oil pressure GREAT WALL SO COOL 2006 Service Manual

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-7Clutch
Clutch Cluster
Clutch cluster
Element drawing
flywheel
clutch rib
clutch pressure plate
separation
bearingclamp separation fork
dust cover
30

specified torque
N*m
Disassembly of clutch cluster
1. Tear down the gear box;
Remark: do not leave the gear oil in drying
2. Tear down the clutch pressure plate and the clutch rib
a) Make aligning marks on the clutch pressure plate and the
flywheel.
b) Loosen the fixing bolts gradually until the spring tension
is released;
c) Tear down the fixing bolts to pull out the clutch pressure
plate and clutch rib.
3. Tear down the bearing and separation fork from the gear
box;
a) Tear down the clamp to pull out the bearing;
b) Tear down the separation fork and dust cover.

MT-2Gear Box
Notice
Notice
Notice for disassembly and assembly of gearbox
Notice shall be taken during the gear disassembly and assembly on the soft handle for the parts, especially
for the coupling faces so as to avoid the collision; each part shall be put down in order to avoid the missing
or mistaking.
Notice shall not only be taken in the aforesaid aspects, but also in the following items
1. Wash all parts before assembly (rubber fittings and washers excluded).
2. Various oil seals, retainer rings for shafts, spring-type pins shall not be reused.
3. Lubricating oil shall be coated on the friction surfaces, and lubricating grease shall be coated on the lips
of oil seals.
4. Rolling elements shall not be used to transfer the pressure during the various bearing assembly.
5. Lip-type oil seal must not be sloping when assembling it.
6. The openness at the two ends of the spring collar shall be misfit when assembling the component
elements of the synchronizing instrument, and
7. No part is allowed to leak the lubricating oil when the gearbox locating at its working place.

MT-39
locking ball
socket spanner
Gearbox
Assembly of Gearbox
7. Mount the steel ball and the five-speed thrust washer.
8. Mount the five-speed gear cluster
(a) Coat the gear oil on the needle bearing.
(b) Mount the five-speed gear cluster.
9. Mount the synchronizing ring and the fifth coupling gear
(a) Mount in the synchronizing ring and the fifth coupling
gear.
(b) Dismantle the old central link plate from the table vice.
(c) Put the gearbox straightly as shown in the drawing.
(d) Flush the groove of synchronizing ring with the sliding
block and mount the fifth coupling gear with pressure
machine.
(e) Mount the new central link plate in the table vice.

TF-2Transfer Box
Notice
Notice
Notice on transfer box disassembly and assembly
Notice shall be taken on the soft handling of the parts (coupling face in particular) during the process of
transfer box disassembly to avoid the collision; each parts shall put down in order so as to avoid of missing
or mistaking.
Notice shall, during assembly process, not only on the aforesaid items, but also on the following items:
1. Wash all parts and fittings before assembly (rubber element and washer excluded).
2. Oil seal, clip for shaft and spring pin of various kinds shall not be reused.
3. Lubricating oil is required to coat on the various friction surface and lubricant on lips of various oil seal.
4. Rolling body is not allowed to use for pressure transmission when mounting various bearings.
5. Lip-type oil seal is not allowed to mount slantwise.
6. The openness on the two sides of spring collar shall not be coupled face-to-face when assembling the
component elements of synchronizer. And
7. No parts is allowed the lubricant leakage and penetration when the transfer box locates at the working
location.

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-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

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-82
11. Mount the new inner oil seal of rear wheel bearing.
Coat the hyperbolic gear oil on the axle housing where matches
with the oil seal; and plaster the moderate lithium base grease
on the lip open of the oil seal, then put them on the pressure
head and press them in.
Mount of Rear Axle Shaft
1. Press the rear brake and the bearing seat assembly on
the haft shaft.
2. Press the heated inner oil seal seat of rear wheel bearing
on he half shaft;
Notice: the face at the chamfering end of inner oil seal of
rear bearing should contact the oil seal closely, do not
mount it at the incorrect position.
Requirement for heat mount: heat the inner oil seal seat into the
22# oil (GB443-1989) to 100
, after the part is heated
completely, take it out for mount.
3. Mount on the flat steel retaining ring with the ring calipers.
4. Encase the half-shaft rear brake in the axle housing,
screw on the self-locking nut.
Tightening moment
(63-79)N
m
Notice: protect the oil seal lip open, bracing wire assembly
and the oil-guard sleeve.
5. Mount on the hand brake wire and the brake pipe.
6. Mount on the liner and rear brake drum;
7. Make a trial gas exhaust on the braking system, and
8. Mount on the rear wheels.
Suspension System and Automobile Axle (rear)
Rear Half Axle Shaft