checking oil GREAT WALL SO COOL 2006 Service Manual

MT-3
Troubleshooting
Gear Box
Troubleshooting
Non-use of clutch
Non-full separation of clutch
Severely warned tooth rings of synchronizing
fittings
Over-hard locating springUse the right driving approach
Checking for adjustment
Change
Change Difficulty in gear engagement
Over-low oil level
Lubricating oil of inferior quality
Non-timely oil change
Unsuitable axial location or clearance of gears
Bearing damage
Burr or collision on gearAdd oil to the specified level
Change it with the specified oil
Change the oil and damaged parts
Check for adjustment
Change
Repair or change the gear
Oil leakage, oil penetration Oil added above the specified level
Loss or missing of bolts
Vent plug trouble
Sealing element damageAdjust oil to the given level
Reassembling or fasten the bolt according to
the specified torque
Change
Change
Damage of synchronizer Overexert in gear shift
Non-use of clutch
Damage on spring collar of synchronizer
Incorrect mounting of drive shaftChange
Use the right driving approach
Change
Check for adjustment
Non-engagement of gear Trouble in controlling mechanism
Incorrect assembling the locating spring or
steel ball
Invalidation of locating spring
Severely worn gear sleeve or fork groove
Seriously worn toggle forkCheck for adjustment
Reassembly
Change
Change
Change
Burning bearing, burning gear Over-low oil level
Inferior lubricating grease
Non-timely oil change, over-dirty oil
Inter-use of differential oil or usage of
additiveChange damaged parts and add oil
Change the damaged parts and lubricating oil
Change damaged parts and lubricating oil
Change damaged parts and lubricating oil
Difficult in gear disengagement Spring invalidation of synchronizer
Warn inner groove of tooth ring of synchronizer
Tooth ring of synchronizer choked on conical
face
Toggle fork deformation or toggle fork axle
deformation
Severely worn toggle forkChange
Change
Change
Change
Change
Methods for troubleshooting
Over-loud or abnormal noise
Common Failures Causes

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-24Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Washing)
1. Washing
Notice: check the metal rag around the magnet first before washing, large granule or irregular metal
granule shows the disintegratation or similar damage. Small or fine metal granule shows the uneven
or serious wear. If the metal rag is founded, notice shall be taken on damage and wear inspection
during checking the rotating parts and the element matched with the rotating parts.
(a) Common washing
Wash the parts in cleaning agent to clean away the old lubricant and deposit. Clean away the deposit in oil hole
with brush. Take notice not to scrape the metal coupling face when washing the parts cannot be cleaned with
brush.
(b) Dry the washed parts by blowing
Dry the washed parts by blowing the low-pressure compressed air (max pressure is 137.9kPa), because cloth
thread may be left during cleaning the parts with cloth. The bearing shall be held by hand to prevent it from
rotating when blowing it.
(c) Bearing lubrication
The ball bearing and needle bearing shall be lubricated with the lubricant for transfer box after washing. As
the non-lubricated bearing may cause damage when be dry. Cover the lubricated bearing to prevent dust
entering in.
Washing, Inspection, Maintenance or Change

TF-25
(b) Normal gear grinding trace.
Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Checking)
Checking
1. Common Checking process
Check all parts by visual check to see whether there is damage
or serious or uneven wear (parts needed be substituted by new
parts such as O-ring, oil seal and etc. shall be excluded).
Abandon the damaged or weary parts that will affect on their
performance. The check items are as follows:

Burr: tips protruded from the material regionally

Rag: broken small blocks or particles

Crack: surface thread showing the material is partly or
completely separated.

Excessive abrasion
Refer to the serious or obvious abra-
sion beyond of application limit.

Reduction change
Material slip caused by the heavy
pressure on part of it.

adhesive bonding
Granules of the soft metal are dis-
persed and bonded on the hard metal surface.

Ditch trance: partial crack or trough that means the material
transfer instead of material loss.

Pitting corrosion
Damages to the metal surface caused by
pressure, which are displayed due to color change caused
by heat generated by metal friction.

Step wear
a weary step may be seen or felled between the
neighboring interface or between the non-touching face
due to the excessive wear.

Uneven wear: Partially, unevenly distributed wear, which
includes holes, bright spots, uneven polishing or other
visual drawbacks.
2. Gear or Chain sprocket tooth inspection
Check the gear and chain sprocket tooth according to the
following process:
(a) Normal gear shaving trace.
normal gear shaving trace
normal gear grinding trace

BE-4
How to make systematic inspection
The inspection order is a simple troubleshooting approach, which is used to check and diagnose the failure on vehicle
when there is part (wiring and plugging elements excluded) failure in the systematic operation or presupposed
system.
Following items should be considered firstly when checking the failure.

wiring failure

open circuit or short circuit of electric wiring

failure in plugging element connection or terminal connection

failure of fuse or maxi-fuse
Notice:
1. The inspection is conducted on vehicle when the system is in operation, therefore, security should be
taken into account when checking.
2. Care should be paid not to make short circuit in the system under the condition that the accumulator is
directly connected, and the applicable voltage should be selected correctly.
Voltage inspection
(a) Verify the voltage situation at the inspection spots.
For example:

Put the ignition switch at
ON
position

Put the ignition switch and SW1 at
ON
position;

Put the ignition switch of SW, SW1 and the relay at

ON
position (SW2 at
OFF
position)
(b) Connect the cathode lead (-) to the normal grounding
place or the cathode terminal of accumulator with the
voltmeter; while connecting the positive lead (+) to the
plugging element or part terminal. Such inspection can
be conducted with the test bubble instead of voltmeter.
Inspection on Conductance and Resistance
(a) Disconnect the terminal or wire of accumulator to guar-
antee there is no voltage between the inspection sports.
(b) Connect the two measuring leads of ohmn meter with the
inspection spots.ohmn meter
SW SW2
electromagnetic coil
relay
SW1

fuse
IG terminal connected to ignigtion
switch of SW
12
0
0


V
Body Electric System
Brief Introduction