Great Wall Sing (2006 year). Service Manual - part 3

MT-19

Gearbox

 Input Shaft Assembly (Bearing Change)

ppq

2.

Mount the new bearing with pressure machine and SST.

3.

Select the retainer ring to obtain the minimum axial clearance

4.

Mount the retainer ring with the split-ring-type pliers.

   5.

Mount the retainer ring with the split-ring-type pliers.

MT-20

Transmission

 Output Shaft Assembly (Components Figure)

Output shaft assembly

Components  figure

synchronizer spring

expansion ring

snap ring

synchronizer

slide block

3th,4th gear synchronizer

meshing sleeve

3th gear needle bearing

synchronizer hub of 3rd

and 4th gear

toothed ring of

synchronizer

gear components of 3rd gear

steel ball

synchronizer sliding block

synchronizer meshing sleeve

of 1st and 2nd gear

gear components

of 1st gear

1st gear shaft sleeve

locking ring of output

shaft rear bearing

spring expansion ring

needle bearing of

2nd gear

gear components

of 2th gear

toothed ring of synchronizer

for 1st and 2nd gear

toothed ring of synchro-

nizer for 1st and 2nd gear

needle bearing of 1st gear

rear bearing of

output shaft

gear of 5th gear

odometer drive gear

drive gear snap ring of odometer

output shaft

snap ring of 5th gear

steel ball

MT-21

Transmission

 Output Shaft Assembly(Disassembly of Output Shaft Assembly)

Disassembly of output shaft assembly

1.

Remove the drive gear of speedometer

(a)  Pry down the two shield rings with open end ring plier

(b)  Dismantle the drive gear of tachometer.

(c)  Take out the steel ball with magnetic stick.

2.

Remove the 5th gear,rear bearing of output shaft,1st

gear assembly,1st gear shaft sleeve and needle bearing

of 1st gear

(a)  Take down the circlip of 5th gear with two screwdrivers

and one hammer.

(b)  Dismantle the rear bearing of output shaft,1st gear assem-

bly and 1st gear sleeve with press machine.

(c)  Remove the needle bearing of 1st gear.

3. 

Remove the synchronized ring

4.

Take down the steel ball

Take out the steel ball with magnetic rod.

5.

Take down the 1st and 2nd gear synchronizer assembly,

2nd gear assembly,and 2nd gear needle bearing.

(a)  Remove the 1st and 2nd synchronizer assembly and 2nd

gear components.

(b)  Take off the needle bearing of the 2nd gear.

6. 

Take down the meshing sleeve ,sliding block and spring.

Remove the three sliding blocks and two springs from the

synchronizer assembly with one screwdriver.

MT-22

Transmission

 Output Shaft Assembly(Disassembly of Output Shaft Assembly)

7. 

Take down the 3rd and 4th gear synchronizer assembly,

3rd gear and needle bearing .

(a)  Remove the snap ring with plier for snap ring.

(b)  Take down the 3rd and 4th gear synchronizer assembly and

3rd gear with press machine.

(c)  Remove the needle bearing .

8.

Take off the meshing sleeve ,sliding block and spring

from 3rd and 4th synchronizer.

Remove the three sliding blocks and spring from the meshing

sleeve  with one screwdriver.

MT-23

Inspection of output shaft assembly

1.

Check the axial clearance of every gear:

For the transmission made by Shang Chi:(0.15

0.33)

mm(1st,2nd,and 3rd gear position)

For the transmission made by Tang Chi:(0.1

0.25)mm

(1st gear position)(0.09

0.26)mm,(2nd and 3rd gear

position)

2. 

Measure the idle clearance of every gear.

Check the radial clearance of every gear with micrometer.

