GREAT WALL SO COOL 2006 Service Manual

BR-20
Front Brake
Element figure
spring gasket12
123
separation padssilent pad
brake padbrake caliper
brake pad snapping ring
guide pin lock spring
sealing ringguide pin
dust cover steel gripping hoop
piston dust cover piston brake disc
: fastening torqueN
M
Change of Brake pad
Remark: In case there is a continuous screaming from the front
wheel when braking the vehicle during driving, check the
alarm pad for friction limit for brake pad. If there is friction
trace on the alarm pad with the brake disc, change the brake pad
1. Disassemble the front wheel;
2. Check the thickness of friction material of brake pad.
Check the thickness of friction material of brake pad, if it fails
to be within the specified range, change the brake pad.
Min thickness
2.0mm SFBraking System
Front Brake(SF)

BR-21
3. Disassemble the following parts:
(a) Guide pin snapping spring;
(b) Two guide pins;
(c) Brake pad snapping ring
(d) Two brake pads;
(e) Two silent pads; and
(f) Two separation pads
4. Measure the thickness of brake disc.
(See BR-24)
5. Measure the radial swinging of the brake disc.
(see page BR-24)
6. Mount on the new brake pad;
(a) Draw out a little brake liquid from the liquid container.
(b) Press in the piston with the hammer lever and similar tool.
Remark: Only one brake pad of the same wheel can be changed
in one time so as to prevent the piston on the other face ejecting
out.
(c) Mount two silent pads and two separation pads on the
new brake pad.
Remark: coat the brake oil for disc on the inner silent
pads.
(d) Mount the brake pad with the worn limit alarm pad on the
inner side, while the other brake pad on the outer side.
Note: Pollution of oil stain or coat is not allowed on the
work faces of brake pad or brake disc.
7. Mount the brake pad snapping spring;
Brake pad snapping spring shall be mounted at the lower
position;
Braking System
Front Brake(SF)

BR-22
8. Mount the two guide pins;
9. Mount the guide pin snapping spring
Disassembly of Wheel brake Pump
1. Disassemble the front wheel;í
2. Disassemble the brake pipeline;
Tear down the brake pipeline with a container containing the
brake liquid.
3. Disassemble the wheel-brake cylinder.
Tear down the two hex bolts and the wheel-brake cylinder.
4. Disassemble the following parts:
(a) Guide pin snapping spring;
(b) Two guide pins;í
(c) Brake pad snapping spring;
(d) Two brake pads;
(e) Two silent pads and
(f) Two separation pads.
Braking System
Front Brake(SF)

BR-23
Wheel-brake cylinder disassembly:
1. Tear down the dust cover steel gripping hoop and the
dust cover.
Tear down the dust cover steel gripping hoops and piston dust
covers of the four wheel-brake cylinders with the screwdriver.
2. Tear down the piston from the wheel-brake cylinder:
(a) Prepare a wooden block with the dimensions as shown in
the drawing (which is used to support the piston)
(b) Put the wooden block between the pistons and insert one
brake pad on one side of the wooden block.
(c) Tear down the four pistons from the wheel-brake cylin-
der by using the compressed air.
Warning: do not put your fingers in front of the piston
when using the compressed air.
3. Tear down the piston sealing ring.
Tear down the four piston sealing ring from the wheel-brake
cylinder with the screwdriver.
Check the front brake parts
1. Measure the thickness of brake pad liner;
Standard thickness
9.0mm
Min thickness
2.0mm
In case the liner is less than the min thickness or the liner is
worn unevenly, change the brake pad. Braking System
Front Brake(SF)
mm
mm
mm

BR-24
2. Measure the thickness of brake disc;
Standard thickness
20.0mm
Min thickness
18.0mm
If the brake pad is scraped, repair it; where the abrasion is
serious and its thickness is smaller than the min thickness,
change the brake disc.
3. Measure the bounding value of the brake disc face;
Remark: the bearing is required to be verified in the suitable
adjustment before measuring.
Max face bouncing value: 0.11mm;
4. Change the brake disc according to the requirement:
(a) Tear down the hub and the brake disc. (see the paragraph
of front wheel hub)
(b) Mount the new brake disc and screw up the connecting
bolts as the specified torque.
(c) Mount the hub and brake disc assembly. (see the para-
graph of front wheel hub).
Fastening torque
(75
5)N
m
(d) Mount the caliper bracket on the steering knuckle and
screw up the bolts according to the specified torque.
Fastening torque
123N
m.
Assembly of Brake-wheel pump
1. Preparation
All parts shall be washed, dried and cleared away the alien
materials, and coat moderate rubber lubricant on the work
faces of piston, piston dust cover and rectangular sealing ring.
2. Encase the piston sealing ring in the caliper body Braking System
Front Brake(SF)

