GREAT WALL SO COOL 2006 Manual PDF

TF-5Transfer Box
Product Description and Simple Maintenance
Transfer Assembly NO. of Manufacturer
product assembly NO.
display
termnumber
displaythe last digit of the year
displaythe specific monthly
manufactuer data
displaythe month numnber
Example display:From January (A) to December (L)
Product instruction and simple maintenanceManufactuer data
Product instruction and simple mainte-
nance
1. Product Introduction
The transfer box adapted by our company is the transfer box
of 45-55 manufactured by Bogeguana, which is two-speed
and time driving, a set of planetary mechanism used is to
obtain the speed-reducing performance, while the driving
force is transmitted to the front driving gear by a highly precise
chain. The planetary gear train and rear output shaft element
of transfer box is lubricated initiatively through oil bath and oil
pump. This transfer box has four gears:

2H-stands for the two high gears
in which, only the two
rear wheel are driven, and the gear ratio of the transfer box
is 1:1


4H-stands for the four high gears, in which , all of the four
wheel are driven, and the gear ratio of the transfer box is
1:1


N- neutral location (this location only exists in the transfer
box of manual gearshift )
No driving force is transmitted
to the wheel when the input shaft and output shaft are
disconnected.

4L-stands for low gears, the four wheels are all driven, and
the gear ratio of transfer box is 2.48:1.
The gearshift of the mechanical gearshift transfer box is
obtained through the shifting-cam-type guide plate that is
operated by the shift rocker arm.
Sign board: which is fastened at the obvious external location
of transfer box, and on which the detailed data are marked.
borgwarner

TF-65D5D-Oil filling plug
5L-Oil drain plug5L2. Regular lubricant change
(a) The oil level of lubricant in transfer box shall be checked
when exchanging the engine lubricant or after the vehicle
covers 8000 kilometers, and the lubricant shall be added
as requirement.
(b) The lubricant shall be changed with the specified one
every year or after the vehicle covers 48000 kilometers.
3. Lubricant inspection approach
(a) Clean the oil filling plug and the around area.
(b) Open the oil-filling plug to check whether the lubricant
can flows out or not.
(c) if the lubricant can flow out, which means the real
lubricant volume is under the prescribed value, and the
specified lubricant shall be added into the transfer box
until the lubricant can flow from the oil filler hole.
(d) Propel the oil-filling plug tightly according to the given
Tightening moment.
Tightening moment
(19
30)N
m
Notice: The vehicle shall run for a certain time before
checking or exchanging the lubricant so that the
temperature of lubricant in transfer box may be a little
higher. Do not use hammer or other punching tools to
open or propel the oil drain plug or oil filling plug, otherwise,
the thread hole on the frame will be damaged
4. Lubricant change
(a) Clean the oil filling plug and oil drain plug and the around
area.
(b) Put down a oil container under the transfer box.
(c) Open the oil drain plug.
(d) Open the oil-filling plug.
(e) Drain the lubricant up.
(f) Mount the oil drain plug and screw it up according to the
given Tightening moment.
Tightening moment
(19
30)N
m
(g) Add the lubricant through the oil filler hole until the
lubricant overflows. Mount the oil-filling plug and tighten
it according to the Tightening moment.
Tightening moment : (19
30)N
m Transfer Box
lubricant grade: ATF--3Product Description and Simple Maintenance

