lock GREAT WALL SO COOL 2006 Manual PDF

SA-88
10. Change for the bearing 7306E and the outer race of
bearing 7607E:
(a) Tap out the bearing outer race with hammer and copper
bar.
(b) Press in the new bearing outer race with pressure ma-
chine and SST.
12. Tear down the axle driven bevel gear.
(a) Tear down the lock plate and bolts on the axle driven
bevel gear.
(b) Mark the assembly marks on the axle driven bevel gear
and the differential housing.
(c) Tap down the axle driven bevel gear with rubber hammer
and copper bar.
11. Tear down the inner race and roller assembly of bearing
200719E from differential.
Pull out the inner race and roller assembly of bearing 200719E
from the differential housing with SST. Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)

SA-89
Assembly of Rear Speed Reducer
1. Mount the inner race and roller assembly of bearing
7306E, oil-guard tray and oil seal.
(a) Put the inner race and roller assembly of bearing 7306E in
the speed reducer housing, and put the oil-guard tray on it.
(b) Coat the lithium base grease on the position of speed
reducer where oil seal locates and on the lips of oil seal,
align the oil seal and press it to mount.
2. Mount the flange and dust cover assembly
Encase the flange and dust cover assembly in the speed reducer
housing, then flat it by hand.
3. Mount the driving bevel gear:
(a) Put the adjusting washer, jacket on the driving bevel gear,
which is mounted with adjusting washer and inner race
and roller assembly of bearing 7607E, then encase the
driving bevel gear in the speed reducer housing.
(b) Screw up the nuts to tighten the flange, flat washer and
the driving bevel gear with SST, and the thread locking
agent is required to be coated when screwing.
Tightening moment
(140
160)N
m
4. Measure the pre-tightening torque of the bearing:
New bearing
(1.2-1.7)N
m
The reused bearing
(0.9-1.3)N
m
Remark: if the requirement is not satisfied, change the adjust-
ing washer under jacket until the requirement is satisfied.
(a) If the measure value is smaller than the standard one,
reduce the thickness of adjusting washer;
(b) If the measure value is larger than the standard one,
increase the thickness of adjusting washer.
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)

SA-90
5. Mount the axle driven bevel gear on the differential housing:
(a) Mount on the lock plate and screw up the bolts to the
specified torque.
Tightening moment
(65-95)N
m
Notice: screw up the bolts diagonally.
(b) Tighten the lock plate with hand hammer and flat head
pinch.
6. Mount the inner race and roller assembly of bearing
200719E;
Mount the bearing inner race and roller assembly in differen-
tial housing with the pressure machine and SST.
7. Mount the differential assembly;
Mount the differential in the speed reducer housing.
When mounting the differential that hasnít changed the inner
race and roller assembly of bearing 200719E, ensure the outer
race of the left and the right bearings that has disassembled
should match with their inner racers respectively.
8. Mount the adjusting ring;
Adjust the clearance between the driving bevel gear and the
axle driven bevel gear to the moderate size. And press the
bearing outer race to flatten it with adjusting ring, and then
screw up moderately.
Notice: the two adjusting rings should be adjusted
synchronically in the movement of same direction.
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)

SA-93
12. Lock the double-eared stop washer to mount the stop
gasket and bolts:
(a) If the engagement trace satisfies the requirement, lock
tightly the double-eared stop washer with hand hammer
and pinch.
(b) Mount on the stop gasket, spring gasket and bolts, and
then screw up the bolts.
Tightening moment
(18-26)N
m
(c) Tap in he adjusting ring with the pinch and hammer.
13. Measure the total preload:
Preload: (1.8-2.4) N
m
If the preload is beyond the specified range, change the gas-
kets between the jacket and bearing 7607E, until they meet
the requirement.
(a) If the preload is larger than the specified value, change
the adjusting washer.
(b) If the preload is smaller than the specified value, screw up
the nuts again slowly but not exceed 160N.m.
Notice: if the screwing torque exceeds the max torque,
change the adjusting washer and repeat the preload
process. Do not screw back the main-tooth nut to reduce
the preload.
14. Check and adjust the flange bouncing
(a) Attach the dial indicating lamp seat on the speed reducer
housing with the measuring head contact the flange face,
run the flange to observe the swing out range of the dial
indicating lamp hand.
Radial full bouncing tolerance
0.10mm
Remark: the two bouncing values should be controlled within
0.10 mm, as for the parts of bounce exceeding the tolerance,
loosen the nut-driving bevel gear to assembly them in another
angle, measure the bounce value again. Observe carefully the
swing direction of the hands, which can be referred when
changing the locations of flange and the driving bevel gear. If
the requirement cannot be satisfied after several trials, change
the new flanges until the requirement is met. Suspension System and Automobile Axle (Rear)
Rear Speed Reducer (Disassembly of Speed Reducer)
30mm
15. Rivet the driving bevel gear nuts.s

