Great Wall service chassis and body Manual - part 19

TF-17

1.25-1.75mm

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3

1

12.70mm

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3

2

4

4

2

1

5

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7

8

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(e)

In the case that the input shaft is taken apart, what need

to do is to fill the needle bearing as shown in the drawing

and press it in the input shaft, meanwhile, press the new

sliding bearing to complete the whole input shaft assembly.

(f)

Raise the planetary mechanism assembly to mount it into

the input shaft assembly; encase the thrust gasket and

press in the bearing through the input shaft end. Encase

the fixed bearing in the snapping ring groove of the input

shaft with a snapping ring.

(g)

If the transfer box front body is taken apart, press the new

located pin in the front body, and the pressing dimensions

are shown in the drawing.

(h)

Put down the oil seal as the drawing shows, and press it

in the front body according to the dimensions shown in

the drawing.

(i)

Put down the front body assembly on two wooden blocks

in the way that the coupling face of the front body and the

housing faces upward, so that there is clearance left

between the input shaft assembly and the worktable. Put

down the input shaft and planetary mechanism assembly

in the front body, in which the input shaft shall be

downward. Open the long ends of the snapping ring to

encase input shaft and planetary mechanism assembly

until the snapping ring enters into the external snapping

ring groove of the bearing.

(j)

Coat the sealing glue of 1.6mm on the coupling locations

of the front end cover and transfer box assembly, The

glue shall be coated continuously without break and steer

clear of the screwed hole.

(k)

Screw up the six bolts.

Fastening torque

(27
46)N
m

6.

Assembly  of front output shaft

Mount the following parts:

(a)

If the dust cover is taken apart, mount it by pressing.

(b)

Encase the input shaft, sealing ring, gasket and nuts in the

transfer front housing.

(c)

Insert the torque arm of T-13-54-002 in the flange hole to

screw up the nuts.

Fastening torque

(203
244)N
m

Transfer Box

 Transfer Box Assembly

1. needle bearing

2. bearing roller

3. input shaft

1. locating pin

2. oil seal

3. front body of transfer box

4. snapping ring

1. fork-type flange

2. dust cover

3. fork-type flange assembly

4. transfer box housing

5. output shaft

6. oil seal

7. washer

8. nut

TF-18

1. deceleration gear

2. output shaft

3. insert face of toggle fork

4. deceleration toggle fork assembly

5. pin, contact roller and sleeve assembly

6. deceleration shift toggle fork

7. plastic sleeve

8. contact roller

9. pin

1

2

6

7

8

9

3

N

O

P

Q

R

S

T

Transfer Box

 Transfer Box Assembly

7.

Deceleration shift parts assembly

The mounting process is as follows:

(a)

If the parts are taken apart for change, assemble the shift

toggle fork assembly with a new pin-contact roller

assembly. Press the pin-contact roller in the deceleration

fork hole until the detent passes the hole completely and

seizes the right location. Ensure that the contact roller can

run freely.

(b)

Mount two inserted faces of toggle fork on the decelera-

tion toggle fork assembly.

(c)

Engage the deceleration fork assembly and deceleration

gear sleeve and put them in the housing, and the decelera-

tion gear sleeve shall be put in the planetary mechanism

assembly that is assembled already. Mount the rear

output shaft and joint the bearings at the ends of output

shaft and input shaft as well as the spline of the gear

sleeve.

Remarks: the output shaft assembly can be delayed until the oil

pump is mounted on the output shaft. The oil pump may be

dipped into the lubricant through the oil pump screen, turn the

output shaft in clockwise from the output shaft direction to see

whether there is lubricant pumped out so as to check whether

the oil pump can work normally or not. The parts mounted

readily may be encased in the transfer box housing as an

assembly

8.

Oil pump assembly

 Ensure the parts of oil pump are completely lubricated when

assembling, and the oil can be pumped out from the conical

hole of the oil pump front cover. The mount of oil pump is as

follows:

(a)

Mount the pin on the rear output shaft.

(b)

Slide the oil pump assembly on the rear output shaft

along with the pin.

