Great Wall service chassis and body Manual - part 16

TF-5

Transfer 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 maintenance

Manufactuer  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-6

5D

5D-Oil filling plug
5L-Oil drain plug

5L

2.

Regular lubricant change

(a)

The oil level of lubricant in transfer box shall be checked

when exchanging the engine lubricant or after the vehicle

covers 8000 kilometers, and the lubricant shall be added

as requirement.

(b)

The lubricant shall be changed with the specified one

every year or after the vehicle covers 48000 kilometers.

3.

Lubricant inspection approach

(a)

Clean the oil filling plug and the around area.

(b)

Open the oil-filling plug to check whether the lubricant

can flows out or not.

(c)

if the lubricant can flow out, which means the real

lubricant volume is under the prescribed value, and the

specified lubricant shall be added into the transfer box

until the lubricant can flow from the oil filler hole.

(d)

Propel the oil-filling plug tightly according to the given

Tightening moment.

Tightening moment

(19
30)N
m

Notice: The vehicle shall run for a certain time before

checking or exchanging the lubricant so that the

temperature of lubricant in transfer box may be a little

higher. Do not use hammer or other punching tools to

open or propel the oil drain plug or oil filling plug, otherwise,

the thread hole on the frame will be damaged

4.

Lubricant change

(a)

Clean the oil filling plug and oil drain plug and the around

area.

(b)

Put down a oil container under the transfer box.

(c)

Open the oil drain plug.

(d)

Open the oil-filling plug.

(e)

Drain the lubricant up.

(f)

Mount the oil drain plug and screw it up according to the

given Tightening moment.

Tightening moment

(19
30)N
m

(g)

Add the lubricant through the oil filler hole until the

lubricant overflows. Mount the oil-filling plug and tighten

it according to the Tightening moment.

Tightening moment : (19

30)N
m

Transfer Box 

lubricant grade: ATF--3

Product Description and Simple Maintenance

TF-7

Transfer Box 

 Disassembly and Mount of Transfer Box

Disassembly and Mount of Transfer Box

1.

Transfer Box Disassembly

(a)

Drive the vehicle on the lifting jack.

(b)

Locate the gear of transfer box at the neutral

position, shift the transfer box to the 2H and

extinguish the engine.

(c)

Disconnect the cell cathode.

(d)

Lift the vehicle.

(e)

Put down an oil disc under the transfer box, tear

down the oil drain plug and oil filling plug of the

transfer to drain all the lubricant up, then re-

mount the two plugs.

(f)

Disconnect all wires and wire harnesses that

connected with the transfer box.

(g)

Take apart the hose on the venting valve of

transfer shaft.

(h)

Disconnect the linkage of the front drive shaft

with the front flange of the transfer box.

(i)

Disconnect the linkage of the rear drive shaft

with the rear flange of the transfer box.

(j)

Raise the transfer box up with the jack.

Notice: The transfer box shall be guaranteed to

support by the lifting jack before tearing down

the sets of bolt and nut that connected with the

transfer box and gearbox. The transfer box is

not allowed to hang directly on the gearbox

through spline because such operation will

damage the transfer box parts.

(l)

Tear down the connecting nuts between the

transfer box and gearbox and take down the

transfer box.

(m) Move the transfer box backward directly until

the linkage between the input shaft of transfer

box and the gearbox spline.

(n)

Put down the lifting jack of the transfer box, and

(o)

Tear down the gasket between the transfer box

and gearbox. Clean the gasket or glue on the

coupling face of front body of transfer box with

rear body of the gearbox. Take notice not to

damage the coupling face.

1

2

3

4

5

6

7

8

9

1. input shaft
2. front frame of transfer box
3. rear cover of transfer box
4. flange
5. front output fork flange
6. venting valve
7. gasket
8. rear body of gearbox
9. bolt

TF-8

Transfer Box 

 Disassembly and Mount of Transfer Box

2.

Transfer box mount

a)

Coat the lubricant grease on the output axial

spline of the gearbox with a thin sleeve contain-

ing lubricant grease.

b)

Mount a new gasket on the mounting face of the

transfer box.

c)

Lift the lifting bracket of transfer box and align

it to the same axle with the gearbox.

Notice: The transfer shall be guaranteed to flush

with the gearbox before connecting the spline.

Do not handle it forcefully to press the transfer

box spline into the gearbox. Otherwise, damage

will be caused, run the rear output shaft where

necessary to aim at the spline.

(d)

Move the transfer box forward slowly so that

the spline and pin of the input shaft of gearbox

reach the front body of the transfer box, and the

gasket attaches on the gearbox completely.

(e)

Ensure that the mounting holes of the front

body of transfer box, gasket, and gearbox are in

alignment and then mount the sets of bolt and

nut.

Fastening torque

(35-48)N
m

(f)

Connect the rear drive shaft and the rear output

flange of the transfer box.

(g)

Connect the front drive shaft and the front

output fork flange of the transfer box.

(h)

Connect the venting valve and the soft ventila-

tion pipe.

(i)

Connect the cables of odometer that locates

nearby the transfer box.

(j)

Connect all wire harnesses that connected with

the transfer box, and

(k)

Add the lubricant of right brand.

Notice: when starting the engine, if the lubricant

is added incorrectly or in unsuitable volume,

which may lead the transfer box to damage.

Notice: as for the transfer box mounted on

vehicle, oil pump shall be used when adding oil

for it.

Notice: In case the transfer box is taken apart for

maintenance or inspection, there will be no

lubricant supplied by oil pump in the oil passage

on the top of transfer box. Therefore, it is not

accurate to control the oil volume by opening the

oil filling plug, in such condition, the oil passage

will be filled with oil once the oil pump runs. If the

wheel can run, such operation can be conducted

on the lifting jack. The oil level shall be rechecked

once the oil pump runs.

(l)

Put down the vehicle after finishing the lubri-

cant inspection, and connect the cell cathode.