oil type GREAT WALL SO COOL 2006 Service Manual

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.

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-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-9
5 4
3
1
6 2
1. rear body of transfer box
2. flange
3. oil seal
1. sensor bracket
2. bolt
3. speed sensor
4. o-ring
5. sensor assembly
6. bolt
7. gasket
8. rear body of transfer box2 1
5 3
4
4
6
7
8
Transfer Box
Disassembly of Transfer Box
4. gasket
5. nut
6. oil plug
Disassembly of Transfer Box
1. Brief instruction
In case the transfer box is required to be repaired for the
damaged specific element, it shall be taken apart to the degree
on which the damaged element is taken out. And the parts
taken apart from the transfer box, if it doesnít include the
damage element, can exist in the form of sub-assembly or
group instead the individual form, otherwise, the parts will be
taken apart individually.
2. Transfer Box Disassembly
Put the transfer box on the worktable and ensure the rear part
or the rear cover faces upward. Put the wooden block under the
front part of transfer box to keep the transfer box stands
horizontally. The disassembly process is as follows:
(a) Fasten the flange with the torque arm typed T-13-54-
002, screw off the nut to take down the gasket, then take
apart the flange and oil seal.
(b) Take down the two oil plugs from the transfer box body.
As for the electric gearshift transfer box, tear down the
electric shifting element according to the following
disassembly approach:
(a) Tear down the three bolts, gaskets, sensor and clip for
wire harness.
(b) Tear down the sensor assembly and take apart the O-
ring.
(c) Tear down the motor assembly.

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-14
7
6
5
4
3
21
1. transfer box front housing assembly
2. gear ring
3. oil seal
4. transfer box front housing
5. locating pin
6. ball bearing
7. snapping ring
NMR23
41
1. oil seal
2. transfer box front housing
3. gear ring
4. locating pin
Transfer Box
Transfer Box Assembly
Transfer box assembly
1. Introduction
Please refer to the given instruction of this chapter during
assembly process. And the following items shall be taken
notice on:
(a) In case that the torque of the threaded parts is required,
torque spanner shall be used to screw up the parts.
(b) The small parts shall be coated with the lubricant grease
during the mounting process, so that they are immobilized
at the mounting locations.
(c) SST such as thimble of T-13-54-001 shall be used to press
the oil seal and bearing during the oil seal mount and
bearing mount, do not use the hammer to strike the oil seal
or bearing directly.
2. Lubricating during assembling
All inner parts without lubricant shall be lubricated with the
suitable lubricant before mounting, so that they can be as-
sembled easily and can supply the original lubricant
performance.
(a) If the O-ring and oil seal were not lubricated before
mounting, they may be damaged.
(b) Be sure that the bearing or liner is lubricated completely
before mounting. Because the bearing or liner may be
leaded into damage even though they are run for a very
short time.
(c) The lips of oil seal and the metal elements that match with
lips shall be lubricated before mounting.
3. Transfer box housing assembly
Parts taken apart from the transfer box shall be mounted
according to the following approaches:
(a) If the gear ring needs to be changed, the tooth-type saddle
rear of new gear ring shall be flushed with the gullet of the
transfer box front housing when pressing the new gear
ring. Press in the gear ring as shown in the left bottom
drawing, in which, the chamfering end is firstly pressed
in. if it is ensured the gear ring is not tilted, then fasten the
gear ring tightly on the housing.
(b) In case there are two locating pins taken apart, mount two
new locating pins into the housing.
(c) Press the bearing into the transfer box front housing and
mount the snapping ring correctly, and
(d) Put down the new oil seal as shown in the left bottom
drawing and press it into the housing.

TF-17
1.25-1.75mm
23
1
12.70mm
13
2
4
4
2
1
5 6
7
83
(e) In the case that the input shaft is taken apart, what need
to do is to fill the needle bearing as shown in the drawing
and press it in the input shaft, meanwhile, press the new
sliding bearing to complete the whole input shaft assembly.
(f) Raise the planetary mechanism assembly to mount it into
the input shaft assembly; encase the thrust gasket and
press in the bearing through the input shaft end. Encase
the fixed bearing in the snapping ring groove of the input
shaft with a snapping ring.
(g) If the transfer box front body is taken apart, press the new
located pin in the front body, and the pressing dimensions
are shown in the drawing.
(h) Put down the oil seal as the drawing shows, and press it
in the front body according to the dimensions shown in
the drawing.
(i) Put down the front body assembly on two wooden blocks
in the way that the coupling face of the front body and the
housing faces upward, so that there is clearance left
between the input shaft assembly and the worktable. Put
down the input shaft and planetary mechanism assembly
in the front body, in which the input shaft shall be
downward. Open the long ends of the snapping ring to
encase input shaft and planetary mechanism assembly
until the snapping ring enters into the external snapping
ring groove of the bearing.
(j) Coat the sealing glue of 1.6mm on the coupling locations
of the front end cover and transfer box assembly, The
glue shall be coated continuously without break and steer
clear of the screwed hole.
(k) Screw up the six bolts.
Fastening torque
(27
46)N
m
6. Assembly of front output shaft
Mount the following parts:
(a) If the dust cover is taken apart, mount it by pressing.
(b) Encase the input shaft, sealing ring, gasket and nuts in the
transfer front housing.
(c) Insert the torque arm of T-13-54-002 in the flange hole to
screw up the nuts.
Fastening torque
(203
244)N
m Transfer Box
Transfer Box Assembly
1. needle bearing
2. bearing roller
3. input shaft
1. locating pin
2. oil seal
3. front body of transfer box
4. snapping ring
1. fork-type flange
2. dust cover
3. fork-type flange assembly
4. transfer box housing5. output shaft
6. oil seal
7. washer
8. nut