BR-2Braking System
Notice and Troubleshooting
Notice:
1. Carefully change each part where necessary because any
mistake will affect the brake system properties, and will lead
accidents during driving. And the parts to be changed must
be the same in part number or equal in quality.
2. Keep the parts and each position clean when repairing the
braking system.
Troubleshooting
Trouble Causes Inspection items
Lower or soft pedal Abrasion of brake shoe
Abrasion of brake pad
Oil leakage of braking system
Master cylinder failure
Air in braking system
Wheel-brake cylinder failure
Failure in the automatic regulator of rear brake.Change the brake shoe; Change the brake
pad;
Repair the oil leakage;
Change the master cylinder;
Drain out the air from braking system;
Change the wheel-brake cylinder;
Repair or change the regulator
Brake stagnantPoor adjustment of parking brake;
The bracing wire of parking brake is seized;
Poor adjustment of vacuum booster pushrod)
Failure of the drag spring or the return spring
Pipe line blockage
Brake shoe breakage or deformation
Brake pad breakage or deformation
Seizing of the wheel-brake cylinder or the brake
caliper piston
Automatic regulator breakage
Master cylinder failureAdjust the parking brake;
Make repairing according to real situation;
Adjust the drag rod;
Change the drag spring or the return spring
Make repairing according to real situation;
Change the brake shoe
Change the brake pad
Make repairing according to real situation;
Change the regulator
Change the master cylinder
Over large braking
distanceUnsuitable tire inflation
There is oil stain or lubricant on the brake shoe or
brake pad;
Brake shoe deforms, the brake liner is worn or polished;
Brake pad deforms or is worn or polished;
Brake drum or brake disc deforms
Drag spring or return spring has trouble
The wheel-brake cylinder has trouble
The inner piston of wheel-brake cylinder is seized;
The brake pad is seized;Inflate the air to suitable pressure;
Change the brake shoe or the brake pad;
Change the brake shoe;
Change brake pad
Change the brake drum or the brake disc;
Change the spring;
Change the wheel-brake cylinder;
Change the wheel-brake cylinder
Change the brake pad
The brake pedal is hard
but doesn
t work;There is oil stain or lubricant on the brake shoe or
brake pad;
The brake shoe deforms, brake liner is worn or
polished, or the brake wheel is worn;
The brake pad deforms, or is worn or polished;
The piston of wheel brake pump is seized;
The vacuum booster has trouble
The vacuum degree is unsuitable
The brake pipe line is blockedChange the brake shoe brake pad;
Change the brake shoe
Change the brake pad;
Change the wheel-brake cylinder;
Change the vacuum booster;
Make repairing according to real situation;
Make repairing according to real situation;

