Great Wall Safe (2006 year). Service Manual - part 4

MT-35

Gearbox

 Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism)

(c)  Coat the sealing agent on the bolt thread.

(d)  Propel the plug with the torque socket spanner.

MT-36

Gearbox

 Bearing Front Cover Assembly (Element Drawing, Change of Oil Seal)

Bearing Front Cover Assembly

element drawing

bearing front cover
assembly

washer

front cover oil seal
assembly

Change of oil seal

The oil seal of the bearing front cover shall be changed where

necessary

(a)

Pry out the oil seal with screwdriver

(b)

Press in the new oil seal with SST.

Depth of oil seal:

Upper tooth

9.5mm

Tang tooth

(12.4 
 0.4)mm

SST

MT-37

Assembly of Gearbox

1.

Mount the output shaft in the central link plate

(a)

Tap the output shaft in the central link plate while pulling

it, until mounting it in the central link plate.

(b)

Mount the stop ring of the rear bearing of output shaft in

with the split-ring-type pliers.

Remarks: The stop ring shall flush with the surface of central

link plate.

2.

Mount the input shaft in output shaft

(a)

Coat the MP lubricant on the bearing with 13 needle

rollers, and mount the needle rollers in input shaft.

(b)

Propel the input shaft in the output shaft and flush the

groove of synchronizing ring with the sliding block.

3.

Mount the countershaft in the central link plate

(a)

Mount the stop ring on the rear bearing of countershaft

with split-ring-type pliers.

alignment

Gearbox

 Assembly of Gearbox

MT-38

Gearbox

 Assembly of Gearbox

(b)

Mount the intermediate-gear shaft in the central link

plate, and mount the backup rear bearing with SST while

holding the intermediate-gear shaft.

4.

Mount the baffle of rear bearing of output shaft

Mount and propel the bolts with torque socket spanner.

Tightening moment

Tang tooth

(17
22)N
m

Upper tooth

(12
17)N
m

5.

Mount the reverse idle gear and shaft

(a)

Mount the reverse idle gear and shaft.

(b)

Mount the axial pressing plate of the reverse idle gear,

and then propel the bolts tightly.

Tightening moment

(15
20)N
m

6.

Mount the bracket cluster of reverse rocker arm

Mount the reverse rocker arm bracket and propel the two bolts

tightly.

SST

MT-39

locking ball

socket spanner

Gearbox

 Assembly of Gearbox

7.

Mount the steel ball and the five-speed thrust washer.

8.

Mount the five-speed gear cluster

(a)

Coat the gear oil on the needle bearing.

(b)

Mount the five-speed gear cluster.

9.

Mount the synchronizing ring and the fifth coupling gear

(a)

Mount in the synchronizing ring and the fifth coupling

gear.

(b)

Dismantle the old central link plate from the table vice.

(c)

Put the gearbox straightly as shown in the drawing.

(d)

Flush the groove of synchronizing ring with the sliding

block and mount the fifth coupling gear with pressure

machine.

(e)

Mount the new central link plate in the table vice.

MT-40

Gearbox

 Assembly of Gearbox

10. Mount the split ring

(a)

Select the retainer for shaft that leaves the minimum

radial clearance, which is not larger than 0.1mm.

(b)

Mount in the retainer for shaft with copper bar and

hammer.

(c)

Mount the spring cylindrical pin of third-fourth-speed

gearshift fork.

Notice: The pin port should align with the direction of the

shaft.(Same sa below)

11. Measure the radial clearance of the five-speed gear

cluster.

Measure the radial clearance of the five-speed gear cluster

with the measuring gauge.

Standard clearance

Shang chi

(0.135
0.325)mm

Tang chi

(0.1
0.3)mm

12. Mount the third-fourth-speed gearshift fork axle and the

first-second-speed gearshift toggle fork as well as the

third-fourth-speed gearshift toggle fork

(a)

Mount the first-second speed and third-fourth speed

gearshift toggle forks.

(b)

Mount the third-fourth-speed gearshift fork axle in the

central link plate and the gearshift toggle fork.

MT-41

Gearbox

 Assembly of Gearbox

13. Mount the first gearshift fork axle and first gearshift fork

(a)

Coat the MP lubricating on the interlocking guidepost

and mount the interlocking guidepost on the first-second-

speed gearshift fork axle.

(b)

Mount the interlocking pin in the central link plate with

the magnetic bar.

(c)

Mount first-second gearshift fork axle in the first gear-

shift toggle fork and central link plate.

d) Mount the setting bolts of the first toggle fork and tighten

them.

Tightening moment

Upper tooth

(15
20)N
m

Tang tooth

(13
17)N
m

14. Mount the reverse yoke rod, reverse rocker arm and

reverse yoke block

(a)

Mount the reverse yoke rod, reverse rocker arm and

reverse yoke block together.

