Great Wall Safe (2006 year). Service Manual - part 11

SA-55

3.

Tear down the retainer ring from the drive shaft with the

calipers, and take down the washer-steering knuckle

shaft spline.

4.

Tear down the front wheel hub and the steering knuckle

together.

5.

Screw off the nuts that connect the constant speed drive

shaft to take down the constant speed drive shaft.

6.

Check and repair the constant speed drive shaft

Inject the molybdenum disulphide lithium grease of 100-110

g in the end of ball-cage type universal joint and the end of

axially movable tripod universal joint.

The ball-cage type universal joint and the axially movable

tripod universal joint should swing freely, and no clipping

stagnant is allowed. The dust cover should be prevented from

deformation and every gripping loop shall be clamping tightly.

Disassembly of Constant Speed Driving

Shaft

1.

Tear down the brake caliper.

2.

Tear down the free hub

Suspension System and Automobile Axle (SF/4WD) 

 Constant Speed Driving Shaft

SA-56

Mount of Constant Speed Drive Shaft

1.

Mount the constant speed drive shaft on the flanges of

the long and short axle shafts.

2.

Mount on the front wheel hub and the steering knuckle.

3.

Mount on the washer-steering knuckle shaft spline, and

then use the caliper to mount on the retainer ring.

4.

Mount on the free hub.

5.

Mount on the brake caliper.

Suspension System and Automobile Axle (SF/4WD) 

 Constant Speed Driving Shaft

SA-57

1.

Support up the front of vehicle to tear down the front

wheel and the steering knuckle.

2.

Drain off lubricant in the front speed reducer.

3.

Disconnect the front speed reducer flange and the drive

shaft.

Notice: Mark the assembly marks on the speed reducer

and the drive shaft before disconnecting them.

4.

Tear down the front speed reducer.

5.

Tear down the flange and dust cover:

(a)

Loosen the riveted position on main-tooth nut with the

hammer and chisel.

Front Speed Reducer

Change of driving bevel gear oil seal of front speed reducer

front speed reducer and

differential assembly

oil-guard tray

 driving bevel gear oil seal

flange and dust cover

140-210

 Parts that cannot be reused after being used

specified torque

N

M

main-tooth nut

Suspension System and Automobile Axle (SF/4WD) 

 Front Speed Reducer (Change of Driving Bevel Gear Oil Seal of Front Speed Reducer)

SA-58

(b)

Lock the flange with special service tool to tear down the

main-tooth nut.

7.

Tear down the inner race of conical roller bearing;

If the bearing is damaged, change a new bearing.

8.

Mount the new bearing.

6.

Tear down the driving bevel gear oil seal and oil-guard

tray:

(a)

Tear down the driving bevel gear oil seal with special

service tool.

(b)

Tear down the oil-guard tray.

   (c)

Tap down the flange and dust cover with copper bar.

Suspension System and Automobile Axle (SF/4WD) 

 Front Speed Reducer (Change of Driving Bevel Gear Oil Seal of Front Speed Reducer)

SA-59

12. Rivet the main-tooth nut.

10. Mount the flange and dust cover:

(a)

Encase the flange and dust cover in the front speed

reducer shell through the clinch of oil seal.

(b)

Lock the flange with the special service tool and screw up

the nuts according to the specified torque.

Fastening torque

(140-210)N
m

11. Adjust the preload of driving bevel gear bearing

Measure the play preload between the driving bevel gear and

the driven bevel gear with the torque tester.

Preload:(1.8-2.4)N

m

Remark: if the requirement is not satisfied, change the

adjusting washer between the adjusting washer jackets and

bearing 32307, see the disassembly and assembly for front

speed reducer, until the requirement is satisfied.

(a)

If the preload is larger than the specified value, change

with a thicker adjusting washer;

(b)

If the preload is smaller than the specified value,

change with a thinner adjusting washer.

9.

Mount the new driving bevel gear oil seal:

(a)

Encase the oil-guard tray.

