Great Wall service chassis and body Manual - part 3

CL-10

Clutch 

 Clutch Cluster

3.

Check the alignment of the diaphragm spring  end.

Check the alignment of diaphragm spring  end with SST.

Max dislocation: 0.5mm

if the difference is more than the specified value, adjust the

alignment of diaphragm spring  end with SST.

4.

Coat the lithium base grease;

Coat the lithium base grease on the following parts:

Contact spot of separation fork and bearing

Contact spot of separation fork and push-rod;

Support spots of separation fork

Spline of clutch rib

5.

Encase the dust cover, separation fork, separation bearing

seat and bearing into the gearbox;

6.

Mount the gearbox.

SST

MT-1

Gear box

page

Notice ........................................................................... MT-2

Troubleshooting ........................................................... MT-3

Dismantle of Gear Box ................................................. MT-4

Mount of Gear Box ....................................................... MT-7

Disassembly of Gear Box ............................................. MT-10

Input Shaft Assembly ................................................... MT-18

Element Drawing ...................................................... MT-18

Inspection on Synchronizing Ring ............................ MT-18

Bearing Change ....................................................... MT-18

Output Shaft Assembly ................................................. MT-20

Element Drawing ...................................................... MT-20

Disassembly of Output Shaft Assembly.................... MT-21

Inspection on Output Shaft Assembly ...................... MT-23

assembly of Output Shaft Assembly ......................... MT-25

Countershaft Assembly  And Reverse Idle Gear

Assembly ...................................................................... MT-29

Element Drawing ...................................................... MT-29

Disassembly Inspection and Assembly of

Countershaft Assembly ............................................. MT-29

Assembly of Reverse Gear ...................................... MT-31

Rear Housing assembly ............................................... MT-33

Element Drawing ...................................................... MT-33

Change of Oil Seal ................................................... MT-33

Change of Shaft Bush .............................................. MT-33

Inspection on and change of Position-Limit

Mechanism Cluster ................................................... MT-34

Front Cover of Bearing ................................................. MT-36

Element Drawing ...................................................... MT-36

Change of Oil Seal ................................................... MT-36

Assembly of Gear Box ................................................. MT-37

MT

MT-2

Gear 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-3

Troubleshooting

Gear Box 

 Troubleshooting

Non-use of clutch

Non-full separation of clutch

Severely warned tooth rings of synchronizing

fittings

Over-hard locating spring

Use the right driving approach

Checking for adjustment

Change

Change

Difficulty in gear engagement

Over-low oil level

Lubricating oil of inferior quality

Non-timely oil change

Unsuitable axial location or clearance of gears

Bearing damage

Burr or collision on gear

Add oil to the specified level

Change it with the specified oil

Change the oil and damaged parts

Check for adjustment

Change

Repair or change the gear

Oil leakage, oil penetration

Oil added above the specified level

Loss or missing of bolts

Vent plug trouble

Sealing element damage

Adjust oil to the given level

Reassembling or fasten the bolt according to

the specified torque

Change

Change

Damage of synchronizer

Overexert in gear shift

Non-use of clutch

Damage on spring collar of synchronizer

Incorrect mounting of drive shaft

Change

Use the right driving approach

Change

Check for adjustment

Non-engagement of gear

Trouble in controlling mechanism

Incorrect assembling the locating spring or

steel ball

Invalidation of locating spring

Severely worn gear sleeve or fork groove

Seriously worn toggle fork

Check for adjustment

Reassembly

Change

Change

Change

Burning bearing, burning gear

Over-low oil level

Inferior lubricating grease

Non-timely oil change, over-dirty oil

Inter-use of differential oil or usage of

additive

Change damaged parts and add oil

Change the damaged parts and lubricating oil

Change damaged parts and lubricating oil

Change damaged parts and lubricating oil

Difficult in gear disengagement

Spring invalidation of synchronizer

Warn inner groove of tooth ring of synchronizer

Tooth ring of synchronizer choked on conical

face

Toggle fork deformation or toggle fork axle

deformation

Severely worn toggle fork

Change

Change

Change

Change

Change

Methods for troubleshooting

Over-loud or abnormal noise

Common Failures

Causes