suspension 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

SA-1
Suspension System and Automobile Axle
Page
Troubleshooting .......................................................... SA-2
Alignment of Front Wheel ............................................ SA-3
(Dr/2WD)
Front Wheel Hub and Steering Knuckle ...................... SA-10
Front Wheel Hub ..................................................... SA-11
Steering Knuckle ..................................................... SA-14
Front Suspension ........................................................ SA-16
Ball Stud .................................................................. SA-17
Torsion bar .............................................................. SA-19
Lower Arm and Vibration Damper ........................... SA-21
Upper Arm ............................................................... SA-24
Guide Level ............................................................. SA-26
Lateral Stabilizer ..................................................... SA-27
(SF/2WD)
Front Wheel Hub and Steering Knuckle ...................... SA-28
Front Wheel Hub ..................................................... SA-29
Steering Knuckle ..................................................... SA-32
Front Suspension ......................................................... SA-36
Ball Stud ................................................................... SA-37
Torsion bar ............................................................... SA-38
Lower Arm and Vibration Damper ............................ SA-39
Upper Arm ................................................................ SA-42
Guide Level .............................................................. SA-43
Lateral Stabilizer ....................................................... SA-43
(SF/4WD)
Front Wheel Hub and Steering Knuckle ....................... SA-44
Front Wheel Hub ...................................................... SA-45
Steering Knuckle ..................................................... SA-49
Constant Speed Drive Shaft ........................................ SA-54
Front Speed Reducer .................................................. SA-57
Change of Oil Seal of Driving Bevel Gear Of
Front Speed Reducer ............................................. SA-57
Dismantle of Front Speed Reducer ......................... SA-61
Change of Axle Shaft Oil Seal ................................. SA-63
Disassembly and Assembly of Front Speed Reducer.... SA-65
Assembly of Front Speed Reducer ......................... SA-74
(Back)
Rear Axle Shaft ........................................................... SA-79
Rear Speed Reducer .................................................. SA-83
On-vehicle Change of Oil Seal of Main Teeth ......... SA-84
Dismantle of Rear Speed Reducer .......................... SA-85
Disassembly of Rear Speed Reducer ..................... SA-85
Assembly of Rear Speed Reducer .......................... SA-89
Mount of Rear Speed Reducer and
Differential Assembly .............................................. SA-94
Rear Differential .......................................................... SA-95
Rear Suspension ......................................................... SA-97
SA

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-3Suspension System and Automobile Axle
Alignment of Front Wheel (Dr SL SK SY SJ)
Alignment of Front Wheel
(Dr SL SK SY SJ)
1. Inspection should be conducted for the following items to
remove the trouble
(a) Check the tire abrasion and air inflation situation
Tire inflation pressure:
Front (220
0)kPa
Back (240
0)kPa
(b) Check the front wheel bearing to see whether it is loose.
(c) Check the front suspension to see whether it is loose.
(d) Check the steering driving device to see whether it is
loose, and
(e) Check the front vibration damper work to see whether it
is loose.
2. Measure the ground clearance of the chassis.
Chassis ground clearance:
Dr
295
0+5mm
SL SK
(255
2)mm
SY
(310
2)mm
SJ
(295
1)mm
If the chassis ground clearance of the vehicle is sub-standard,
push down the body or raise it for a trial adjustment, if fails,
check the spring or suspension element to see whether they are
normal.
Remarks: adjust the chassis ground clearance to a specified
value before checking the Alignment of Front Wheel
parameters.
3. Mount on the four-wheel locating device.
The mount should be conducted according to the manufacturerís
instructions.

SA-4Suspension System and Automobile Axle
Alignment of Front Wheel (Dr SL SK SY SJ)
5. Adjustment for inner tilt angle of kingpin, outer tilt angle
of front wheel and back tilt angle of kingpin
Item
Inner tilt
angle of
kingpin
Outer tilt
angle of
front
wheelApplicable vehicle type
Dr SL SK SY
SJ
Mechanic
steeringDr SL SK SY
Power
steeringDr
SL SK SY
SJ
Back tilt
angle of
kingpinMechanic
steeringDr SL SK SY
Power steer-
ingDr SL SK SY
SJ9
30
45

14
52

0
30
20

0
10
10

0
20
10

0
30
15

2
45
15

3
15
Location parameter
4. Adjust the wheel angle
Take apart the limit bolts of the steering knuckle to check the
steering angle A of inner wheel.
Inner wheel steering angle
Dr SL SK SY
( 36
40
)
SJ
( 32
34
)
Remark: The wheel should not contact the body or brake hose
when the steering wheel reaches the limit position.
In case the steering angle of inner wheel doesnít conform to the
standard value, adjust the wheel angle through adjusting the
limit bolts of the steering knuckle.
Fastening torque
(90
0)N
m(SJ)
If the wheel angle fails to be adjusted within the standard value,
change the weary or damaged parts of steering system.
If the tilt angle fails to fall within the specified values, make an
adjustment through adding or reducing the gaskets on the
location of upper arm.
Gasket thickness: 3.0, 2.0 and 1.0mm
Once the gasket thickness increases by 1mm, the outer tilt
angle of wheel will change by 7', while the back tilt angle of
kingpin will change 20'.
After the wheel outer tilt angle and the back tilt angle of kingpin
are adjusted, if the inner tilt angle of kingpin still fails to the
specified value, check the steering knuckle or front wheel to
see whether they are bending or loose.
1
50
-20

adjusting bolt
outer tilt
angle of
front wheel inner tilt angle of kingpin
back tilt angle of
kingpin
front AB AB
HPM

