GREAT WALL SO COOL 2006 Service Manual
Manufacturer: GREAT WALL, Model Year: 2006, Model line: SO COOL, Model: GREAT WALL SO COOL 2006Pages: 484, PDF Size: 16.35 MB
Page 471 of 484
B0-88BodySize of Chasis
Unitmm
size in 2D
Sing
Axial spacing3025 front
Mark
A,a
B,b
C,c
D,dName
Cab mounting hole
Cab mounting hole
Cab mounting hole
Cab mounting holeBore diameter
Mark NameBore diameter
Cab mounting hole
E,e
Cab mounting hole
F,f
central line of front wheel
assuming
standard line
Page 472 of 484
B0-89BodySize of Chasis
Unitmm
size in 2D
Pegasus
Axial spacing2760assuming
standard line front
central line of front wheel
Mark
A,a
B,b
C,c
D,dName
Cab mounting hole
Cab mounting hole
Cab mounting hole
Cab mounting holeBore diameter
MarkNameBore diameter
Cab mounting hole
E,e
Page 473 of 484
A-1
Specifications of Maintenance
and Up-keeping
page
Clutch .......................................................................... A-2
Gear box ..................................................................... A-2
Transfer box ................................................................ A-3
Drive shaft ................................................................... A-4
Suspension system and automobile axle .................... A-4
Braking system ............................................................ A-5
Steering system .......................................................... A-6
A
Page 474 of 484
A-2
Clutch
Specification
Item Specification
Fastening torque for clutch tube on master cylinder
Fastening torque for clutch tube on wheel-brake cylinder
Fastening torque for clutch pressure plate160
190-200
5-15
0.3
0.8
0.2
0.6
5
Max misplacement0.5 Pedal height (calculated from front wall
Pedal free stroke
Min depth of clutch-facing rivet
Max radial swing difference of clutch rib
Max radial swing difference of flywheel
Max width of wear of diaphragm spring
Max width of wear of diaphragm spring
Alignment degree of diaphragm spring endApplicable vehicle model
Dr SF
SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Torsion moment
Fastening location (N*m)
15-17
15-17
30 Applicable Vehicle model
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Gearbox
Three-grade maintenance for gearbox
1. Grade I maintenance for gear box
Grade I maintenance: Check the lubricant level to see whether the lubricant level is in alignment with the lower edge of oil
filler; if the lubricant is lower than the oil filler lower edge, add the lubricant; or the insufficient lubricant will lead to the poor
lubrication or burn-out of bearing and teeth; while the over-high lubricant will cause the overheating and oil leakage.
2. Grade II maintenance for gear box
Grade II maintenance: The gear box of a new vehicle should be maintained by exchanging the lubricant during the
first grade II maintenance and should be washed with kerosene; and the lubricant quality should be checked in the
grade II maintenance in later time, if the lubricant is diluted, gumming or over-dirty, it should be changed.
3. Grade III maintenance
The gearbox should be disassembled for inspection, washing and oil change.
Notice: As the new vehicle is in the running-in status, the gearbox should be maintained by exchanging lubricant
after the vehicle covers 1500 km,
Lubricant TypeGL-5 SAE80W/90
Torsion moment of relative connecting elements
Tung Teeth: Tang tooth(5DYA4TWD5DYA8FWD)
Unitãã Specification of Maintenance and Up-KeepingClutch and Gearbox
Locating screw of fork axle at first and second gear
Locating screw of yoke block
Screw on baffle of rear bearing of output shaft
Screw of reverse idler shaft
Bolt of gearshift cover
Bolt of front cover
Bolt of rear body
Bolt of clutch shell
Bolt of locating spring1317
1520
1722
1720
1520
1520
3045
3045
1722 Fastening location N*m
Page 475 of 484
A-3
Fastening location N*m
Upper tooth(JK72TWD)
Fastening location N*m
Specification of Maintenance and Up-KeepingTransfer Box
Maintenance and Up-keeping of Transfer Box
1. The oil level of transfer box should be checked when exchanging the engine lubricant or the vehicle
covers more than 8000 kmand add the lubricant where necessary.
2. Change with the appointed lubricant each year or after the vehicle covers more than 48000 km.
Notice: lubricant brand: 85W/90 GL-5.