PR-5Drive Shaft
Drive Shaft
(4WD)
Rear axle drive shaft
1. Take apart the universal joint flange fork of rear axle drive
shaft from the differential flange.
(a) Label the two flanges with assembly marks.
(b) Take apart the four sets of bolt and nut.
Disassembly of Drive Shaft
(2WD)
1. Take apart the universal joint flange fork of the drive shaft
from the differential flange.
(a) Label the two flanges with assembly remarks.
(b) Take apart the four sets of bolt and nut.
assembly mark
2. Take apart the center support bearing from the frame
beam (for the three-joint type)
3. Take apart the drive shaft from the gearbox
(a) Pull out the universal joint yoke from the gearbox.
(b) Insert the SST in gearbox for oil leakage prevention.
2. Take apart the center support bearing from the frame
beam (three-joint type
SST
assembly mark

SA-54
Constant Speed Drive Shaft
Element figure
Suspension System and Automobile Axle (SF/4WD)
Constant Speed Drive Shaft
axially movable three-ball
universal joint
triangular joint
mobile joint
snapping ring
extensible-end large
gripping hoop
extensible-end
dust cover
extensible-end small
gripping hoop
shaf
fixed-end small gripping hoop
fixed-end large gripping hoopfixed-end dust cover
steel retainer ring
ball-cage type universal joint
inner oil seal- drive shaft
front drive axle shaft
sleeve assembly



Parts that cannot be reused after being used
N
M
specified torque
SF4WD
front speed reducer and
differential assembly
constant speed
drive shaft

BR-3
Troubleshooting (continued)
Braking System
Notice and Troubleshooting
Trouble Causes Inspection items
There is clatter noise when using
the brake(Drum-type brake)
The brake shoe is seized on the flange of rear baffle;
The flange of rear baffle is worn;
The pressure spring of brake shoe is loose or missing;
The fixed bolts of brake bottom plate is loose;
(disc type brake)
The brake pad support plate is loose or missing
The mounting bolts are loose;Add lubricant
Change the lubricating flange
Change
Tightening it
Change
Tightening it
There is hoarse noise or quack-
quack when using the brakeThe brake shoe or brake pad is worn;
The brake caliper, the wheel or the rotator interferes each
other.
There is friction between the dust cover and brake disc,
the brake bottom plate and the brake drum;
The other braking part has trouble
There is friction between the tire and bodyChange the part, and re-process
precisely the brake drum or
rotator if the abrasion is serious;
Make change according to real
situation;
repair or change
Make repairing according to
real situation;
Change
Check or maintain the part
There is such noise as
continuous screaming, quack-
quack, oscillating sound, etc.
Notice: the braking materials
may generate the natural noise
and heat during friction, and
thus emit the energy. Therefore,
it is normal to have the
screaming noise. These
phenomena will be more serious
under the condition of frigidity,
torridity, and over humidity,
snowing and mud. the
screaming noise occurring
occasionally will not lead the
fatal brake trouble nor reduce
the effective properties of the
brake.The brake drum, brake liner, liner or brake pad is worn
or scraped
The brake liner or brake pad is dirty or with oil stain or
polished.
The brake liner or brake pad is improperly used.
The brake pedal or vacuum booster drag rod is unsuitably
adjusted.
(disc type brake)
The brake pad silent pad is loss or damaged;
The brake pad is worn to the degree that the abrasion-
indicating lamp of brake pad has friction with the rotator.
There is burr or rust on the brake caliper.
(Drum type brake)
The pressure spring of brake shoe is soft in rigidity, or is
damaged or unsuitable.
The pressure spring pin or spring of brake shoe is loose
or damaged;
There is crack on the brake bottom plate flangeCheck, repair or change
Clean or change
Check or change
Check for adjustment
Change
Change
Clean or polish the burr
Check, repair or change
Check, repair or change
Check, repair or change