change wheel GREAT WALL SO COOL 2006 Service Manual

IN-4
Overall Repairing Description
1. Keep the vehicle clean and prevent it from
damage with guard plate, seat and floor cover
cloth.
2. Put down the dismantled parts in order during
the dismantle process so as to facilitate the re-
assembly
3. Observe the following items:
a) Disconnect the cable cathode from the
accumulator terminal before the electric
operation;.
b) Disconnect the cable from the cathode
connected to the vehicle body when check-
ing or repairing the accumulator where
necessary.
c) In order to avoid the damage of terminal
post of accumulator, loose the bolts first,
then pull up the cable vertically when
dismantling, don
t wring it or prize it.
d) Clean the terminal posts of the accumula-
tor with dishcloth, and do not scrape them
with file or other similar tools to avoid
damage.e) Mount the cable terminal on the post with loosened nut, then
fasten the nut. donít tap the terminal onto the post with
hammer.
f) Be sure to check whether the cover of positive terminal (+) is
well located or not.
4. Check all hoses and wire plugs to verify whether they are
connected solidly and correctly.
5. Parts that cannot be reused after being used.
a) The following parts should be changed with new one regularly:
split pin, sealing washer, O-ring and oil seal, etc.
b) parts that cannot be reused after being used is marked with

 in the element figure.
6. Pre-coated parts
The pre-coated parts including the bolt and nut are coated with
locking seal glue in factory.
a) In case the pre-coated parts are moved due to its fastening,
loosening or other causes, they must be coated again with the
specified seal glue.
b) Coating procedure of pre-coated parts
1) Clear away the former seal glue from the screw thread of
the said parts.
2) Dry the parts with compressed air.
3) Coat the screw thread of the parts with the specified
locking seal glue.
c) The pre-coated parts are marked with the
 in element
figure.
7. When necessary, sealing agent or sealing ring to prevent the
leakage.
8. Each specification shall be followed strictly. And the torque
spanners should be used.
9. Determine the necessity of using the special service tools (SST)
or special service materials (SSM) according to the real situation.
SST and SSM must be used where necessary and the repairing
should be in accordance with the repairing approach. SST list
and SSM list are attached to this manual.
10. Be sure to check whether the rated current of the new fuse is
correct when changing the fuse. The fuse rated current should
not larger than that of securing fitting and the fuse of smaller
rated current must not be used.
11. Be careful to hang or support the vehicle on the suitable place
when propping up or raising it.
a) In case prop up the vehicle at the front or back part, the wheels
must be blocked to guarantee the safety work. Introduction
Overall Repairing Rescription
tighten seal glue

CL-2Clutch
Troubleshooting
Troubleshooting
Trouble Causes Repairing approaches
Difficulty in gearshift
or non-gearshiftOverlarge free stroke of clutch pedal
There is air in clutch pipe
Failure of clutch brake-wheel cylinder
Failure of clutch master cylinder
Overlarge clutch pendulum difference due to incorrect mounting, the
friction liner is stained with oil or is breaking
There is dirty or adhesive materials on spline of input shaft or clutch rib
Failure of clutch pressure plateAdjust the free stroke of pedal
Exhaust the air in clutch pipe
Change the clutch brake-wheel cylinder
Change the master cylinder
Check the clutch rib
Repair according to requirement
Change the clutch pressure plate
Disengagement of gear
box or clutch slipAbrasion of clutch guide shaft
Insufficient free stroke of clutch pedal
The friction liner of clutch rib is stained with oil or is worn
Failure of clutch pressure plate
Seize up of separation forkChange the guide shaft
Adjust the free stroke of pedal
Check the clutch rib
Change the clutch pressure plate
Check the separation fork
Clutch seize-up or
shakingThe friction liner of clutch rib is stained with oil or is worn
Failure of clutch pressure plate
Looseness of engine seatCheck the clutch rib
Change the clutch pressure plate
Repair according to requirement
Looseness of clutch
pedalThere is air in clutch pipe
Failure of clutch brake-wheel cylinder
Failure of clutch master cylinderExhaust the air in clutch pipe
Change the clutch brake-wheel cylinder
Change the master cylinder
Over-loud clutch noiseSeize up of separation fork;
Abrasion or stained spot of separation bearing
Abrasion of guide bearing
Parts looseness in clutch pressure plateRepair according to requirement
Change the separation bearing
Change the guide bearing
Change the clutch pressure plate

