lock GREAT WALL SO COOL 2006 Owner's Guide

TF-10
1. output shaft
2. shift engagement sleeve assembly
3. locking sleeve
4. return spring
5. engagement sleeve
6. snapping ring
7. shift lock hub
8. clutch assembly
9. fastening snapping ring
10.shift guide shaft
11.toggle fork
Transfer Box
Disassembly of Transfer Box
1. front case of transfer box
2. rear output shaft
3. cluch coil assembly
4. clip
5. bearing
6. nut
7. transfer cover assembly
8. mark plat
9. bolt
10. odometer drave gear
11. oil seal
12. oil seal
13. bearing
14. rear cover of transfer box
15. rolling needle bearing
16. shift guide shaft
17. back spring
18. magnet
19. bundle clip10
9
8
12
13
14
157 7
6
5
4
3
16
17
18 2
1
19
911
3. The disassembly approach for rear cover is as follows (above figure)
(a) Dismantle the nine screws and take down the clip of wire harness and
signboard in the same time.
Notice shall be taken to good keeping for the signboard, which includes the
information for the substitutes to be changed.
(b) Pry the frame lightly so that the sealing glue on the surface disengages, and
then take up the transfer box rear cover assembly directly.
(c) As for the electric gearshift transfer box, tear down the oil seal, bearing and
three nuts and clutch coil assembly.
(d) Tear down the snapping ring, pull out the bearing from the rear cover and
take apart the odometer meanwhile.
(f) Pull out the oil seal from the rear cover of the transfer box.
(g) Tear down the magnet from the front body of transfer box.
(h) Take apart the return spring from the shift guide shaft
(i) Clear away the sealing glue on the coupling face of the front housing and
rear cover of transfer box, take notice not to damage the coupling face of
the two housings or cause the materials removed dropping into the transfer
box.
4. Tear down the shifting element connected with the front axle.
Tear down the following parts from the remaining transfer box housing
assembly (electric gearshift).
(a) Electric gearshift assembly, tear down the snapping ring and sliding clutch
sleeve from the shift locking hub.
(b) Tear down the shift-locking hub from the rear output shaft.
(c) Tear down the shift engagement sleeve assembly and shift toggle fork from
the rear output shaft and shift guide shaft. Separate the assemblies one
another and tear down the shift guide shaft.
(d) Disassemble the shift engagement sleeve assembly by taking apart the
snapping ring, engagement sleeve, return spring, and locking sleeve.
(e) A plastic toggle fork that substitutes the metal toggle fork assembly and a
independent contact roller in earlier time.
1
9
8
7
6
5
Q
32
10
11

TF-17
1.25-1.75mm
23
1
12.70mm
13
2
4
4
2
1
5 6
7
83
(e) In the case that the input shaft is taken apart, what need
to do is to fill the needle bearing as shown in the drawing
and press it in the input shaft, meanwhile, press the new
sliding bearing to complete the whole input shaft assembly.
(f) Raise the planetary mechanism assembly to mount it into
the input shaft assembly; encase the thrust gasket and
press in the bearing through the input shaft end. Encase
the fixed bearing in the snapping ring groove of the input
shaft with a snapping ring.
(g) If the transfer box front body is taken apart, press the new
located pin in the front body, and the pressing dimensions
are shown in the drawing.
(h) Put down the oil seal as the drawing shows, and press it
in the front body according to the dimensions shown in
the drawing.
(i) Put down the front body assembly on two wooden blocks
in the way that the coupling face of the front body and the
housing faces upward, so that there is clearance left
between the input shaft assembly and the worktable. Put
down the input shaft and planetary mechanism assembly
in the front body, in which the input shaft shall be
downward. Open the long ends of the snapping ring to
encase input shaft and planetary mechanism assembly
until the snapping ring enters into the external snapping
ring groove of the bearing.
(j) Coat the sealing glue of 1.6mm on the coupling locations
of the front end cover and transfer box assembly, The
glue shall be coated continuously without break and steer
clear of the screwed hole.
(k) Screw up the six bolts.
Fastening torque
(27
46)N
m
6. Assembly of front output shaft
Mount the following parts:
(a) If the dust cover is taken apart, mount it by pressing.
(b) Encase the input shaft, sealing ring, gasket and nuts in the
transfer front housing.
(c) Insert the torque arm of T-13-54-002 in the flange hole to
screw up the nuts.
Fastening torque
(203
244)N
m Transfer Box
Transfer Box Assembly
1. needle bearing
2. bearing roller
3. input shaft
1. locating pin
2. oil seal
3. front body of transfer box
4. snapping ring
1. fork-type flange
2. dust cover
3. fork-type flange assembly
4. transfer box housing5. output shaft
6. oil seal
7. washer
8. nut