Standard clearance:

For the transmission made by Shang Chi:0.05mm

(1st,2nd,and 3rd gear position)

For the transmission made by Tang Chi:

(0.009

0.033)mm(2nd and 3rd gear position)

(0.009

0.032)mm(1st gear position)

Max clearance

For the transmission made by Shang Chi:0.05mm

For the transmission made by Tang Chi:0.033mm

(2nd,and 3rd gear position);0.032(1st gear position)

If the clearance value exceeds the limit above , the gear,

needle bearing or shaft should be changed.

PK Inspection for output shaft and 1st gear shaft sleeve

(a)  Measure the thickness of output shaft flange with callipers

Min thickness

 For the transmission made by Shang Chi:4.75mm

 For the transmission made by Tang Chi:4.65mm

(b)  Measure the thickness of flange of 1st gear shaft sleeve

with callipers

Min thickness

  For the transmission made by Shang Chi:3.87mm

  For the transmission made by Tang Chi:3.795mm

(c)  Measure the outside diameter of the journal of output shaft

with micrometer.

Min diameter:19.216mm

Gear of 2nd gear:37.984mm

Gear of 3rd gear:34.984mm

Transmission

 Output Shaft Assembly(Inspection of Output Shaft Assembly)

1st gear position

2nd gear position

3rd gear position

MT-24

(d)  Measure the outside diameter of the gear sleeve of 1st gear

with micrometer.

Min diameter:38.984mm.

(e)  Measure the radial run out torlerance of the shaft with

micrometer.

Max radial run out torlerance

  For the transmission made by Shang Chi:0.015mm

  For the transmission made by Tang Chi:0.05mm

4.

Check the synchronized ring

(a)  Turn the ring ,and put it into to check the brake action.

(b)  Measure the gap between the rear of the synchronized ring

and gear end.

Standard clearance:

  For the transmission made by Shang Chi:(1.5

1.8)mm

  For the transmission made by Tang Chi:(1.2

0.4)mm

Limit clearance:0.8mm

5.

Measure the clearance between the gear shifting fork

and meshing sleeve

Check the clearance between the gear sleeve and gear shifting

fork with feeler gauge.

Max clearance

  For the transmission made by Shang Chi: 0.54mm

  For the transmission made by Tang Chi: 0.7mm

Transmission

 Output Shaft Assembly(Inspection of Output Shaft Assembly)

MT-25

Transmission

 Output Shaft Assembly(Assembly of Output Shaft Assembly)

Assembly of output shaft assembly

1.

Assembly of synchronizer

(a)   Insert the synchronizer hub and sliding block into the gear

sleeve.

(b)  Install the spring expansion ring under the  sliding block.

Note:The openings of spring expansion ring should be

staggered during installation .

2.

Install the gear components of 3rd gear and synchronizer

of 3rd and 4th gear on the output shaft.

(a)   Smear the gear oil on the shaft and the needle bearing of

3rd gear.

(b)   Put the synchronized ring on the components of gear of 3rd

gear, and align the notch of synchronized ring and sliding

block.

(c)   Install the needle bearing into gear components of 3rd gear.

(d)   Assembly the gear components of 3rd gear and synchro-

nizer of 3rd and 4th gear with pressing machine.

3.

Assembly of snap ring for shaft

To choose one snap ring which make the axial clearance be

Min, and install it on the shaft.

3/4 gear posititon

1/2gear posititon

front

front side

MT-26

Transmission

 Output Shaft Assembly(Assembly of Output Shaft Assembly)

Standard clearance:

 For the transmission made by Shang Chi

(0.15
0.33)mm

 For the transmission made by Tang Chi:

(0.09
0.33)mm

5.

Assembly for the gear components of 2nd and

synchronizer of 1st and 2nd gear

(a)   Smear the gear oil on the needle bearing of gear of 2nd

gear.

(b)   Put the synchronized ring on the gear,and align the notch

and shift key.

(c)   Install the needle bearing into the gear components of 2nd

gear.

(d)   Assembly the gear components of 2nd gear and meshing

sleeve of synchronzer of 1st and 2nd gear with pressing

machine.

