GREAT WALL SO COOL 2006 Service Manual

SA-80
Dismantle of Rear half Axle Shaft
1. Tear down the wheels.
2. Tear down the rear brake drum.
3. Tear down the grab end of the bracing wire of hand brake
from the rear brake.
4. Tear down the half-shaft and the rear brake assembly
from the rear axle housing.
5. Tear down the flat steel retainer ring for shaft from the
half-shaft;
Tear down the flat steel retainer ring for shaft with the ring
calipers.
6. Tear down the half-shaft:
Put down a wooden plate on the flat ground, and thrust the end
of spline of half-shaft and rear brake assembly toward the
wooden plate to separate the shaft and the rear brake assembly.
Inspection on and repairing of half-shaft parts
1. Check the wear, damage and swing difference half-shaft
and the flange.
Max shaft run-out: 2 mm
Max flange run-out: 0.2 mm
In case the half-shaft is damaged, or wearied or the measuring
value of the swing difference is excessive, change the half-
shaft.
2. Check he oil seal of rear wheel bearing:
Check to see whether there is wear or damage, and change the
oil seal if necessary.
3. The disassembly of the outer oil seal of rear wheel
bearing;
Tear down the outer oil seal of rear wheel bearing with SST. Suspension System and Automobile Axle (rear)
Rear Half Axle Shaft

SA-81
4. Check the grooved ball bearing
Check the grooved bearing to see whether there is damage or
wear.
5. Change the bearing where necessary:
(a) Press out the grooved ball bearing with SST.
(b) Press in the new grooved ball bearing with SST.
6. Mount the new oil seal of rear wheel bearing.
Press in the new oil seal of rear wheel bearing with SST
Coat moderate lithium base grease on the lip open of oil seal.
7. Check the bearing seat.
Check the wear or damage situation.
8. Change the bearing seat where necessary:
(a) Tear down the oil seal of rear wheel bearing and the
grooved ball bearing with SST.
(b) Tap the bolts with copper bar to tear down the bearing seat.
(c) Mount the new grooved ball bearing and the oil seal of
rear wheel bearing on the bearing seat
(d) Press the rear brake, which is put on with bolts, in the
bearing seat.
9. Check the wear or damage of the inner oil seal of the rear
wheel bearing.
10. Change the rear wheel bearing where necessary:
(a) Tear down the oil seal of rear wheel bearing with SST. Suspension System and Automobile Axle (rear)
Rear half Axle Shaft

SA-82
11. Mount the new inner oil seal of rear wheel bearing.
Coat the hyperbolic gear oil on the axle housing where matches
with the oil seal; and plaster the moderate lithium base grease
on the lip open of the oil seal, then put them on the pressure
head and press them in.
Mount of Rear Axle Shaft
1. Press the rear brake and the bearing seat assembly on
the haft shaft.
2. Press the heated inner oil seal seat of rear wheel bearing
on he half shaft;
Notice: the face at the chamfering end of inner oil seal of
rear bearing should contact the oil seal closely, do not
mount it at the incorrect position.
Requirement for heat mount: heat the inner oil seal seat into the
22# oil (GB443-1989) to 100
, after the part is heated
completely, take it out for mount.
3. Mount on the flat steel retaining ring with the ring calipers.
4. Encase the half-shaft rear brake in the axle housing,
screw on the self-locking nut.
Tightening moment
(63-79)N
m
Notice: protect the oil seal lip open, bracing wire assembly
and the oil-guard sleeve.
5. Mount on the hand brake wire and the brake pipe.
6. Mount on the liner and rear brake drum;
7. Make a trial gas exhaust on the braking system, and
8. Mount on the rear wheels.
Suspension System and Automobile Axle (rear)
Rear Half Axle Shaft

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

SA-84
On-vehicle Change of main-teeth oil seal
1. Disconnect the drive shaft from the speed reducer:
(a) Mark the assembly mark on the two flanges;
(b) Tear down the four sets of bolt and nut.
2. Tear down the flange and dust cover assembly.
3. Tear down the oil seal.
Tear down the oil seal with SST.



4. Mount on the new oil seal:
(a) Coat the lithium base grease on the lips of oil seal;
(b) Tap in the new oil seal with SST.
Remark: tap the new oil seal until it is in place.
5. Mount the flange and dust cover assembly.
6. Screw up the nut to the specified torque.
Specified torque: (140-160)N
m
7. Rivet the nut.
8. Connect the drive shaft flange with the speed reducer
flange:
Align the assembly mark and connect the flanges with bolts.
Tightening moment
(69-79)N
m
9. Check the oil level of the speed reducer.
Change the gear oil where necessary.
Oil brand: heavy-duty oil of grade
GL-5
Oil volume: add the oil until it overflows from the oil filler
outlet.
Viscosity: SAE 85W/90 Suspension System and Automobile Axle (Rear)
Rear Speed Reducer

