light GREAT WALL SAFE 2006 Service Manual

Preface
With the increase of automobile demand in China, our automobile industry also experiences a rapid
development. The trucks including SUV, manufactured by Great Wall Motor Co., Ltd, which are sold all over
China, are in the leading place in terms of their sales volume, in order to satisfy the demands of various maintain-
ing staff, technicians and managing staff of Changcheng Co., Ltd, we compile this maintenance manual accord-
ing to the latest technological data. This manual covers six vehicle models including Deer, Safe, Sailor, Sing, So
Cool and Pegasus, its main content includes:
Part I is general introduction, which introduces the application index of this manual.
Part II introduces the chassis system, which mainly includes the technologies of dismantle, inspection,
adjustment, repairing, assembly and mount of the clutch, gear box, transfer box, drive shaft, suspension system
and automobile axle, braking system and steering system, etc. each operation approach is illustrated with figure,
which not only presents the maintenance procedure, but also clearly describes the technical requirements and
application limit.
Part III introduces the electric system and air-conditioning system of the automobile body, which mainly
covers such items as the location and content of protective box, power supply system, starting system, lighting
system, combination instrument, backup radar system, wiping and washing system, center control locking and
power window system, acoustical equipment system, full wire harness and air-conditioning system, etc. Electric-
ity diagrams for those electric systems are given in this manual so as to facilitate the maintaining technicians to
find out the problem easily and quickly.
Part IV introduces the external and internal body decoration, which mainly covers the dismantling, inspect-
ing and assembling requirements of the engine cover, front and rear doors, adhesive strip of body collision
avoidance, wheel shield, wrapping angle of wheel-shield and exterior trim panel, front and rear windshields,
side-window glass, rear-door glass, rear platform of cargo compartment, rear door, instrument panel, safety belt,
seat, tail-fin, luggage rack, and reserve tire bracket etc. The dimensions of vehicle body and frame are also given
to maintaining staff for reference during their repairing.
During the narrations of each part, items such as troubleshooting, maintenance notice, maintenance data
and application limit, fastening torques of bolts and nuts for special purpose, SST, SSM and lubricant materials
and so on are also introduced. Various maintenance data are briefed in attachment for reference.
Altogether, this manual is comprehensive in content, visual in illustration, clarifying in requirement and
plain in language. It can be referred by the maintaining staff, technicians and professional managing staff.
Even though we try our best to compile this manual in a strict earnest manner, we cannot guarantee that all
contents in this manual are correct. Therefore, users shall not put forward any claim with Great Wall Company
according to this manual; we are not in the position to hold the responsibility for the loss caused by usage of this
manual. Due to our limited knowledge, it is unavoidable to find error in this manual, any criticism and correction
from you is welcomed.
The final explanation power for this manual is subject to Great Wall Motor Co., Ltd
Compiler
May 2006

CL-3Clutch
Inspection and Adjustment of Clutch Pedal, Air Exhausting of Clutch
Air-exhausting of clutch
Remark: in case operation needs to be conducted for the clutch
system or if there is air in clutch, exhaust the air.
Notice : Do not stain the painted surface with brake liquid,
if any brake liquid is left, wash it away immediately.
1.
Fill the brake liquid into the oil cup of clutch master cylinder;
The oil cup of master cylinder shall often be checked and, if
necessary, added with brake liquid.
2.
Connect the ethene resin pipe to the air-exhausting valve.
Insert the other end of the pipe into the container, half of which
is filled with brake liquid.
3. Air-exhausting in clutch system
a) Move the clutch pedal up and down slowly for several times.
b) Loosen the air-exhausting valve when pressing the pedal
increasingly until there is brake liquid overflowing, then
tighten the air-exhausting valve.
c)
Repeat this operation until the bubble in brake liquid disappears.
Inspection on and adjustment
of clutch pedal
1. Check whether the pedal height is correct
Pedal height that begins from front wall board:
Dr SF
(165
5)mm
SL SK SY SJ
(190-200)mm
2. Adjust the pedal height where necessary
Loosen the locking nut and screw off the adjusting bolts until
the pedal height is correct. Then screw up the locking nut.
Pedal free stroke
3. Check whether the pedal free stroke is correct
Press the pedal lightly until the resistance generated by clutch
occurs.
pedal free stroke: (5-15)mm
4. Adjust the pedal free stroke where necessary;
a) Loosen the locking nut and rotate the push-rod until the
stroke is correct;
b) Screw up the locking nuts;
c) Check the pedal height after the adjustment of pedal free
stroke.
adjusting spot in
pedal height
pedal height
pedal free stroke

MT-10Gearbox
Disassembly of Gear Box
Disassembly of Gear Box
1. Tear down the separation toggle fork and separation
bearing.
2. Tear down the backup switch, the driven gear of
speedometer.
3. Tear down the clutch from the gearbox frame.
Take apart the nine boits.
4. Tear down bolts of locating spring of the five-speed
toggle fork, locating spring and locking ball.
(a) Dismantle the bolts from the rear cover with the torque
socket spanner.
(b) Take out the spring and locking ball with magnetic rod.
5. Tear down the operating seat of gear change lever.
(a) Dismantle the setting bolts of the operating seat of gear
change lever.
(b) Take away the operating seat lightly and put it at the
suitable place.
6. Tear down axial locating pin assembly of shifting gear.
7. Tear down the fastening nuts of extension frame.
(a) Tear down the fixing bolts of gearshift shaft.
(b) Tear down the fastening nuts of expansion shell.

