Great Wall Pegasus (2006 year). Service Manual - part 13

SA-87

6.

Tear down the oil seal and oil-guard tray:

(a)

Support the face at the teeth end of the driving bevel gear

to tear down the oil seal with SST.

(b)

Take out the oil-guard tray.

7.

Tear down the inner race and roller assembly of bearing

7306E;

Tear down the inner race and roller assembly of bearing 7306E

with SST.

8.

Tear down the driving bevel gear;

Tear down the driving bevel gear, which is mounted with

adjusting washer and inner race of bearing 7306E, together

with another adjusting washer and jacket

9.

Change the bearing 7306E:

(a)

Press out the bearing from the driving bevel gear with

pressure machine and SST.

(b)

Mount the new inner race and roller assembly of bearing

7306E on he driving bevel gear with pressure machine

and SST.

Suspension System and Automobile Axle (Rear)

(Dismantle of Rear Speed Reducer)

SA-88

10. Change for the bearing 7306E and the outer race of

bearing 7607E:

(a)

Tap out the bearing outer race with hammer and copper

bar.

(b)

Press in the new bearing outer race with pressure ma-

chine and SST.

12. Tear down the axle driven bevel gear.

(a)

Tear down the lock plate and bolts on the axle driven

bevel gear.

(b)

Mark the assembly marks on the axle driven bevel gear

and the differential housing.

(c)

Tap down the axle driven bevel gear with rubber hammer

and copper bar.

11. Tear down the inner race and roller assembly of bearing

200719E from differential.

Pull out the inner race and roller assembly of bearing 200719E

from the differential housing with SST.

Suspension System and Automobile Axle (Rear) 

(Dismantle of Rear Speed Reducer)

SA-89

Assembly of Rear Speed Reducer

1.

Mount the inner race and roller assembly of bearing

7306E, oil-guard tray and oil seal.

(a)

Put the inner race and roller assembly of bearing 7306E in

the speed reducer housing, and put the oil-guard tray on it.

(b)

Coat the lithium base grease on the position of speed

reducer where oil seal locates and on the lips of oil seal,

align the oil seal and press it to mount.

2.

Mount the flange and dust cover assembly

Encase the flange and dust cover assembly in the speed reducer

housing, then flat it by hand.

3.

Mount the driving bevel gear:

(a)

Put the adjusting washer, jacket on the driving bevel gear,

which is mounted with adjusting washer and inner race

and roller assembly of bearing 7607E, then encase the

driving bevel gear in the speed reducer housing.

(b)

Screw up the nuts to tighten the flange, flat washer and

the driving bevel gear with SST, and the thread locking

agent is required to be coated when screwing.

Tightening moment

(140
160)N
m

4.

Measure the pre-tightening torque of the bearing:

New bearing

(1.2-1.7)N
m

The reused bearing

(0.9-1.3)N
m

Remark: if the requirement is not satisfied, change the adjust-

ing washer under jacket until the requirement is satisfied.

(a)

If the measure value is smaller than the standard one,

reduce the thickness of adjusting washer;

(b)

If the measure value is larger than the standard one,

increase the thickness of adjusting washer.

Suspension System and Automobile Axle (Rear) 

(Dismantle of Rear Speed Reducer)

SA-90

5.

Mount the axle driven bevel gear on the differential housing:

(a)

Mount on the lock plate and screw up the bolts to the

specified torque.

Tightening moment

(65-95)N
m

Notice: screw up the bolts diagonally.

(b)

Tighten the lock plate with hand hammer and flat head

pinch.

6.

Mount the inner race and roller assembly of bearing

200719E;

Mount the bearing inner race and roller assembly in differen-

tial housing with the pressure machine and SST.

7.

Mount the differential assembly;

Mount the differential in the speed reducer housing.

When mounting the differential that hasnít changed the inner

race and roller assembly of bearing 200719E, ensure the outer

race of the left and the right bearings that has disassembled

should match with their inner racers respectively.

8.

Mount the adjusting ring;

Adjust the clearance between the driving bevel gear and the

axle driven bevel gear to the moderate size. And press the

bearing outer race to flatten it with adjusting ring, and then

screw up moderately.

Notice: the two adjusting rings should be adjusted

synchronically in the movement of same direction.

Suspension System and Automobile Axle (Rear) 

(Dismantle of Rear Speed Reducer)

SA-91

9.

Mount on the differential bearing cover:

(a)

Align the assembly marks on differential bearing cover

and the speed reducer housing, and press down the

differential bearing by hand.

(b)

Mount on the double-eared stop washer and the hex nut.

