Great Wall V200. Service Manual - part 15

a. Make the assembly mark on the inner trumpet connector and

three-pin section assembly.

Caution: remove the grease in the connector before make the

mark and don’t make the mark by the hard object such as

punch.

b. Remove the inner trumpet connector.

4. Disassembly of three-pin section assembly

a. Use the circlip pliers to remove the circlip.

b. Use the adz and hand hammer to make the assembly mark on

the shaft and three-pin section assembly.

    c. Use the cooper bar and hand hammer to remove the three-pin

section.

Caution: Remove the cooper chip on the shaft or three-pin

section assembly if has.

5. Remove the inner jacket

a. Use the pliers to disassemble the small clip of inner jacket.

b. Pull out the inner jacket.

Caution: Remove the grease in the jacket and maintain the

clean field.

6. Use the straight screwdriver to disassemble the

large and small clip of outer jacket.

assembly mark

assembly mark

7. Remove the outer jacket

Caution: Clean the protective jacket and remove the grease on

the outer trumpet connector. Do not disassemble the outer

trumpet connector.

8. Use the screwdriver and hand hammer to remove

the dustproof cover.

Assembly of constant-speed drive shaft assembly

1. Use the hand hammer and screwdriver to install

the dustproof cover

Caution: The dustproof cover should be replaces when

itisdeformed heavily.

2. Install the large clip of outer jacket, outer jacket

and small clip of outer jacket.

Caution: The outer jacket should be replaced when it is

damaged or aged heavily and warp the end of the shaft with the

plastic band and coat with small grease before insert it.

3. Insert the small clip of inner jacket, inner jacket

and large clip of inner jacket.

Caution: The inner jacket should be replaced when it is

damaged or aged heavily.

4. Install the three-pin section assembly on the front

drive shaft.

a.Let the end of three-pin section assembly with chamfer faces the

   shaft inner direction.

Caution: The three-pin section assembly should be replaced if

its needle bearing position is damaged.

b.Align the assembly mark made before disassembly.

c. Use the hand hammer and copper bar to install the three-pin sec

    tion assembly to the front drive shaft.

d.Use the circlip pliers to install the new circlip.

5 Install the outer jacket on the outertrump  etconn

     ector.

       Fill the jacket with the grease supplied with the jacket before

       install the jacket.

       (Recommend used grease is CAPLEX or KY1)

       Grease using amount: About 110g

with chamfer

6

Install the inner trumpet connector on the front

     drive shaft

a. Fill the inner trumpet connector and inner jacket with the

   grease supplied with the jacket

(Recommend used grease is CAPLEX or KY1).  Amount About140g

       b. Align the assembly mark made during disassembly; covered

           with inner trumpet connector.

       c. Cover the inner jacket on the inner trumpet connector.

7

Use the inner and outer jacket clip pliers to

      clamp the inner and outer jacket.

a. Use the special non-ear clip pliers to lock the large clip of

inner jacket.

b. Use the nutcracker to lock the small clip of inner jacket.

Caution: Ensure the large and small connecting place of jacket

is in the corresponding groove of trumpet connector and shaft.

assembly mark

outer jacket clip

inner jacket clip

non-ear clip pliers

nutcracker

c.Use the special pneumatic pliers to lock the large and small clip of

   outer jacket.

d.Ensure the jacket of both sides does not be prolonged or shortened

   when the front drive shaft has the standard length.

Standard length: 400.5mm

If only need to replace the outer components of front drive

shaft assembly on car, it can remove the left and right steer-

ing knuckle of car, then disconnect the inner trumpet con-

nector of front drive shaft assembly, then take out the three-

pin section assembly and shaft from the inner trumpet con-

nector for replacement.

Installation of constant-speed drive shaft assem-
bly on front drive axle

1. Insert the hanger plank into the drive shaft, inserted

with oil seal; use the circlip pliers to install the inner

circlip.

Caution: It should replace the oil seal if damaged.

special tools

circlip pliers

support the lower end

 Use the special tools to knock bearing in slightly.

Caution: Support the lower end of the drive shaft assembly

when knock the bearing in. The lower end must not slide out.

3. Use the circlip pliers to install the outer circlip on

the front drive shaft assembly.

4. Repeat the previous method to install the hanger

plank, oil seal, circlip, bearing and circlip on another

end.

5. Insert the spline of connecting end of drive shaft

and reducer into the differential halfaxle gear spline

hole of electric clutch and reducer slowly.

6. Drip 1-2 drop of screw lock agent on the middle of

screw of connecting bolt of hanger plank andreducer.