TF-18
1. deceleration gear
2. output shaft
3. insert face of toggle fork
4. deceleration toggle fork assembly
5. pin, contact roller and sleeve assembly
6. deceleration shift toggle fork
7. plastic sleeve
8. contact roller
9. pin
12
6
7
8
9 3
NO PQ
R
S T
Transfer Box
Transfer Box Assembly
7. Deceleration shift parts assembly
The mounting process is as follows:
(a) If the parts are taken apart for change, assemble the shift
toggle fork assembly with a new pin-contact roller
assembly. Press the pin-contact roller in the deceleration
fork hole until the detent passes the hole completely and
seizes the right location. Ensure that the contact roller can
run freely.
(b) Mount two inserted faces of toggle fork on the decelera-
tion toggle fork assembly.
(c) Engage the deceleration fork assembly and deceleration
gear sleeve and put them in the housing, and the decelera-
tion gear sleeve shall be put in the planetary mechanism
assembly that is assembled already. Mount the rear
output shaft and joint the bearings at the ends of output
shaft and input shaft as well as the spline of the gear
sleeve.
Remarks: the output shaft assembly can be delayed until the oil
pump is mounted on the output shaft. The oil pump may be
dipped into the lubricant through the oil pump screen, turn the
output shaft in clockwise from the output shaft direction to see
whether there is lubricant pumped out so as to check whether
the oil pump can work normally or not. The parts mounted
readily may be encased in the transfer box housing as an
assembly
8. Oil pump assembly
Ensure the parts of oil pump are completely lubricated when
assembling, and the oil can be pumped out from the conical
hole of the oil pump front cover. The mount of oil pump is as
follows:
(a) Mount the pin on the rear output shaft.
(b) Slide the oil pump assembly on the rear output shaft
along with the pin.
(c) Put the gripping hoop at the end of oil pipe that is
mounted on the oil nozzle of the pump housing, screw up
the gripping hoop.
1. filter
2. oil pump hose
3. gripping hoop
4. oil pump assembly
5. output shaft
6. pump pin
7. output shaft and pump assembly5
4

TF-19
1
9
8
7
6
5
4
32
10
11
12
345
6 7
Transfer Box
Transfer Box Assembly
9. Assembly of driving chain
The parts assembly process is as follows:
(a) Put the driving chain sprocket at the rear end of the output
shaft, and the driven chain sprocket is put at the rear end
of the front output shaft on the worktable after the transfer
box housing assembly mount.
(b) Mount the chain on the sprocket.
(c) Holding the two chain sprockets parallel with the transfer
box in the space that the chain on the two sprockets are
straightened, and encase the chain and sprocket assembly
through the output shaft, it is required to run the chain
sprocket slowly to ensure that they engage with the front
output shaft and the spline.
(d) Mount the gasket and snapping ring on the front output
shaft.
10. Shift locking element assembly
The parts mounting process is as follows (for the electric shift
transfer box):
(a) Mount the return spring and locking hub on the locking
sleeve and fasten them with snapping ring to finish the
2W-4W locking sleeve assembly.
(b) Encase the shift guide shaft in the blind hole of the
housing through the deceleration toggle fork assembly
that is already assembled.
(c) Mount the shift toggle fork on the 2W-4W locking sleeve
assembly, which will slide through the shift guide shaft
and rear output shaft.
(d) Joint the combined external gear sleeve spline and the
rear output shaft spline as well as the 2W-4W locking
sleeve.
1. output shaft
2. driving chain sprocket
3. driven chain sprocket
4. washer
5. snapping ring
6. transmission chain
7. front output shaft
1. output shaft
2. shift engagement
sleeve assembly
3. locking sleeve
4. return spring
5. engagement sleeve6. snapping ring
7. shift lock hub
8. clutch assembly
9. fastening snapping ring
10. shift guide shaft
11. toggle fork

