Great Wall Hover. Service Manual - part 17

13. Place an adjusting shim in the position of front

reducer housing side bearing and close to exterior.

14. Install the other adjusting shim and the bearing

outer race of another side with the differential

assembly into the front reducer housing.

Remarks: Ensure the selected adjusting shim has

not gap with front reducer housing.

15. Rotate the driven bevel gear to make the differ-

ential assembly closed to the front reducer housing.

16. Use the dial indicator to measure the tooth side

gap between the drive and driven bevel gear.

The rational range of gap is: 0.15-0.25mm.

If the measured gap is beyond the range, then adjust it by

adding or reducing the thickness of shim. ( When add in

one side, the other side should be reduced with same

thickness)

Caution: Ensure the selected adjusting shim is

without clearance form front reducer housing.

17. Adjust the pre-applled axial load of side bearing.

a. Remove two adjusting shim, remeasure the thickness of two

adjusting shims.

b. Install the new adjusting shim with thickness 0.06-0.09mm

more than that of removed adjusting shim, then install it with

the differential in the reducer housing.

c. Remeasure the tooth side clearance between the drive bevel

gear and driven bevel gear.

Rational range of clearance: 0.15-0.25mm

Remarks: If the measured gap is beyond the range, then adjust

it by adding or reducing the thickness of shim. ( When add in

one side, the other side should be reduced with same

thickness)

Caution: Ensure the selected adjusting shim has not the

clearance with the front reducer housing.

18. Install the bearing gland of both sides and use

the wrench to tighten it to the specified torque.

specified torque : 90-115N

m

Remarks: Distinguish the left and right during assembly.

19. Use the torque measuring meter to measure the

total pre-applied load of front reducer.

specified torque : 1.8-2.4N

m

sound contact

large end contact

toe contact

select the adjusting washer which can make the drive gear close to the

driven bevel gear

select the adjusting washer which can make the drive

gear away form the driven bevel gear r

small end contact

dedendum contact

20. Check the meshing mark of drive and driven

bevel gear.

a. Paint 3-4 teeth with the red lead in three different positions

of driven bevel gear.

b. Hold the flange of drive gear; rotate the driven bevel gear in

clockwise and anticlockwise.

c. Check the contacting condition of gear tooth.If the meshing

mark of drive and driven bevel gear does not consist with

thatshown in figure, it should select the proper adjusting

washer for modification according to the detailed form of

meshing mark.

convex of driven

concave of driven bevel

d. Remove the drive bevel gear and use the special toolsto remove

           the large bearing of drive bevel gear beforereplacethe adjusting

     washer.

e.   Insert the new adjusting washer and usethespecial tools to

      press in the large bearing of drivebevel gear.

 f.    Place the adjusting washer above the large bearing on the

           drive  bevel gear, install the spacer in the reducer housing;

       install the drive gear flange andtighten the nut to the specified

           torque.

 g.   Remeasure the pre-applied load of drive gear bearing clearance

          and the total pre-applied load of reducer; ensure it meets the

          requirement.

21. Use the dial indicator to measure the axial and

radial run-out tolerance of . Drive bevel gear flange.

Max. Axial runout : 0.1mm

Max. Radial run-out tolerance: 0.1mm

Remarks: It should check the big and small bearing of drive

bevel gear  when the runout is more than 0.1mm.

22. Rivet the nut of drive bevel gear.

23. Use the bolt coated with screw lock agent toconnect

the clump weight bracket welded assembly to the front

reducer housing and tighten it to the specified torque.

Specified torque : 20-26N

m

24.Use the bolt coated with screw lock agent to

connect the clump weight assembly to the clump

weight bracket assembly and tighten it to the speci-

fied torque.

Specified torque : 20-26N

m

The amount of screw lock agent could cover the screw.

25.Use the pneumaticto screw two studs on the correspon

ding screw hole on the front axle housing until the

limitation.

26. Coat the plane of front axle housing with the

continuous 1596 silicon rubber plane sealant, scrape

it to level by plate.

Caution: Avoid the screw hole when paint the sealant; prevent

the sealant enters into the screw hole.

27. Install the front reducer assembly on the front

drive axle housing and screw on the hexagon bolt and

spring washer combination; cap the spring washer on

the stud, tighten the nut to the specified torque.

(The screw of all bolts should be precoated with screw lock agent)

The specified tightening force of hexagon bolt and spring washer

combination, stud and nut should be: 18-25N

m

Caution: The bolt should be tightened in diagonal sequence

evenly; check the reducer housing and axle housing contacting

surface for gap; check the sealant from break. It should

remove the reducer for reinstallation if has the gap or break.

28. Screw the oil filling plug with washer on the front

drive axle.

Caution: Do not tighten it.

29. Screw the oil drain plug on the front drive axle.

Specified torque : 30-35N

m

30. Use the special tools to install the major semiaxle

oil seal in the front axle tube.

