Great Wall Pegasus (2006 year). Service Manual - part 30

B0-87

Body

 Size of Chasis

Unit

mm

size in 2D

Safe

front

Axial spacing

2630

assuming standard

line

Mark

A,a

B,b

C,c

D,d

Name

Cab mounting hole

Cab mounting hole

Cab mounting hole

Cab mounting hole

Bore diameter

Mark

Name

Bore diameter

Cab mounting hole

E,e

central line of front wheel

B0-88

Body

 Size of Chasis

Unit

mm

size in 2D

Sing

Axial spacing

3025

front

Mark

A,a

B,b

C,c

D,d

Name

Cab mounting hole

Cab mounting hole

Cab mounting hole

Cab mounting hole

Bore diameter

Mark

Name

Bore diameter

Cab mounting hole

E,e

Cab mounting hole

F,f

central line of front wheel

assuming

standard line

B0-89

Body

 Size of Chasis

Unit

mm

size in 2D

Pegasus

Axial spacing

2760

assuming

standard line

front

central line of front wheel

Mark

A,a

B,b

C,c

D,d

Name

Cab mounting hole

Cab mounting hole

Cab mounting hole

Cab mounting hole

Bore diameter

Mark

Name

Bore diameter

Cab mounting hole

E,e

A-1

Specifications of Maintenance

and Up-keeping

page

Clutch .......................................................................... A-2

Gear box ..................................................................... A-2

Transfer box ................................................................ A-3

Drive shaft ................................................................... A-4

Suspension system and automobile axle .................... A-4

Braking system ............................................................ A-5

Steering system .......................................................... A-6

A

A-2

Clutch

Specification

Item

Specification

Fastening torque for clutch tube on master cylinder
Fastening torque for clutch tube on wheel-brake cylinder
Fastening torque for clutch pressure plate

160
190-200
5-15
0.3
0.8
0.2
0.6
5
Max misplacement

0.5

Pedal height (calculated from front wall

Pedal free stroke
Min depth of clutch-facing rivet
Max radial swing difference of clutch rib
Max radial swing difference of flywheel
Max width of wear of diaphragm spring
Max width of wear of diaphragm spring
Alignment degree of diaphragm spring end

Applicable vehicle model

Dr SF
SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ

Torsion moment

Fastening location

(N*m)

15-17
15-17
30

Applicable Vehicle model

Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ

Gearbox

Three-grade maintenance for gearbox

1.

Grade I maintenance for gear box

Grade I maintenance: Check the lubricant level to see whether the lubricant level is in alignment with the lower edge of oil

filler; if the lubricant is lower than the oil filler lower edge, add the lubricant; or the insufficient lubricant will lead to the poor

lubrication or burn-out of bearing and teeth; while the over-high lubricant will cause the overheating and oil leakage.

2.

Grade II maintenance for gear box

Grade II maintenance: The gear box of a new vehicle should be maintained by exchanging the lubricant during the

first grade II maintenance and should be washed with kerosene; and the lubricant quality should be checked in the

grade II maintenance in later time, if the lubricant is diluted, gumming or over-dirty, it should be changed.

3.

Grade III maintenance

The gearbox should be disassembled for inspection, washing and oil change.

Notice: As the new vehicle is in the running-in status, the gearbox should be maintained by exchanging lubricant

after the vehicle covers 1500 km,

Lubricant Type

GL-5 SAE80W/90

Torsion moment of relative connecting elements

Tung Teeth: Tang tooth(5DYA4TWD

5DYA8FWD)

Unit

ãã

Specification of Maintenance and Up-Keeping

 Clutch and Gearbox

Locating screw of fork axle at first and second gear
Locating screw of yoke block
Screw on baffle of rear bearing of output shaft
Screw of reverse idler shaft
Bolt of gearshift cover
Bolt of front cover
Bolt of rear body
Bolt of clutch shell
Bolt of locating spring

13

 17

15

 20

17

 22

17

 20

15

 20

15

 20

30

 45

30

 45

17

 22

Fastening location

N*m

A-3

Fastening location

N*m

Upper tooth(JK72TWD)

Fastening location

N*m

Specification of Maintenance and Up-Keeping

 Transfer Box

Maintenance and Up-keeping of Transfer Box

1.

The oil level of transfer box should be checked when exchanging the engine lubricant or the vehicle

covers more than 8000 km

and add the lubricant where necessary.

2.

Change with the appointed lubricant each year or after the vehicle covers more than 48000 km.

Notice: lubricant brand: 85W/90 GL-5.

