Great Wall Safe (2006 year). Service Manual - part 10

SA-39

Lower arm and Vibration Damper

Disassembly of Lower Arm

1.

Tear down the transverse stabilizer rod;

2.

Tear down the vibration damper;

3.

Disconnect the lower arm ball stud seat and the lower

ball stud;

Remove the cotter pin and the groove nut.

4.

Tear down the lower arm

(a)

Make a mark on the mounting position of the eccentric

gasket.

(b)

Tear down the lower arm.

Suspension System and Automobile Axle (SF/2WD)

 Front Suspension (Lower Arm and Vibration Damper)

SA-40

Change of Lower Arm Shaft Bush and Tube

1.

Tear down the lower arm shaft bush and shaft tube:

(a)

Tear down the large and small pinch-off gaskets of the

lower arm shaft bush first.

(b)

Tear down the lower arm shaft bush and tube.

2.

Mount the lower arm shaft bush and tube.

(a)

Press down the lower arm shaft bush and tube.

(b)

Press down the large and small pinch-off gaskets of the

lower arm shaft bush.

Mount of Lower Arm

1.

Mount on the lower arm

Align the marks on the eccentric gasket and on the frame, and

then screw up the lower arm bolt.

2.

Connection for lower ball stud and lower arm:

Mount the lower ball stud and the lower arm ball stud seat

together.

Fastening torque

(142 
 0)N
m

3.

Vibration damper mount

Mount the vibration damper on the lower arm bracket;

Fastening torque

(137 
 0)N
m

Suspension System and Automobile Axle (SF/2WD)

 Front Suspension (Lower Arm and Vibration Damper)

SA-41

4.

Mount the transverse stabilizer rod on the lower arm;

Fastening torque

(23 
)N
m

5.

Check the Alignment of Front Wheel;

(See Page SA-6)

Suspension System and Automobile Axle (SF/2WD)

 Front Suspension (Lower Arm and Vibration Damper)

SA-42

Upper Arm

Dismantle of Upper Arm

1.

Tear down the torsion rod spring:

(See page SA-19)

2.

Tear down the upper ball stud:

(a)

Support the upper arm with a jack.

(b)

Tear down the four sets of bolt and nut.

3.

Upper arm dismantle

Tear down the bolts to take down the upper arm.

Change of the Upper Arm Shaft Bush

(Short) and the Upper Arm Shaft Bush

and Tube

1.

Tear down the upper arm shaft bush (short) and the

upper arm shaft bush and tube (long)

(a)

Tear down the torsion bar yoke, the nuts as well as the

large and small pinch-off gaskets of the upper arm shaft

bush.

(b)

Push out the upper arm shaft bush (short) and upper arm

shaft bush and tube.

2.

Mount on the upper arm shaft bush (short) and the upper

arm shaft bush and tube (long):

(a)

Press the upper arm shaft bush and tube (long) in the

upper arm, and encase the upper swing arm shaft, and

then encase the upper arm shaft bush (short).

(b)

Mount on the large and small pinch-off gaskets of upper

arm shaft bush and screw up the nuts.

Fastening torque

(225 
)N
m

(c)

Mount on the torsion bar yoke.

Notice: the notch of torsion bar yoke should face

downward;

Fastening torque

(89 
)N
m

Suspension System and Automobile Axle (SF/2WD) 

 Front Suspension (Upper Arm)

SA-43

Mount of Upper Arm

1.

Screw up the axle nut of upper arm according to the

specified torque;

Fastening torque

(225 
)N
m

2.

Mount on the upper arm;

Screw up the three bolts of the upper swing arm shaft according

to the specified torque;

Fastening torque

(178 
 5)N
m

3.

Connect the upper arm ball stud with the upper arm;

Use four sets of bolt and nut to connect the upper arm ball stud

and the upper arm.

Fastening torque

(27 
)N
m

4.

Mount the torsion rod spring;

5.

Check the Alignment of Front Wheel:

(See Page SA-6)

Suspension System and Automobile Axle (SF/2WD)

Front Suspension \(Lower arm, Guide Lever and Transverse Stabilizer Rod)

Guide Lever

(See page SA-26)

Transverse Stabilizer rod

(See page SA-27)

SA-44

Front Wheel Hub and Steering Knuckle

Element Figure

Suspension System and Automobile Axle (SF/4WD)

 Front Wheel Hub and Steering Knuckle

lock ring

cushion block

nut

lock ring

cushion
block

shock
absorber

upper arm

transverse stabilizer rod

bolt

transverse stabilizer
rod gasket

rubber snubber
washer

stabilizer rod limit tube

brake
caliper

rubber
snubber
washer

constant speed
drive shaft

needle
bearing

steering knuckle

steering knuckle
small sleeve

retainer ring

washer-spline of
steering knuckle
shaft

thrust plate-
steering knuckle

 inner oil

seal- drive shaft

brake oil pipe bracket

steering
knuckle arm

brake shell

dust cover

 oil seal -
front hub

front hub bearing
(inner)

front wheel hub and
front brake disc

stop washer

lock plate

front hub bearing
(out)

steering knuckle
big nut

free wheel hub
noumenon

gasket

free wheel
hub cap

gasket

liner

lower ball stud

 Parts that cannot be reused after being used

specified torque

N

m

135-155

6-12

25-29

25-29

70-90

132-152

20-26

180

127-147

132-152

123

SF 4WD

transverse stabilizer rod gasket

transverse stabilizer rod gasket

transverse stabilizer
rod gasket

transverse stabilizer
rod gasket

SA-45

2.

