GREAT WALL SO COOL 2006 Repair Manual

MT-42Gearbox
Assembly of Gearbox
(d) Mount the interlocking pin in the central link plate with
the magnetic bar.
(e) Mount the reverse gearshift fork axle in the reverse yoke
rod and central link plate.
(f) Mount the spring cylindrical pin with the drift punch and
hammer.
15. Mount the five-speed reverse gearshift guide block and
five-speed reverse gearshift fork axis.
(a) Mount the five-speed reverse gearshift guide block in the
five-speed reverse gearshift guide shaft.
(b) Mount the reverse gearshift fork axle in the next step.
(c) Mount the steel ball in the five-speed gearshift guide
block with the magnetic bar.
(d) Mount the five-speed gearshift fork axle as shown in the
drawing.
(e) Mount the steel ball in the central link plate with mag-
netic bar.
(f) Mount the five-speed gearshift fork axle in the central
link plate.

MT-43Gearbox
Assembly of Gearbox
(g) Tap the pin in the five-speed gearshift toggle fork with
the drift punch and hammer.
(h) Mount the five reverse gearshift guide shaft in the five-
speed reverse guide block and central link plate, and
(i) Tap the spring cylindrical pin in the five-speed reverse
guide block with drift punch and hammer.
16. Mount the retainer ring gripped by the gearshift fork axle.
Mount the clamp retainer ring with the steel bar and hammer

MT-44
sealed material
Gearbox
Assembly of Gearbox
17. Mount the steel ball, locating spring and locating spring
plug
(a) Mount the steel ball and locating spring.
Remarks:
Mount the short spring at the bottom of the central link plate.
(b) Coat the sealing agent on the plug thread.
(c) Mount the plug and tighten them with the torque socket
spanner.
Tightening moment
(17
22)N
m
18. Tear down the central link plate from the table vice
(a) Tear down central link plate from the table vice.
(b) Dismantle the bolts, nuts and washers
19. Mount the gearbox frame
(a) Coat the sealing material on the coupling face of the
gearbox frame as shown in the drawing.
(b) Put down the central link plate straightly as shown in the
drawing.
(c) Mount the gearbox frame on the central link plate as
shown in the drawing.

MT-45
sealed material
Gearbox
Assembly of Gearbox
20. Mount the stop ring of the front bearing
(a) Mount the two stop rings in the input shaft bearing and
countershaft front bearing with the split-ring-type pliers.
(b) Mount the coated component elements of front cover.
(c) Coat the sealing agent on the bolt thread, and
(d) Mount and propel tightly the bolts.
Tightening moment
(15
20)N
m
21. Mount the rear body, gear-change bar and selection bar
and their housings
(a) Coat the sealing materials on the rear body as shown in
the drawing.
(b) Mount the gearshift shaft and gearshift yoke block in the
rear body.
(c) Mount the gearshift catching head in the groove of guide
block, and
(d) Mount the catching head with the rear body together.
(e) Mount and propel tightly the bolts.
Tightening moment

Shang chi
(30
40)N
m
Tang chi
(30
45)N
m

MT-46
4WD
Gearbox
Assembly of Gearbox
(f) Fasten the rear cover bolts of the four-gear driving
gearbox
Tightening moment:(30
45)N
m(Tang tooth)
(g) Mount and propel tightly the setting bolts of the gearshift
yoke block.
Tightening moment
(17
22)N
m
22. Mount the steel ball spring and plug
(a) Coat the sealing agent on the plug thread.
(b) Mount the steel ball, setting spring and setting spring
plug.
Tightening moment
(17
22)N
m
23. Check the following items after mounting the rear body
or gearbox
(a) Check the stability of the running input shaft and output
shaft.
(b) Check the gearshift stability of each speed
24. Mount the component elements of the locating mecha-
nism
(a) Mount the black component elements of the locating
mechanism on the side of the five-speed reverse gear.
(b) Mount another component element of locating mecha-
nism and propel it tightly.
Tightening moment
(30
40)N
m
25. Mount the gearshift cover of the gearbox.
(a) Mount the gearshift cover coated with sealing agent.
(b) Mount six bolts and then tighten them.
Tightening moment
(15
20)N
m

MT-47Gearbox
Assembly of Gearbox
26. Mount the clutch frame
(a) Mount the clutch frame.
(b) Coat the sealing agent on the bolt thread.
(c) Mount the nine bolts and then tighten them.
Tightening moment

Upper tooth
(60
70)N
m
Tang tooth
(30
45)N
m
27. Mount the back-up lamp switch.
Tightening moment
(20
40)N
m
28. Mount the driven gear of odometer
(a) Mount the driven gear of odometer.
(b) Mount the bolts and tighten them.
Tightening moment
(10
15)N
m

TF-1
page
Notice ........................................................................... TF-2
Troubleshooting ........................................................... TF-3
Product Description and Simple Maintenance ............. TF-5
Dismantle and Mount of Transfer Box .......................... TF-7
Disassembly of Transfer Box ....................................... TF-9
Assembly of Transfer Box ............................................ TF-14
Washing, Inspection, Maintenance and Change .......... TF-24
Washing ................................................................... TF-24
Inspection ................................................................ TF-25
Maintenance and Change of Gear and Chain gear .. TF-28
Attachment for Inspection, Maintenance and
Change of Parts ....................................................... TF-30
Transfer Box
TF

