torque GREAT WALL SAILOR 2006 Owner's Manual

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-22
12
3 4
6
7
8
95
21
Transfer Box
Transfer 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
(8
11)N
m
(d) Mount the bolts and gaskets on the end of motor clip.
Fastening torque
(8
11)N
m

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

PR-3
Drive Shaft
Element Drawing
2WD
two-joint type

snapping ring
bearing of cross shaft




universal joint flange fork


rear axle drive shaft
universal joint foke
cross shaft
three-joint type

snapping ring
bearing of cross shaft
universal
joint foke
cross shaftfront joint of rear
axle drive shaftcenter support
bearingflange
washer
washer
74
5
40
5
universal joint
flange fork
74
5
74
5universal joint
flange fork
rear section of
rear axle drive
shaft










N*m: specified torque

Parts that cannot be reused after being used
Drive Shaft
Drive Shaft

PR-4Drive Shaft
Drive Shaft
Element Drawing(continued)
4WD
front axle drive shaft
front axle drive shaft74
5
74
5
rear axle drive shaft
two-joint type

snapping ring
bearing of cross shaft
74
5
74
5

cross shaftuniversal joint yokerear axle drive shaft


universal joint flange fork
three-joint type









74
5
40
5
snapping ring
bearing of cross shaftcenter support
bearing
flange
front joint of rear
axle drive shaftwasher
universal joint flange fork
74
5
74
5
rear section of
rear axle drive
shaft
universal joint
flange fork

Parts that cannot be reused after being used
N*m
: specified torque

PR-11Drive Shaft
Drive Shaft
Drive shaft assembly
1. Mount the center support bearing on the front joint of rear
axle drive shaft.
Remarks: The notch of the center support bearing shall face
backward when mounting it.
2. Mount the flange joint on the front joint of rear axle drive
shaft.
(a) Coat the spline of front joint of rear axle drive shaft with
lithium base grease.
(b)
Mount flange joint on the shaft and align the assembly marks.
Remarks: if the central flange joint or the front joint of the rear
axle drive shaft is required to change, the front and back
universal joint yokes of the rear axle drive shaft shall face in the
same direction when re-assembling.
(c) Lock the flange joint with SST and screw up the newly-
changed nut to press the bearing in place.
(d) Loosen the nuts.
(e) Tighten the nuts again, and
(f) Rivet the nuts with hammer and punch.
3. Drive shaft mount
(a) Align the assembly marks on flanges, and connect the
two flanges with four sets of bolt and nut.
Remarks: if the central flange or the front joint of the rear axle
drive shaft is required to be changed, the front and back
universal joint yokes of the front joint of rear axle drive shaft
shall face in the same direction when reassembling them.
(b) Screw up the sets of bolt and nut according to the
specified torque.
Fastening torque: (74
5)N
m
4. Insert the universal joint yoke in the universal joint yoke
(4WD).
(a) Coat the lithium base grease on the sliding surfaces of the
drive shaft spline and the universal joint yoke.
(b) Align the assembly marks on universal joint yoke and
drive shaft.
(c) Insert the universal joint yoke in drive shaft.
assembly mark
2WD 4WD
forward
assembly mark
SST
assembly mark

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

PR-13Drive Shaft
Drive Shaft
2. Mount on the front axle drive shaft.
Mount on it and screw up the four bolts according to the
specified torque.
Fastening torque
(74
5)N
m
3. Connect the universal joint flange fork of the rear axle
drive shaft on the relative differential flange.
(a) Align the assembly marks on flanges and connect the
flanges with four sets of bolt and nut, and
(b) Tighten the sets of bolt and nut according to the specified
torque.
Fastening torque
(74
5)N
m
4. Mount the center support bearing on the frame beam
(three joint type)
(a) Use two mounting bolts to mount the center support
bearing on the frame beam and screw up them manually.
(b) Check the bearing seat, which shall be vertical with the
drive shaft, and adjust the bearing seat when necessary.
(c) Check the central line of the central bearing. The central
line of the central bearing shall be the same with that of
the bearing seat when vehicle is in the non-loaded stage.
(d) Adjust the bearing seat if necessary, and
(e) Screw up the mounting bolts according to the specified
torque.
Fastening torque
(40
5)N
m
assembly mark
forward

SA-4Suspension System and Automobile Axle
Alignment of Front Wheel (Dr SL SK SY SJ)
5. Adjustment for inner tilt angle of kingpin, outer tilt angle
of front wheel and back tilt angle of kingpin
Item
Inner tilt
angle of
kingpin
Outer tilt
angle of
front
wheelApplicable vehicle type
Dr SL SK SY
SJ
Mechanic
steeringDr SL SK SY
Power
steeringDr
SL SK SY
SJ
Back tilt
angle of
kingpinMechanic
steeringDr SL SK SY
Power steer-
ingDr SL SK SY
SJ9
30
45

14
52

0
30
20

0
10
10

0
20
10

0
30
15

2
45
15

3
15
Location parameter
4. Adjust the wheel angle
Take apart the limit bolts of the steering knuckle to check the
steering angle A of inner wheel.
Inner wheel steering angle
Dr SL SK SY
( 36
40
)
SJ
( 32
34
)
Remark: The wheel should not contact the body or brake hose
when the steering wheel reaches the limit position.
In case the steering angle of inner wheel doesnít conform to the
standard value, adjust the wheel angle through adjusting the
limit bolts of the steering knuckle.
Fastening torque
(90
0)N
m(SJ)
If the wheel angle fails to be adjusted within the standard value,
change the weary or damaged parts of steering system.
If the tilt angle fails to fall within the specified values, make an
adjustment through adding or reducing the gaskets on the
location of upper arm.
Gasket thickness: 3.0, 2.0 and 1.0mm
Once the gasket thickness increases by 1mm, the outer tilt
angle of wheel will change by 7', while the back tilt angle of
kingpin will change 20'.
After the wheel outer tilt angle and the back tilt angle of kingpin
are adjusted, if the inner tilt angle of kingpin still fails to the
specified value, check the steering knuckle or front wheel to
see whether they are bending or loose.
1
50
-20

adjusting bolt
outer tilt
angle of
front wheel inner tilt angle of kingpin
back tilt angle of
kingpin
front AB AB
HPM

SA-5
7. Check the sliding measuring situation.
Check the sliding situation with the sliding measuring tester.
Sliding measuring value:
.5m/km
push forward the vehicle;
forward
A=BB A
6. Wheel toe-in adjustment
(a) Verify that each wheel has been located forward in a line.
(b) Mark the tire center at the bearing height on the tread of
left and right tire, and measure the distance between the
marks on left and right treads.
(c) Push forward the vehicle until the mark on the back tread
of tire moves to the front.
Remark: the toe-in measurement should be conducted from the
same spot at the same height.
(d) Measure the distance between the two marks on the front
of two treads.
Toe-in value: (0-2)mm
(e) Loosen the clamping bolts of connecting pipe.
(f) Adjust the toe-in angle through the approach according to
which rotate the left and right drag rod tube by a same
angle.
Remark: check the lengths of the two drag rods to see whether
the two rods are same in length.
Length error of the left and right drag rod should not
be larger than 2.0mm.
(g) Tighten the clamping bolts.
Fastening torque
(20
) N
m
(h) Locate the split pin well.
Suspension System and Automobile Axle
Alignment of Front Wheel (Dr SL SK SY SJ)