Tear down the free hub.

3.

Tear down the retainer ring and the axle spine of washer-

steering knuckle:

Tear down the retainer ring with the pliers for retainer ring, and

take down the axle spline of washer-steering knuckle by hand.

4.

Tear down the front wheel hub and front brake disc:

(a)

Prize up the lock plate with screwdriver.

(b)

Tear down the steering knuckle nut with special service

tool to take out the lock plate.

(c)

Tear down another steering knuckle nut with special

service tool to take out the stop washer.

(d)

Tear down the front wheel hub and the front brake disc.

Front Wheel Hub

Disassembly of Front Wheel Hub

1.

Tear down the brake caliper:

(a)

Tear down the Bundy tube from the brake caliper and

block the pipeline of Bundy tube with cork.

(b)

Tear down the brake caliper from the steering knuckle.

Suspension System and Automobile Axle (SF/4WD)

 Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-46

5.

Tear down the front hub, the oil seal and the inner race

of front hub bearing (inner)

(a)

Prize out the oil seal.

(b)

Take out the inner race of front hub bearing (inner).

6.

Inspection on and change of the outer race of front hub

bearing

(a)

Check each bearing:

Wash the inner and outer races of each bearing to check

their wear or damage situation.

(b)

Tear down the outer race of each bearing:

Tap out the outer bearing race with copper bar and hammer.

Notice: bind the inner and outer races of the same

bearing together to prevent from mixing.

7.

Inspection and change for front brake disc

(a)

Check the wear situation of the front brake disc.

(b)

Tear down the bolts that connect the front wheel hub and

the front brake disc.

(c)

Connect the front wheel hub and the front brake disc with

bolts, which are tightened diagonally with moment span-

ner according to the specified torque.

Fastening torque

(70-80)N
m

(d)

Make the dynamic balance test on the dynamic balancer,

and the amplitude value displayed should not be smaller

than 13.5g under the condition that the measuring rotat-

ing velocity is 796 r/m and the locking rotating velocity

of 786 r/m, otherwise, tap the counter balanced clip,

which is 4g each, in the corresponding position, the clip

number should not be more than 4.

(e)

Tap in the new bearing outer race carefully with the

special service tool.

Notice: the inner and outer races of the same bearing

should be changed in one time.

Suspension System and Automobile Axle (SF/4WD)

 Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-47

Assembly of Front Wheel Hub

1.

Mount on the inner race and roller assembly of front hub

bearing as well as the oil seal of front hub.

Coat the lithium base grease of (4-5)mm on the inside surfaces

of the bearing outer race and the front wheel hub, put in the

inner race and roller assembly of front hub bearing (inner),

then plaster the lubricant. Plaster a little lubricant on the lips of

front wheel hub oil seal, and finally tap the front hub in place

with special service tool.

Notice: Do not plaster the lubricant on the face of front

brake disc.

2.

Mount the inner race of front hub bearing (outer) and

roller assembly

Coat 4

 5 mm of lithium base grease on the outer race of

bearing, and then put the inner race of front hub bearing (outer)

and roller assembly in it, finally plaster with lubricant.

(c)

Loosen the steering knuckle nut to ensure the front brake

disc can run freely. Screw up the steering knuckle nut

again to the specified torque.

Fastening torque

25N
m

(d)

Mount on the lock plate and mount on another steering

knuckle nut.

Fastening torque

60N
m

3.

Mount the front wheel hub on the steering knuckle

Coat a little lubricant on the oil seal of steering knuckle, and

then mount the front wheel hub and front brake disc on the

steering knuckle, finally mount on the stop washer.

4.

Adjust preload:

(a)

Mount on the steering knuckle nut and screw it up

according to the specified torque.

Fastening torque

(100-120)N
m

(b)

Run the front wheel hub by 1/4-1/3 round so as to seat the

bearings.

Suspension System and Automobile Axle (SF/4WD)

 Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-48

(e)

Hold the bolt of front wheel hub with the spring-tension meter

and drag slowly in the direction of the spot tangent line.

Suitable tension range

(29-54)N

The nut should be screwed up again within the suitable range if the

tension value is overlarge or over small.

(f)

Check the bearing to ensure it cannot leap excessively (the

axial clearance should not be more than 0.05mm).

(g)

Measure the bouncing value of the front brake disc, which

should not be more than 0.11mm, and

5.

Mount the liner and the free hub:

(a)

Tear down the free wheel hub cap firstly.

(b)

Mount the liner and the free hub on the front wheel hub.

Fastening torque

(25-29)N
m

(c)

Mount on the free wheel hub cap.

Fastening torque

(6-12)N
m

6.