SA-85
Dismantle of Rear Speed Reducer
1. Take out the oil drain plug to drain the oil in the speed
reducer up.
2. Tear down the rear axle shaft.
3. Disconnect the drive shaft from the speed reducer.
4. Tear down the nuts on the bolts that connect the rear axle
housing and the speed reducer.
5. Tear down the rear speed reducer.
Disassembly of Rear Speed Reducer
Remark: in case the noise is over loud, the following item
should be checked before taking apart it to find out the causes.
If the speed reducer has serious drawback, take it apart for
repairing where necessary.
1. Check the play between the axle driven bevel gear;
In case the play value fails to be within the specified range,
adjust the preload of bearing 200719E or repair it where
necessary.
(see page SA-91)
Standard play: (0.13-0.25)mm
2. Check the teeth engagement of the driving bevel gear
with the axle driven bevel gear.
(See Page SA-92)
Record the teeth engagement positions.
3. Check the clearance between the half-shaft gear thrust
gasket and the differential housing.
Check the clearance between the half-shaft gear thrust gasket
and the differential housing with the feeler.
Standard clearance
(0.45-0.75)mm
Remark: in case the clearance value fails to fall within the
above range, change the half-shaft gear stop gasket, and
ensure the half-shaft gear stop gaskets on the left and right
sides are same in thickness.
(See Page SA-95)
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)

SA-86
4. Tear down the differential and the axle driven bevel gear:
(a) Mark the assembly marks on the differential bearing
cover and the speed reducer housing.
(b) Tear down the stop gasket and take down the adjusting
ring.
(c) Loosen the double-stop washer and screw off the nut to
take down the differential bearing cover.
(d) Tear down the differential and axle driven bevel gear
from the rear speed reducer.
(e) Tear down the outer race of bearing 200719E.
5. Tear down the flange and dust cover assembly:
(a) Loosen the riveted part of the nut with hammer and
chisel;
(b) Lock the flange with SST to tear down the nuts.
Notice: those nuts should not be reuse.


leftright
(c) Tear down the flange and dust cover assembly with
copper bar.
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)
Remark: mark the label on the parts to clarify the position for
re-assembling

SA-87
6. Tear down the oil seal and oil-guard tray:
(a) Support the face at the teeth end of the driving bevel gear
to tear down the oil seal with SST.
(b) Take out the oil-guard tray.


7. Tear down the inner race and roller assembly of bearing
7306E;
Tear down the inner race and roller assembly of bearing 7306E
with SST.
8. Tear down the driving bevel gear;
Tear down the driving bevel gear, which is mounted with
adjusting washer and inner race of bearing 7306E, together
with another adjusting washer and jacket
9. Change the bearing 7306E:
(a) Press out the bearing from the driving bevel gear with
pressure machine and SST.
(b) Mount the new inner race and roller assembly of bearing
7306E on he driving bevel gear with pressure machine
and SST.
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)

SA-88
10. Change for the bearing 7306E and the outer race of
bearing 7607E:
(a) Tap out the bearing outer race with hammer and copper
bar.
(b) Press in the new bearing outer race with pressure ma-
chine and SST.
12. Tear down the axle driven bevel gear.
(a) Tear down the lock plate and bolts on the axle driven
bevel gear.
(b) Mark the assembly marks on the axle driven bevel gear
and the differential housing.
(c) Tap down the axle driven bevel gear with rubber hammer
and copper bar.
11. Tear down the inner race and roller assembly of bearing
200719E from differential.
Pull out the inner race and roller assembly of bearing 200719E
from the differential housing with SST. Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)

SA-89
Assembly of Rear Speed Reducer
1. Mount the inner race and roller assembly of bearing
7306E, oil-guard tray and oil seal.
(a) Put the inner race and roller assembly of bearing 7306E in
the speed reducer housing, and put the oil-guard tray on it.
(b) Coat the lithium base grease on the position of speed
reducer where oil seal locates and on the lips of oil seal,
align the oil seal and press it to mount.
2. Mount the flange and dust cover assembly
Encase the flange and dust cover assembly in the speed reducer
housing, then flat it by hand.
3. Mount the driving bevel gear:
(a) Put the adjusting washer, jacket on the driving bevel gear,
which is mounted with adjusting washer and inner race
and roller assembly of bearing 7607E, then encase the
driving bevel gear in the speed reducer housing.
(b) Screw up the nuts to tighten the flange, flat washer and
the driving bevel gear with SST, and the thread locking
agent is required to be coated when screwing.
Tightening moment
(140
160)N
m
4. Measure the pre-tightening torque of the bearing:
New bearing
(1.2-1.7)N
m
The reused bearing
(0.9-1.3)N
m
Remark: if the requirement is not satisfied, change the adjust-
ing washer under jacket until the requirement is satisfied.
(a) If the measure value is smaller than the standard one,
reduce the thickness of adjusting washer;
(b) If the measure value is larger than the standard one,
increase the thickness of adjusting washer.
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)