GREAT WALL SO COOL 2006 Workshop Manual

MT-32Gear Box
Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly)
2. Measure the clearance between the reverse idle gear
and gearshift yoke block
Measure the clearance between the reverse idle gear and the
gearshift yoke block with feeler.
Standard clearance:
Shang Chi
0.2mm
Tang Chi
(0.05
0.27)mm
Max clearance

Shang Chi
0.35mm
Tang Chi
0.5mm

MT-33Gearbox
Rear Housing Assembly (Element Drawing, Change of Oil Seal, Change of Shaft Bush)
Rear Housing Assembly
Element drawing
Change of Oil Seal
1. The rear housing oil seal shall be changed where necessary.
(a) Dismantle the oil seal with SST.
(b) Press in the new oil seal with SST
2. The driven oil seal of speedometer shall be changed
where necessary
(a) Pry out the oil seal with SST.
(b) Tap the new oil seal into the shaft bracket with SST.
Change of Shaft Bush
The shaft bush shall be changed where necessary
(a) Tear down the oil seal and dust bush.
(b) Heat the ending parts of extension frame to 80
-100
in
the oil groove.
(c) Tear down the shaft bush with SST and mount on the new
shaft bush.
SST
SST
SST
SST
SST
oil reservoirlocating spring bolts and
spring cylindrical pinrear housing oil seal
assemblyrear housing dust
cover
oil groove
component element
of position-limit
mechanismrear housing
cluster

MT-34Gearbox
Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism)
Inspection on and change of the component
elements of position-limit mechanism
1. Tear down the component elements of position-limit
mechanism
(a) Dismantle the bolts with the torque socket spanner.
(b) Punch out the spring cylindrical pin with the drift punch
and hammer.
(c) Tear the component elements of position-limit mechanism
down.
2. Check the component element of position-limit mechanism.
Run and propel the limit stop and the limit stop can return
to the original location automatically, otherwise, change the
limit stop.
3.
Mount the component element of position-limit mechanism
(a) Mount the component elements of position-limit mecha-
nism in the rear housing.
(b) Tap the spring cylindrical pins in with drift punch and
hammer as shown in the drawing.

MT-35Gearbox
Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism)
(c) Coat the sealing agent on the bolt thread.
(d) Propel the plug with the torque socket spanner.

MT-36Gearbox
Bearing Front Cover Assembly (Element Drawing, Change of Oil Seal)
Bearing Front Cover Assembly
element drawing
bearing front cover
assembly
washerfront cover oil seal
assembly
Change of oil seal
The oil seal of the bearing front cover shall be changed where
necessary
(a) Pry out the oil seal with screwdriver
(b) Press in the new oil seal with SST.
Depth of oil seal:
Upper tooth
9.5mm
Tang tooth
(12.4
0.4)mm
SST

MT-37
Assembly of Gearbox
1. Mount the output shaft in the central link plate
(a) Tap the output shaft in the central link plate while pulling
it, until mounting it in the central link plate.
(b) Mount the stop ring of the rear bearing of output shaft in
with the split-ring-type pliers.
Remarks: The stop ring shall flush with the surface of central
link plate.
2. Mount the input shaft in output shaft
(a) Coat the MP lubricant on the bearing with 13 needle
rollers, and mount the needle rollers in input shaft.
(b) Propel the input shaft in the output shaft and flush the
groove of synchronizing ring with the sliding block.
3. Mount the countershaft in the central link plate
(a) Mount the stop ring on the rear bearing of countershaft
with split-ring-type pliers.
alignment
Gearbox
Assembly of Gearbox

MT-38Gearbox
Assembly of Gearbox
(b) Mount the intermediate-gear shaft in the central link
plate, and mount the backup rear bearing with SST while
holding the intermediate-gear shaft.
4. Mount the baffle of rear bearing of output shaft
Mount and propel the bolts with torque socket spanner.
Tightening moment

Tang tooth
(17
22)N
m
Upper tooth
(12
17)N
m
5. Mount the reverse idle gear and shaft
(a) Mount the reverse idle gear and shaft.
(b) Mount the axial pressing plate of the reverse idle gear,
and then propel the bolts tightly.
Tightening moment
(15
20)N
m
6. Mount the bracket cluster of reverse rocker arm
Mount the reverse rocker arm bracket and propel the two bolts
tightly.
SST

MT-39
locking ball
socket spanner
Gearbox
Assembly of Gearbox
7. Mount the steel ball and the five-speed thrust washer.
8. Mount the five-speed gear cluster
(a) Coat the gear oil on the needle bearing.
(b) Mount the five-speed gear cluster.
9. Mount the synchronizing ring and the fifth coupling gear
(a) Mount in the synchronizing ring and the fifth coupling
gear.
(b) Dismantle the old central link plate from the table vice.
(c) Put the gearbox straightly as shown in the drawing.
(d) Flush the groove of synchronizing ring with the sliding
block and mount the fifth coupling gear with pressure
machine.
(e) Mount the new central link plate in the table vice.

MT-40Gearbox
Assembly of Gearbox
10. Mount the split ring
(a) Select the retainer for shaft that leaves the minimum
radial clearance, which is not larger than 0.1mm.
(b) Mount in the retainer for shaft with copper bar and
hammer.
(c) Mount the spring cylindrical pin of third-fourth-speed
gearshift fork.
Notice: The pin port should align with the direction of the
shaft.(Same sa below) 11. Measure the radial clearance of the five-speed gear
cluster.
Measure the radial clearance of the five-speed gear cluster
with the measuring gauge.
Standard clearance

Shang chi
(0.135
0.325)mm
Tang chi
(0.1
0.3)mm
12. Mount the third-fourth-speed gearshift fork axle and the
first-second-speed gearshift toggle fork as well as the
third-fourth-speed gearshift toggle fork
(a) Mount the first-second speed and third-fourth speed
gearshift toggle forks.
(b) Mount the third-fourth-speed gearshift fork axle in the
central link plate and the gearshift toggle fork.

MT-41Gearbox
Assembly of Gearbox
13. Mount the first gearshift fork axle and first gearshift fork
(a) Coat the MP lubricating on the interlocking guidepost
and mount the interlocking guidepost on the first-second-
speed gearshift fork axle.
(b) Mount the interlocking pin in the central link plate with
the magnetic bar.
(c) Mount first-second gearshift fork axle in the first gear-
shift toggle fork and central link plate.

d) Mount the setting bolts of the first toggle fork and tighten
them.
Tightening moment

Upper tooth
(15
20)N
m
Tang tooth
(13
17)N
m
14. Mount the reverse yoke rod, reverse rocker arm and
reverse yoke block
(a) Mount the reverse yoke rod, reverse rocker arm and
reverse yoke block together.
(b) Mount the reverse rocker arm on the reverse rocker arm
bracket.
(c) Coat the MP lubricant on the interlocking guidepost and
mount the guidepost on the reverse gearshift fork axle.