Great Wall service chassis and body Manual - part 1

CL-2

Clutch

 Troubleshooting

Troubleshooting

Trouble

Causes

Repairing approaches

Difficulty in gearshift

or non-gearshift

Overlarge 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 plate

Adjust 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 slip

Abrasion 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 fork

Change 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

shaking

The friction liner of clutch rib is stained with oil or is worn

Failure of clutch pressure plate

Looseness of engine seat

Check the clutch rib

Change the clutch pressure plate

Repair according to requirement

Looseness of clutch

pedal

There is air in clutch pipe

Failure of clutch brake-wheel cylinder

Failure of clutch master cylinder

Exhaust the air in clutch pipe

Change the clutch brake-wheel cylinder

Change the master cylinder

Over-loud clutch noise

Seize up of separation fork;

Abrasion or stained spot of separation bearing

Abrasion of guide bearing

Parts looseness in clutch pressure plate

Repair according to requirement

Change the separation bearing

Change the guide bearing

Change the clutch pressure plate

CL-3

Clutch

 Inspection and Adjustment of Clutch Pedal, Air Exhausting of Clutch

Air-exhausting of clutch

Remark: in case operation needs to be conducted for the clutch

system or if there is air in clutch, exhaust the air.

Notice : Do not stain the painted surface with brake liquid,

if any brake liquid is left, wash it away immediately.

1.

Fill the brake liquid into the oil cup of clutch master cylinder;

The oil cup of master cylinder shall often be checked and, if

necessary, added with brake liquid.

2.

Connect the ethene resin pipe to the air-exhausting valve.

Insert the other end of the pipe into the container, half of which

is filled with brake liquid.

3.

Air-exhausting in clutch system

a)  Move the clutch pedal up and down slowly for several times.

b)  Loosen the air-exhausting valve when pressing the pedal

increasingly until there is brake liquid overflowing, then

tighten the air-exhausting valve.

c)  Repeat this operation until the bubble in brake liquid disappears.

Inspection on and adjustment

of clutch pedal

1.

Check whether the pedal height is correct

Pedal height that begins from front wall board:

Dr SF

(165 
 5)mm

SL SK SY SJ

(190-200)mm

2.

Adjust the pedal height where necessary

Loosen the locking nut and screw off the adjusting bolts until

the pedal height is correct. Then screw up the locking nut.

Pedal free stroke

3.

Check whether the pedal free stroke is correct

Press the pedal lightly until the resistance generated by clutch

occurs.

pedal free stroke: (5-15)mm

4.

Adjust the pedal free stroke where necessary;

a)  Loosen the locking nut and rotate the push-rod until the

stroke is correct;

b)  Screw up the locking nuts;

c)  Check the pedal height after the adjustment of pedal free

stroke.

adjusting spot in

pedal height

pedal height

pedal free stroke

CL-4

Clutch

 Clutch Master Cylinder

Clutch Master Cylinder

Element drawing

SST

Disassembly of master cylinder

1.

Tear down the pin of push-rod

2.

Tear down the clutch pipe

Disconnect the jointed pipe nuts with SST

3.

Tear down the master cylinder

a)  Tear down the fixing nuts;

b)  Pull out the master cylinder.

 spring pin with groove

clutch master

cylinder

18

 2

19

 1

 ring pipe

 oil cup of clutch master cylinder

spring

piston

U-clamp

pin

open pin of nut

open ring

push-rod

gasket

dust cover

N*m

specified torque

  Parts that cannot be reused after using.

nut

CL-5

Clutch

 Clutch Master Cylinder

Disassembly of oil cup of master cylinder

1.

Tear down the oil cup

a)  Use the pinch and hammer to tap out the spring pin with

 groove;

b)  Tear down the oil cup and ring pipe.

Assembly of master cylinder

1.

Mount the oil cup

a)  Mount the oil cup and the new ring pipe.

b)  Use the pinch and hammer to tap in the spring pin with

 groove.

Mount of master cylinder

1.

Mount the master cylinder

Mount the fixing nuts and screw them up.

2.

Connect the clutch pipes;

Connect the clutch pipes with SST

3.

Connect the push-rod and mount the pin;

Encase the pin of push-rod with clamping pliers.

4.

Exhaust the air in clutch system and adjust the clutch

pedal.