Great Wall service chassis and body Manual - part 22

TF-29

Transfer Box

 Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear)

(d)

The gear, being peeled off at the center of one side of

contact face, may be repaired for reuse

(e)

The gear, being peeled off in the center of contact area,

shall be changed.

(f)

The gear, being peeled off at two sides of tooth top, shall

be changed.

TF-30

Transfer Box

 Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts)

Change the parts and fittings as requirement

Attachment for Inspection Maintenance or Change of Parts

Checking items

Acceptance/Refusal

Parts (items)

All parts (including

all springs)

Crack inspection, distortion inspection and ero-

sion inspection

All parts with crack, all parts that are bended,

distorted or poor in round bouncing are refused.

All threaded parts

Thread inspection for buckle missing or other

damage

Those parts cannot be threaded or bottomed in

overlap manner shall be refused.

F l a n g e   a n d   f o r k

flange

Please refer to the paragraph of 

inspection
 to

check the spline.

Please refer to the 

inspection paragraph
 for

spline inspection.

Velocity sensor, mo-

tor assembly

Parts of electric clutch

system

Please refer to the part of electric appliance

Sliding bearing

Inside surface inspection for the sliding bearing

In the case that the bearing has pitting corrosion

or other damage, refuse it.

Ball bearing

Check visually the ball and track of the ball

bearing to see whether there is damage such as

adhesive bonding, pitting corrosion, etc.

Ensure that the bearing are all lubricated, run the

outer race of the bearing while holding the inner

one to feel whether there is poor running or

corrosion, the bearing shall be run smoothly

without excessive clearance.

Refuse to use the damaged bearing;

Refuse to use the damaged or loose bearing; or

Check the axial clearance to see whether it

exceeds 0.23mm.

Needle bearing

Check the bearing needle roller and track to see

whether there is damage such as adhesive

bonding, pitting corrosion, etc.

Refuse to use the damaged bearing.

The rear cover, front

body and front hous-

ing of transfer box

Check to see whether there is burr on the cou-

pling face or other damage that impedes assem-

bling or sealing.

Clear away the burr according to the paragraph

of 

inspection
, otherwise, change the dam-

aged element

Rear cover of trans-

fer box

Check the bearing hole

Refuse to use the assembly that has pitting

corrosion

Odometer gear

Check the gear teeth referring to the Inspection

Paragraph

Refer to the gear or chain sprocket inspection in

inspection paragraph
.

Clutch shell, joint

outer gear sleeve and

joint cover

Check the spline according to the Inspection

paragraph

Refer to the spline inspection of 

inspection

paragraph

Locking sleeve

Check the wear or damage of the toggle fork

groove

Refuse the parts with step slipping or damage.

Shift guide shaft

Check the deformation situation

Check the burr or other damage on outer race

Check the wear of outer race

Refuse to use the bend shaft; clear away the burr

according to the 

inspection
 paragraph, oth-

erwise refuse to use.

Refuse to use the shaft with step slipping or

other damage.

Shift toggle fork

Check whether there is wear or damage at the

location where the toggle fork combines with

the shifting cam and gear sleeve.

If any step slipping or damage is found, refuse

to use it.

TF-31

Transfer Box

 Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts)

Attachment for Inspection Maintenance or Change of Parts

Parts (items)

Checking items

Acceptance/Refusal

Shift toggle fork as-

sembly

Check the wear and damage of the inserted face

that is combined with gear sleeve;

Check to see whether the contact roller can

rotate freely or is damaged or not

If any step wear or damage is found, the inserted

face shall be refused to use.

If the contact runs difficultly or is damaged, a

new pin-contact roller and new cage assembly

shall be used.

Driving and driven

chain sprocket

C h e c k   t h e   s p r o c k e t   t e e t h   a c c o r d i n g   t o

the 

inspection
 paragraph

Refer to the sprocket teeth inspection of

inspection
 paragraph

Shift toggle fork as-

sembly

Check the inner diameter that matches with the

output shaft

If any pitting corrosion or damage is found,

refuse to use it.

Driving chain

Check the step sliding, looseness or damage of

pin or connecting element

Refuse to use the weary or damaged driving

chain

Filtering screen

Check to see the filtering screen is clean or with

small hole or damage

Clean it where necessary, and abandon the dam-

aged one.

TF-32

Transfer Box

 Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection

Maintenance or Change of Parts

Pump shell

Check to see whether there is pitting corrosion

or step slipping

Abandon it in case it is seriously damaged or

worn

Output shaft

Check the spline, check the surface that matches

with bearing and check the distortion according

to 

inspection
 paragraph

Refer to the spline inspection of 

inspection

paragraph;

Refuse to use the one with pitting corrosion or

damage;

Refuse to use the one that is bending or poor in

round bouncing.

Deceleration hub

Check the spline of chain sprocket and check the

wear or damage of the location where matches

with the toggle fork according to the

inspection
 paragraph

Refer to the spline inspection of 

inspection

paragraph; refuse to use the one with step slid-

ing or damage.

Front output shaft

Check the surface where matches with the

bearing;

Check the spline according to the 

inspection
:

paragraph

Refuse to use the one with pitting corrosion or

damage

Input shaft

Check the spline according to the 

inspection

paragraph

Check the distortion

Refer to the spline inspection of 

inspection

paragraph;

Refuse the one that is bending or poor in round

bouncing.

Thrust washer and

thrust disc

Check the pitting corrosion

Refuse to use the one with pitting corrosion or

damage

Sun wheel

Check the gear teeth and spline according to the

inspection
 paragraph

Refer to the gear teeth inspection and spline

inspection of 

inspection
 paragraph.

Planetary mechanism

assembly

Check the gear teeth according to the

inspection
 paragraph;

Check the wear and looseness of the planetary

gear pin; check the wear of thrust gasket

R e f e r   t o   t h e   g e a r   t e e t h   i n s p e c t i o n   o f

inspection
 paragraph;

If any step sliding or pitting corrosion is found,

refuse to use it

Electric shifting cam

Check to see whether there is step slipping or

pitting corrosion

If any step sliding or pitting corrosion is found,

refuse to use it

Shift guide shaft

Check to see whether there is step slipping or

pitting corrosion

Check the distortion situation

If any step sliding or pitting corrosion is found,

refuse to use it

Refuse to use the bending one

Planetary gear ring

Check the match performance of it with the

transfer box housing

Check the gear teeth according to the

inspection
 paragraph

Check the transfer box housing assembly to see

whether the gear ring is loose or not in the

housing

R e f e r   t o   t h e   g e a r   t e e t h   i n s p e c t i o n   o f

inspection
 paragraph

Transfer box housing

Check the holes matches with the bearing

Abandon the one with pitting corrosion or

damage.