oil GREAT WALL SAFE 2006 Owner's Guide

TF-13
1
234
5
7
6
5
4
3
21
Transfer Box
Disassembly of Transfer Box
10. Take apart the shift convex plate parts (for the electric
shift transfer box)
(a) Take apart the integrated electric shifting cam from the
transfer box housing.
(b) Take apart the electric shifting cam from the shift guide
shaft.
(c) Grip the end of shift guide shaft with soft-jaw vices, and
tap the shaft with a screwdriver until the torsion spring
drops off.
1. front body of transfer box housing
2. shift guide shaft
3. torsion spring
4. electric gearshift
5. gasket
1. transfer box front housing assembly
2. gear ring
3. oil seal
4. transfer box front housing
5. locating pin
6. ball bearing
7. snapping ring
11. Disassemble the transfer box housing assembly
Disassemble the transfer box housing assembly in the manner
as follows.
(a) Take apart the oil seal.
(b) Take apart the snapping ring, and pull out the bearing.
(c) The locating pin may only be taken apart from the transfer
box front housing in the case that the pin is loose or
damaged, and
(d) Where the gear ring needs to be changed, it may be
pressed out from the transfer box housing.

TF-14
7
6
5
4
3
21
1. transfer box front housing assembly
2. gear ring
3. oil seal
4. transfer box front housing
5. locating pin
6. ball bearing
7. snapping ring
NMR23
41
1. oil seal
2. transfer box front housing
3. gear ring
4. locating pin
Transfer Box
Transfer Box Assembly
Transfer box assembly
1. Introduction
Please refer to the given instruction of this chapter during
assembly process. And the following items shall be taken
notice on:
(a) In case that the torque of the threaded parts is required,
torque spanner shall be used to screw up the parts.
(b) The small parts shall be coated with the lubricant grease
during the mounting process, so that they are immobilized
at the mounting locations.
(c) SST such as thimble of T-13-54-001 shall be used to press
the oil seal and bearing during the oil seal mount and
bearing mount, do not use the hammer to strike the oil seal
or bearing directly.
2. Lubricating during assembling
All inner parts without lubricant shall be lubricated with the
suitable lubricant before mounting, so that they can be as-
sembled easily and can supply the original lubricant
performance.
(a) If the O-ring and oil seal were not lubricated before
mounting, they may be damaged.
(b) Be sure that the bearing or liner is lubricated completely
before mounting. Because the bearing or liner may be
leaded into damage even though they are run for a very
short time.
(c) The lips of oil seal and the metal elements that match with
lips shall be lubricated before mounting.
3. Transfer box housing assembly
Parts taken apart from the transfer box shall be mounted
according to the following approaches:
(a) If the gear ring needs to be changed, the tooth-type saddle
rear of new gear ring shall be flushed with the gullet of the
transfer box front housing when pressing the new gear
ring. Press in the gear ring as shown in the left bottom
drawing, in which, the chamfering end is firstly pressed
in. if it is ensured the gear ring is not tilted, then fasten the
gear ring tightly on the housing.
(b) In case there are two locating pins taken apart, mount two
new locating pins into the housing.
(c) Press the bearing into the transfer box front housing and
mount the snapping ring correctly, and
(d) Put down the new oil seal as shown in the left bottom
drawing and press it into the housing.