(b)

Mount the reverse rocker arm on the reverse rocker arm

bracket.

(c)

Coat the MP lubricant on the interlocking guidepost and

mount the guidepost on the reverse gearshift fork axle.

MT-42

Gearbox

 Assembly of Gearbox

(d)

Mount the interlocking pin in the central link plate with

the magnetic bar.

(e)

Mount the reverse gearshift fork axle in the reverse yoke

rod and central link plate.

(f)

Mount the spring cylindrical pin with the drift punch and

hammer.

15. Mount the five-speed reverse gearshift guide block and

five-speed reverse gearshift fork axis.

(a)

Mount the five-speed reverse gearshift guide block in the

five-speed reverse gearshift guide shaft.

(b)

Mount the reverse gearshift fork axle in the next step.

(c)

Mount the steel ball in the five-speed gearshift guide

block with the magnetic bar.

(d)

Mount the five-speed gearshift fork axle as shown in the

drawing.

(e)

Mount the steel ball in the central link plate with mag-

netic bar.

(f)

Mount the five-speed gearshift fork axle in the central

link plate.

MT-43

Gearbox

 Assembly of Gearbox

(g)

Tap the pin in the five-speed gearshift toggle fork with

the drift punch and hammer.

(h)

Mount the five reverse gearshift guide shaft in the five-

speed reverse guide block and central link plate, and

(i)

Tap the spring cylindrical pin in the five-speed reverse

guide block with drift punch and hammer.

16. Mount the retainer ring gripped by the gearshift fork axle.

Mount the clamp retainer ring with the steel bar and hammer

MT-44

sealed material

Gearbox

 Assembly of Gearbox

17. Mount the steel ball, locating spring and locating spring

plug

(a)

Mount the steel ball and locating spring.

Remarks:

Mount the short spring at the bottom of the central link plate.

(b)

Coat the sealing agent on the plug thread.

(c)

Mount the plug and tighten them with the torque socket

spanner.

Tightening moment

(17
22)N
m

18. Tear down the central link plate from the table vice

(a)

Tear down central link plate from the table vice.

(b)

Dismantle the bolts, nuts and washers

19. Mount the gearbox frame

(a)

Coat the sealing material on the coupling face of the

gearbox frame as shown in the drawing.

(b)

Put down the central link plate straightly as shown in the

drawing.

(c)

Mount the gearbox frame on the central link plate as

shown in the drawing.

MT-45

sealed material

Gearbox

 Assembly of Gearbox

20. Mount the stop ring of the front bearing

(a)

Mount the two stop rings in the input shaft bearing and

countershaft front bearing with the split-ring-type pliers.

(b)

Mount the coated component elements of front cover.

(c)

Coat the sealing agent on the bolt thread, and

(d)

Mount and propel tightly the bolts.

Tightening moment

(15
20)N
m

21. Mount the rear body, gear-change bar and selection bar

and their housings

(a)

Coat the sealing materials on the rear body as shown in

the drawing.

(b)

Mount the gearshift shaft and gearshift yoke block in the

rear body.

(c)

Mount the gearshift catching head in the groove of guide

block, and

(d)

Mount the catching head with the rear body together.

(e)

Mount and propel tightly the bolts.

Tightening moment

Shang chi

(30
40)N
m

Tang chi

(30
45)N
m

MT-46

4WD

Gearbox

 Assembly of Gearbox

(f)

Fasten the rear cover bolts of the four-gear driving

gearbox

Tightening moment:(30

45)N
m(Tang tooth)

(g)

Mount and propel tightly the setting bolts of the gearshift

yoke block.

Tightening moment

(17
22)N
m

22. Mount the steel ball spring and plug

(a)

Coat the sealing agent on the plug thread.

(b)

Mount the steel ball, setting spring and setting spring

plug.

Tightening moment

(17
22)N
m

23. Check the following items after mounting the rear body

or gearbox

(a)

Check the stability of the running input shaft and output

shaft.

(b)

Check the gearshift stability of each speed

24. Mount the component elements of the locating mecha-

nism

(a)

Mount the black component elements of the locating

mechanism on the side of the five-speed reverse gear.

(b)

Mount another component element of locating mecha-

nism and propel it tightly.

Tightening moment

(30
40)N
m

25. Mount the gearshift cover of the gearbox.

(a)

Mount the gearshift cover coated with sealing agent.

(b)

Mount six bolts and then tighten them.

Tightening moment

(15
20)N
m

MT-47

Gearbox

 Assembly of Gearbox

26. Mount the clutch frame

(a)

Mount the clutch frame.

(b)

Coat the sealing agent on the bolt thread.

(c)

Mount the nine bolts and then tighten them.

Tightening moment

Upper tooth

(60
70)N
m

Tang tooth

(30
45)N
m

27. Mount the back-up lamp switch.

Tightening moment

(20
40)N
m

28. Mount the driven gear of odometer

(a)

Mount the driven gear of odometer.