MT-11Gearbox
Disassembly of Gear Box
(c) Dismantle the nuts of the four-gear driven extension fram.
(d) Tap the extension frame lightly with rubber hammer to tear
down the selective gearshift shaft and selective rocker
arm.
8. Tear down front cover.
Dismantle the eight bolts and front cover and axial oil seal.
9. Tear down the input shaft, axial/bearing open ring and
countershaft bearing open ring.
10. Dismantle the gearbox frame from the central link plate,
(a) Put the gearbox straightly as shown in the drawing.
(b) Tap out the gearbox frame out carefully with the rubber
hammer. And
(c) Pull out the gearbox frame out from the central link plate
as the drawing shows
4WD

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-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.

TF-10
1. output shaft
2. shift engagement sleeve assembly
3. locking sleeve
4. return spring
5. engagement sleeve
6. snapping ring
7. shift lock hub
8. clutch assembly
9. fastening snapping ring
10.shift guide shaft
11.toggle fork
Transfer Box
Disassembly of Transfer Box
1. front case of transfer box
2. rear output shaft
3. cluch coil assembly
4. clip
5. bearing
6. nut
7. transfer cover assembly
8. mark plat
9. bolt
10. odometer drave gear
11. oil seal
12. oil seal
13. bearing
14. rear cover of transfer box
15. rolling needle bearing
16. shift guide shaft
17. back spring
18. magnet
19. bundle clip10
9
8
12
13
14
157 7
6
5
4
3
16
17
18 2
1
19
911
3. The disassembly approach for rear cover is as follows (above figure)
(a) Dismantle the nine screws and take down the clip of wire harness and
signboard in the same time.
Notice shall be taken to good keeping for the signboard, which includes the
information for the substitutes to be changed.
(b) Pry the frame lightly so that the sealing glue on the surface disengages, and
then take up the transfer box rear cover assembly directly.
(c) As for the electric gearshift transfer box, tear down the oil seal, bearing and
three nuts and clutch coil assembly.
(d) Tear down the snapping ring, pull out the bearing from the rear cover and
take apart the odometer meanwhile.
(f) Pull out the oil seal from the rear cover of the transfer box.
(g) Tear down the magnet from the front body of transfer box.
(h) Take apart the return spring from the shift guide shaft
(i) Clear away the sealing glue on the coupling face of the front housing and
rear cover of transfer box, take notice not to damage the coupling face of
the two housings or cause the materials removed dropping into the transfer
box.
4. Tear down the shifting element connected with the front axle.
Tear down the following parts from the remaining transfer box housing
assembly (electric gearshift).
(a) Electric gearshift assembly, tear down the snapping ring and sliding clutch
sleeve from the shift locking hub.
(b) Tear down the shift-locking hub from the rear output shaft.
(c) Tear down the shift engagement sleeve assembly and shift toggle fork from
the rear output shaft and shift guide shaft. Separate the assemblies one
another and tear down the shift guide shaft.
(d) Disassemble the shift engagement sleeve assembly by taking apart the
snapping ring, engagement sleeve, return spring, and locking sleeve.
(e) A plastic toggle fork that substitutes the metal toggle fork assembly and a
independent contact roller in earlier time.
1
9
8
7
6
5
Q
32
10
11

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

PR-8Drive Shaft
Drive Shaft
3. Inspection for the front axle drive shaft
(a) Check the wear or damage situation of the shaft.
(b) Check the wear or damage situation of the two universal
joints
grease nozzle
rear axle drive shaft front axle drive shaft
assembly mark
assembly mark
SST
A4. Inspection for the drive shaft lubrication
If the drive shaft is not lubricated completely, add the Lithium
base lubricant grease with SST.
Cross bearing change
1. Label the shaft and universal joint yoke with assembly
marks.
2. Take apart the snapping ring.
(a) Tap in the outer bearing race lightly.
(b) Take apart the four snapping rings in the grooves with
two screwdrivers.
3. Take apart the cross shaft bearing
(a) Pull out the bearing from the drive shaft with SST tools.
Remarks: Pull up the part A in the drawing to a enough height
so that it cannot contact the bearing.

PR-9Drive Shaft
Drive Shaft
SST
(c) Mount the two outer bearing races that are taken apart on
the cross shaft.
(d) Pull out the bearing on the universal joint yoke with SST
tool, and (b) Grip the outer bearing race with a vice to tap out the drive
shaft lightly with a hammer.
Remarks: Take apart another bearing with the same approach.
4. Cross shaft bearing mount
(a) Coat the lithium base grease on the cross shaft and the
bearing.
Remarks: do not over coat the lubricant.
(b) Align the assembly marks on the universal yoke and on
the shaft. (e) Grip the outer bearing race in the vice and tap lightly out
the universal joint yoke with a hammer.
Remarks: the bearing at the other end may be taken apart with
the same approach.