Great Wall Hover. Manual - part 66

Reducer

Replace the oil seal on the car

1. Disconnect the reducer from the drive shaft.

a. Make the assembly mark on two flanges.

b. Remove four bolts and nuts.

2. Remove the flange and dustproof cover assembly

3. Remove the oil seal

Use the special tools to remove the oil seal.

bearing spacer

adjusting washer

rear bearing

drive bevel gear

adjusting ring

side bearing

driven bevel gear

differential housing

locking plate

plain washer

flange

dustproof cover

oil seal

oil baffle disc

front bearing

bearing gland

stop plate

lock washer with

double ears

 N 

m:       Specified torque

 Used component which can not be used any more.

assembly mark

4. Install the new oil seal

a. Coat the lip of oil seal with the HP-R grease.

b. Use the special tools to knock in the new oil seal.

Insertion depth of oil seal:   1.0mm

5. Install the flange and dustproof cover assembly

6. Rivet the drive bevel gear nut.

7. Connect the drive shaft flange to the reducer

    flange Align the assembly mark ; then connect them

    by bolt.

Tightening force:   78

5N

m

8. Check the oil level of reducerReplace the hyperbolic

    gear oil if necessary.

     Oil number :  GL-5 hyperbolic gear

     Viscosity : SAE80W/90

Amount: Filled with oil until the oil flows out form oil filling

port.

Removal of reducer

1.Remove the oil drain plug; drain the oil from the

   reducer

2. Remove the rear axle

(Refer to Step 2 in “Disassembly of Rear Axle”)

3. Disconnect the drive shaft from the reducer

     (Refer to step 1 in “Replace the Oil Seal on Car”)

4

Remove the assembly of reducer.

special tools

insertion depth

:   1mm

assembly mark

assembly mark

Disassembly of reducer

Remarks: If the noise of differential is loud, process the follow-

ing inspection before disassembles the differential to determine

its reason. When the differential has serious problems, it can be

disassembled for repair if necessary.

1. Check the internal clearance of driven bevel gear.

If the clearance is beyond the specified range; adjust the preapplied

load of bearing or repair if necessary.

(Refer to step 13 “Assembly of Reducer”)

Standard internal clearance:   0.15-0.25mm

2. Check the intertooth contact of drive bevel gear

    and driven bevel gear.

(Refer to Step 14 in “Assembly of Reducer”)

Record the contact position of tooth.

3. Check the clearance between the thrust plate of

     axle shaft gear and differential housing.

Use the feeler to measure the clearance between the thrust plate

of axle shaft gear and differential housing.

Standard clearance:   0.45-0.75mm

It should be replaced by the proper thrust washer if the clearance

is beyond the specified range.

(Refer to Step 2 in “Replacement of Differential Components”)

4. Measure the pre-applied load of drive bevel gear

Use the torsion meter to measure the pre-applied load on the

internal clearance between the drive small gear and driven bevel

gear.

Pre-applied load:   0.4-0.6N

m

5. Total pre-applied load

Use the torsion meter to measure the total pre-applied load.

Pre-applied load :    0.9-1.3N

m

6. Remove the differential and driven bevel gear

a. Make the assembly mark on the differential bearing gland and

    reducer housing.

b.Remove two stop plates.

c.Remove two bearing glands and two adjusting rings.

d.Remove the bearing outer race.

e.Remove the differential form the reducer housing.

Remarks: Mark the label on the removed components to indi-

cate the position of reassembly.

7. Remove the flange and dustproof cover assembly

a.Use the hammer and chisel to loose the riveted part of nut.

b.Use the special tools to clamps the flange; then remove the nut.

Caution: The used nut can not be used any more.

c.Remove the flange and dustproof cover assembly.

8. Remove the oil seal

    Use the tools to pry out the oil seal.

9. Remove the drive bevel gear and spacer

     Remove the drive bevel gear, bearing and spacer from the reducer

      housing.

10. Remove the oil baffle disc and front bearing inner

      race

11. Replace the rear bearing of  drive bevel gear

      a. Use the press machine and special tools to pull out the rear

bearing from the drive bevel gear.

special tools

special tools