maintenance GREAT WALL SO COOL 2006 Service Manual

Preface
With the increase of automobile demand in China, our automobile industry also experiences a rapid
development. The trucks including SUV, manufactured by Great Wall Motor Co., Ltd, which are sold all over
China, are in the leading place in terms of their sales volume, in order to satisfy the demands of various maintain-
ing staff, technicians and managing staff of Changcheng Co., Ltd, we compile this maintenance manual accord-
ing to the latest technological data. This manual covers six vehicle models including Deer, Safe, Sailor, Sing, So
Cool and Pegasus, its main content includes:
Part I is general introduction, which introduces the application index of this manual.
Part II introduces the chassis system, which mainly includes the technologies of dismantle, inspection,
adjustment, repairing, assembly and mount of the clutch, gear box, transfer box, drive shaft, suspension system
and automobile axle, braking system and steering system, etc. each operation approach is illustrated with figure,
which not only presents the maintenance procedure, but also clearly describes the technical requirements and
application limit.
Part III introduces the electric system and air-conditioning system of the automobile body, which mainly
covers such items as the location and content of protective box, power supply system, starting system, lighting
system, combination instrument, backup radar system, wiping and washing system, center control locking and
power window system, acoustical equipment system, full wire harness and air-conditioning system, etc. Electric-
ity diagrams for those electric systems are given in this manual so as to facilitate the maintaining technicians to
find out the problem easily and quickly.
Part IV introduces the external and internal body decoration, which mainly covers the dismantling, inspect-
ing and assembling requirements of the engine cover, front and rear doors, adhesive strip of body collision
avoidance, wheel shield, wrapping angle of wheel-shield and exterior trim panel, front and rear windshields,
side-window glass, rear-door glass, rear platform of cargo compartment, rear door, instrument panel, safety belt,
seat, tail-fin, luggage rack, and reserve tire bracket etc. The dimensions of vehicle body and frame are also given
to maintaining staff for reference during their repairing.
During the narrations of each part, items such as troubleshooting, maintenance notice, maintenance data
and application limit, fastening torques of bolts and nuts for special purpose, SST, SSM and lubricant materials
and so on are also introduced. Various maintenance data are briefed in attachment for reference.
Altogether, this manual is comprehensive in content, visual in illustration, clarifying in requirement and
plain in language. It can be referred by the maintaining staff, technicians and professional managing staff.
Even though we try our best to compile this manual in a strict earnest manner, we cannot guarantee that all
contents in this manual are correct. Therefore, users shall not put forward any claim with Great Wall Company
according to this manual; we are not in the position to hold the responsibility for the loss caused by usage of this
manual. Due to our limited knowledge, it is unavoidable to find error in this manual, any criticism and correction
from you is welcomed.
The final explanation power for this manual is subject to Great Wall Motor Co., Ltd
Compiler
May 2006

Service manual for
chassis and body
GeneralIN
ClutchCL
Gear boxMT
Transfer boxTF
Drive shaftPR
Suspension system and automobile axleSA
Braking systemBR
Steering systemSR
Body electric systemBE
Air-conditioning systemAC
Vehicle bodyBO
Maintenance and Up-keepingA
Special ToolB

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-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-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-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-28Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear)
Maintenance or Change of Gear or Chain
Sprocket Gear
1. Maintenance principle
(a) Conduct the maintenance for the partial, small peel off
with the suitable manual high-speed grinding tool.
(b) Do not clear away the metal as can as possible when
grinding the matrix metal.
(c) All pointed angles and sides must be repaired as the slip-
pery contour line. Because the pointed angle or edges
may be peeled off again or developed into crack.
(d) Clear away the burr with the suitable grinding stone. Take
notice not to damage the matrix when clearing away the
projecting materials, and
(e) When substituting the non-repaired parts (such as
bearing), if the part is doubted in its re-application
capability, it must be changed.
2. Cases for gear or chain sprocket maintenance or substi-
tuting
(a) The gear, being peeled off at the two sides of tooth top in
contact face, may be repaired for reuse.
(b) The gear, being peeled off at the central tooth top of
contact face, may be repaired for reuse.
(c) The gear, being peeled off at one side of the non-contact
face, may be repaired for reuse.

TF-29Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear)
(d) The gear, being peeled off at the center of one side of
contact face, may be repaired for reuse
(e) The gear, being peeled off in the center of contact area,
shall be changed.
(f) The gear, being peeled off at two sides of tooth top, shall
be changed.

TF-30Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts)
Change the parts and fittings as requirement
Attachment for Inspection Maintenance or Change of Parts
Checking items
Acceptance/Refusal
Parts (items)
All parts (including
all springs)Crack inspection, distortion inspection and ero-
sion inspectionAll parts with crack, all parts that are bended,
distorted or poor in round bouncing are refused.
All threaded partsThread inspection for buckle missing or other
damageThose parts cannot be threaded or bottomed in
overlap manner shall be refused.
Flange and fork
flangePlease refer to the paragraph of
inspection
to
check the spline.Please refer to the
inspection paragraph
for
spline inspection.
Velocity sensor, mo-
tor assembly
Parts of electric clutch
systemPlease refer to the part of electric appliance
Sliding bearing Inside surface inspection for the sliding bearing In the case that the bearing has pitting corrosion
or other damage, refuse it.
Ball bearingCheck visually the ball and track of the ball
bearing to see whether there is damage such as
adhesive bonding, pitting corrosion, etc.
Ensure that the bearing are all lubricated, run the
outer race of the bearing while holding the inner
one to feel whether there is poor running or
corrosion, the bearing shall be run smoothly
without excessive clearance.Refuse to use the damaged bearing;
Refuse to use the damaged or loose bearing; or
Check the axial clearance to see whether it
exceeds 0.23mm.
Needle bearing Check the bearing needle roller and track to see
whether there is damage such as adhesive
bonding, pitting corrosion, etc.Refuse to use the damaged bearing.
The rear cover, front
body and front hous-
ing of transfer boxCheck to see whether there is burr on the cou-
pling face or other damage that impedes assem-
bling or sealing.Clear away the burr according to the paragraph
of
inspection
, otherwise, change the dam-
aged element
Rear cover of trans-
fer boxCheck the bearing holeRefuse to use the assembly that has pitting
corrosion
Odometer gear Check the gear teeth referring to the Inspection
ParagraphRefer to the gear or chain sprocket inspection in

inspection paragraph
.
Clutch shell, joint
outer gear sleeve and
joint coverCheck the spline according to the Inspection
paragraphRefer to the spline inspection of
inspection
paragraph

Locking sleeveCheck the wear or damage of the toggle fork
grooveRefuse the parts with step slipping or damage.
Shift guide shaft Check the deformation situation
Check the burr or other damage on outer race
Check the wear of outer raceRefuse to use the bend shaft; clear away the burr
according to the
inspection
paragraph, oth-
erwise refuse to use.
Refuse to use the shaft with step slipping or
other damage.
Shift toggle forkCheck whether there is wear or damage at the
location where the toggle fork combines with
the shifting cam and gear sleeve.If any step slipping or damage is found, refuse
to use it.