BR-25
3. Encase the piston in the caliper body.
4. Encase the piston dust cover, dust cover steel-
gripping hoop in the caliper body.
Mount of Brake Calipers
1. Mount the brake caliper and screw up the two
mounting bolts.
Fastening torque
123N
m
2. Mount the brake pads;
3. Connecting the brake pipeline;
Use the open spanner to connect the pipeline.
Fastening torque
(21
1)N
m
4. Observe the height of brake liquid level and, if
necessary, add in the brake liquid and exhaust the air
in braking system.
Notice: avoid the brake liquid of spraying on the brake disc
when exhausting the air.
5. Check to see whether there is leakage of brake liquid. Braking System
Front Brake(SF)

BR-26
Rear brake
Element figure
wheel-brake cylinder cluster
pressure spring drag rod
self clearance-
adjusting bracing
wireparking brake arm
flat washer
split pinbrake shoe gear
return spring
parking brake push plate
push-plate spring back brake
shoe
self clearance-
adjusting toggle
tension spring
brake drum
clearance adjuster
pressure spring seatpressure spring front brake shoe
Disassembly of Rear drum-type Brake
Remark: if the braking torque of manual brake cannot satisfies
the braking requirement, it is suggested to check the thickness
of brake shoe liner, where the thickness is less than the min
thickness, change the brake shoe.
Min thickness
1.0mm
1. Tear down the rear wheel;
2. Tear down the brake drum;
Remark: in case the brake drum is not easy to tear down, the
following steps shall be adapted:
(a) Tear down the clearance-adjusting hole; insert a screw-
driver in the brake bottom plate hole to prize up the
adjusting bolt inner tilt angle with the self-adjusting fork.
(b) Use another screwdriver to adjust the adjusting bolt inner
tilt angle to loosen the clearance adjuster of brake shoe. DrBraking System
Rear Brake (Dr)

Parts that cannot be reused after being used

BR-27
3. Tear down the return springs of the two brake
shoes.
4. Tear down the self-adjusting bracing wire, brake shoe
retainer ring, bracing wire guide seat and the self-
clearance adjusting toggle plate.
(a) Press and push the self clearance-adjusting toggle plate to
teardown the bracing wire of self clearance-adjuster,
brake shoe retainer ring and bracing wire guide seat.
(b) Take out the spring from the self clearance-adjusting
toggle plate to tear down the clearance-adjusting toggle
plate and the spring.
5. Tear down the tension spring;
Tear down the tension spring with the pliers.
6. Tear down the brake shoe, clearance adjuster and
parking brake push plate.
(a) Tear down the pressure spring seat, pressure spring and
pressure spring drag rod.
(b) Tear down the brake shoe, clearance adjuster and parking
brake push plate.
(c) Tear down the bracing wire from the parking brake. Braking System
Rear Brake (Dr)

BR-28
7. Tear down the parking brake arm;
Tear down the split pin with pliers to take apart the parking
brake arm.
8. Take apart the brake pipeline from the wheel pump;
Tear down the brake pipeline and block the oil pipe with a clean
cork.
9. Tear down the wheel brake pump;
Tear down the two bolts and the wheel-brake cylinder.
10. Tear down the following bolts and wheel-brake
cylinder parts:
(a) Two piston rod;
(b) Two dust cover
(c) Two pistons
(d) Two piston rubber bows
(e) Spring. Braking System
Rear Brake (Dr)

BR-29
Check and Repair the Rear Brake Parts
1. Check and test the disassembled parts;
Check the disassembled parts to see whether there is abrasion,
rust or damage.
2. Measure the inner diameter of brake drum;
Standard inner diameter)
254.0mm
Mix inner diameter: 256.0mm
3. Measure the thickness of brake shoe liner;
Standard thickness
5.0mm
Min thickness
1.0mm
In case the thickness of brake shoe liner is less than the min
thickness or there is uneven abrasion, change the liner.
Remark: if one of the brake shoes is needed to change, all of the
brake shoes are required to change so that the even braking
performance is maintained.
4. Measure the brake liner and the brake drum to see
whether they contact closely;
If there is poor contact between the brake liner and the brake
drum, repair the brake shoe with the grinding devices, or
change the brake shoe cluster. Braking System
Rear Brake (Dr)