Great Wall service chassis and body Manual - part 18

TF-13

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Transfer Box

 Disassembly of Transfer Box

10. Take apart the shift convex plate parts (for the electric

shift transfer box)

(a)

Take apart the integrated electric shifting cam from the

transfer box housing.

(b)

Take apart the electric shifting cam from the shift guide

shaft.

(c)

Grip the end of shift guide shaft with soft-jaw vices, and

tap the shaft with a screwdriver until the torsion spring

drops off.

1. front body of transfer box housing

2. shift guide shaft

3. torsion spring

4. electric gearshift

5. gasket

1. transfer box front housing assembly

2. gear ring

3. oil seal

4. transfer box front housing

5. locating pin

6. ball bearing

7. snapping ring

11. Disassemble the transfer box housing assembly

Disassemble the transfer box housing assembly in the manner

as follows.

(a)

Take apart the oil seal.

(b)

Take apart the snapping ring, and pull out the bearing.

(c)

The locating pin may only be taken apart from the transfer

box front housing in the case that the pin is loose or

damaged, and

(d) Where the gear ring needs to be changed, it may be

pressed out from the transfer box housing.

TF-14

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1. transfer box front housing assembly

2. gear ring

3. oil seal

4. transfer box front housing

5. locating pin

6. ball bearing

7. snapping ring

NMR

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1. oil seal

2. transfer box front housing

3. gear ring

4. locating pin

Transfer Box

 Transfer Box Assembly

Transfer box assembly

1.

Introduction

Please refer to the given instruction of this chapter during

assembly process. And the following items shall be taken

notice on:

(a)

In case that the torque of the threaded parts is required,

torque spanner shall be used to screw up the parts.

(b)

The small parts shall be coated with the lubricant grease

during the mounting process, so that they are immobilized

at the mounting locations.

(c)

SST such as thimble of T-13-54-001 shall be used to press

the oil seal and bearing during the oil seal mount and

bearing mount, do not use the hammer to strike the oil seal

or bearing directly.

2.

Lubricating during assembling

All inner parts without lubricant shall be lubricated with the

suitable lubricant before mounting, so that they can be as-

sembled easily and can supply the original lubricant

performance.

(a)

If the O-ring and oil seal were not lubricated before

mounting, they may be damaged.

(b)

Be sure that the bearing or liner is lubricated completely

before mounting. Because the bearing or liner may be

leaded into damage even though they are run for a very

short time.

(c)

The lips of oil seal and the metal elements that match with

lips shall be lubricated before mounting.

3.

Transfer box housing assembly

Parts taken apart from the transfer box shall be mounted

according to the following approaches:

(a)

If the gear ring needs to be changed, the tooth-type saddle

rear of new gear ring shall be flushed with the gullet of the

transfer box front housing when pressing the new gear

ring. Press in the gear ring as shown in the left bottom

drawing, in which, the chamfering end is firstly pressed

in. if it is ensured the gear ring is not tilted, then fasten the

gear ring tightly on the housing.

(b)

In case there are two locating pins taken apart, mount two

new locating pins into the housing.

(c)

Press the bearing into the transfer box front housing and

mount the snapping ring correctly, and

(d)

Put down the new oil seal as shown in the left bottom

drawing and press it into the housing.

TF-15

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1. shift guide shaft

2. torsion spring

3. electric shift convex plate

4. gasket

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1. torsion spring

2. gasket

3. shift shaft

Transfer Box

 Transfer Box Assembly

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3

1. torsion spring

2. gasket

3. shift shaft

4.

Mechanic shift convex plate assembly (for electric shift

transfer box)

The mounting process for the electric shifting element is as

follows:

(a)

Insert the gasket into the inside of free end of the torsion

spring.

(b)

Slide the torsion spring and gasket along with the shift

shaft to the driving tongue and put down the first spring

ring at the left side of the driving tongue (from the

direction of free end of shift shaft).

(c)

Twist the second spring ring of the torsion spring on shift

shaft to the right side of the driving tongue.

TF-16

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16

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Transfer Box

 Transfer Box Assembly

1. torsion spring

2. gasket

3. shift 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

frontbody assembly

12. oil seal

13. locating pin

14. transfer box front body

15. snapping ring

16. transfer box housing

17. bearing

18. bearing gripping loop

19. bolt

20. vent

(d)

Push the torsion spring and gasket backward together as

can as possible

(e)

Mount the electric shifting cam on the shift shaft in such

way that the free end of the driving tongue of the cam is

put in first, fasten the cam driving tongue, which shall be

between the two spring ring of two torsion spring, under

the driving tongue of shift shaft and put it innermost as

can as possible.

(f)

After mounting the toggle fork, then mount the electric

shifting cam assembly in the transfer box housing assembly

5.

Assemble for front body, input shaft assembly and plan-

etary component element.

Mount the following element on the worktable:

(a)

Put the planetary bracket assembly on worktable, and the

end with snapping ring groove shall face upward.

(b)

Mount in the sun wheel and let the part with projecting

end upward, run the gear of the planetary bracket assem-

bly until it completely engages with the sun wheel.

(c)

Flush the projecting teeth, and then mount the thrust disc

into the planetary bracket assembly.

(d)

Mount in the snapping ring to complete the whole plan-

etary bracket assembly.