SA-5
7. Check the sliding measuring situation.
Check the sliding situation with the sliding measuring tester.
Sliding measuring value:
.5m/km
push forward the vehicle;
forward
A=BB A
6. Wheel toe-in adjustment
(a) Verify that each wheel has been located forward in a line.
(b) Mark the tire center at the bearing height on the tread of
left and right tire, and measure the distance between the
marks on left and right treads.
(c) Push forward the vehicle until the mark on the back tread
of tire moves to the front.
Remark: the toe-in measurement should be conducted from the
same spot at the same height.
(d) Measure the distance between the two marks on the front
of two treads.
Toe-in value: (0-2)mm
(e) Loosen the clamping bolts of connecting pipe.
(f) Adjust the toe-in angle through the approach according to
which rotate the left and right drag rod tube by a same
angle.
Remark: check the lengths of the two drag rods to see whether
the two rods are same in length.
Length error of the left and right drag rod should not
be larger than 2.0mm.
(g) Tighten the clamping bolts.
Fastening torque
(20
) N
m
(h) Locate the split pin well.
Suspension System and Automobile Axle
Alignment of Front Wheel (Dr SL SK SY SJ)

SA-6Suspension System and Automobile Axle
Alignment of Front Wheel
Alignment of Front Wheel (SF)
Alignment of Front Wheel
(SF)
1. The following items should be checked to remove the
troubles.
(a) Check the tire abrasion and the air inflation to see it is
suitable or not.
Tire inflation pressure: (250
0)kPa
(b) Check the front wheel bearing to see whether it is loose.
(c) Check the front suspension to see whether it is loose.
(d) Check the steering driving device to see whether it is
loose, and
(e) Check the front vibration through elastic force test to see
whether it is normal in performance.
2. Height adjustment of vehicle
Adjust the vehicle height to the standard value so as to make
the Alignment of Front Wheel inspection.
A-B-58 5mm
A: The height of steering knuckle shaft center.
B: The center height of the adjusting cam bolt at front end
The standard value for the unloaded height is: the
difference of the center height of drive shaft climax and
the front adjusting cam bolt is 58.5mm.
3. Mount on the four wheel locating device
This approach should be conducted according to the detailed
instruction of the equipment manufacturer.
4. Adjust the outer tilt angle of front wheel and the back tilt
angle of kingpin
The outer tilt angle of front wheel: 0
5'
0'
The back tilt angle of kingpin: 2
0'
0'
Outer inclination of front wheel:
BA
the outer tilt angle of
front wheelthe back tilt angle
of kingpin
front

SA-7Suspension System and Automobile Axle
Alignment of Front Wheel
Alignment of Front Wheel (SF)
In case the outer tilt angle of front wheel or the back tilt angle
of kingpin fails to conform to the specified value, adjust the
cam forward or backward may amend them.
5. Wheel angel adjustment
Take apart the limit bolt cap of the steering knuckle to check
the inner wheel steering angle A.
The inner wheel steering angle: =32

Notice:The wheel should not touch the body brake hose
when the steering wheel is rotated to the bottom.
In case the max steering angle is not in the conformity with the
standard value, adjust the wheel angle through the limit bolts
of steering knuckle.
In case the wheel angle still fails to fall within the standard
range, make a inspection and change the weary and damaged
steering mechanism parts.
6. Wheel toe-in adjustment
Adjust the wheel toe-in according to the following approach
(a) Raise or reduce the vehicle until the suspension stands in
balance.
(b) Push the vehicle on the ground 5 meters forward under
the condition that the front wheels locate forward in a
line.front cam adjustment
rear cam adjustment
reduce increaseincrease reduce
A
B
A B
front

SA-8Suspension System and Automobile Axle
Alignment of Front Wheel (SF)
(c) Mark the center of the back of front wheel, and measure
the distance ìBî between the remarks on the left and right
tires.
(d) Push the vehicle forward so that the mark on the back of
tire moves to the measuring height of the instrument.
Remark: if the tire moves too far, repeat the approach (b).
(e) Measure the distance ìAî between the marks on the front
of tire.
(f) Measure the wheel toe-in.
Toe-in = B-A
Inspection standard: (0-2)mm
In case the toe-in fails to conform to the specified value, it can
be amended through adjusting the left and right drag rods.
(g) Loosen the clamping bolt and nut.
(h) Adjust the toe-in situation by the approach of rotating the
left and right drag rod by a same angle.
(i) Ensure the left and the right drag rods are same in length.
B
forward
move the vehicle forward
A
front
A
B
A=B