Caution: Precoat the lip of oil seal with thin lithium base grease

and the oil seal should be installed in position.

 (It should coat the screw of the stud which is screwed

in the front axle housing with the screw lock agent, and

the amount should be just can cover the screw which is

screw in the front axle housing)

Caution: The position of stud should consist with that before

disassembly.

31.Use the special tools to install the needle bearing in

the major semiaxle.

32.Use the special tools to install the major semiaxle

bearing by press..

33. Use the circlip pliers to install the circlip to clamp

the bearing inner race of major semiaxle.

34.Insert the spline on small end of major semiaxle

into the spline of front reducer half axle gear; use

the brass rod and hand hammer to knock the major

semiaxle into the front reducer.

Caution: Does not damage the inside needle bearing.

On spline of large end of major semiaxle when

knock in the major semiaxle.

35.Use the circlip pliers to install the circlip in the

flange and clamp the major semiaxle bearing outer

race.

36. Push the mechanical wheel of separator into

theneedle bearing inner race in major semiaxle until

can not move.

special tools

special tools

special tools

electric clutch detector

37. Detect the electric clutch assembly .

a. Measure the clearance between the shift fork and shift fork

sleeve.

Range of clearance : 0.2-0.4mm
It should replace the electric clutch assembly and shift fork

sleeve when the clearance is not in the range.

b. Connect the electric clutch assembly to the electric clutch

detector and power the electric clutch detector with 220V
power supply to test the electric clutch (Before the test,
adjustthe test controller status to make the motor starting time
is 3s ,the time form found the actuator is not in position to
restartingis 2.5s and the time of controller to redrive the
electric clutch is2s)  The motor starts for 3s when the gear
switch is shifted form 2WD to 4WD, the lamp flashes at the
same time, the clutch is in 4WD status, the indicator lamp is
light always. If does not reach the 4WD status in the first
time, then the controller restarts it for 2s after 2.5s delay, the
lamp flashes at the same time; if it is still not in position, then
the indicator lamp flashes twice continuously, the indicator
lamp is extinguished for 1s, the motor is stopped. That means
the electric clutch is unqualified and should be replaced by the
qualified product. The motor starts for 3s normally when the
clutch is shifted form 4WD to 2WD, the lamp flashes at the
same time, when the clutch is in 2WD status, the indicator
lamp is extinguished always. If does not reach the 2WD status
in the first time, then the controller restarts it for 2s after 2.5s
delay, the lamp flashes at the same time; if it is still not in
2WD status, then the indicator lamp flashes twice
continuously, the indicator lamp is extinguished for 1s, the
motor is stopped.
That means the electric clutch is unqualified and should be
replaced by the qualified product.

38. Cover the shift fork sleeve on the major
semiaxle spline.
39. Install the separator housing on the front axle
tube flange and use the bolt to tighten it to the
specified torque 

 (The bolt should be precoated

with the screw lock agent and the amount should be
just can cover the complete screw)

specified torque : 90-110N

m

Caution: Before installation, remove the foreign material on
two matching surfaces of separator housing and front axle
tube flange; and precoat the 1596 silicon rubber plane sealant
on the front axle tube flange. Caution: Prevent the sealant
from entering into the screw hole.

40. Press in the plastic vent tube on the electric
clutch housing and front axle tube.
41. Install two location pins in the location pin hole
of electric clutch housing respectively.
42. Coat the connecting surface of electric clutch
housing and electric clutch with 1596 silicon rubber
sealant uniformly; level it by plate.
Caution: The connecting surface should be cleaned
and must not have the oil and other foreign
matters. The sealant must not enter into the elec-
tric clutch housing and screw hole.

44.Insert the clip into the vent tube bracket.

45. Clamp the vent tube  clip on the front drive axle

vent tube connecting tube assembly.

46. Connect the front drive axle vent tube connecting

tube assembly to three ports, the front axle tube,

electric clutch and electric clutch housing.

43. Install the electric clutch assembly on the electric

clutch housing.

a. Make the shift fork cross on the shift fork sleeve.

b. Align the location pin hole of electric clutch with two

location pins, and tighten it by bolt; tighten the bolt to the

specified torque. (Precoat the medium screw of bolt with one

or two drop of screw lock agent)

Specified torque : 23-26N

m

47. Screw off the oil filling plug of front drive axle

housing, then fill the axle housing with the  hypoid

gear oil; then tighten the oil filling plug to the speci-

fied torque.

Gear oil number: GL-5

Filling amount: The oil level is flush with the lower edge of oil filling

port.

specified torque : 140-150N

m

48. Fill the electric clutch housing with the gear oil ;

then tighten the oil filling plug to the specified

torque.

Gear oil number: GL-5

Filling amount: The oil level is flush with the lower edge of oil filling

port.