(b)

Press the new oil seal in the speed reducer shell with the

special service tool; the mounted oil seal should be 1.5

mm away from the end face of the housing.

Notice: Coat the lithium base grease evenly on the lips of

oil seal.

Suspension System and Automobile Axle (SF/4WD) 

 Front Speed Reducer (Change of Driving Bevel Gear Oil Seal of Front Speed Reducer)

SA-60

13. Mount the front speed reducer assembly on the frame.

14. Connect the drive shaft to the flange:

(a)

Align the assembly mark and then connect the drive

shaft and the front drive axle flange with four sets of

bolt and nut.

(b)

Screw up the nuts according to the specified torque.

Specified torque

(69-79)N
m

Suspension System and Automobile Axle (SF/4WD) 

 Front Speed Reducer (Change of Driving Bevel Gear Oil Seal of Front Speed Reducer)

SA-61

Dismantle of  Front Speed Reducer

constant speed drive shaft

front drive axle shaft

sleeve assembly

front drive axle hanger

front speed reducer and

differential assembly

front speed reducer shell hanger

rubber jacket and

shaft tube

constant speed

drive shaft

 Parts that cannot be reused after being used

N

M

cpecified torque

Suspension System and Automobile Axle (SF/4WD)

 Front Speed Reducer (DisassEmbly of Front Speed Reducer)

SA-62

1.

Disconnect the front speed reducer flange and the drive

shaft.

2.

Screw off the nuts that connect the constant speed drive

shaft.

3.

Screw off the bolts connecting the rubber jacket and

shaft tube of the front speed reducer cover and the

frame.

4.

Screw off the bolts connecting the front drive axle hanger

assembly and the front speed reducer shell hanger, and

tear down the front speed reducer.

Suspension System and Automobile Axle (SF/4WD)

 Front Speed Reducer (DisassEmbly of Front Speed Reducer)

SA-63

1.

Tear down the front long semi-axis and the front minor

half-shaft

Pull out the front long and minor semi-axis from the front

speed reducer with tool.

2.

Tear down the front drive axle shaft sleeve and screw off

the bolts connecting the half-shaft sleeve.

3.

Tear down the oil seal - front half-shaft:

Tear down the oil seal-front half-shaft with the special service

tool.

Change of Axle Shaft Oil Seal

 snapping ring

front minor half-shaft

front speed reducer and differential

 oil seal-front half-shaft

front long

semi-axis

 snapping ring

88

N

M

specified torque

 Parts that cannot be reused after being used)

Suspension System Automobile Axle (SF/4WD)

 Front Speed Reducer (Change of Axle Shaft Oil Seal)

SA-64

5.

Mount on the upper front drive axle shaft sleeve,

Coat the bolt thread with thread locking agent.

Fastening torque

88N
m

4.

Mount on the new oil seal-front half-shaft:

Press in the new oil seal with the special service tool until it

flush with the outer ending of the oil seal, coat moderate

lubricant on the lips of the oil seal.

6.

Mount on the front long semi-axis and the front minor

half-shaft.

(a)

Mount the new snapping ring on the half-shaft.

(b)

Mount on the long semi-axis and the minor half-shaft

with the special service tool.

Suspension System Automobile Axle (SF/4WD)

 Front Speed Reducer (Change of Axle Shaft Oil Seal)

SA-65

Disassembly and Assembly of Front Speed Reducer

Element figure

front minor half-shaft

 snapping ring

bearing 31306

front speed

reducer shell

oil-guard tray

flange and dust cover

driving bevel gear oil seal

jacket

oil seal-front half-shaft

 Parts that cannot be reused after being used

specified torque

N

M

140-210

bearing 32307

driving bevel gear oil seal

speed reducer cover

adjusting washer

bearing 50KB801

47

cap-differential
bearing

78

 lock plate

adjusting washer

half axle gear thrust

gasket

planetary gear shaft

half-axle gear

planetary gear stop gasket

planetary gear

axle driven bevel gear

front differential housing

adjusting gasket

pin

70-90

retainer ring

front long semi-axis

bearing B36Z-10

 oil seal-front half-shaft

adjusting washer

snapping ring

Suspension System Automobile Axle (SF/4WD)

 Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-66

Disassembly of Front Speed Reducer

1.