10. Adjust the clearance between the driving bevel gear and

the axle driven bevel gear

(a)

Screw up the hex nuts connecting the differential bearing

cover to the specified torque.

Tightening moment

(80-110)N
m

(b)

Attach the measuring meter seat on the face of speed

reducer housing with the measuring head touching the

teeth face, run the axle driven bevel gear with hand to

measure the teeth engagement clearance, and then com-

pare it with the clearance value in step (d) to decide the

order of the adjusting ring tightening according to the

values.

(c)

Adjust and screw up the adjusting rings with SST.

Tightening moment

(115-135)N
m

(d)

Check the engagement clearance again until the clear-

ance value of the three spots evenly locates on the

circumference of axle driven bevel gear. Otherwise,

adjusting ring adjustment is suggested.

Engagement clearance

(0.13-0.25)mm

Suspension System and Automobile Axle (Rear) 

(Dismantle of Rear Speed Reducer)

SA-92

tooth top engagement

select the adjusting washers that make the main teeth apart from the axle driven bevel gear.

teeth convex

                 =

teeth concave

11. Check the engagement situation of the axle driven bevel

gear and the driving bevel gear:

(a)

Coat four teeth locating on different spots of axle driven

bevel gear with red powder.

(b)

Rotate the axle driven bevel gear in different directions.

(c)

Check the teeth engagement situation.

The teeth trace of axle driven bevel gear should satisfy

this requirement. If not, select the suitable adjusting

washer to correct according to the poor teeth engagement

situation.

Washer thickness (unit: mm) see the following table:

Suspension System and Automobile Axle (Rear)

 Rear Speed Reducer (Disassembly of Speed Reducer)

heel end engagement

toe end engagement

teeth root engagement

select the adjusting washer that make the main teeth

contact the axle driven bevel gear more closer.

Group NO.

Washer thickness

Group NO.

Washer thickness

1

1.60

7

1.90

2

1.65

8

1.95

3

1.70

9

2.00

4

1.75

10

2.05

5

1.80

11

2.10

6

1.85

12

2.15

SA-93

12. Lock the double-eared stop washer to mount the stop

gasket and bolts:

(a)

If the engagement trace satisfies the requirement, lock

tightly the double-eared stop washer with hand hammer

and pinch.

(b)

Mount on the stop gasket, spring gasket and bolts, and

then screw up the bolts.

Tightening moment

(18-26)N
m

(c)

Tap in he adjusting ring with the pinch and hammer.

13. Measure the total preload:

Preload: (1.8-2.4) N

m

If the preload is beyond the specified range, change the gas-

kets between the jacket and bearing 7607E, until they meet

the requirement.

(a)

If the preload is larger than the specified value, change

the adjusting washer.

(b)

If the preload is smaller than the specified value, screw up

the nuts again slowly but not exceed 160N.m.

Notice: if the screwing torque exceeds the max torque,

change the adjusting washer and repeat the preload

process. Do not screw back the main-tooth nut to reduce

the preload.

14. Check and adjust the flange bouncing

(a)

Attach the dial indicating lamp seat on the speed reducer

housing with the measuring head contact the flange face,

run the flange to observe the swing out range of the dial

indicating lamp hand.

Radial full bouncing tolerance

0.10mm

Remark:  the two bouncing values should be controlled within

0.10 mm, as for the parts of bounce exceeding the tolerance,

loosen the nut-driving bevel gear to assembly them in another

angle, measure the bounce value again. Observe carefully the

swing direction of the hands, which can be referred when

changing the locations of flange and the driving bevel gear. If

the requirement cannot be satisfied after several trials, change

the new flanges until the requirement is met.

Suspension System and Automobile Axle (Rear)

 Rear Speed Reducer (Disassembly of Speed Reducer)

30mm

15. Rivet the driving bevel gear nuts.s

SA-94

Mount of Rear Speed Reducer and

Differential Assembly

1.

Mount the speed reducer and differential assembly on

the rear axle housing.

Tightening moment

(18-26)N
m

Remark: in case the sealing gasket is mounted, it should be

checked to see whether it is damaged before mounting, if

damaged, change with the new sealing gasket, and the dam-

aged sealing gasket should be clear away; if no sealing gasket

is mounted, no mount is required to mount. Clean the contact

face of the mounted axle housing and coat it with silicon-

rubber plain sealing agent.

2.

Connect the drive shaft and flange well and be careful to

align the assembly marks marked when disassembling.

Tightening moment

(69-79)N
m

Screw up the oil drain plug with the Tightening moment

of (140-150)N

m

 Mount on the half-shaft and the brake assembly to adjust the

brake oil path so that the wheel brake pump is filled with brake

liquid.