Specified torque: 140-150N

m

Installation of front reducer assembly

1. Install the front drive shaft assembly on the reducer assembly (Refer to “Assembly of Front

Drive Shaft”)

assembly mark

2. Use the jack to support the front drive axle, insert the

hanger plank bolt with washer and tighten it to the speci-

fied torque.

Remarks: Do not insert the previous two bolts in reverse direction.

Specified torque : 200-220N

m

3. Use the bolt to connect the front drive axle flange to

the drive shaft according to the mark made before

disassembly, and tightens it to the specified torque.

Specified torque : 73-83N

m

4. Install the beam under the front drive axle; tighten

the connecting bolt of the beam to the specified torque.

Specified torque : 73-83N

m

5. Connect the power sire connector of the electric

clutch to the power output wire of the car.

Axle drving assembly

Removal of semiaxle

1. Remove the wheel.

2. Disconnect the manual brake pull-wire from the

    carriage; loose the small bracket.

3. Remove the brake caliper; remove the brake disc .

4. Remove the rear halfaxle assembly from the rear

    axle housing

a.  Use the bolt to connect the special tools to the semiaxle flange

  surface.

b.  Use the hammer of special tools to remove the rear axle.

brake caliper assembly

brake disc

circlip

oil seal base

bearing

oil seal

oil seal pressing block

parking brake assembly

rear axle

N 

m:   Specified torque

Used component which can not be used any more.

pull-wire assembly

5. Remove the circlip from the halfaxle assembly.

Use the circlip pliers to remove the circlip.

limitation

limitation

Check and repair of rear axle components

1. Check the rear axle and flange for wear, damage

and run-out.

Max. Run-out of axle:   2mm

Max. Run-out of flange:   0.2mm

It should replace the rear axle if the rear axle or flange is worn or

damaged, or the measured run-out is beyond the specified value.

2. Check the external oil seal

    a. Check for the wear or damage; especially for the lip of oil seal.

    b. Replace it if necessary.

3. Check the bearing and oil seal holder

Check for wear and damage, replace it if necessary.

4. Remove the bearing and oil seal holder

    a. Move the brake and oil seal pressing block to the limit position

       along flange direction; move the external oil seal to the limit

       position of oil seal.

    b. Place the hook of the special tools in sequence, the position is

        shown as figure; make the hook holds the bearing tightly; then

        use the bolt to connect the hook to the hammer fixedly;  at last,

        place it on the pad with halfaxle spline end facing ground.

    c. Hold the hammer to beat downwardly with force for several

        times to remove the bearing and oil seal holder.

Caution:   Do not damage the oil seal .

5. Install the new external oil seal

a. Clean the semiaxle.

b. Coat the lip of external oil seal with proper HP-R grease.

Caution: When install the oil seal, the lip of oil seal must not

contact the semishaft to avoid scratching the oil seal .

6. Replace the bearing and oil seal holder

a. Heat the oil seal pressing block in 22# engine oil to 100

.

Caution: The end of oil seal pressing block with larger chamfer

faces the halfaxle spline. Install it immediately after taken out.

b. Use the hydraulic press to install the new bearing and new oil

    seal pressing block by press.

7. Install the circlip

Use the circlip pliers to install the new circlip in the slot of semiaxle.

8. Check the inner oil seal for wear or damage.

9. Remove the inner oil seal

Use the special tools to remove the inner oil seal.

10. Install the new inner oil seal

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

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

Installation of rear axle

1. Install the halfaxle assembly in the axle housing

a. Use the kerosene to clean the semiaxle and inner oil seal holder.

b.  Assemble the halfaxle spline and halfaxle gear spline firstly,

    then use the brass rod to beat knock the halfaxle assembly into

    the axle housing.

Caution:  Protect the lip of inner external oil seal and pull-wire

assembly during assembly; do not damage the oil sleeve

assembly; align the brake bolt with the flange bolt of rear axle.

Tightening force:   95-105N

m

2. Install the rear brake disc

3. Install the brake caliper

Tightening force:   95-105N

m

4. Connect the manual brake wire.

5. Install the wheel.

6. Discharge the air of brake system by test.

special tools

special tools

brake disc

axle housing

flange

halfaxle

assembly

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

b.Use the press machine and special tools to install the reused

   adjusting washer and new rear bearing on the drive bevel gear.

12. Replacement of front and rear bearing outer race

      of drive bevel gear.

a. Use the hammer and brass bar to knock out the front and rear

    bearing.

b. Use the press machine and special tools to install the new

    bearing outer race by press.

13. Remove the side bearing form the differential

     housing.

Use the special tools to pull out the side bearing from the differ

ential housing.

14. Remove the driven bevel gear

a.Remove the connecting bolt and lock plate of driven bevel gear.

b.Make the assembly mark on the driven bevel gear and differen

    tial housing.

c.Use the rubber hammer or brass rod to knock down the driven

   bevel gear.

Assembly of reducer

1. Install the bearing outer race of drive bevel gear.

(Refer to Step 12 in “Disassembly of Reducer”)

special tools