differential GREAT WALL SO COOL 2006 Owner's Manual

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-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-90
5. Mount the axle driven bevel gear on the differential housing:
(a) Mount on the lock plate and screw up the bolts to the
specified torque.
Tightening moment
(65-95)N
m
Notice: screw up the bolts diagonally.
(b) Tighten the lock plate with hand hammer and flat head
pinch.
6. Mount the inner race and roller assembly of bearing
200719E;
Mount the bearing inner race and roller assembly in differen-
tial housing with the pressure machine and SST.
7. Mount the differential assembly;
Mount the differential in the speed reducer housing.
When mounting the differential that hasnít changed the inner
race and roller assembly of bearing 200719E, ensure the outer
race of the left and the right bearings that has disassembled
should match with their inner racers respectively.
8. Mount the adjusting ring;
Adjust the clearance between the driving bevel gear and the
axle driven bevel gear to the moderate size. And press the
bearing outer race to flatten it with adjusting ring, and then
screw up moderately.
Notice: the two adjusting rings should be adjusted
synchronically in the movement of same direction.
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)

SA-91
9. Mount on the differential bearing cover:
(a) Align the assembly marks on differential bearing cover
and the speed reducer housing, and press down the
differential bearing by hand.
(b) Mount on the double-eared stop washer and the hex nut.
10. Adjust the clearance between the driving bevel gear and
the axle driven bevel gear
(a) Screw up the hex nuts connecting the differential bearing
cover to the specified torque.
Tightening moment
(80-110)N
m
(b) Attach the measuring meter seat on the face of speed
reducer housing with the measuring head touching the
teeth face, run the axle driven bevel gear with hand to
measure the teeth engagement clearance, and then com-
pare it with the clearance value in step (d) to decide the
order of the adjusting ring tightening according to the
values.
(c) Adjust and screw up the adjusting rings with SST.
Tightening moment
(115-135)N
m
(d) Check the engagement clearance again until the clear-
ance value of the three spots evenly locates on the
circumference of axle driven bevel gear. Otherwise,
adjusting ring adjustment is suggested.
Engagement clearance
(0.13-0.25)mm
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)

SA-94
Mount of Rear Speed Reducer and
Differential Assembly
1. Mount the speed reducer and differential assembly on
the rear axle housing.
Tightening moment
(18-26)N
m
Remark: in case the sealing gasket is mounted, it should be
checked to see whether it is damaged before mounting, if
damaged, change with the new sealing gasket, and the dam-
aged sealing gasket should be clear away; if no sealing gasket
is mounted, no mount is required to mount. Clean the contact
face of the mounted axle housing and coat it with silicon-
rubber plain sealing agent.
2. Connect the drive shaft and flange well and be careful to
align the assembly marks marked when disassembling.
Tightening moment
(69-79)N
m
Screw up the oil drain plug with the Tightening moment
of (140-150)N
m
Mount on the half-shaft and the brake assembly to adjust the
brake oil path so that the wheel brake pump is filled with brake
liquid.
3. Inject in the heavy-duty oil.
Oil brand: heavy-duty oil graded GL-5;
Viscosity: SAE 85W/90
Oil volume: add the oil until it overflows from the oil filler
outlets.
Screw up the oil-filling plug.
Tightening moment
(140-150)N
m
Suspension System and Automobile and Axle (Rear)
Rear speed reducer (Mount of Rear Speed Reducer and Differential Assembly)

SA-95
Rear Differential
Element Figure
half axle gear
thrust gasket differential housing
pin
planetary
gear shaftplanetary gear
stop gaskethalf-axle gearplanetary gear
1. Tear down the speed reducer and the differential
assembly.
2. Tear down the differential from the speed reducer and
differential assembly.
Change of Differential Parts
1. Disassembly of Differential
(a) Tap out the pin with hammer and pinch.
Suspension System and Automobile Axle (Rear)
Rear differential
(b) Tear down the planetary gear shaft, the planetary gear,
planetary gear stop gasket, half-shaft gear and half axle
gear thrust gasket.

SA-96
2. Assembly of Differential
(a) Put the half-axle gear thrust gasket on the half-axle gear
and then encase them in the differential housing.
(b) Encase the planetary gear stop gasket, planetary gear and
encase the planetary gear shaft.
(c) Check the clearance between the half-axle gear thrust
gasket and the differential housing.
Remark: the half-axle gear and the planetary gear should run
freely without stagnant, push the planetary gear inside, then
measure the clearance between the half-axle gear thrust gasket
and the differential housing with dial indicating lamp.
Reasonable clearance range: (0.45-0.75)mm.
Remark: if the clearance value fails to fall within the above
range, change the half axle gear thrust gasket, at the same time,
ensure the left and right half axle gear thrust gasket are same
in thickness.
(d) Tap the pin in the pinhole, and rivet the end of the pinhole
so as to prevent from the pin missing.
Mount of Differential
1. Encase the differential assembly in the speed reducer
housing.
2. Mount the speed reducer and differential.
Suspension System and Automobile Axle (Rear)
Rear differential

BE-34Body Electric System
Combination Instrument
Electric circuit diagram (continued)
A16 A1 B16 B1
SL SK
B1
B16
A1
A16
speed and mileage meter
4P
G
VA9vehicle speed signal
A11odometer sensorA10odometer sensor anode
B11sensor signalelectronic tachometer
water thermometer
fuel gaugecoolant temperature sensor
B5
A12
fuel gauge sensor
B14
A2
B3
upper beam
_NPdifferential latch-in
safety belt
preheating
sediment water alarmingelectricity charging/
discharging
fuel level alarming
brake failure alarming lamp
oil pressure alarming lamp
rear fog lamp
engine failure
four wheel drive indicating lamp
A1 Aturn indicating lamp
B16 left turn indicating lamp
A8
B4 +B7 - B8 A16 B15 B2B1 A15 A14B6 A13 B10B9
SY SJaccumulator plus four door-closing indicating lampA3turn on when the door is opened.
A11odometer sensor_NO
electronic odometer
electronic tachometerA10
B11
engine ignition coil
water thermometer
fuel gauge
B5
A12
neutral gear indicating lampA9
_NP
upper beamB14
differential latch-in
vacuum alarming
preheating
sediment water alarming
electricity charging/
discharging
fuel level alarming
brake failure alarming lamp
oil pressure alarming lamp
rear fog lamp
engine failure
four wheel drive indicating lamp
A1 left turn indicating lamp
B16 right turn indicating lamp
A8
B4 +
instrument lighting
system
B8
B7 - A16 B15 B2
B1 A15A14 B6 A13 B9 B3 B10A2
instrument lighting
system

B-4
3916021
Press fitting tool of oil
seal of long semi-axis
3916022
Disassembling bracket of
long semi-axis bearing
3916023


Disassembling tool of
inner race of small bear-
ing of main teeth
3916024



Disassembling bracket of
inner race of large bear-
ing of main teeth
3916025



Press fitting casing of
inner race of large bear-
ing of main teeth
3916026



Press fitting casing of
outer race of large bear-
ing of main teeth
3916027



Press fitting casing of
outer race of small bear-
ing of main teeth
3916028


Disassembling tool of
differential side bearing
3916029

Press fitting tool of dif-
ferential side bearing
3916030

Mounting tool of needle
bearing of long semi-axis
SSTSpecial Service tool
Diagram Tool name tool number
SST Special Tool
Special Service Tool
Application position
Front axle
Rear axle
2WD 4WDRemark