TF-2Transfer Box
Notice
Notice
Notice on transfer box disassembly and assembly
Notice shall be taken on the soft handling of the parts (coupling face in particular) during the process of
transfer box disassembly to avoid the collision; each parts shall put down in order so as to avoid of missing
or mistaking.
Notice shall, during assembly process, not only on the aforesaid items, but also on the following items:
1. Wash all parts and fittings before assembly (rubber element and washer excluded).
2. Oil seal, clip for shaft and spring pin of various kinds shall not be reused.
3. Lubricating oil is required to coat on the various friction surface and lubricant on lips of various oil seal.
4. Rolling body is not allowed to use for pressure transmission when mounting various bearings.
5. Lip-type oil seal is not allowed to mount slantwise.
6. The openness on the two sides of spring collar shall not be coupled face-to-face when assembling the
component elements of synchronizer. And
7. No parts is allowed the lubricant leakage and penetration when the transfer box locates at the working
location.

TF-3Transfer Box
Troubleshooting
Common troubles Causes Resolving approaches
Change the lubricant or supplement the
lubricant volume.
Guarantee the torque of all connecting
elements stand at the specified value.
Open the transfer case to check the
bearing and othe parts whether is weared
or daamaged,if this happened,change
the parts.
Difficulty in mechanic gearshift or
outplace gear engagement
Troubleshooting
Incorrect lubricant or insufficient
lubricant volume.
Looseness of connecting bolt or other
connecting element.
Noise from the transfer box bearing Noise, which is spreader by the transfer
box instead of clutch, engine, drive shaft
and other parts, occurs in each speed. No driving of front wheel in the four-
gear engagementDrive chain breakDisassemble and check the damage of
inner parts, and change the chain. Adjust or repair shift lever.Open the
transfer box to check the toggle fork and
guide shaft, and change the parts as
requirement.Open the transfer box to
check whether the parts is wearied or not,
and, if any, change the weary parts.Open
the transfer box to check whether the
parts is wearied or not, and, if any, change
the weary parts.Open the transfer box to
check whether the parts is wearied or not,
and, if any, change the weary parts. Overlarge loose fit clearance of the
shift toggle fork on the shift guide
shaft.
Wear of the shift toggle fork
assembly including pin and contact
roller.
Wear of the shift cam hub and the
liner.
Attainment of coupling gear Mechanic gearshift seizing at a certain
location Engagement failure of the mechanically
shift transfer boxDamage or unsuitable adjustment of
the shifting mechanism.
Damage or serious wear of the inner
shifting parts, or looseness or
attainment of the shift toggle fork
assembly on the guide shaft.
Unsuitable adjustment of shift lever.Adjust or repair the shift lever mechanism.
Change the seriously wearied parts.
Change the loose or weary parts. Refer to the vehicle manual for correct
operation.
Add the specified oil of given volume.
Open the rear cover of transfer box to check
and changer the damaged parts.
Open the rear cover of the transfer box to
check whether the sliding parts can slide
freely along the axle, if not, dismantle it and
change the damaged parts. Incorrect operation.
Lubricant of inferior quality or
insufficient volume.
Adhesive bonding of shift toggle fork.
Adhesive bonding of the sliding joint
cover, locking sleeve or gear. Mechanic gearshift failure under the
movement of shifting handleBreak or damage of the shift rocker
arm or shift lever.
Damage of the guide plate of shifting
cam;Change the damaged element.
Open the rear cover of the transfer box to
check the damaged element and change
it. Electric gearshift troubleDamage or failure of electrically
controlled element, electric module,
speed sensor, electric motor, electric
clutch, or built-in wire harness.
Damage or worn of shifting cam,
joint cover, locking sleeve, toggle
fork or shift guide axle.Adhesive
bonding shiftRefer to the vehicle usage manual to
diagnose the failure element and change
it as requirement.
Dismantle the weary or damaged parts
and change it as requirement.
Dismantle and check the free movement
of sliding element, and change it as
requirement

TF-4Transfer Box
Troubleshooting
Common troubles CausesResolving approaches
Unsuitable tire pressure.
Noise, which is spread by the transfer
box instead of the clutch, engine or other
parts, occurs at each speed.Gear noise.
Damage or wear of chain gear or
chain.Open to check whether there is weary
element or damaged element (including
the odometer gear) and, if any, change
them
Noise occurs in the high-speed or low-
speed four-gear driving.Open to check whether there is wear or
damage, and if any, adjust the tire pressure
to suitable value.
Oil leakage in transfer box. Frame Break of transfer box.
Oil leakage of other element.
Ventilation pipe block
Over-added lubricant or lubricant of
unsuitable brand
Looseness of the bolts on sealing
face.
Sealing glue of different brand or
unused sealing glue.
Oil seal wear or damage.Change the frame.
Check the leakage by wiping dry.
Open and clean it and, if necessary,
change it.
Use the specified lubricant and adjust the
lubricant to suitable volume.
Propel the bolts tightly as requirement.
Use the specified sealing glue and propel
the bolts tightly as required.