CL-8Clutch
Clutch Cluster
Inspection on clutch parts
1. Check whether there is abrasion or damage of clutch rib;
Measure the depth of the rivet head with calipers.
Min depth of rivet head: 0.3mm
If the depth of rivet head exceeds the limit value, change the
clutch rib.
2. Check the radial pendulum difference of the clutch
Check the radial pendulum difference of the clutch rib with
multi-meter.
Max radial pendulum difference: 0.8mm
If the radial pendulum difference exceeds the max value,
change the clutch rib.
3. measure the rdial pendulum difference of the flywheel;
Check the radial pendulum difference of flywheel with multi-
meter;
Max radial pendulum difference: 0.2mm
If the radial pendulum difference exceeds the max value,
change the flywheel.
4. Check the guide bearing
Exert the force in radial direction to rotate the bearing by hand.
If the guide bearing doesn
t run or if there is great resistance,
change the guide bearing.
Remark: as this bearing is lubricated permanently, it needs not
to be cleaned or lubricated.
5. Change the guide bearing where necessary.
a) Tear down the guide bearing with SST;
SST

CL-9Clutch
Clutch cluster
b) Mount the guide bearing with SST.
Remark: the bearing shall be verified in good running after it
is encased in the flywheel hub.
2. Check whether there is abrasion on the diaphragm spring.
Check the abrasion depth and width of diaphragm spring with
calipers.
Limit value: Max depth: 0.6mm
Max width: 5mm
If the abrasion depth or width of the diaphragm spring exceeds
the limit value, change the diaphragm spring .
3. Check the separation bearing
Exert force in radial direction by hand to rotate the bearing.
If it cannot be rotated or if the resistance is too large, change
the separation bearing.
Remark:
Remark: as this bearing is lubricated permanently, it doesnít
need to be cleaned or lubricated.
Mount of clutch cluster
1. Mount the clutch rib on flywheel;
Mount the clutch rib on flywheel with SST.
2. Mount the clutch pressure plate
a) Align the marks on clutch pressure plate and that on flywheel;
b) Screw up the bolts in even manner around the clutch pressure
plate until pressure plate and the flywheel contact closely,
then tighten the bolts.
Tightening moment: 30 N
m
Remark: tighten the uppermost bolt of the three that is near to
the locating pin.
SST
flywheel sideSST
alignment
mark

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-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-32Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection
Maintenance or Change of Parts
Pump shell Check to see whether there is pitting corrosion
or step slippingAbandon it in case it is seriously damaged or
worn
Output shaftCheck the spline, check the surface that matches
with bearing and check the distortion according
to
inspection
paragraphRefer to the spline inspection of
inspection

paragraph;
Refuse to use the one with pitting corrosion or
damage;
Refuse to use the one that is bending or poor in
round bouncing.
Deceleration hubCheck the spline of chain sprocket and check the
wear or damage of the location where matches
with the toggle fork according to the

inspection
paragraphRefer to the spline inspection of
inspection

paragraph; refuse to use the one with step slid-
ing or damage.
Front output shaftCheck the surface where matches with the
bearing;
Check the spline according to the
inspection
:
paragraphRefuse to use the one with pitting corrosion or
damage
Input shaft Check the spline according to the
inspection

paragraph
Check the distortionRefer to the spline inspection of
inspection

paragraph;
Refuse the one that is bending or poor in round
bouncing.
Thrust washer and
thrust discCheck the pitting corrosionRefuse to use the one with pitting corrosion or
damage
Sun wheelCheck the gear teeth and spline according to the