TF-20
1 convex plate
groove2
3
4
5 6
1234
5
6
7
1. electric shift convex plate
2. torsion spring
3. shift shaft
4. gear down shift fork assembly
5. shift fork
6. gear shifting shaft
Transfer Box
Transfer Box Assembly
1. clutch washer assembly
2. snapping ring
3. ball bearing
4. transfer box rear body
5. nut
6. oil seal
7. bearing
8. needle bearing
11. Rear cover Assembly
Mount the parts into the rear cover according to the following
process:
(a) Locate the rear cover on the suitable press machine, the
coupling face of the rear cover shall face upward and
parallel with the work face of the press machine.
(b) Locate the needle bearing, of which the marked end
facing upward, and press it in the rear cover until the
upper end of needle bearing is 40.47
40.97 lower than
the coupling face of the rear cover that matches with the
front housing.
(c) Press the ball bearing in the rear cover and mount the
snapping ring well.
(d) As for the electric shift transfer box, the parts shall be
encased according to the following process:
(1) Confirm the four O-rings are set on the clutch
washer assembly (one O-ring is located on the coil,
the other three on studs).
Mount on the clutch coil assembly, of which the
wire and stud shall protrude out the rear cover, take
notice not to damage the wire when screwing up the
nuts.
Fastening torque
(8
11)N
m
(2) Encase the motor bearing and oil seal in the rear
cover. (e) As for the electric shift transfer box, encase the as-
sembled electric shifting cam group and clutch shell in
the process as follows:
(1) Put down the electric shifting cam group as shown in
the drawing.
(2) Hold the shift guide shaft downward and raise lightly
the toggle fork assembly. Run the electric shifting
cam group in place, so that the contact roller on
deceleration toggle fork assembly enters in the groove
of shifting cam, and the projecting part of lock
toggle fork is at the rear end of the shifting cam, and
then take reduce the component elements in the
transfer box housing, meanwhile, joint the shift
shaft on the pin in transfer box housing.
(3) Locate the clutch shell well through the shift exter-
nal gear sleeve and mount on the snapping ring.
8

TF-22
12
3 4
6
7
8
95
21
Transfer Box
Transfer Box Assembly
1. motor assembly
2. shift shaft
1. fixed sensor bracket
2. bolt
3. sensor assembly
4. velocity sensor
5. o-ring6. motor assembly
7. bolt
8. gasket
9. transfer box rear body
12. Mount the external electric shifting element (for the elec-
tric shift transfer box)
(a) Locate the motor assembly by aligning the triangle
groove on motor to the shift shaft.
(b) Move the motor to combine the shift shaft and keep it
close to the rear cover. Then run the motor clockwise
until the motor locates the correct place and the mooting
holes are aligned.
(c) Mount the O-ring on the velocity sensor and encase the
velocity sensor assembly in rear cover. A clip and three
bolts shall be mounted on the velocity sensor.
Fastening torque
(8
11)N
m
(d) Mount the bolts and gaskets on the end of motor clip.
Fastening torque
(8
11)N
m

TF-25
(b) Normal gear grinding trace.
Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Checking)
Checking
1. Common Checking process
Check all parts by visual check to see whether there is damage
or serious or uneven wear (parts needed be substituted by new
parts such as O-ring, oil seal and etc. shall be excluded).
Abandon the damaged or weary parts that will affect on their
performance. The check items are as follows:

Burr: tips protruded from the material regionally

Rag: broken small blocks or particles

Crack: surface thread showing the material is partly or
completely separated.

Excessive abrasion
Refer to the serious or obvious abra-
sion beyond of application limit.

Reduction change
Material slip caused by the heavy
pressure on part of it.

adhesive bonding
Granules of the soft metal are dis-
persed and bonded on the hard metal surface.

Ditch trance: partial crack or trough that means the material
transfer instead of material loss.

Pitting corrosion
Damages to the metal surface caused by
pressure, which are displayed due to color change caused
by heat generated by metal friction.

Step wear
a weary step may be seen or felled between the
neighboring interface or between the non-touching face
due to the excessive wear.

Uneven wear: Partially, unevenly distributed wear, which
includes holes, bright spots, uneven polishing or other
visual drawbacks.
2. Gear or Chain sprocket tooth inspection
Check the gear and chain sprocket tooth according to the
following process:
(a) Normal gear shaving trace.
normal gear shaving trace
normal gear grinding trace

