Gear box GREAT WALL SAILOR 2006 Owner's Guide

MT-35Gearbox
Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism)
(c) Coat the sealing agent on the bolt thread.
(d) Propel the plug with the torque socket spanner.

MT-36Gearbox
Bearing Front Cover Assembly (Element Drawing, Change of Oil Seal)
Bearing Front Cover Assembly
element drawing
bearing front cover
assembly
washerfront cover oil seal
assembly
Change of oil seal
The oil seal of the bearing front cover shall be changed where
necessary
(a) Pry out the oil seal with screwdriver
(b) Press in the new oil seal with SST.
Depth of oil seal:
Upper tooth
9.5mm
Tang tooth
(12.4
0.4)mm
SST

MT-37
Assembly of Gearbox
1. Mount the output shaft in the central link plate
(a) Tap the output shaft in the central link plate while pulling
it, until mounting it in the central link plate.
(b) Mount the stop ring of the rear bearing of output shaft in
with the split-ring-type pliers.
Remarks: The stop ring shall flush with the surface of central
link plate.
2. Mount the input shaft in output shaft
(a) Coat the MP lubricant on the bearing with 13 needle
rollers, and mount the needle rollers in input shaft.
(b) Propel the input shaft in the output shaft and flush the
groove of synchronizing ring with the sliding block.
3. Mount the countershaft in the central link plate
(a) Mount the stop ring on the rear bearing of countershaft
with split-ring-type pliers.
alignment
Gearbox
Assembly of Gearbox

MT-38Gearbox
Assembly of Gearbox
(b) Mount the intermediate-gear shaft in the central link
plate, and mount the backup rear bearing with SST while
holding the intermediate-gear shaft.
4. Mount the baffle of rear bearing of output shaft
Mount and propel the bolts with torque socket spanner.
Tightening moment

Tang tooth
(17
22)N
m
Upper tooth
(12
17)N
m
5. Mount the reverse idle gear and shaft
(a) Mount the reverse idle gear and shaft.
(b) Mount the axial pressing plate of the reverse idle gear,
and then propel the bolts tightly.
Tightening moment
(15
20)N
m
6. Mount the bracket cluster of reverse rocker arm
Mount the reverse rocker arm bracket and propel the two bolts
tightly.
SST

MT-39
locking ball
socket spanner
Gearbox
Assembly of Gearbox
7. Mount the steel ball and the five-speed thrust washer.
8. Mount the five-speed gear cluster
(a) Coat the gear oil on the needle bearing.
(b) Mount the five-speed gear cluster.
9. Mount the synchronizing ring and the fifth coupling gear
(a) Mount in the synchronizing ring and the fifth coupling
gear.
(b) Dismantle the old central link plate from the table vice.
(c) Put the gearbox straightly as shown in the drawing.
(d) Flush the groove of synchronizing ring with the sliding
block and mount the fifth coupling gear with pressure
machine.
(e) Mount the new central link plate in the table vice.

MT-40Gearbox
Assembly of Gearbox
10. Mount the split ring
(a) Select the retainer for shaft that leaves the minimum
radial clearance, which is not larger than 0.1mm.
(b) Mount in the retainer for shaft with copper bar and
hammer.
(c) Mount the spring cylindrical pin of third-fourth-speed
gearshift fork.
Notice: The pin port should align with the direction of the
shaft.(Same sa below) 11. Measure the radial clearance of the five-speed gear
cluster.
Measure the radial clearance of the five-speed gear cluster
with the measuring gauge.
Standard clearance

Shang chi
(0.135
0.325)mm
Tang chi
(0.1
0.3)mm
12. Mount the third-fourth-speed gearshift fork axle and the
first-second-speed gearshift toggle fork as well as the
third-fourth-speed gearshift toggle fork
(a) Mount the first-second speed and third-fourth speed
gearshift toggle forks.
(b) Mount the third-fourth-speed gearshift fork axle in the
central link plate and the gearshift toggle fork.

MT-41Gearbox
Assembly of Gearbox
13. Mount the first gearshift fork axle and first gearshift fork
(a) Coat the MP lubricating on the interlocking guidepost
and mount the interlocking guidepost on the first-second-
speed gearshift fork axle.
(b) Mount the interlocking pin in the central link plate with
the magnetic bar.
(c) Mount first-second gearshift fork axle in the first gear-
shift toggle fork and central link plate.

d) Mount the setting bolts of the first toggle fork and tighten
them.
Tightening moment

Upper tooth
(15
20)N
m
Tang tooth
(13
17)N
m
14. Mount the reverse yoke rod, reverse rocker arm and
reverse yoke block
(a) Mount the reverse yoke rod, reverse rocker arm and
reverse yoke block together.
(b) Mount the reverse rocker arm on the reverse rocker arm
bracket.
(c) Coat the MP lubricant on the interlocking guidepost and
mount the guidepost on the reverse gearshift fork axle.

MT-42Gearbox
Assembly of Gearbox
(d) Mount the interlocking pin in the central link plate with
the magnetic bar.
(e) Mount the reverse gearshift fork axle in the reverse yoke
rod and central link plate.
(f) Mount the spring cylindrical pin with the drift punch and
hammer.
15. Mount the five-speed reverse gearshift guide block and
five-speed reverse gearshift fork axis.
(a) Mount the five-speed reverse gearshift guide block in the
five-speed reverse gearshift guide shaft.
(b) Mount the reverse gearshift fork axle in the next step.
(c) Mount the steel ball in the five-speed gearshift guide
block with the magnetic bar.
(d) Mount the five-speed gearshift fork axle as shown in the
drawing.
(e) Mount the steel ball in the central link plate with mag-
netic bar.
(f) Mount the five-speed gearshift fork axle in the central
link plate.

MT-43Gearbox
Assembly of Gearbox
(g) Tap the pin in the five-speed gearshift toggle fork with
the drift punch and hammer.
(h) Mount the five reverse gearshift guide shaft in the five-
speed reverse guide block and central link plate, and
(i) Tap the spring cylindrical pin in the five-speed reverse
guide block with drift punch and hammer.
16. Mount the retainer ring gripped by the gearshift fork axle.
Mount the clamp retainer ring with the steel bar and hammer

MT-44
sealed material
Gearbox
Assembly of Gearbox
17. Mount the steel ball, locating spring and locating spring
plug
(a) Mount the steel ball and locating spring.
Remarks:
Mount the short spring at the bottom of the central link plate.
(b) Coat the sealing agent on the plug thread.
(c) Mount the plug and tighten them with the torque socket
spanner.
Tightening moment
(17
22)N
m
18. Tear down the central link plate from the table vice
(a) Tear down central link plate from the table vice.
(b) Dismantle the bolts, nuts and washers
19. Mount the gearbox frame
(a) Coat the sealing material on the coupling face of the
gearbox frame as shown in the drawing.
(b) Put down the central link plate straightly as shown in the
drawing.
(c) Mount the gearbox frame on the central link plate as
shown in the drawing.