Mount the brake caliper:

(a)

Mount the brake caliper on the steering knuckle and screw

up the bolts according to the specified torque.

Fastening torque

123N
m

(b)

Connect the Bundy tube.

Fastening torque

20-22N
m

7.

Check the height of brake liquid level and, if required, add

the brake liquid, exhaust the gas from the brake system.

Suspension System and Automobile Axle (SF/4WD)

 Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

(h)

Bend one tooth of lock plate inside and other teeth outside

so as to lock the steering knuckle nut.

SA-49

Steering Knuckle

Dismantle of Steering Knuckle

1.

Tear down the brake caliper, he front wheel and the front

brake disc.

2.

Tear down the dust cover and the brake shell;

3.

Tear down the steering knuckle arm from the steering

knuckle;

4.

Tear down the vibration damper from the lower arm;

6.

Tear down the steering knuckle:

(a)

Tear down the split pin and groove nut from the position

where the ball stud locates.

(b)

Tear down the steering knuckle from the position where

the ball stud locates with the special service tool.

5.

Tear down the transverse stabilizer rod from the lower

arm;

Suspension System and Automobile Axle (SF/4WD) 

 Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-50

(c)

Tear down the split pin and groove nut from the position

where the lower ball stud.

(d)

Tear down the steering knuckle from the position where

the lower ball stud with the special service tool, and

(e)

Press down the lower arm to tear down the steering

knuckle.

7.

Tear down the Lower ball stud assembly from the posi-

tion where the steering knuckle locates.

Steering knuckle inspection and change

Inspection on and Change of Steering

knuckle

1.

Check the steering knuckle

Check the steering knuckle with the dye penetration agent to

see weather has crack, if any crack is found, change the

steering knuckle.

2.

Tear down the inner oil seal 

 drive shaft and the thrust

plate

 steering knuckle.

Prize out the inner oil seal 

 drive shaft from the steering

knuckle with the screwdriver to take out the thrust plate 

steering knuckle.

Suspension System and Automobile Axle(SF/4WD) 

 Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-51

3.

Tear down the needle bearing;

Tap out the steering knuckle small sleeve with hammer and

copper.

4.

Tear down the needle bearing.

Tap out the needle bearing with the hammer and copper bar.

5.

Mount the steering knuckle small sleeve;

Tap in the steering knuckle small sleeve with the special

service tool.

6.

Mount on the needle bearing;

Tap in the needle bearing with the special service tool.

7.

Mount on the thrust plate- steering knuckle;

Coat the needle roller of the needle bearing with the lithium

base grease, and plaster the lubricant on the both sides of the

thrust plate ñsteering knuckle.

Suspension System and Automobile Axle(SF/4WD) 

 Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-52

8.

Mount the inner oil seal óon the steering knuckle.

Check the oil seal visually, if any deformation or glue lack is

found, change the oil seal

Mount of Steering Knuckle

1.

Mount the lower ball stud on the steering knuckle;

Connect the lower ball stud and the steering knuckle with

bolts, and screw up the bolts according to the specified torque.

Fastening torque

(70-90)N
m

2.

Mount on the steering knuckle

(a)

Coat the lubricant HP-R on the drive shaft.

(b)

Press down the lower arm to mount on the steering

knuckle.

(c)

Mount on the groove nut of lower ball stud and screw up

the nut according to the specified torque, and then mount

on the split pin.

Fastening torque

(132-152)N
m

(d)

Mount on the groove nut of upper ball stud and screw up

the nut according to the specified torque, and then mount

on the split pin.

Fastening torque

(132-152)N
m

Suspension System and Automobile Axle (SF/4WD)

 Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-53

3.

Mount the stabilizer rod on the lower arm.

Fastening torque

(20-26)N
m

4.

Mount the vibration damper on the lower arm.

Fastening torque

(127-147)N
m

5.

Mount the steering knuckle arm and the brake oil pipe

bracket on the steering knuckle, and coat the sealing

agent 1271 on the bolt thread.

Fastening torque

180N
m

6.

Mount on the dust cover and the brake shell.

Align the locating hole of dust cover and the groove of the

steering knuckle so as to guarantee the dust cover and the

steering knuckle are concentric.

Fastening torque

(25-29)N
m

7.

Mount the front wheel hub and the front brake disc as well

as the brake caliper.

8.

Check the height of the brake liquid level and, if required,

add the brake liquid, exhaust the gas of the braking

system.

Suspension System and Automobile Axle (SF/4WD) 

 Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-54

Constant Speed Drive Shaft

Element figure

Suspension System and Automobile Axle (SF/4WD) 

 Constant Speed Drive Shaft

axially movable three-ball
universal joint

triangular joint

mobile joint
snapping ring

extensible-end large
gripping hoop

extensible-end
dust cover

extensible-end small
gripping hoop

shaf

fixed-end small gripping hoop

fixed-end large gripping hoop

fixed-end dust cover

steel retainer ring

ball-cage type universal joint

inner oil seal- drive shaft

front drive axle shaft

sleeve assembly

 Parts that cannot be reused after being used

N

M

specified torque

SF4WD

front speed reducer and
differential assembly

constant speed
drive shaft