6.

Check the axial clearance of gear components of 2nd

gear

Measure the axial clearance of gear components of 2nd gear

with feeler gauge.

Standard clearance:

For the transmission made by Shang Chi:(0.15

0.33)mm

For the transmission made by Tang Chi:(0.09

0.33)mm

7.

Assembly the locking ball and gear components of 1st

gear

(a)   Install the locking ball into the shaft.

MT-27

Transmissio

 Output Shaft Assembly(Assembly of Output Shaft Assembly)

SST

SST

(b)   Smear the gear oil on the needle bearing of gear of 1st gear.

(c)   Assembly the gear components of 1st gear,synchronized

ring,needle bearing and sleeve of gear of 1st gear.

(d)   Install the assembly on the output shaft,and align the notch

of synchronized ring and sliding block .

(e)   Turn the sleeve of 1st gear shaft to align the it with the

locking ball.

8.

Installation for rear bearing of output shaft

Fix the bearing of output shaft to the output shaft with SST and

pressing machine, make the notch of locking ring of output

shaft rear bearing expose to the tail.

Remark: Hold the sleeve of gear of 1st gear and don

t let it fall

off.

9.

Install the gear of 5th gear

Fix the gear of 5th gear with SST and pressing machine.

10. Assembly the snap ring of shaft

(a)   To choose one snap ring which make the axial clearance

be Min, and install it on the shaft.

Max clearance

 0.1mm

(b)   Knock the snap ring of shaft of 5th gear tightly with

screwdriver and hammer.

11. Measure the axial clearance of gear of 1st gear

Measure the axial clearance of gear of 1st gear with feeler

gauge

Standard clearance:

 For the transmission made by Shang Chi:(0.15

0.33)mm

 For the transmission made by Tang Chi:(0.09

0.33)mm

MT-28

Transmission

 Output Shaft Assembly(Installation of Output Shaft Assembly)

12. Fix the drive gear of speedometer

(a)  Install the locking ball and drive gear.

(b)  Install the drive gear of tachometer with plier for shaft

shield ring

MT-29

Gear Box

 Countershaft Assembly and Reverse Idle Gear Assembly (Element Drawing, Countershaft Assembly Disassembly, Testing and Assembly)

Countershaft Assembly and Reverse Idle Gear Assembly

Element drawing

Disassembly, Testing and Assembly of

Countershaft

1.

Tear down the coupling gear, sliding block and the five-

speed spring collar.

Tear down the coupling collar, three sliding blocks and the two

five-speed spring collars with screwdriver.

2.

Measure the radial clearance of the reverse idle gear

with dial gauge

Standard clearance:

Shang chi:0.05mm

Tang chi:(0.10~0.30)mm (Tang chi is the close Spline

match, which belongs to radial clearance)

Max clearanle:

Shang chi:0.05mm

Tang chi:(0.10~0.30)mm (Tang chi is the close spline

match, which belongs to radial clearance)

front bearing of
countershaft

intermediate-gear shaft

steel ball

rear bearing of
countershaft

stop ring of the rear bearing
of countershaft

five-speed thrust washer

five-speed needle
bearing

sliding block of
synchronize

five-speed cluster

engagement sleeve of the

five-speed synchronizer

spring collar

synchronizer tooth
of spring collar

axial pressing plate
for reverse idle gear

reverse idle
gear shaft

reverse idle gear
cluster

coupling gear around
the five-speed gear

retainer ring for front
countershaft

stop ring for front bearing
of countershaft

MT-30

                Gear Box

 Countershaft Assembly and Reverse Idle Gear Assembly ( Countershaft Assembly Disassembly, Testing and Assembly)

3.

Reverse gear inspection

Measure the diameter of needle bearing with micrometer.

Standard diameter

Shang Chi

26.000mm

Tang Chi

(25.98
26.00)

Limit Diameter

Shang Chi

25.984mm

Tang Chi

25.86mm

4. 