TF-16
110
9
8
6
5
4
3
2
11
15
14
13
12
17
18
19
207
16
1
2
3
Transfer Box
Transfer Box Assembly
1. torsion spring
2. gasket
3. shift shaft
1. planetary mechanism
assembly
2. gasket
3. snapping ring
4. thrust disc
5. sun wheel
6. planetary bracket
7. input shaft assembly
8. input shaft
9. needle bearing
10. bearing shell11. transfer box
frontbody assembly
12. oil seal
13. locating pin
14. transfer box front body
15. snapping ring
16. transfer box housing
17. bearing
18. bearing gripping loop
19. bolt
20. vent(d) Push the torsion spring and gasket backward together as
can as possible
(e) Mount the electric shifting cam on the shift shaft in such
way that the free end of the driving tongue of the cam is
put in first, fasten the cam driving tongue, which shall be
between the two spring ring of two torsion spring, under
the driving tongue of shift shaft and put it innermost as
can as possible.
(f) After mounting the toggle fork, then mount the electric
shifting cam assembly in the transfer box housing assembly
5. Assemble for front body, input shaft assembly and plan-
etary component element.
Mount the following element on the worktable:
(a) Put the planetary bracket assembly on worktable, and the
end with snapping ring groove shall face upward.
(b) Mount in the sun wheel and let the part with projecting
end upward, run the gear of the planetary bracket assem-
bly until it completely engages with the sun wheel.
(c) Flush the projecting teeth, and then mount the thrust disc
into the planetary bracket assembly.
(d) Mount in the snapping ring to complete the whole plan-
etary bracket assembly.

TF-17
1.25-1.75mm
23
1
12.70mm
13
2
4
4
2
1
5 6
7
83
(e) In the case that the input shaft is taken apart, what need
to do is to fill the needle bearing as shown in the drawing
and press it in the input shaft, meanwhile, press the new
sliding bearing to complete the whole input shaft assembly.
(f) Raise the planetary mechanism assembly to mount it into
the input shaft assembly; encase the thrust gasket and
press in the bearing through the input shaft end. Encase
the fixed bearing in the snapping ring groove of the input
shaft with a snapping ring.
(g) If the transfer box front body is taken apart, press the new
located pin in the front body, and the pressing dimensions
are shown in the drawing.
(h) Put down the oil seal as the drawing shows, and press it
in the front body according to the dimensions shown in
the drawing.
(i) Put down the front body assembly on two wooden blocks
in the way that the coupling face of the front body and the
housing faces upward, so that there is clearance left
between the input shaft assembly and the worktable. Put
down the input shaft and planetary mechanism assembly
in the front body, in which the input shaft shall be
downward. Open the long ends of the snapping ring to
encase input shaft and planetary mechanism assembly
until the snapping ring enters into the external snapping
ring groove of the bearing.
(j) Coat the sealing glue of 1.6mm on the coupling locations
of the front end cover and transfer box assembly, The
glue shall be coated continuously without break and steer
clear of the screwed hole.
(k) Screw up the six bolts.
Fastening torque
(27
46)N
m
6. Assembly of front output shaft
Mount the following parts:
(a) If the dust cover is taken apart, mount it by pressing.
(b) Encase the input shaft, sealing ring, gasket and nuts in the
transfer front housing.
(c) Insert the torque arm of T-13-54-002 in the flange hole to
screw up the nuts.
Fastening torque
(203
244)N
m Transfer Box
Transfer Box Assembly
1. needle bearing
2. bearing roller
3. input shaft
1. locating pin
2. oil seal
3. front body of transfer box
4. snapping ring
1. fork-type flange
2. dust cover
3. fork-type flange assembly
4. transfer box housing5. output shaft
6. oil seal
7. washer
8. nut

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
12
6
7
8
9 3
NO PQ
R
S T
Transfer Box
Transfer 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
4

TF-20
1 convex plate
groove2
3
4
5 6
1234
5
6
7
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 Box
Transfer 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 40.47
40.97 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
(8
11)N
m
(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.
8

TF-21
QR
NOP
NMSTN
UV
NOPQ
RS
(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
NO
P
Q
Transfer Box
Transfer 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

TF-23
5 4
3
1
6 2
Transfer Box
Transfer 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
(203
244)N
m

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

TF-25
(b) Normal gear grinding trace.
Transfer Box
Washing, 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 abrasion
Refer to the serious or obvious abra-
sion beyond of application limit.

Reduction change
Material slip caused by the heavy
pressure on part of it.

adhesive bonding
Granules 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 corrosion
Damages to the metal surface caused by
pressure, which are displayed due to color change caused
by heat generated by metal friction.

Step wear
a 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