Locating screw of gearshift yoke block
Bolt of front cover
Bolt of gearshift cover
Pillar of clutch toggle fork
Bolt of clutch cover
Bolt of rear body (M10X1.25X130)
Bolt of rear body (M10X1.25X80)
Plug of locating spring
Oil filling/draining plug
Reverse gear switch assembly
Location mechanism cluster
Locking nut at rear end of countershaft
Fastening location N*m
Flange nut
Oil drain plug
Bolt of motor clip
Fixing bolt of motor
Clutch coil nut
Housing bolt
Oil pump bolt
Venting valve
Bolt of front connecting body203
244
19
30
8
11
8
11
8
11
27
46
4.0
8.5
8
19
27
46 Oil filling/draining plug
Location mechanism cluster
Pillar of clutch toggle fork
Bolt on odometer pressure plate
Reverse gear switch assembly30
50
30
50
30
50
10
15
30
50