Fastening torque of relative connecting elements
1520
1015
1217
1520
1520
1520
1520
3040
6070
3040
3040
1722
3050
2040
3040
90125 Toggle fork at first, second and fifth gears and the screw of
toggle fork
Bolt on odometer pressure plate
Screw on baffle of rear bearing of output shaft
Screw on baffle of reverse idler shaft
Locating screw of gearshift yoke block
Bolt of front cover
Bolt of gearshift cover
Pillar of clutch toggle fork
Bolt of clutch cover
Bolt of rear body (M10X1.25X130)
Bolt of rear body (M10X1.25X80)
Plug of locating spring
Oil filling/draining plug
Reverse gear switch assembly
Location mechanism cluster
Locking nut at rear end of countershaft
Fastening location N*m
Flange nut
Oil drain plug
Bolt of motor clip
Fixing bolt of motor
Clutch coil nut
Housing bolt
Oil pump bolt
Venting valve
Bolt of front connecting body203244
1930
811
811
811
2746
4.08.5
819
2746 Oil filling/draining plug
Location mechanism cluster
Pillar of clutch toggle fork
Bolt on odometer pressure plate
Reverse gear switch assembly3050
3050
3050
1015
3050
Page 476 of 484
A-4
Drive Shaft
Torsion moment
Fastening location Applicable vehicle model N*m
Connecting bolt
Fixing bolt of central supporter745
405 Dr SF SL SK SY SJ
Dr SL SK SY SJ
Inflation pressure of tire
Ground clearance of chassis
Steering angle of inner wheel
Kingpin inner inclination
Outer inclination of front wheel
Mechanical steering
Power steering
Kingpin rear inclination (inclination)
Mechanical steering
Power steering
Toe-in
Error in length between left and right
drag rod
Side slip valueFront:2200kPa
Back:2400kPa
Front:2500kPa
Back:2500kPa
295mm
255mm
58.5mm(difference in height between
shaft center of lower arm and wheel
center)
310mm
295mm
3640
32
3234
930'5'
1452'
030'0'
010'0'
020'0'
020'5'
150'
-20'
25'5'
20'0'
0-2mm
=2mm
=5m/km
.5m/km
Suspension System and Automobile Axle
Specification
Item Applicable vehicle model Specification
Dr SL SK SY SJ
SF
Dr
SL SK
SF
SY
SJ
Dr SL SK SY
SF
SJ
Dr SL SK SY
SJ
Dr SL SK SY
Dr
SL SK SY
SJ
Dr SL SK SY
Dr SL SK SY
SJ
Dr SL SK SF SY SJ
Dr SL SK SF SY SJ
Dr SF
SL SK SY SJ
HPM
Specification of Maintenance and Up-KeepingDrive shaft, Suspension System and Automobile Axle
Page 477 of 484
A-5
Torsion moment
Fastening location Applicable vehicle model N*m
Limit bolt of steering knuckle
U-type fixing bolt
Bolt of spring pin of rear plate and shackle
Central bolt of rear steel plate spring
Connecting bolt of rear vibration damper and rear axle
Connecting bolt of front vibration damper and lower swing arm
Connecting bolt of rear vibration damper and frame
Connecting bolt of rear vibration damper and lower swing arm
Fixing bolt of pedestal arm of torsion rod spring
Locking nut of torsion rod spring
Fixing bolt at two ends of transverse stabilizer rod
Fixing bolt of transverse stabilizer rod bracket
Connection bolt of guide lever and lower arm
Fixing nut at front end of guide lever
Axial fixing nut of front suspension and lower arm
Axial fixing nut of lower arm of front suspension
Connecting nut of steering knuckle and upper ball stud
Connecting bolt of steering knuckle and lower ball stud9010
11010
9010
505
645
255
255
13710
835
835
233
295
233
255
9610
15010
9610
17815
22625
19610
226
025
210025
11010
14210
14210 SJ
Dr SL SK SY SJ
Dr SL SK SY SJ
SL SK SY SJ
SF
SL SK SY SJ
SL SK SY SJ
SF
SL SK SY SJ
SL SK SY SJ
Dr
SL SK SY SJ
Dr SF
SL SK SY SJ
Dr SF SL SK SY
Dr
Dr SL SK SY SJ
SF
Dr
SF
SL SK SY
SJ
Dr SL SK SY SJ
SF
Dr SF SL SK SY SJ
Braking system
specification
Item Applicable vehicle model specification
Pedal height
Free stroke of pedal
Stroke of operating lever of parking brake160mm
190-200mm
3-6mm
9-10
7-9 Dr SF
SL SK SY SJ
Dr SL SK SF SY SJ
Dr
SL SK SY
torsion moment
Fastening location Applicable vehicle model N*m
Brake oil pipeDr SF
SL SK SY SJ182
191
Specification of Maintenance and Up-KeepingBraking System
Page 478 of 484
A-6
Torsion moment
Fastening location Applicable vehicle model N*m
Fixing nut of steering wheel
Connecting nut of steering ger and swing arm
Fixing bolt of steering driven arm
Fixing bolt of steering gear
Connecting nut of steering drag rod and swing arm of
steering gear
Connecting nut of steering drag rod and steering driven
arm
Connecting nut of steering drag rod and front brake
Steering limit boltDr SF
SL SK SY SJ
Dr SF
Dr
SF
SL SK SY
SJ
Dr
SF
SL SK SY
SJ
Dr SF
Dr
SF
Dr SF
SJ505
302
24525
8010
14210
8310
7810
9610
14510
9610
7810
9110
9110
595
9110
9010
Steering system
Specification
Item Applicable vehicle model Specification
Max play of steering wheel
Tension degree of driving belt:
When f=98N New belt
Old beltDr SF
Dr SL SK SF SY SJ
Dr SL SK SF SY SJ6
5-7mm
7-9mm
Specification of Maintenance and Up-KeepingSteering System
Page 479 of 484
B-1
SST Special tool
page
Special tool ................................................................... B-2
B
Page 480 of 484
B-2
Disassembling and as-
sembling tools for lock-
ing nut of steering
knuckle3916001
Press fitting tool for in-
ner bearing of front wheel
hub3916002
3916003
3916004
3916005
3916006
3916007
3916008
3916009
3916010 Press fitting tool for outer
bearing of front wheel
hub
Disassembling tool of
ball stud
Fixing tool of main teeth
flange of needle bearing
Press fitting tool for steer-
ing knuckle oil seal
Disassembling tool of
shorter liner of lower arm
Mounting tool of shorter
liner of lower arm
Mounting and disassem-
bling tool of long liner of
lower arm
Disassembling tool of
upper arm liner
SST Special Service tool
Diagram Tool name tool number Remark
SST Special ToolSpecial Service Tool
Application position
Front axle
Rear axle
2WD 4WD