differential GREAT WALL SO COOL 2006 User Guide

SA-63
1. Tear down the front long semi-axis and the front minor
half-shaft
Pull out the front long and minor semi-axis from the front
speed reducer with tool.
2. Tear down the front drive axle shaft sleeve and screw off
the bolts connecting the half-shaft sleeve.
3. Tear down the oil seal - front half-shaft:
Tear down the oil seal-front half-shaft with the special service
tool.
Change of Axle Shaft Oil Seal

snapping ring
front minor half-shaft
front speed reducer and differential

oil seal-front half-shaft
front long
semi-axis

snapping ring
88
N
M
specified torque

Parts that cannot be reused after being used)
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Change of Axle Shaft Oil Seal)

SA-65
Disassembly and Assembly of Front Speed Reducer
Element figure
front minor half-shaft

snapping ringbearing 31306 front speed
reducer shell
oil-guard trayflange and dust cover
driving bevel gear oil seal
jacketoil seal-front half-shaft

Parts that cannot be reused after being used

s pecified torqueN
M
140-210 bearing 32307
driving bevel gear oil seal
speed reducer coveradjusting washer
bearing 50KB801
47
cap-differential
bearing
78

lock plate adjusting washer
half axle gear thrust
gasket
planetary gear shaft
half-axle gearplanetary gear stop gasket
planetary gearaxle driven bevel gear front differential housing
adjusting gasket
pin
70-90 retainer ring
front long semi-axisbearing B36Z-10







oil seal-front half-shaft
adjusting washer
snapping ring
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-68
10. Tear down the inner race of bearing 31306 with SST;
If the bearing is damaged, change with a new bearing.
11. Tear down the cap-differential bearing.
12. Take out the differential.
13. Take down the outer race of bearing 50KB801 and mark
clearly the left and right parts to avoid of confusion during
reassembling. 9. Tear down the driving bevel gear oil seal and the oil-
guard tray:
(a) Tear down the oil seal from the driving bevel gear with
SST.
(b) Take out the oil-guard tray.
right
left
left
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)
14. Tear down the adjusting gaskets and clearly mark the left
and right to avoid of confusion during re-assembling.
right

SA-70
4. Tear down the inner race and roller assembly of the two
bearings 50KB801 from the differential housing.
Tear down the inner race and roller assembly of bearing
50KB801 with SST.
5. Tear down the axle driven bevel gear:
Tear down the bolts and lock plate by tapping lightly the axle
driven bevel gear with the copper until tear them down. 3. Change the outer race of bearing 31306:
(a) Tap down the outer race of bearing 31306 with copper bar
and hammer.
(b) Press in the new outer race of bearing 31306 with SST.
Remark: the inner race of the bearing should be changed with
the outer race together.
6. Differential disassembly
(a) Tap out the pin with SST.
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-71
(b) Tear down the planetary gear shaft to take out the planetary
gear, planetary gear stop gasket, half-axle gear and the
half axle gear thrust gasket
7. Differential assembly mount
(a) Clean the differential housing.
(b) Encase the half-axle thrust gasket in the differential
housing after covering on the half-shaft gear.
(c) Run the half-axle gear to encase the planetary gear and
planetary gear stop gasket, and put on the planetary gear
shaft.
Remark: The half-axle gear and the planetary gear should run
freely without stagnant.
(d) Measure the clearance between the half axle gear thrust
gasket and differential housing.
Push the planetary gear to the inside and then measure
the clearance between half-axle gear thrust gasket and
the differential housing with the dial-indicating lamp.
Suitable clearance range: (0.4-0.75)mm
Remark:If the clearance fails to fall within the above-
mentioned range, change the half-axle gear thrust gasket,
and ensure that the thrust gaskets on the both sides are
same thick.
(e) Tap the pin in the pinhole of differential housing and the
planetary gear shaft with SST, and rivet the hole port so
as to prevent the pin from missing.
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-72
(f) Clean the differential housing surface, mount the axle
driven bevel gear on the differential housing with copper
bar.
Notice: align the assembly marks made when
disassembling when mounting the axle driven bevel
gear, and tap in the driven bevel gear evenly alongside
the direction of circumference.
(g) Mount on the lock plate and screw on the bolts, then lock
the lock plate with the drift pinch and hammer.
Fastening torque
(70-90)N
m
Notice: the bolts should be screwed up in the diagonal
order in such manner that tighten a little at first, and then
screw up evenly to the specified torque, the lock plate
claw should contact closely the side face of bolt head.
(h) Press the inner race and roller assembly of bearing
50KB801 in the bearing position at the both sides of
differential housing.
(i) Put the adjusting gasket in the outer position of the side
bearing of front speed reducer shell.
(j) Encase another adjusting gasket with the outer race of
bearing 50KB801 in the front speed reducer shell to-
gether with the differential.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)
(k) Mount on the right and left cap-differential bearing, and
screw up the bolts with spanner according to the specified
torque.
Fastening torque
78N
m