BR-5Braking System
Inspection and Adjustment
pedal push rodbraking lamp switch
pedal push-rod
free stroke of
pedal: (3-6) mm
Inspection and adjustment
Inspection on and adjustment of brake pedal
1. Check the pedal height as shown in the drawing to
whether it is correct,
The height from the pedal to the front floor:
Dr SF
160mm
SL SK SY SJ
(190-200)mm
2. Adjust the pedal height if necessary:
(a) Loosen the locking nuts of braking lamp switch;
(b) Loosen the braking lamp switch to the most degree.
(c) Loosen the locking nuts of drag rod;
(d) Adjust the pedal height through rotating the pedal drag
rod;
(e) Rotate the stop light switch reversibly until it contact
with the stop baffle of pedal.
(f) Screw up the two locking nuts.
(g) Check the braking lamp is lightened or not when tread
down the brake pedal.
(h) Check and adjust the pedal free stroke after adjusting the
pedal height
QKAdjust the free stroke of pedal if necessary:
(a) Loosen the locking nuts of the pedal drag rod and rotate
the pedal drag rod to adjust the pedal free stroke.
(b) Start the engine to confirm the free stroke.
(c) Check the pedal height after adjusting the pedal free
stroke. 3. Inspection on Pedal Free Stroke:
(a) Stop the engine working and tread down the brake pedal
several times until the vacuum booster is not in the stage
of vacuum.
(b) Tread down the pedal until the resistance occurs, and
measure the distance shown in the drawing.
Pedal free stroke
(3-6)mm
pedal height

BR-7
Check and adjust the parking brake
1. Check the stroke of operating lever of the parking
brake to see whether it is correct.
Drag the brake operating lever to the max stroke and count the
grooves it passes.
Stroke of operating lever of parking brake:
Dr
(9-10) Teeth
SL SK SY
(7-9) Teeth
2. Adjust the parking brake lever where necessary:
Remark: Adjust the rear brake shoe clearance before the
adjustment.
Brake shoe clearance: 0.6mm
(a) Loosen the locking nut and then rotate the adjustable nut
until the stroke is correct, then screw up the nuts.
(b) The brake shoe shall not be stagnant after the adjustment.
Braking System
Inspection and Adjustment

BR-13
Front Brake
Element figure
No. 2 lock plate of brake padNo. 1 lock plate of brake pad
silent pad cluster
brake pad assembly
silent pad cluster
caliper body
No. 2 lock plate of
brake pad No. 1 lock plate of
brake pad
long sliding caliper liner
sliding sleeve dust cover
caliper body
rectangular sealing ring
piston piston dust cover
piston dust cover
snapping spring
sliding sleeve dust cover
short sliding caliper linershort sliding caliper sleevesliding sleeve dust cover vent screwvent screw dust cover
long sliding caliper sleeve
sliding sleeve dust cover
DrBraking System
Front Brake (Dr)

BR-14
Brake pad change
Remark: Check the thickness of the friction material of brake
pad through the observation hole on caliper body after the
vehicle covers thirty thousand; if the thickness fails to fall
within the specified range, change is required. (If the brake is
used often, the thickness of friction materials of brake
pad is required to check whether it is within the specified
range after the vehicle covers more than ten thousand,
if not, change it.
1. Tear down the front wheel;
2. Check the thickness of friction material of brake pad:
Check the thickness of friction material of brake pad through
the observation hole on caliper body, if it fails to be within the
specified range, change it.
Min thickness: 2.0mm
3. Raise the wheel-brake cylinder:
(a) Tear down the short bolts of sliding sleeve;
(b) Uplift the wheel brake pump and hang it with rope to
protect the brake oil pipe.
Remark: Do not loosen the brake oil pipe and the bleeding plug.
4. Tear down the following parts:
(a) Two braking pads;
(b) Two silent pad clusters;
(c) Four braking pad lock plates.
Braking System
Front Brake (Dr)

BR-15
5. Brake disc measurement
(See page BR-17)
6. Measure the radial run-out of the brake disc;
(See BR-18)
7. Mount the lock plate of brake pad.
8. Mount the new brake pad.
(a) Mount the silent pad cluster on brake pads of both the
inner and outer sides;
Remark: Pollution of oil stain or coat is not allowed on the
work faces of brake pad or brake disc.
(b) Draw out a little brake liquid from the liquid container to
prevent the brake liquid overflowing from the liquid
container;
(c) Press in the piston with the hammer lever or similar tool.
9. Mount the wheel-brake cylinder;
Mount and screw up the hex bolts (the hex bolts shall be coated
with the thread locking sealing agents.
Fastening torque
(38-50)N
m
Remark: only one brake pad can be changed in one time so as
to prevent the piston of other wheel being shot out.
Braking System
Front Brake (Dr)