TF-7Transfer Box
Disassembly and Mount of Transfer Box
Disassembly and Mount of Transfer Box
1. Transfer Box Disassembly
(a) Drive the vehicle on the lifting jack.
(b) Locate the gear of transfer box at the neutral
position, shift the transfer box to the 2H and
extinguish the engine.
(c) Disconnect the cell cathode.
(d) Lift the vehicle.
(e) Put down an oil disc under the transfer box, tear
down the oil drain plug and oil filling plug of the
transfer to drain all the lubricant up, then re-
mount the two plugs.
(f) Disconnect all wires and wire harnesses that
connected with the transfer box.
(g) Take apart the hose on the venting valve of
transfer shaft.
(h) Disconnect the linkage of the front drive shaft
with the front flange of the transfer box.
(i) Disconnect the linkage of the rear drive shaft
with the rear flange of the transfer box.
(j) Raise the transfer box up with the jack.Notice: The transfer box shall be guaranteed to
support by the lifting jack before tearing down
the sets of bolt and nut that connected with the
transfer box and gearbox. The transfer box is
not allowed to hang directly on the gearbox
through spline because such operation will
damage the transfer box parts.
(l) Tear down the connecting nuts between the
transfer box and gearbox and take down the
transfer box.
(m) Move the transfer box backward directly until
the linkage between the input shaft of transfer
box and the gearbox spline.
(n) Put down the lifting jack of the transfer box, and
(o) Tear down the gasket between the transfer box
and gearbox. Clean the gasket or glue on the
coupling face of front body of transfer box with
rear body of the gearbox. Take notice not to
damage the coupling face.
1234
5 6 7
8
9
1. input shaft
2. front frame of transfer box
3. rear cover of transfer box
4. flange
5. front output fork flange
6. venting valve
7. gasket
8. rear body of gearbox
9. bolt

TF-8Transfer Box
Disassembly and Mount of Transfer Box
2. Transfer box mount
a) Coat the lubricant grease on the output axial
spline of the gearbox with a thin sleeve contain-
ing lubricant grease.
b) Mount a new gasket on the mounting face of the
transfer box.
c) Lift the lifting bracket of transfer box and align
it to the same axle with the gearbox.
Notice: The transfer shall be guaranteed to flush
with the gearbox before connecting the spline.
Do not handle it forcefully to press the transfer
box spline into the gearbox. Otherwise, damage
will be caused, run the rear output shaft where
necessary to aim at the spline.
(d) Move the transfer box forward slowly so that
the spline and pin of the input shaft of gearbox
reach the front body of the transfer box, and the
gasket attaches on the gearbox completely.
(e) Ensure that the mounting holes of the front
body of transfer box, gasket, and gearbox are in
alignment and then mount the sets of bolt and
nut.
Fastening torque
(35-48)N
m
(f) Connect the rear drive shaft and the rear output
flange of the transfer box.
(g) Connect the front drive shaft and the front
output fork flange of the transfer box.(h) Connect the venting valve and the soft ventila-
tion pipe.
(i) Connect the cables of odometer that locates
nearby the transfer box.
(j) Connect all wire harnesses that connected with
the transfer box, and
(k) Add the lubricant of right brand.
Notice: when starting the engine, if the lubricant
is added incorrectly or in unsuitable volume,
which may lead the transfer box to damage.
Notice: as for the transfer box mounted on
vehicle, oil pump shall be used when adding oil
for it.
Notice: In case the transfer box is taken apart for
maintenance or inspection, there will be no
lubricant supplied by oil pump in the oil passage
on the top of transfer box. Therefore, it is not
accurate to control the oil volume by opening the
oil filling plug, in such condition, the oil passage
will be filled with oil once the oil pump runs. If the
wheel can run, such operation can be conducted
on the lifting jack. The oil level shall be rechecked
once the oil pump runs.
(l) Put down the vehicle after finishing the lubri-
cant inspection, and connect the cell cathode.