TF-30Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts)
Change the parts and fittings as requirement
Attachment for Inspection Maintenance or Change of Parts
Checking items
Acceptance/Refusal
Parts (items)
All parts (including
all springs)Crack inspection, distortion inspection and ero-
sion inspectionAll parts with crack, all parts that are bended,
distorted or poor in round bouncing are refused.
All threaded partsThread inspection for buckle missing or other
damageThose parts cannot be threaded or bottomed in
overlap manner shall be refused.
Flange and fork
flangePlease refer to the paragraph of
inspection
to
check the spline.Please refer to the
inspection paragraph
for
spline inspection.
Velocity sensor, mo-
tor assembly
Parts of electric clutch
systemPlease refer to the part of electric appliance
Sliding bearing Inside surface inspection for the sliding bearing In the case that the bearing has pitting corrosion
or other damage, refuse it.
Ball bearingCheck visually the ball and track of the ball
bearing to see whether there is damage such as
adhesive bonding, pitting corrosion, etc.
Ensure that the bearing are all lubricated, run the
outer race of the bearing while holding the inner
one to feel whether there is poor running or
corrosion, the bearing shall be run smoothly
without excessive clearance.Refuse to use the damaged bearing;
Refuse to use the damaged or loose bearing; or
Check the axial clearance to see whether it
exceeds 0.23mm.
Needle bearing Check the bearing needle roller and track to see
whether there is damage such as adhesive
bonding, pitting corrosion, etc.Refuse to use the damaged bearing.
The rear cover, front
body and front hous-
ing of transfer boxCheck to see whether there is burr on the cou-
pling face or other damage that impedes assem-
bling or sealing.Clear away the burr according to the paragraph
of
inspection
, otherwise, change the dam-
aged element
Rear cover of trans-
fer boxCheck the bearing holeRefuse to use the assembly that has pitting
corrosion
Odometer gear Check the gear teeth referring to the Inspection
ParagraphRefer to the gear or chain sprocket inspection in

inspection paragraph
.
Clutch shell, joint
outer gear sleeve and
joint coverCheck the spline according to the Inspection
paragraphRefer to the spline inspection of
inspection
paragraph

Locking sleeveCheck the wear or damage of the toggle fork
grooveRefuse the parts with step slipping or damage.
Shift guide shaft Check the deformation situation
Check the burr or other damage on outer race
Check the wear of outer raceRefuse to use the bend shaft; clear away the burr
according to the
inspection
paragraph, oth-
erwise refuse to use.
Refuse to use the shaft with step slipping or
other damage.
Shift toggle forkCheck whether there is wear or damage at the
location where the toggle fork combines with
the shifting cam and gear sleeve.If any step slipping or damage is found, refuse
to use it.

PR-7Drive Shaft
Drive Shaft
(b) Lock the flange with SST tools to tear down the nuts.
(c) Label the assembly marks on flange and shaft.
SST
SST
assembly mark assembly mark
(d) Tear down the flange from the front joint of rear axle
drive shaft with SST tools.
3. Take apart the universal joint yoke from the rear joint of
rear axle drive shaft.
(a) Label the universal joint yoke and the shaft with assem-
bly marks.
(b) Pull out the universal joint yoke from the shaft.
Inspection on Drive Shaft Parts
1. Cross shaft bearing inspection
Check the wear or damage situation of the cross shaft bearing
and change the weary or damaged bearing where necessary.
2. Check the wear and damage situation of the central
bearing.
Check the bearing to see whether it can run freely.
In case that the bearing is damaged or wearied or cannot run
freely, change it in time.

PR-11Drive Shaft
Drive Shaft
Drive shaft assembly
1. Mount the center support bearing on the front joint of rear
axle drive shaft.
Remarks: The notch of the center support bearing shall face
backward when mounting it.
2. Mount the flange joint on the front joint of rear axle drive
shaft.
(a) Coat the spline of front joint of rear axle drive shaft with
lithium base grease.
(b)
Mount flange joint on the shaft and align the assembly marks.
Remarks: if the central flange joint or the front joint of the rear
axle drive shaft is required to change, the front and back
universal joint yokes of the rear axle drive shaft shall face in the
same direction when re-assembling.
(c) Lock the flange joint with SST and screw up the newly-
changed nut to press the bearing in place.
(d) Loosen the nuts.
(e) Tighten the nuts again, and
(f) Rivet the nuts with hammer and punch.
3. Drive shaft mount
(a) Align the assembly marks on flanges, and connect the
two flanges with four sets of bolt and nut.
Remarks: if the central flange or the front joint of the rear axle
drive shaft is required to be changed, the front and back
universal joint yokes of the front joint of rear axle drive shaft
shall face in the same direction when reassembling them.
(b) Screw up the sets of bolt and nut according to the
specified torque.
Fastening torque: (74
5)N
m
4. Insert the universal joint yoke in the universal joint yoke
(4WD).
(a) Coat the lithium base grease on the sliding surfaces of the
drive shaft spline and the universal joint yoke.
(b) Align the assembly marks on universal joint yoke and
drive shaft.
(c) Insert the universal joint yoke in drive shaft.
assembly mark
2WD 4WD
forward
assembly mark
SST
assembly mark