Clutch master cylinder GREAT WALL SAILOR 2006 Service Manual

CL-1
CL
Page
Troubleshooting .......................................................... CL-2
Inspection and adjustment of clutch pedal ................... CL-3
Air exhausting of clutch ................................................ CL-3
Clutch master cylinder ................................................ CL-4
Clutch wheel-brake cylinder ......................................... CL-6
Clutch cluster ............................................................... CL-7
Clutch

CL-2Clutch
Troubleshooting
Troubleshooting
Trouble Causes Repairing approaches
Difficulty in gearshift
or non-gearshiftOverlarge free stroke of clutch pedal
There is air in clutch pipe
Failure of clutch brake-wheel cylinder
Failure of clutch master cylinder
Overlarge clutch pendulum difference due to incorrect mounting, the
friction liner is stained with oil or is breaking
There is dirty or adhesive materials on spline of input shaft or clutch rib
Failure of clutch pressure plateAdjust the free stroke of pedal
Exhaust the air in clutch pipe
Change the clutch brake-wheel cylinder
Change the master cylinder
Check the clutch rib
Repair according to requirement
Change the clutch pressure plate
Disengagement of gear
box or clutch slipAbrasion of clutch guide shaft
Insufficient free stroke of clutch pedal
The friction liner of clutch rib is stained with oil or is worn
Failure of clutch pressure plate
Seize up of separation forkChange the guide shaft
Adjust the free stroke of pedal
Check the clutch rib
Change the clutch pressure plate
Check the separation fork
Clutch seize-up or
shakingThe friction liner of clutch rib is stained with oil or is worn
Failure of clutch pressure plate
Looseness of engine seatCheck the clutch rib
Change the clutch pressure plate
Repair according to requirement
Looseness of clutch
pedalThere is air in clutch pipe
Failure of clutch brake-wheel cylinder
Failure of clutch master cylinderExhaust the air in clutch pipe
Change the clutch brake-wheel cylinder
Change the master cylinder
Over-loud clutch noiseSeize up of separation fork;
Abrasion or stained spot of separation bearing
Abrasion of guide bearing
Parts looseness in clutch pressure plateRepair according to requirement
Change the separation bearing
Change the guide bearing
Change the clutch pressure plate

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

CL-4Clutch
Clutch Master Cylinder
Clutch Master Cylinder
Element drawing
SST
Disassembly of master cylinder
1. Tear down the pin of push-rod
2. Tear down the clutch pipe
Disconnect the jointed pipe nuts with SST
3. Tear down the master cylinder
a) Tear down the fixing nuts;
b) Pull out the master cylinder.
spring pin with groove
clutch master
cylinder
18
2
19
1
ring pipe oil cup of clutch master cylinder
springpiston
U-clamppin open pin of nut
open ring
push-rod
gasketdust cover
N*m
specified torque

Parts that cannot be reused after using.nut

CL-5Clutch
Clutch Master Cylinder
Disassembly of oil cup of master cylinder
1. Tear down the oil cup
a) Use the pinch and hammer to tap out the spring pin with
groove;
b) Tear down the oil cup and ring pipe.
Assembly of master cylinder
1. Mount the oil cup
a) Mount the oil cup and the new ring pipe.
b) Use the pinch and hammer to tap in the spring pin with
groove.
Mount of master cylinder
1. Mount the master cylinder
Mount the fixing nuts and screw them up.
2. Connect the clutch pipes;
Connect the clutch pipes with SST
3. Connect the push-rod and mount the pin;
Encase the pin of push-rod with clamping pliers.
4. Exhaust the air in clutch system and adjust the clutch
pedal.

A-2
Clutch
Specification
Item Specification
Fastening torque for clutch tube on master cylinder
Fastening torque for clutch tube on wheel-brake cylinder
Fastening torque for clutch pressure plate160
190-200
5-15
0.3
0.8
0.2
0.6
5
Max misplacement
0.5 Pedal height (calculated from front wall
Pedal free stroke
Min depth of clutch-facing rivet
Max radial swing difference of clutch rib
Max radial swing difference of flywheel
Max width of wear of diaphragm spring
Max width of wear of diaphragm spring
Alignment degree of diaphragm spring endApplicable vehicle model
Dr SF
SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Torsion moment
Fastening location (N*m)
15-17
15-17
30 Applicable Vehicle model
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Gearbox
Three-grade maintenance for gearbox
1. Grade I maintenance for gear box
Grade I maintenance: Check the lubricant level to see whether the lubricant level is in alignment with the lower edge of oil
filler; if the lubricant is lower than the oil filler lower edge, add the lubricant; or the insufficient lubricant will lead to the poor
lubrication or burn-out of bearing and teeth; while the over-high lubricant will cause the overheating and oil leakage.
2. Grade II maintenance for gear box
Grade II maintenance: The gear box of a new vehicle should be maintained by exchanging the lubricant during the
first grade II maintenance and should be washed with kerosene; and the lubricant quality should be checked in the
grade II maintenance in later time, if the lubricant is diluted, gumming or over-dirty, it should be changed.
3. Grade III maintenance
The gearbox should be disassembled for inspection, washing and oil change.
Notice: As the new vehicle is in the running-in status, the gearbox should be maintained by exchanging lubricant
after the vehicle covers 1500 km,
Lubricant Type
GL-5 SAE80W/90
Torsion moment of relative connecting elements
Tung Teeth: Tang tooth(5DYA4TWD
5DYA8FWD)
Unit
ãã Specification of Maintenance and Up-Keeping
Clutch and Gearbox
Locating screw of fork axle at first and second gear
Locating screw of yoke block
Screw on baffle of rear bearing of output shaft
Screw of reverse idler shaft
Bolt of gearshift cover
Bolt of front cover
Bolt of rear body
Bolt of clutch shell
Bolt of locating spring13
17
15
20
17
22
17
20
15
20
15
20
30
45
30
45
17
22 Fastening location N*m