TF-9
5 4
3
1
6 2
1. rear body of transfer box
2. flange
3. oil seal
1. sensor bracket
2. bolt
3. speed sensor
4. o-ring
5. sensor assembly
6. bolt
7. gasket
8. rear body of transfer box2 1
5 3
4
4
6
7
8
Transfer Box
Disassembly of Transfer Box
4. gasket
5. nut
6. oil plug
Disassembly of Transfer Box
1. Brief instruction
In case the transfer box is required to be repaired for the
damaged specific element, it shall be taken apart to the degree
on which the damaged element is taken out. And the parts
taken apart from the transfer box, if it doesnít include the
damage element, can exist in the form of sub-assembly or
group instead the individual form, otherwise, the parts will be
taken apart individually.
2. Transfer Box Disassembly
Put the transfer box on the worktable and ensure the rear part
or the rear cover faces upward. Put the wooden block under the
front part of transfer box to keep the transfer box stands
horizontally. The disassembly process is as follows:
(a) Fasten the flange with the torque arm typed T-13-54-
002, screw off the nut to take down the gasket, then take
apart the flange and oil seal.
(b) Take down the two oil plugs from the transfer box body.
As for the electric gearshift transfer box, tear down the
electric shifting element according to the following
disassembly approach:
(a) Tear down the three bolts, gaskets, sensor and clip for
wire harness.
(b) Tear down the sensor assembly and take apart the O-
ring.
(c) Tear down the motor assembly.

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-11
5. Tear down the Chain drive system
Take apart the following parts from the transfer box housing
assembly.
(a) Take apart the snapping ring and washer from the front
output shaft.
(b) Take apart the driving chain sprocket, driven chain
sprocket and drive chain together from the two output
shafts.
(c) Separate the chain sprocket from the chain.
12
345
6 7
1. output shaft
2. driving chain sprocket
3. driven chain sprocket
4. washer
12 34
5
6 7
6. Oil pump assembly
Take apart the shaft and pump assembly, pipe clip, oil pipe and
filter from the remaining transfer box housing assembly.
1
2
7
6 3
4
5
8 1. deceleration gear hub
2. inserted face of Shift
toggle fork
3. plastic sleeve
4. contact roller
5. pin
6. pin, contact roller and sleeve assembly
7. deceleration shift toggle fork
8. deceleration shift toggle fork assembly7. Deceleration shifting element disassembly
Tear down the following parts from the remaining transfer box
housing assembly.
(a) Take apart the deceleration hub, and deceleration shift
fork assembly from the housing.
(b) Take apart two plastic inserted faces from the decelera-
tion shift fork assembly
(c) Disassembly the deceleration shift fork assembly only if
it were broken.Cut the plastic cover,and take out the pin
and truckle. Transfer Box
Disassembly of Transfer Box
1. output shaft
2. driving chain sprocket
3. driven chain sprocket
4. washer
5. snapping ring
6. transmission chain
7. front output shaft5. snapping ring
6. transmission chain
7. front output shaft

TF-12
110
9
8
6
5
4
3
2
11
15
14
13
12
17
18
19
207
16
Transfer Box
Disassembly of Transfer Box
1. fork-type flange
2. dust cover
3. fork-type flange assembly
4. transfer box front housing
8. Take apart the following parts from the remaining trans-
fer box housing assembly
(a) Fasten the front fork-type flange with the torque arm of
T-13-54-002 and screw off the nuts to take apart the
gasket, pull out the front fork-type flange assembly and
sealing ring.
(b) The dust cover may also be pressed down from the front
fork-type flange where necessary, and
(c) Take apart the front output shaft.
1. planetary mechanism
assembly
2. gasket
3. snapping ring
4. thrust disc
5. sun wheel
6. planetary bracket
7. input shaft assembly
8. input shaft
9. needle bearing
10. bearing shell
11. transfer box front
body assembly
9. Tear down the front body, input shaft assembly and
planetary mechanism assembly
Tear down the following parts from the remaining transfer box
housing assembly
(a) Take apart the venting valve.
(b) Take apart the six bolts to separate the front body from
the transfer box housing and take down the front body
(take notice not to damage the front-end cover and the
transfer housing).
(c) Take apart the front body assembly, input shaft assembly
and planetary mechanism assembly in grouping manner
(loose the snapping ring to take apart the input shaft from
the front end cover).
(d) Hold one end of the input shaft on the worktable while
open the long end of the snapping ring, press the front
body tightly to disassemble the front body assembly from
the remaining assembly.
(e) Take apart the snapping ring and oil seal from the front
body, the pin is only be taken apart where change is
necessary.
(f) Take apart the bearing and gasket from the input shaft
assembly after the bearing gripping loop is taken apart;
and take apart the input shaft assembly from the planetary
mechanism assembly.
(g) Take apart the needle bearing and bearing shell from the
input shaft assembly, and
(h) Take apart the snapping ring, thrust disc and sun wheel
from the planetary assembly, and
(i) Do not try to disassemble the planetary bracket.
4
2
1
5 6
7
83
5. front output shaft
6. oil seal
7. washer
8. nut
12. oil seal
13. locating pin
14. transfer box front
body
15. snapping ring
16. transfer box front
housing
17. bearing
18. bearing gripping
loop
19. bolt
20. vent

