odometer GREAT WALL SO COOL 2006 Service Manual

MT-4Gearbox
Dismantle of Gear Box
3. Tear down the shifting ball of gear change lever
Loose the locking nuts by dextroroting the ball.
4. Tear down the glove box
Dismantle the four bolts of the glove box and put the glove box
into the suitable place.
5. Tear down the dust cover.
6. Tear down the gear change lever.
7. Raise the vehicle to discharge the oil in gearbox.
Warning: the reliability of vehicle shall be verified.
8. Tear down the drive shaft.
(See page PR-5)
9. Tear down the odometer sensor and the plugging
elements of backup switch
10. Tear down the vent pipe.
Tear down the heading exhaust pipe from branch exhaust pipe
Dismantle of gearbox
1. Disconnect the cathode wire from the cathode of storage
cell.
2. Tear down the setting bolts of fan cover.
Tear down 4

MT-8Gear Box
Mount of Gear Box
4WD:
(a) Mount the bracket and supporter of leg washers of rear
engine in 4WD vehicle;(SF)
(b) Mount and tighten the third beam of 4WD vehicle. (SF)
4. Remove the wooden spill.
5. Mount exhaust pipe.
Mount the exhaust pipe on the branch exhaust pipe.
Tightening moment
(62
3)N
m
6. Mount the wheel-brake cylinder of clutch.
Tightening moment
(18
2)N
m
7. Mount odometer sensor and plugging elements of backup
switch.
8. Connect the drive shaft.
(See page PR-12)
9. Add oil into the gearbox.
Lubricating oil grade: GL-5 85W/90
Volume: 2.4L(dry)
Remark: the Tightening moment of oil filling/draining
plug: (30
50)N
m
4WD
4WD

MT-20Transmission
Output Shaft Assembly (Components Figure)
Output shaft assembly
Components figure
synchronizer spring
expansion ring
snap ringsynchronizer
slide block3th,4th gear synchronizer
meshing sleeve3th gear needle bearing
synchronizer hub of 3rd
and 4th geartoothed ring of
synchronizergear components of 3rd gear
steel ball
synchronizer sliding blocksynchronizer meshing sleeve
of 1st and 2nd gear
gear components
of 1st gear1st gear shaft sleeve
locking ring of output
shaft rear bearing
spring expansion ring
needle bearing of
2nd gear
gear components
of 2th geartoothed ring of synchronizer
for 1st and 2nd geartoothed ring of synchro-
nizer for 1st and 2nd gearneedle bearing of 1st gearrear bearing of
output shaft
gear of 5th gearodometer drive geardrive gear snap ring of odometer output shaft
snap ring of 5th gear
steel ball

MT-47Gearbox
Assembly of Gearbox
26. Mount the clutch frame
(a) Mount the clutch frame.
(b) Coat the sealing agent on the bolt thread.
(c) Mount the nine bolts and then tighten them.
Tightening moment

Upper tooth
(60
70)N
m
Tang tooth
(30
45)N
m
27. Mount the back-up lamp switch.
Tightening moment
(20
40)N
m
28. Mount the driven gear of odometer
(a) Mount the driven gear of odometer.
(b) Mount the bolts and tighten them.
Tightening moment
(10
15)N
m

TF-4Transfer Box
Troubleshooting
Common troubles CausesResolving approaches
Unsuitable tire pressure.
Noise, which is spread by the transfer
box instead of the clutch, engine or other
parts, occurs at each speed.Gear noise.
Damage or wear of chain gear or
chain.Open to check whether there is weary
element or damaged element (including
the odometer gear) and, if any, change
them
Noise occurs in the high-speed or low-
speed four-gear driving.Open to check whether there is wear or
damage, and if any, adjust the tire pressure
to suitable value.
Oil leakage in transfer box. Frame Break of transfer box.
Oil leakage of other element.
Ventilation pipe block
Over-added lubricant or lubricant of
unsuitable brand
Looseness of the bolts on sealing
face.
Sealing glue of different brand or
unused sealing glue.
Oil seal wear or damage.Change the frame.
Check the leakage by wiping dry.
Open and clean it and, if necessary,
change it.
Use the specified lubricant and adjust the
lubricant to suitable volume.
Propel the bolts tightly as requirement.
Use the specified sealing glue and propel
the bolts tightly as required.

