Gear box GREAT WALL SAILOR 2006 Workshop Manual

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-11
5. Tear down the Chain drive system
Take apart the following parts from the transfer box housing
assembly.
(a) Take apart the snapping ring and washer from the front
output shaft.
(b) Take apart the driving chain sprocket, driven chain
sprocket and drive chain together from the two output
shafts.
(c) Separate the chain sprocket from the chain.
12
345
6 7
1. output shaft
2. driving chain sprocket
3. driven chain sprocket
4. washer
12 34
5
6 7
6. Oil pump assembly
Take apart the shaft and pump assembly, pipe clip, oil pipe and
filter from the remaining transfer box housing assembly.
1
2
7
6 3
4
5
8 1. deceleration gear hub
2. inserted face of Shift
toggle fork
3. plastic sleeve
4. contact roller
5. pin
6. pin, contact roller and sleeve assembly
7. deceleration shift toggle fork
8. deceleration shift toggle fork assembly7. Deceleration shifting element disassembly
Tear down the following parts from the remaining transfer box
housing assembly.
(a) Take apart the deceleration hub, and deceleration shift
fork assembly from the housing.
(b) Take apart two plastic inserted faces from the decelera-
tion shift fork assembly
(c) Disassembly the deceleration shift fork assembly only if
it were broken.Cut the plastic cover,and take out the pin
and truckle. Transfer Box
Disassembly of Transfer Box
1. output shaft
2. driving chain sprocket
3. driven chain sprocket
4. washer
5. snapping ring
6. transmission chain
7. front output shaft5. snapping ring
6. transmission chain
7. front output shaft

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-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-19
1
9
8
7
6
5
4
32
10
11
12
345
6 7
Transfer Box
Transfer Box Assembly
9. Assembly of driving chain
The parts assembly process is as follows:
(a) Put the driving chain sprocket at the rear end of the output
shaft, and the driven chain sprocket is put at the rear end
of the front output shaft on the worktable after the transfer
box housing assembly mount.
(b) Mount the chain on the sprocket.
(c) Holding the two chain sprockets parallel with the transfer
box in the space that the chain on the two sprockets are
straightened, and encase the chain and sprocket assembly
through the output shaft, it is required to run the chain
sprocket slowly to ensure that they engage with the front
output shaft and the spline.
(d) Mount the gasket and snapping ring on the front output
shaft.
10. Shift locking element assembly
The parts mounting process is as follows (for the electric shift
transfer box):
(a) Mount the return spring and locking hub on the locking
sleeve and fasten them with snapping ring to finish the
2W-4W locking sleeve assembly.
(b) Encase the shift guide shaft in the blind hole of the
housing through the deceleration toggle fork assembly
that is already assembled.
(c) Mount the shift toggle fork on the 2W-4W locking sleeve
assembly, which will slide through the shift guide shaft
and rear output shaft.
(d) Joint the combined external gear sleeve spline and the
rear output shaft spline as well as the 2W-4W locking
sleeve.
1. output shaft
2. driving chain sprocket
3. driven chain sprocket
4. washer
5. snapping ring
6. transmission chain
7. front output shaft
1. output shaft
2. shift engagement
sleeve assembly
3. locking sleeve
4. return spring
5. engagement sleeve6. snapping ring
7. shift lock hub
8. clutch assembly
9. fastening snapping ring
10. shift guide shaft
11. toggle fork

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-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