TF-13
1
234
5
7
6
5
4
3
21
Transfer Box
Disassembly of Transfer Box
10. Take apart the shift convex plate parts (for the electric
shift transfer box)
(a) Take apart the integrated electric shifting cam from the
transfer box housing.
(b) Take apart the electric shifting cam from the shift guide
shaft.
(c) Grip the end of shift guide shaft with soft-jaw vices, and
tap the shaft with a screwdriver until the torsion spring
drops off.
1. front body of transfer box housing
2. shift guide shaft
3. torsion spring
4. electric gearshift
5. gasket
1. transfer box front housing assembly
2. gear ring
3. oil seal
4. transfer box front housing
5. locating pin
6. ball bearing
7. snapping ring
11. Disassemble the transfer box housing assembly
Disassemble the transfer box housing assembly in the manner
as follows.
(a) Take apart the oil seal.
(b) Take apart the snapping ring, and pull out the bearing.
(c) The locating pin may only be taken apart from the transfer
box front housing in the case that the pin is loose or
damaged, and
(d) Where the gear ring needs to be changed, it may be
pressed out from the transfer box housing.

TF-14
7
6
5
4
3
21
1. transfer box front housing assembly
2. gear ring
3. oil seal
4. transfer box front housing
5. locating pin
6. ball bearing
7. snapping ring
NMR23
41
1. oil seal
2. transfer box front housing
3. gear ring
4. locating pin
Transfer Box
Transfer Box Assembly
Transfer box assembly
1. Introduction
Please refer to the given instruction of this chapter during
assembly process. And the following items shall be taken
notice on:
(a) In case that the torque of the threaded parts is required,
torque spanner shall be used to screw up the parts.
(b) The small parts shall be coated with the lubricant grease
during the mounting process, so that they are immobilized
at the mounting locations.
(c) SST such as thimble of T-13-54-001 shall be used to press
the oil seal and bearing during the oil seal mount and
bearing mount, do not use the hammer to strike the oil seal
or bearing directly.
2. Lubricating during assembling
All inner parts without lubricant shall be lubricated with the
suitable lubricant before mounting, so that they can be as-
sembled easily and can supply the original lubricant
performance.
(a) If the O-ring and oil seal were not lubricated before
mounting, they may be damaged.
(b) Be sure that the bearing or liner is lubricated completely
before mounting. Because the bearing or liner may be
leaded into damage even though they are run for a very
short time.
(c) The lips of oil seal and the metal elements that match with
lips shall be lubricated before mounting.
3. Transfer box housing assembly
Parts taken apart from the transfer box shall be mounted
according to the following approaches:
(a) If the gear ring needs to be changed, the tooth-type saddle
rear of new gear ring shall be flushed with the gullet of the
transfer box front housing when pressing the new gear
ring. Press in the gear ring as shown in the left bottom
drawing, in which, the chamfering end is firstly pressed
in. if it is ensured the gear ring is not tilted, then fasten the
gear ring tightly on the housing.
(b) In case there are two locating pins taken apart, mount two
new locating pins into the housing.
(c) Press the bearing into the transfer box front housing and
mount the snapping ring correctly, and
(d) Put down the new oil seal as shown in the left bottom
drawing and press it into the housing.