3.

Inject in the heavy-duty oil.

Oil brand: heavy-duty oil graded GL-5;

Viscosity: SAE 85W/90

Oil volume: add the oil until it overflows from the oil filler

outlets.

Screw up the oil-filling plug.

Tightening moment

(140-150)N
m

Suspension System and Automobile and Axle (Rear)

 Rear speed reducer (Mount of Rear Speed Reducer and Differential Assembly)

SA-95

Rear Differential

Element Figure

half axle gear
thrust gasket

differential housing

pin

planetary
gear shaft

planetary gear
stop gasket

half-axle gear

planetary gear

1.

Tear down the speed reducer and the differential

assembly.

2.

Tear down the differential from the speed reducer and

differential assembly.

Change of Differential Parts

1.

Disassembly of Differential

(a)

Tap out the pin with hammer and pinch.

Suspension System and Automobile Axle (Rear)

 Rear differential

(b)

Tear down the planetary gear shaft, the planetary gear,

planetary gear stop gasket, half-shaft gear and half axle

gear thrust gasket.

SA-96

2.

Assembly of Differential

(a)

Put the half-axle gear thrust gasket on the half-axle gear

and then encase them in the differential housing.

(b)

Encase the planetary gear stop gasket, planetary gear and

encase the planetary gear shaft.

(c)

Check the clearance between the half-axle gear thrust

gasket and the differential housing.

Remark: the half-axle gear and the planetary gear should run

freely without stagnant, push the planetary gear inside, then

measure the clearance between the half-axle gear thrust gasket

and the differential housing with dial indicating lamp.

Reasonable clearance range: (0.45-0.75)mm.

Remark: if the clearance value fails to fall within the above

range, change the half axle gear thrust gasket, at the same time,

ensure the left and right half axle gear thrust gasket are same

in thickness.

(d)

Tap the pin in the pinhole, and rivet the end of the pinhole

so as to prevent from the pin missing.

Mount of Differential

1.

Encase the differential assembly in the speed reducer

housing.

2.

Mount the speed reducer and differential.

Suspension System and Automobile Axle (Rear)

 Rear differential

SA-97

Suspension System and Vehicle Axle

 Rear Suspension (Leaf Spring Type)

Rear suspension(leaf spring)

Leaf spring and shock absorber

N

m

specified torque

90

 10

110

 10

liner

rront ear pin

rear ear pin

liner

u-shaped bolt

spring seat

90

 10

Dismantle of leaf spring and vibration

damper

1.

Raise the vehicle body with a jack and support it with a

bracket;

(a)

Raise the vehicle body with a jack and support it with a

bracket;

(b)

Lower the axle housing until the leaf spring is loosened

to the degree there is no tension existing. Keep the leaf

spring in such status.

2.

Tear down the vibration damper.

SA-98

3.

Tear down the U-shaped bolt;

(a)

Tear down the mounting nuts of U-shaped bolts.

(b)

Tear down the spring seat;

(c)

Tear down the U-shaped bolts.

4.

Tear down the leaf spring;

(a)

Tear down the mounting nuts of front ear pin;

(b)

Tear down the front ear pin;

(c)

Disconnect the leaf spring from the bracket;

(d)

Tear down the rear ear pin and the leaf, and then take

apart the leaf spring.

Change of leaf spring

1.

Loosen the spring clip;

Loosen the spring clip with a chisel.

2.

Tear down the central bolt;

Clamp the spring with a table vice at the position near to the

central bolt to take apart the central bolt.

3.

Change the spring clip if necessary;

(a)

Cut the rivet-head with a drill-head and tap the rivet out.

(b)

Tap a new rivet in the hole of leaf spring and spring clip

and rivet it with pressure machine.

Suspension System and Vehicle Axle

 Rear Suspension (Leaf Spring Type)

SA-99

4.

Mount the central bolt of leaf spring;

(a)

Align the bolt with the spring hole after clamping the

steel spring with a table vice.

(b)

Mount on and tighten the spring central bolt.

Tighten torque:

(50 
 5)N
m

5.

Bend the spring clip to a correct angle.

Bend the spring clip to the correct position with a hammer.

Mount of leaf spring

1.

Mount the steel spring;

(a)

Encase the front end of leaf spring into the front bracket;

(b)

Mount on the bolt of front ear pin.

(c)

Screw on the nut of front ear pin with fingers;

(d)

Encase the rear end of leaf spring into the rear bracket and

mount on the rear ear pin.

(e)

Mount on the leaf and tighten the nuts with fingers.