(c)

Put the gripping hoop at the end of oil pipe that is

mounted on the oil nozzle of the pump housing, screw up

the gripping hoop.

1. filter

2. oil pump hose

3. gripping hoop

4. oil pump assembly

5. output shaft

6. pump pin

7. output shaft and pump assembly

5

4

TF-19

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9

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10

11

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Transfer Box

 Transfer Box Assembly

9.

Assembly of driving chain

The parts assembly process is as follows:

(a)

Put the driving chain sprocket at the rear end of the output

shaft, and the driven chain sprocket is put at the rear end

of the front output shaft on the worktable after the transfer

box housing assembly mount.

(b)

Mount the chain on the sprocket.

(c)

Holding the two chain sprockets parallel with the transfer

box in the space that the chain on the two sprockets are

straightened, and encase the chain and sprocket assembly

through the output shaft, it is required to run the chain

sprocket slowly to ensure that they engage with the front

output shaft and the spline.

(d)

Mount the gasket and snapping ring on the front output

shaft.

10. Shift locking element assembly

The parts mounting process is as follows (for the electric shift

transfer box):

(a)

Mount the return spring and locking hub on the locking

sleeve and fasten them with snapping ring to finish the

2W-4W locking sleeve assembly.

(b)

Encase the shift guide shaft in the blind hole of the

housing through the deceleration toggle fork assembly

that is already assembled.

(c)

Mount the shift toggle fork on the 2W-4W locking sleeve

assembly, which will slide through the shift guide shaft

and rear output shaft.

(d)

Joint the combined external gear sleeve spline and the

rear output shaft spline as well as the 2W-4W locking

sleeve.

1. output shaft

2. driving chain sprocket

3. driven chain sprocket

4. washer

5. snapping ring

6. transmission chain

7. front output shaft

1. output shaft

2. shift engagement

sleeve assembly

3. locking sleeve

4. return spring

5. engagement sleeve

6. snapping ring

7.  shift lock hub

8. clutch assembly

9. fastening snapping ring

10. shift guide shaft

11. toggle fork

TF-20

1

convex plate

groove

2

3

4

5

6

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2

3

4

5

6

7

1. electric shift convex plate

2. torsion spring

3. shift shaft

4. gear down shift fork assembly

5. shift fork

6. gear shifting shaft

Transfer Box

 Transfer Box Assembly

1. clutch washer assembly

2. snapping ring

3. ball bearing

4. transfer box rear body

5. nut

6. oil seal

7. bearing

8. needle bearing

11. Rear cover Assembly

Mount the parts into the rear cover according to the following

process:

(a)

Locate the rear cover on the suitable press machine, the

coupling face of the rear cover shall face upward and

parallel with the work face of the press machine.

(b)

Locate the needle bearing, of which the marked end

facing upward, and press it in the rear cover until the

upper end of needle bearing is 40.47

40.97 lower than

the coupling face of the rear cover that matches with the

front housing.

(c)

Press the ball bearing in the rear cover and mount the

snapping ring well.

(d)

As for the electric shift transfer box, the parts shall be

encased according to the following process:

(1)

Confirm the four O-rings are set on the clutch

washer assembly (one O-ring is located on the coil,

the other three on studs).

Mount on the clutch coil assembly, of which the

wire and stud shall protrude out the rear cover, take

notice not to damage the wire when screwing up the

nuts.

Fastening torque

(8
11)N
m

(2)

Encase the motor bearing and oil seal in the rear

cover.

(e)

As for the electric shift transfer box, encase the as-

sembled electric shifting cam group and clutch shell in

the process as follows:

(1) Put down the electric shifting cam group as shown in

the drawing.

(2) Hold the shift guide shaft downward and raise lightly

the toggle fork assembly. Run the electric shifting

cam group in place, so that the contact roller on

deceleration toggle fork assembly enters in the groove

of shifting cam, and the projecting part of lock

toggle fork is at the rear end of the shifting cam, and

then take reduce the component elements in the

transfer box housing, meanwhile, joint the shift

shaft on the pin in transfer box housing.

(3) Locate the clutch shell well through the shift exter-

nal gear sleeve and mount on the snapping ring.

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