SA-73
(l) Run the flange to check the swing difference of axle
driven bevel gear.
Max swing difference
0.07mm
Remark: if the requirement is not satisfied, tear down the axle
driven bevel gear from the differential, and then screw up the
bolts again.
8. Change the bearing of the long semi-axis:
(a) Take down the retainer ring with the calipers.
(b) Tear down the grooved ball bearing from the long semi-
axis.
(c) Mount on the new grooved ball bearing on the long semi-
axis
(d) Mount on the retainer ring with calipers.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-75
8. Encase in the differential:
(a) Put the adjusting gasket in the outer position of bearing
at the side of the front speed reducer shell, and then
Encase the differential in the front speed reducer shell, be
sure there is a play between the driving gear and the
driven gear.
(b) Tap the axle driven bevel gear with the rubber hammer,
so that the bearing 50KB801 on the differential, together
with the adjusting gasket, contact the mounting part of
the side face of speed reducer closely.
9. Measure the clearance between the axle driven bevel
gear and the driving bevel gear with the dial indicator to
select the adjusting gasket that satisfy the reasonable
play of (0.15-0.25)mm.
10. Select the adjusting washer for the other side:
The thickness of adjusting gasket should eliminate the clear-
ance between the bearing 50KB801 and the front speed re-
ducer shell, on the other side, the adjusting gasket should not
be over thick because the over-thick gasket will lead in too
large pre-tightening force on the bearing 50KB801 of
differential.
11. Tear down the adjusting gasket and differential, and
encase the new adjusting gasket in the front speed
reducer shell, and another adjusting gasket, together
with the differential housing, should be encased in the
front speed reducer shell correctly.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Assembly of Front Speed Reducer)

SA-76
12. Measure the clearance between the axle driven bevel
gear and the driving bevel gear with dial indicating lamp.
Clearance: 0.15-0.25mm
Remark: if the play fails to fall within the specified range,
change with the adjusting gasket of other thickness to satisfy
the requirement under the precondition there is no clearance
between the adjusting gasket and the differential.
14. Measure the total preload of the front speed reducer with
torque tester;
Fastening torque
(1.8-2.4)N
m 13. Mount on the left and the right cap-differential bearing:
Screw up the bolts with spanner to the specified torque;
Fastening torque
78N
m
15. Check the teeth engagement between the axle driven
bevel gears:
(a) Coat three or four teeth at three different positions of the
axle driven bevel gear in red
(b) Hold the flange tightly while rotating the axle driven
bevel gear.
(c) Check the teeth engagement situation.
Remark: the trace of the teeth of axle driven bevel gear should
satisfy this requirement. Otherwise, select the suitable adjust-
ing washer for correcting according to the situation of poor
teeth engagement;
Select the adjusting gasket that makes the main teeth apart
from the axle driven bevel gear.
convex surface of gear
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Assembly of Front Speed Reducer)
concave surface of gear

SA-83
Rear speed reducer
Element figure
column bolt
bearing7306E
oil-guard tray

oil seal
flange and dust
cover assembly
flat washer

adjusting ring
bearing 200719Espeed reducer housing and
differential bearing coverstop gasket80-110
18-26

washer
adjusting washer
driving bevel gear
Bearing 7607E jacketadjusting washer
65-95
=
lock plate
differential housing
axle driven
bevel gear

Parts that cannot be reused after being used:specified torque
N
M
Suspension System and Automobile Axle (Rear)
Rear Speed Reducer
double-eared stop washer