Great Wall service chassis and body Manual - part 17

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 box

2

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-10

1. output shaft

2. shift engagement sleeve assembly

3. locking sleeve

4. return spring

5. engagement sleeve

6. snapping ring

7. shift lock hub

8. clutch assembly

9. fastening snapping ring

10.shift guide shaft

11.toggle fork

Transfer Box

 Disassembly of Transfer Box

1. front case of transfer box

2. rear output shaft

3. cluch coil assembly

4. clip

5. bearing

6. nut

7. transfer cover assembly

8. mark plat

9. bolt

10. odometer drave gear

11. oil seal

12. oil seal

13. bearing

14. rear cover of transfer box

15. rolling needle bearing

16. shift guide shaft

17. back spring

18. magnet

19. bundle clip

10

9

8

12

13

14

15

7

7

6

5

4

3

16

17

18

2

1

19

9

11

3. The disassembly approach for rear cover is as follows (above figure)

(a)

Dismantle the nine screws and take down the clip of wire harness and

signboard in the same time.

Notice shall be taken to good keeping for the signboard, which includes the

information for the substitutes to be changed.

(b) Pry the frame lightly so that the sealing glue on the surface disengages, and

then take up the transfer box rear cover assembly directly.

(c) As for the electric gearshift transfer box, tear down the oil seal, bearing and

three nuts and clutch coil assembly.

(d) Tear down the snapping ring, pull out the bearing from the rear cover and

take apart the odometer meanwhile.

(f)

Pull out the oil seal from the rear cover of the transfer box.

(g) Tear down the magnet from the front body of transfer box.

(h) Take apart the return spring from the shift guide shaft

(i)

Clear away the sealing glue on the coupling face of the front housing and

rear cover of transfer box, take notice not to damage the coupling face of

the two housings or cause the materials removed dropping into the transfer

box.

4. Tear down the shifting element connected with the front axle.

Tear down the following parts from the remaining transfer box housing

assembly (electric gearshift).

(a) Electric gearshift assembly, tear down the snapping ring and sliding clutch

sleeve from the shift locking hub.

(b) Tear down the shift-locking hub from the rear output shaft.

(c) Tear down the shift engagement sleeve assembly and shift toggle fork from

the rear output shaft and shift guide shaft. Separate the assemblies one

another and tear down the shift guide shaft.

(d)

Disassemble the shift engagement sleeve assembly by taking apart the

snapping ring, engagement sleeve, return spring, and locking sleeve.

(e)

A plastic toggle fork that substitutes the metal toggle fork assembly and a

independent contact roller in earlier time.

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9

8

7

6

5

Q

3

2

10

11

TF-11

5.

Tear down the Chain drive system

Take apart the following parts from the transfer box housing

assembly.

(a)

Take apart the snapping ring and washer from the front

output shaft.

(b)

Take apart the driving chain sprocket, driven chain

sprocket and drive chain together from the two output

shafts.

(c)

Separate the chain sprocket from the chain.

1

2

3

4

5

6

7

1. output shaft

2. driving chain sprocket

3. driven chain sprocket

4. washer

1

2

3

4

5

6

7

6.

Oil pump assembly

Take apart the shaft and pump assembly, pipe clip, oil pipe and

filter from the remaining transfer box housing assembly.

1

2

7

6

3

4

5

8

1. deceleration gear hub

2. inserted face of Shift

    toggle fork

3. plastic sleeve

4. contact roller

5. pin

6. pin, contact roller and sleeve assembly

7. deceleration shift toggle fork

8. deceleration shift toggle fork assembly

7.

Deceleration shifting element disassembly

Tear down the following parts from the remaining transfer box

housing assembly.

(a)

Take apart the deceleration hub, and deceleration shift

fork assembly from the housing.

(b)

Take apart two plastic inserted faces from the decelera-

tion shift fork assembly

(c)

Disassembly the deceleration shift fork assembly only if

it were broken.Cut the plastic cover,and take out the pin

and truckle.

Transfer Box

 Disassembly of Transfer Box

1. output shaft

2. driving chain sprocket

3. driven chain sprocket

4. washer

5. snapping ring

6. transmission chain

7. front output shaft

5. snapping ring

6. transmission chain

7. front output shaft

TF-12

1

10

9

8

6

5

4

3

2

11

15

14

13

12

17

18

19

20

7

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

8

3

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