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-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-21
QR
NOP
NMSTN
UV
NOPQ
RS
(d) All of the following aligning conditions shall be satisfied
when the rear cover assembly is mounted on the transfer
box front housing:
a) Align the pin hole in the rear cover to the pin on the
housing.
b) Align the rear output shaft to the inner bearing in
cover rear hole.
c) Align the blind hole in the rear cover and the shift
guide shaft; ensure the return spring is not tilted.
Check the hole in velocity sensor of the rear cover
with a pen.
d) Align the shift shaft and the inner bearing in rear
cover.
(e) Screw up the nine bolts after locating the sign bolts
correctly.
(f) Encase the gear of odometer in the rear cover assembly
through the spline of the rear output shaft.
(g) Press the new oil seal in the cover assembly
NO
P
Q
Transfer Box
Transfer Box Assembly
1. bolt
2. wire harness
3. magnet
4. return spring
5. shift guide shaft
6. transfer box rear
body assembly
7. sign board
8. driving gear of Odometer
9. oil seal
10. transfer box front housing
1. locating pin
2. output shaft
3. shift shaft4. return spring
5. shift guide shaft
6. output shaft.12. Assembly of Rear Cover
Mount the aforesaid accomplished cover assembly on the
transfer box housing according to the following process:
(a) Mount the return spring on the shift guide shaft of the
transfer box.
(b) Mount the magnet in the groove of the housing.
(c) Coat the Letai glue 598 of 1.6mm on the coupling face of
housing, steer clear of the screwed hole when coating
continuously.
Notice: try to button the rear cover on the transfer box front
housing with the moderate force during the following process.
Not too much force is required when mounting the rear cover
on the front housing when all aligning conditions are satisfied,
in case the rear cover cannot be mounted on the front housing,
take down the rear cover assembly to check the aligning
condition
1. wire harness clip
2. motor assembly
3. bolt
4. sign board

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.

BE-34Body Electric System
Combination Instrument
Electric circuit diagram (continued)
A16 A1 B16 B1
SL SK
B1
B16
A1
A16
speed and mileage meter
4P
G
VA9vehicle speed signal
A11odometer sensorA10odometer sensor anode
B11sensor signalelectronic tachometer
water thermometer
fuel gaugecoolant temperature sensor
B5
A12
fuel gauge sensor
B14
A2
B3
upper beam
_NPdifferential latch-in
safety belt
preheating
sediment water alarmingelectricity charging/
discharging
fuel level alarming
brake failure alarming lamp
oil pressure alarming lamp
rear fog lamp
engine failure
four wheel drive indicating lamp
A1 Aturn indicating lamp
B16 left turn indicating lamp
A8
B4 +B7 - B8 A16 B15 B2B1 A15 A14B6 A13 B10B9
SY SJaccumulator plus four door-closing indicating lampA3turn on when the door is opened.
A11odometer sensor_NO
electronic odometer
electronic tachometerA10
B11
engine ignition coil
water thermometer
fuel gauge
B5
A12
neutral gear indicating lampA9
_NP
upper beamB14
differential latch-in
vacuum alarming
preheating
sediment water alarming
electricity charging/
discharging
fuel level alarming
brake failure alarming lamp
oil pressure alarming lamp
rear fog lamp
engine failure
four wheel drive indicating lamp
A1 left turn indicating lamp
B16 right turn indicating lamp
A8
B4 +
instrument lighting
system
B8
B7 - A16 B15 B2
B1 A15A14 B6 A13 B9 B3 B10A2
instrument lighting
system