2.

Mount the U-shaped bolt;

(a)

Mount the U-shaped bolt on the axle housing.

(b)

Mount the spring seat and nut under the steel spring.

(c)

Tighten the mounting nut of U-shaped bolt.

Tightening moment: (110

 0)N
m

Suspension System and Vehicle Axle

 Rear Suspension (Leaf Spring Type)

SA-100

Suspension System and Vehicle Axle

 Rear Suspension (Leaf Spring Type)

Remark: Tightening U-shaped bolt to the degree that the

protruding lengths of all U-shaped bolts under the spring seat

are the same.

3.

Mount the rear vibration damper

(a)

Connect the vibration damper to the vehicle frame with

bolts and then tighten the bolts.

Tightening moment: (25

)N
m

(b) Connect the vibration damper to the sprint seat with bolts

and tighten these bolts.

Tightening moment: (25

)N
m

4.

Keep the suspension frame in stable status;

(a)

Mount on the wheel;

(b)

Remove the bracket, and make the vehicle bounce verti-

cally for several times so as conduce it in stable status.

5.

Tighten the front ear pin and rear ear pin;

Tighten the nuts of front ear pin;

Tightening moment: (90

 0)N
m

Tighten the nuts of rear ear pin;

Tightening moment: (90

 0)N
m

all lengths of bolts protruding are same

BR-1

Braking System

Notice .......................................................................... BR-2

Troubleshooting .......................................................... BR-2

Inspection and Adjustment .......................................... BR-5

Master Cylinder ........................................................... BR-8

Vacuum Booster .......................................................... BR-10

Front Brake ................................................................. BR-13

Dr

.......................................................................... BR-13

SF .......................................................................... BR-20

Rear Brake .................................................................. BR-26

Dr

.......................................................................... BR-26

SF .......................................................................... BR-34

Load sensing proportion valve .................................... BR-42

Page

BR

BR-2

Braking System

 Notice and Troubleshooting

Notice:

1.

Carefully change each part where necessary because any

mistake will affect the brake system properties, and will lead

accidents during driving. And the parts to be changed must

be the same in part number or equal in quality.

2.

Keep the parts and each position clean when repairing the

braking system.

Troubleshooting

Trouble

Causes

Inspection items

Lower or soft pedal

Abrasion of brake shoe

Abrasion of brake pad

Oil leakage of braking system

Master cylinder failure

Air in braking system

Wheel-brake cylinder failure

Failure in the automatic regulator of rear brake.

Change the brake shoe; Change the brake

pad;

Repair the oil leakage;

Change the master cylinder;

Drain out the air from braking system;

Change the wheel-brake cylinder;

Repair or change the regulator

Brake stagnant

Poor adjustment of parking brake;

The bracing wire of parking brake is seized;

Poor adjustment of vacuum booster pushrod)

Failure of the drag spring or the return spring

Pipe line blockage

Brake shoe breakage or deformation

Brake pad breakage or deformation

Seizing of the wheel-brake cylinder or the brake

caliper piston

Automatic regulator breakage

Master cylinder failure

Adjust the parking brake;

Make repairing according to real situation;

Adjust the drag rod;

Change the drag spring or the return spring

Make repairing according to real situation;

Change the brake shoe

Change the brake pad

Make repairing according to real situation;

Change the regulator

Change the master cylinder

Over large braking

distance

Unsuitable tire inflation

There is oil stain or lubricant on the brake shoe or

brake pad;

Brake shoe deforms, the brake liner is worn or polished;

Brake pad deforms or is worn or polished;

Brake drum or brake disc deforms

Drag spring or return spring has trouble

The wheel-brake cylinder has trouble

The inner piston of wheel-brake cylinder is seized;

The brake pad is seized;

Inflate the air to suitable pressure;

Change the brake shoe or the brake pad;

Change the brake shoe;

Change brake pad

Change the brake drum or the brake disc;

Change the spring;

Change the wheel-brake cylinder;

Change the wheel-brake cylinder

Change the brake pad

The brake pedal is hard

but doesn

t work;

There is oil stain or lubricant on the brake shoe or

brake pad;

The brake shoe deforms, brake liner is worn or

polished, or the brake wheel is worn;

The brake pad deforms, or is worn or polished;

The piston of wheel brake pump is seized;

The vacuum booster has trouble

The vacuum degree is unsuitable

The brake pipe line is blocked

Change the brake shoe brake pad;

Change the brake shoe

Change the brake pad;

Change the wheel-brake cylinder;

Change the vacuum booster;

Make repairing according to real situation;

Make repairing according to real situation;