Fastening torque of relative connecting elements

15

 20

10

 15

12

 17

15

 20

15

 20

15

 20

15

 20

30

 40

60

 70

30

 40

30

 40

17

 22

30

 50

20

 40

30

 40

90

 125

Toggle fork at first, second and fifth gears and the screw of

toggle fork

Bolt on odometer pressure plate

Screw on baffle of rear bearing of output shaft

Screw on baffle of reverse idler shaft

Locating screw of gearshift yoke block

Bolt of front cover

Bolt of gearshift cover

Pillar of clutch toggle fork

Bolt of clutch cover

Bolt of rear body (M10X1.25X130)

Bolt of rear body (M10X1.25X80)

Plug of locating spring

Oil filling/draining plug

Reverse gear switch assembly

Location mechanism cluster

Locking nut at rear end of countershaft

Fastening location

N*m

Flange nut

Oil drain plug

Bolt of motor clip

Fixing bolt of motor

Clutch coil nut

Housing bolt

Oil pump bolt

Venting valve

Bolt of front connecting body

203

 244

19

 30

8

 11

8

 11

8

 11

27

 46

4.0

 8.5

8

 19

27

 46

Oil filling/draining plug

Location mechanism cluster

Pillar of clutch toggle fork

Bolt on odometer pressure plate

Reverse gear switch assembly

30

 50

30

 50

30

 50

10

 15

30

 50

A-4

Drive Shaft

Torsion moment

Fastening location

Applicable vehicle model

N*m

Connecting bolt

Fixing bolt of central supporter

74

 5

40

 5

Dr SF SL SK SY SJ

Dr SL SK SY SJ

Inflation pressure of tire

Ground clearance of chassis

Steering angle of inner wheel

Kingpin inner inclination

Outer inclination of front wheel

Mechanical steering

Power steering

Kingpin rear inclination (inclination)

Mechanical steering

Power steering

Toe-in

Error in length between left and right

drag rod

Side slip value

Front:220

 0kPa

Back:240

 0kPa

Front:250

 0kPa

Back:250

 0kPa

295mm

255

 mm

58.5mm(difference in height between

shaft center of lower arm and wheel

center)

310

 mm

295

 mm

36

 40

 32

32

 34

9

30' 
 5'

14

52'

0

30' 
 0'

0

10' 
 0'

0

20' 
 0'

0

20' 
 5'

1

50'

-20'

2

5' 
 5'

2

0' 
 0'