Check the synchronizing ring

(a)

Run the retainer ring for shaft and put it onto the shaft to

check itsstopping performance

(b)

Measure the clearance between the rear section of the

synchronizing ring and the spline.

Standard clearance:

Shang Chi

(1.5
1.8)mm

Tang Chi

(1
2)mm

Limit clearance: 0.8mm

5.

Measure the clearance of the shift fork and gear sleeve.

Test the clearance of the shift fork and gear sleeve with the

feeler gauge.

Max clearance:

Shang Chi: 0.54mm

Tang Chi:1.0mm

6.

Change the bearing

The front bearing of the reverse gear shall be changed when

necessary

(a)

Pry down the retainer ring for shaft with a split-ring-type

pliers.

MT-31

Gear Box

 Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly)

SST

sleeve wrench

front

(b)

Press out the bearing with SST.

(c)

Press in the bearing, side race and inner race with the

socket spanner.

(d)

Select the split ring that leave the radial clearance to

minimum level, and mount it on the shaft.

7.

Mount the engagement sleeve of synchronizer, sliding

block and the five-speed spring collar.

Remark: the opens of the spring collar shall be in non-

alignment

Encase the sliding pad into the gear hub and then cover the

gear sleeve.

Mount the spring retainer under the sliding pad.

Notice, the opening direction of the spring retainer shall

not face-to-face.

Mount of Reverse Gear Assembly

1.

Check the reverse idle gear

Measure the radial clearance of the reverse idle gear with dial

gauge.

Standard clearance:

Shang Chi

0.05mm; Tang Chi
(0.04
0.08)mm

Max clearance

Shang Chi

0.05mm; Tang Chi
0.13mm

MT-32

Gear Box

 Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly)

2.

Measure the clearance between the reverse idle gear

and gearshift yoke block

Measure the clearance between the reverse idle gear and the

gearshift yoke block with feeler.

Standard clearance:

Shang Chi

0.2mm

Tang Chi

(0.05
0.27)mm

Max clearance

Shang Chi

0.35mm

Tang Chi

0.5mm

MT-33

Gearbox

 Rear Housing Assembly (Element Drawing, Change of Oil Seal, Change of Shaft Bush)

Rear Housing Assembly

Element drawing

Change of Oil Seal

1.

The rear housing oil seal shall be changed where necessary.

(a)  Dismantle the oil seal with SST.

(b)  Press in the new oil seal with SST

2.

The driven oil seal of speedometer shall be changed

where necessary

(a)  Pry out the oil seal with SST.

(b)  Tap the new oil seal into the shaft bracket with SST.

Change of Shaft Bush

The shaft bush shall be changed where necessary

(a)  Tear down the oil seal and dust bush.

(b)  Heat the ending parts of extension frame to 80

-100
 in

the oil groove.

(c)  Tear down the shaft bush with SST and mount on the new

shaft bush.

SST

SST

SST

SST

SST

oil reservoir

locating spring bolts and
spring cylindrical pin

rear housing oil seal
assembly

rear housing dust
cover

oil groove

component element
o f   p o s i t i o n - l i m i t
mechanism

rear housing
cluster

MT-34

Gearbox

 Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism)

Inspection on and change of the component

elements of position-limit mechanism

1.

Tear down the component elements of position-limit

mechanism

(a)  Dismantle the bolts with the torque socket spanner.

(b)  Punch out the spring cylindrical pin with the drift punch

and hammer.

(c)   Tear the component elements of position-limit mechanism

down.

2.

Check the component element of position-limit mechanism.

Run and propel the limit stop and the limit stop can return

to the original location automatically, otherwise, change the

limit stop.

3.

Mount the component element of position-limit mechanism

(a)  Mount the component elements of position-limit mecha-

nism in the rear housing.

(b)  Tap the spring cylindrical pins in with drift punch and

hammer as shown in the drawing.