inspection
paragraphRefer to the gear teeth inspection and spline
inspection of
inspection
paragraph.
Planetary mechanism
assemblyCheck the gear teeth according to the

inspection
paragraph;
Check the wear and looseness of the planetary
gear pin; check the wear of thrust gasketRefer to the gear teeth inspection of

inspection
paragraph;
If any step sliding or pitting corrosion is found,
refuse to use it
Electric shifting camCheck to see whether there is step slipping or
pitting corrosionIf any step sliding or pitting corrosion is found,
refuse to use it
Shift guide shaftCheck to see whether there is step slipping or
pitting corrosion
Check the distortion situationIf any step sliding or pitting corrosion is found,
refuse to use it
Refuse to use the bending one
Planetary gear ringCheck the match performance of it with the
transfer box housing
Check the gear teeth according to the

inspection
paragraphCheck the transfer box housing assembly to see
whether the gear ring is loose or not in the
housing
Refer to the gear teeth inspection of

inspection

paragraph
Transfer box housingCheck the holes matches with the bearingAbandon the one with pitting corrosion or
damage.

SA-1
Suspension System and Automobile Axle
Page
Troubleshooting .......................................................... SA-2
Alignment of Front Wheel ............................................ SA-3
(Dr/2WD)
Front Wheel Hub and Steering Knuckle ...................... SA-10
Front Wheel Hub ..................................................... SA-11
Steering Knuckle ..................................................... SA-14
Front Suspension ........................................................ SA-16
Ball Stud .................................................................. SA-17
Torsion bar .............................................................. SA-19
Lower Arm and Vibration Damper ........................... SA-21
Upper Arm ............................................................... SA-24
Guide Level ............................................................. SA-26
Lateral Stabilizer ..................................................... SA-27
(SF/2WD)
Front Wheel Hub and Steering Knuckle ...................... SA-28
Front Wheel Hub ..................................................... SA-29
Steering Knuckle ..................................................... SA-32
Front Suspension ......................................................... SA-36
Ball Stud ................................................................... SA-37
Torsion bar ............................................................... SA-38
Lower Arm and Vibration Damper ............................ SA-39
Upper Arm ................................................................ SA-42
Guide Level .............................................................. SA-43
Lateral Stabilizer ....................................................... SA-43
(SF/4WD)
Front Wheel Hub and Steering Knuckle ....................... SA-44
Front Wheel Hub ...................................................... SA-45
Steering Knuckle ..................................................... SA-49
Constant Speed Drive Shaft ........................................ SA-54
Front Speed Reducer .................................................. SA-57
Change of Oil Seal of Driving Bevel Gear Of
Front Speed Reducer ............................................. SA-57
Dismantle of Front Speed Reducer ......................... SA-61
Change of Axle Shaft Oil Seal ................................. SA-63
Disassembly and Assembly of Front Speed Reducer.... SA-65
Assembly of Front Speed Reducer ......................... SA-74
(Back)
Rear Axle Shaft ........................................................... SA-79
Rear Speed Reducer .................................................. SA-83
On-vehicle Change of Oil Seal of Main Teeth ......... SA-84
Dismantle of Rear Speed Reducer .......................... SA-85
Disassembly of Rear Speed Reducer ..................... SA-85
Assembly of Rear Speed Reducer .......................... SA-89
Mount of Rear Speed Reducer and
Differential Assembly .............................................. SA-94
Rear Differential .......................................................... SA-95
Rear Suspension ......................................................... SA-97
SA