0-2mm

=2mm

=5m/km

.5m/km

Suspension System and Automobile Axle

Specification

Item

Applicable vehicle model

Specification

Dr SL SK SY SJ

SF

Dr

SL SK

SF

SY

SJ

Dr SL SK SY

SF

SJ

Dr SL SK SY

SJ

Dr SL SK SY

Dr

SL SK SY

SJ

Dr SL SK SY

Dr SL SK SY

SJ

Dr SL SK SF SY SJ

Dr SL SK SF SY SJ

Dr SF

SL SK SY SJ

HPM

Specification of Maintenance and Up-Keeping

 Drive shaft, Suspension System and Automobile Axle

A-5

Torsion moment

Fastening location

Applicable vehicle model

N*m

Limit bolt of steering knuckle

U-type fixing bolt

Bolt of spring pin of rear plate and shackle

Central bolt of rear steel plate spring

Connecting bolt of rear vibration damper and rear axle

Connecting bolt of front vibration damper and lower swing arm

Connecting bolt of rear vibration damper and frame

Connecting bolt of rear vibration damper and lower swing arm

Fixing bolt of pedestal arm of torsion rod spring

Locking nut of torsion rod spring

Fixing bolt at two ends of transverse stabilizer rod

Fixing bolt of transverse stabilizer rod bracket

Connection bolt of guide lever and lower arm

Fixing nut at front end of guide lever

Axial fixing nut of front suspension and lower arm

Axial fixing nut of lower arm of front suspension

Connecting nut of steering knuckle and upper ball stud

Connecting bolt of steering knuckle and lower ball stud

90

 10

110

 10

90

 10

50

 5

64

 5

25

 5

25

 5

137

 10

83

 5

83

 5

23

 3

29

 5

23

 3

25

 5

96

 10

150

 10

96

 10

178

 15

226

 25

196

 10

226

0

25

210

0

25

110

 10

142

 10

142

 10

SJ

Dr SL SK SY SJ

Dr SL SK SY SJ

SL SK SY SJ

SF

SL SK SY SJ

SL SK SY SJ

SF

SL SK SY SJ

SL SK SY SJ

Dr

SL SK SY SJ

Dr SF

SL SK SY SJ

Dr SF SL SK SY

Dr

Dr SL SK SY SJ

SF

Dr

SF

SL SK SY

SJ

Dr SL SK SY SJ

SF

Dr SF SL SK SY SJ

Braking system

specification

Item

Applicable vehicle model

specification

Pedal height

Free stroke of pedal

Stroke of operating lever of parking brake

160mm

190-200mm

3-6mm

9-10

7-9

Dr SF

SL SK SY SJ

Dr SL SK SF SY SJ

Dr

SL SK SY

torsion moment

Fastening location

Applicable vehicle model

N*m

Brake oil pipe

Dr SF

SL SK SY SJ

18

 2

19

 1

Specification of Maintenance and Up-Keeping

 Braking System

A-6

Torsion moment

Fastening location

Applicable vehicle model

N*m

Fixing nut of steering wheel

Connecting nut of steering ger and swing arm

Fixing bolt of steering driven arm

Fixing bolt of steering gear

Connecting nut of steering drag rod and swing arm of

steering gear

Connecting nut of steering drag rod and steering driven

arm

Connecting nut of steering drag rod and front brake

Steering limit bolt

Dr SF

SL SK SY SJ

Dr SF

Dr

SF

SL SK SY

SJ

Dr

SF

SL SK SY

SJ

Dr SF

Dr

SF

Dr SF

SJ

50

 5

30

 2

245

 25

80

 10

142

 10

83

 10

78

 10

96

 10

145

 10

96

 10

78

 10

91

 10

91

 10

59

 5

91

 10

90

 10

Steering system

Specification

Item

Applicable vehicle model

Specification

Max play of steering wheel

Tension degree of driving belt:

When f=98N

New belt

Old belt

Dr SF

Dr SL SK SF SY SJ

Dr SL SK SF SY SJ

6

5-7mm

7-9mm

Specification of Maintenance and Up-Keeping

 Steering System

B-1

SST Special tool

page

Special tool ................................................................... B-2

B

B-2

Disassembling and as-

sembling tools for lock-

i n g   n u t   o f   s t e e r i n g

knuckle

3916001

Press fitting tool for in-

ner bearing of front wheel

hub

3916002

3916003

3916004

3916005

3916006

3916007

3916008

3916009

3916010

Press fitting tool for outer

bearing of front wheel

hub

Disassembling tool of

ball stud

Fixing tool of main teeth

flange of needle bearing

Press fitting tool for steer-

ing knuckle oil seal

Disassembling tool of

shorter liner of lower arm

Mounting tool of shorter

liner of lower arm

Mounting and disassem-

bling tool of long liner of

lower arm

Disassembling tool of

upper arm liner

SST Special Service tool

Diagram

Tool name

tool number

Remark

SST Special  Tool

 Special Service Tool

Application position

Front axle

Rear axle

2WD

4WD

B-3

Application position

Front axle

Rear axle

2WD

4WD

3916011

3916012

3916013

3916014

3916015

3916016

3916017

3916018

3916019

3916020

Press fitting tool of up-

per arm liner

Disassembling and as-

sembling tools of wheel

brake cylinder of front

brake caliper

Disassembling tool of

front drive shaft bearing

Pneumatic caliper of

outer sleeve of front drive

shaft

Press fitting casing of

front drive shaft bearing

Disassembling tool of

main teeth oil seal

Press fitting tool of main

teeth oil seal

Disassembling tool of

long semi-axis

Electric cutch tester

Disassembling tool of oil

seal and needle bearing

Oil seal of long semi-
axis of front axle
Inner oil seal of rear axle
shaft
Needle bearing of long
semi-axis

SST Special  tool

Diagram

Tool Name

tool number

Remark

SST Special  Tool

 Special Service Tool

B-4

3916021

Press fitting tool of oil

seal of long semi-axis

3916022

Disassembling bracket of

long semi-axis bearing

3916023

Disassembling tool of

inner race of small bear-

ing of main teeth

3916024

Disassembling bracket of

inner race of large bear-

ing of main teeth

3916025

Press fitting casing of

inner race of large bear-

ing of main teeth

3916026

Press fitting casing of

outer race of large bear-

ing of main teeth

3916027

Press fitting casing of

outer race of small bear-

ing of main teeth

3916028

Disassembling tool of

differential side bearing

3916029

Press fitting tool of dif-

ferential side bearing

3916030

Mounting tool of needle

bearing of long semi-axis

SSTSpecial Service tool

Diagram

Tool name

tool number

SST Special  Tool

 Special Service Tool

Application position

Front axle

Rear axle

2WD

4WD

Remark

B-5

3916031

Press fitting tool of long

semi-axis bearing

3916032

Electric cutch tester

3916033

Disassembling tool of

half-shaft bearing

3916034

Press fitting casing of

half-shaft bearing and oil

seal

3916035

Mounting tool of rear

axle oil seal

3916036

Mounting tool of main

teeth oil seal

3916037

Change oil seal of rear

axle main teeth on

vehicle

3916038

Mounting tool of main

teeth oil seal

3916039

Mounting tool of main

teeth oil seal

3916040

Spanners of adjusting

ring of side bearing of

differential

Use with torsion

spanner together

Change oil seal of

rear axle main teeth

on vehicle

SSTSpecial Service tool

Diagram

Tool name

tool number

SST Special  Tool

 Special Service Tool

Application position

Front axle

Rear axle

2WD

4WD

Remark