Tear down the speed reducer cover:

Screw off the eight bolts connecting the speed reducer cover.

2.

Tear down the front long semi-axis and the front minor

half-shaft:

Tear down the front long semi-axis and the front minor half-

shaft from the speed reducer assembly with the special service

tool.

3.

Tear down the front drive axle shaft sleeve

Screw off the four bolts connecting the front drive axle shaft

sleeve.

4.

Tear down the oil seal ó front half-shaft;

Tear down the oil seal ófront half shaft with the special service

tool.

5.

Check the swing difference of the axle driven bevel gear;

Run the flange to measure the axle driven bevel gear with the

dial-indicating lamp.

Swing difference)

0.07mm

Max swing difference: 0.07 mm

In case the swing difference is more than 0.07 mm, change the

compete package of driven bevel gear.

Suspension System Automobile Axle (SF/4WD)

 Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-67

6.

Check the teeth-clearance of the driving bevel gear and

the axle driven bevel gear:

(a)

Install the dial-indicating lamp and ensure the axial line

of measuring head is vertical with the contact teeth face.

(b)

Run the flanges, and record the clearance values of

driving bevel gear and the axle driven bevel gear.

Specified clearance range

(0.15-0.25)mm

Remark: the inspection should be conducted at no less than

three equally divided spots on the circumference of the axle

driven bevel gear.

7.

Check the engagement trace of the axle driven bevel

gear.

(See page SA-76)

8.

Tear down the flange and dust cover:

(a)

Loosen the riveted position of main-tooth nut with the

hammer and chisel.

(b)

Lock the main-tooth flange with SST to tear down the

main-tooth nut.

Suspension System Automobile Axle (SF/4WD)

 Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

(c)

Tap down the driving bevel gear flange and dust cover

with copper bar.

SA-68

10. Tear down the inner race of bearing 31306 with SST;

If the bearing is damaged, change with a new bearing.

11. Tear down the cap-differential bearing.

12. Take out the differential.

13. Take down the outer race of bearing 50KB801 and mark

clearly the left and right parts to avoid of confusion during

reassembling.

9.

Tear down the driving bevel gear oil seal and the oil-

guard tray:

(a)

Tear down the oil seal from the driving bevel gear with

SST.

(b)

Take out the oil-guard tray.

right

left

left

Suspension System Automobile Axle (SF/4WD) 

Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

14. Tear down the adjusting gaskets and clearly mark the left

and right to avoid of confusion during re-assembling.

right

SA-69

15. Tear down the driving bevel gear.

Inspection on and Change of Front Speed

Reducer

1.

Change the bearing 32307 on driving bevel gear

(a)

Press out the inner race and roller assembly of bearing

32307 with the special service tool.

(b)

Press in the new inner race and roller assembly of bearing

32307 with SST.

2.

Change the outer race of bearing 32307:

(a)

Tap down the outer race of bearing 32307 with the copper

bar and hammer.

(b)

Press in the new outer race of bearing 32307 with the

SST.

Suspension System Automobile Axle (SF/4WD) 

 Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

.

SA-70

4.

Tear down the inner race and roller assembly of the two

bearings 50KB801 from the differential housing.

Tear down the inner race and roller assembly of bearing

50KB801 with SST.

5.

Tear down the axle driven bevel gear:

Tear down the bolts and lock plate by tapping lightly the axle

driven bevel gear with the copper until tear them down.

3.

Change the outer race of bearing 31306:

(a)

Tap down the outer race of bearing 31306 with copper bar

and hammer.

(b)

Press in the new outer race of bearing 31306 with SST.

Remark: the inner race of the bearing should be changed with

the outer race together.

6.

Differential disassembly

(a)

Tap out the pin with SST.

Suspension System Automobile Axle (SF/4WD)

 Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)