(b)

Mount the bolts and tighten them.

Tightening moment

(10
15)N
m

TF-1

page

Notice ........................................................................... TF-2

Troubleshooting ........................................................... TF-3

Product Description and Simple Maintenance ............. TF-5

Dismantle and Mount of Transfer Box .......................... TF-7

Disassembly of Transfer Box ....................................... TF-9

Assembly of Transfer Box ............................................ TF-14

Washing, Inspection, Maintenance and Change .......... TF-24

Washing ................................................................... TF-24

Inspection ................................................................ TF-25

Maintenance and Change of Gear and Chain gear .. TF-28

Attachment for Inspection, Maintenance and

Change of Parts....................................................... TF-30

Transfer Box

TF

TF-2

Transfer Box 

 Notice

Notice

Notice on transfer box disassembly and assembly

Notice shall be taken on the soft handling of the parts (coupling face in particular) during the process of

transfer box disassembly to avoid the collision; each parts shall put down in order so as to avoid of missing

or mistaking.

Notice shall, during assembly process, not only on the aforesaid items, but also on the following items:

1.

Wash all parts and fittings before assembly (rubber element and washer excluded).

2.

Oil seal, clip for shaft and spring pin of various kinds shall not be reused.

3.

Lubricating oil is required to coat on the various friction surface and lubricant on lips of various oil seal.

4.

Rolling body is not allowed to use for pressure transmission when mounting various bearings.

5.

Lip-type oil seal is not allowed to mount slantwise.

6.

The openness on the two sides of spring collar shall not be coupled face-to-face when assembling the

component elements of synchronizer. And

7.

No parts is allowed the lubricant leakage and penetration when the transfer box locates at the working

location.

TF-3

Transfer Box

 Troubleshooting

Common troubles

Causes

Resolving approaches

Change the lubricant or supplement the
lubricant volume.
Guarantee the torque of all connecting
elements stand at the specified value.
Open the transfer case to check the
bearing and othe parts whether is weared
or daamaged,if this happened,change
the parts.

Difficulty in mechanic gearshift or
outplace gear engagement

Troubleshooting

Incorrect lubricant or insufficient
lubricant volume.
Looseness of connecting bolt or other
connecting element.
Noise from the transfer box bearing

Noise, which is spreader by the transfer
box instead of clutch, engine, drive shaft
and other parts, occurs in each speed.

No driving of front wheel in the four-
gear engagement

Drive chain break

Disassemble and check the damage of
inner parts, and change the chain.

Adjust or repair shift lever.Open the
transfer box to check the toggle fork and
guide shaft, and change the parts as
requirement.Open the transfer box to
check whether the parts is wearied or not,
and, if any, change the weary parts.Open
the transfer box to check whether the
parts is wearied or not, and, if any, change
the weary parts.Open the transfer box to
check whether the parts is wearied or not,
and, if any, change the weary parts.

Overlarge loose fit clearance of the
shift toggle fork on the shift guide
shaft.
Wear of the shift toggle fork
assembly including pin and contact
roller.
Wear of the shift cam hub and the
liner.
Attainment of coupling gear

Mechanic gearshift seizing at a certain
location

Engagement failure of the mechanically
shift transfer box

Damage or unsuitable adjustment of
the shifting mechanism.
Damage or serious wear of the inner
shifting parts, or looseness or
attainment of the shift toggle fork
assembly on the guide shaft.
Unsuitable adjustment of shift lever.

Adjust or repair the shift lever mechanism.

Change the seriously wearied parts.

Change the loose or weary parts.

Refer to the vehicle manual for correct
operation.
Add the specified oil of given volume.

Open the rear cover of transfer box to check
and changer the damaged parts.
Open the rear cover of the transfer box to
check whether the sliding parts can slide
freely along the axle, if not, dismantle it and
change the damaged parts.

Incorrect operation.

Lubricant of inferior quality or
insufficient volume.
Adhesive bonding of shift toggle fork.

Adhesive bonding of the sliding joint
cover, locking sleeve or gear.

Mechanic gearshift failure under the
movement of shifting handle

Break or damage of the shift rocker
arm or shift lever.
Damage of the guide plate of shifting
cam;

Change the damaged element.

Open the rear cover of the transfer box to
check the damaged element and change
it.

Electric gearshift trouble

Damage or failure of electrically
controlled element, electric module,
speed sensor, electric motor, electric
clutch, or built-in wire harness.
Damage or worn of shifting cam,
joint cover, locking sleeve, toggle
fork or shift guide axle.Adhesive
bonding shift

Refer to the vehicle usage manual to
diagnose the failure element and change
it as requirement.
Dismantle the weary or damaged parts
and change it as requirement.
Dismantle and check the free movement
of sliding element, and change it as
requirement