SA-2
Troubleshooting
Suspension System and Automobile Axle
Troubleshooting
Change the tire or inflate to the proper pressure
Balance the wheels
Change vibration damper
Check Alignment of Front Wheel
Change or adjust the wheel bearing
Check ball joint) or liner
Tighten or change steering linkage
Adjust or repair the steering device
Discharge the oil and change with new one
Check the wandering clearance
Check the gears
Change the bearing
Change the bearing
Tighten or change the bearing Trouble Causes
Inspection items
Body wandering/body
draggingTire wear or improper air inflation
Incorrect alignment of front wheel
Over-tightened wheel bearing
Part looseness or damage of front/rear sus-
pension
Wear or looseness of steering rod system
Poor connection or damage of steering de-
viceInflate the tire to the proper pressure or change
the tire.
Check the situation of alignment of front wheel
Adjust the wheel bearing
Tighten or change the suspension element
Tighten or change the steering rod system
Adjust or repair the steering device
Body sink Overloaded vehicle
Wear of vibration damper
Poor spring performanceCheck the loading mass
Change vibration damper
Change spring
Left-right vibration/up-
down bouncingImproper air inflation
Bending or damaged lateral stabilizer
Vibration damper wearInflate the tire to suitable pressure
Change stabilizer
Change vibration damper
Front wheel vibration Tire wear or improper air inflation
Imbalance of wheels
Vibration damper wear)
Improper Alignment of Front Wheel
Wheel bearing wear or improper adjustment
Ball joint or liner wear
Steering linkage looseness or wear
Poor adjustment or damage of steering mecha-
nism
Abnormal tire wear Improper air inflation
Vibration damper wear
Poor Alignment of Front Wheel
Suspension system wearInflate the tire to the proper pressure
Change vibration damper
Check the Alignment of Front Wheel
Change suspension element
Speed reducer leakage Over-high oil level or improper oil quality
Oil seal wear or damage
Flange looseness or damageDischarge the oil for change
Change oil seal
Tighten or change the flange
Noise inside the
axleNoise inside the axleOver-low oil level or inferior oil quality
Over-large wandering clearance between
driving bevel gear and driven bevel gear
Wear and disintegration of driving bevel
gear and driven bevel gear
Bearing wear of driving bevel gear
Bearing wear of rear axle shaft
Bearing looseness or wear of speed reducer

SA-4Suspension System and Automobile Axle
Alignment of Front Wheel (Dr SL SK SY SJ)
5. Adjustment for inner tilt angle of kingpin, outer tilt angle
of front wheel and back tilt angle of kingpin
Item
Inner tilt
angle of
kingpin
Outer tilt
angle of
front
wheelApplicable vehicle type
Dr SL SK SY
SJ
Mechanic
steeringDr SL SK SY
Power
steeringDr
SL SK SY
SJ
Back tilt
angle of
kingpinMechanic
steeringDr SL SK SY
Power steer-
ingDr SL SK SY
SJ9
30
45

14
52

0
30
20

0
10
10

0
20
10

0
30
15

2
45
15

3
15
Location parameter
4. Adjust the wheel angle
Take apart the limit bolts of the steering knuckle to check the
steering angle A of inner wheel.
Inner wheel steering angle
Dr SL SK SY
( 36
40
)
SJ
( 32
34
)
Remark: The wheel should not contact the body or brake hose
when the steering wheel reaches the limit position.
In case the steering angle of inner wheel doesnít conform to the
standard value, adjust the wheel angle through adjusting the
limit bolts of the steering knuckle.
Fastening torque
(90
0)N
m(SJ)
If the wheel angle fails to be adjusted within the standard value,
change the weary or damaged parts of steering system.
If the tilt angle fails to fall within the specified values, make an
adjustment through adding or reducing the gaskets on the
location of upper arm.
Gasket thickness: 3.0, 2.0 and 1.0mm
Once the gasket thickness increases by 1mm, the outer tilt
angle of wheel will change by 7', while the back tilt angle of
kingpin will change 20'.
After the wheel outer tilt angle and the back tilt angle of kingpin
are adjusted, if the inner tilt angle of kingpin still fails to the
specified value, check the steering knuckle or front wheel to
see whether they are bending or loose.
1
50
-20

adjusting bolt
outer tilt
angle of
front wheel inner tilt angle of kingpin
back tilt angle of
kingpin
front AB AB
HPM