7. Use the wrench to tighten the connecting bolt of

hanger plank and drive axle to specified torque.

specified torque : 90-110N

m

Caution: It should screw on all bolts before tighten

them, then tighten them in diagonal direction.

Check the hanger plank for levelness after tightened

the bolt to the specified torque. Remove the   hanger

plank and reinstall it if is not planished.

8. Install the vent tube connector assembly; connect

all ports to front drive axle.

(Refer to “Assembly of Front Reducer Assembly”)

special tools

support the lower end

Specified torque : 200-220N

m

Caution: Drip 1-2 drop of screw lock agent on the middle front

part of the lifting bolt

10 Use the bolt to connect the front drive axle flange

and drive shaft according to the mark mage before

disassembly and tighten it to the specified torque.

specified torque: 73-83N.m

11. Install the beam under the front drive axle.

Tighten the beam connecting bolt to the specified

torque.

specified torque: 73-83N.m

Replacement of drive gear oil seal of front reducer assembly

1. Support the front of car; remove the left and right

front wheel and the beam under the reducer.

2. Drain the lubricant oil in the front reducer; remove

the left and right steering knuckle

3. Disconnect the front reducer assembly flange from

the drive shaft and use the jack to remove the front

drive axle

Caution: Make the assembly mark on the reducer and

drive shaft before separate them.

4. Remove the front differential assembly

(Caution:  Drain the oil in front differential before the

disassembly)

front reducer

assembly

washer

spacer 

drive

bevel gear

bearing

oil seal

front reducer drive gear flange,

main gear flange and dustproof

cover assembly

Used component which can not be used

any more.

N 

m:

 specified torque

assembly mark

5. Remove the drive gear flange and dustproof cover

assembly

a. Use the hand hammer and chisel to loose the riveted part on

      nut.

b. Use the special tools to clamp the drive gear flangeandremove

      the drive gear nut.

c. Use the cooper bar to knock down the drive gear flange and

     dustproof cover assembly.

6. Remove the drive gear oil seal

Use the special tools to remove the oil seal; do not

damage the inner wall of reducer housing.

7. Install the new drive gear oil seal

a. Use the special tools to knock into the new oil seal.

b. The top of the oil seal is level to the top of reducer housing.

Caution: Coat the oil seal lip with the lithium base grease and

the oil seal should be in correct position.

special

rotate the wrench in clockwise.

special

special

8

Install the drive gear flange and dustproof cover

     assembly

a. Match the drive gear flange and dustproof cover assembly on

      the front drive gear.

b. Coat the new nut with the lithium base grease.

c. Use the special tools to clamp the flange and tighten the nut

      to the specified torque.

Tighten torque:140-160N.m

a. Use the torque meter to measure the pre-applied load of the

gap between the drive bevel gear and driven bevel gear.

 pre-applied load:  1.2-1.7N.m

b.   Is should be replaced by the thicker washer if the pre-ap

          plied load is more than specified value

(The step of thickness of washer is 0.03mm)

c. Is should be replaced by the thinner washer if the pre-applied

load is less than specified value. Repeat the previous

operation until meet the requirement.

Caution: Do not reduce the load by loosing the nut.

10.  Check the axial and radial run-out tolerance

       offlange.

a. Use the dial indicator to measure the axial runout of flange.

  Max. axial runout: 0.1mm

b.   The max. radial run-out tolerance is 0.1mm

It should check the bearing if the radial run-out tolerance is large.

9

Adjust the pre-applied load of the drive

      bevelgear bearing

11

Rivet the drive gear nut after meet the previ-

ous requirements.

12

Install the reducer assembly on the front drive

axle assembly and assemble the front drive shaft

assembly (refer to Assembly of Front Reducer Assembly

and Assembly of Front Drive Shaft Assembly)

13

Install the oil drain plug; screw off the oil

filling plug and filled with the hypoid gear oil.

Tightening force of oil drain plug: 30-35N

m

Model of lubrication oil: GL-5

Filling amount: Flush to the lower edge of oil filling open

14

Insert the oil filling plug washer and tighten

the oil filling plug to the specified torque.

Specified torque : 140-150N

m

15

Install the front drive axle assembly on the

carriage.

16

Connect the drive shaft to the flange

a. Align the assembly mark; use four bolts and nuts to connect

the flange of drive shaft and front drive axle.

b.Tighten the nut to the specified torque.

specified torque:

Remarks: Keep the clean of the field during the maintenance.

Front reducer assembly

front drive shaft assembly

hanger plank 

R

oil seal  

front vibration damper

bearing  

front vibration damper

front reducer 

electric clutch assembly

Power plug of electric clutch

circlip

bearing 

front vibration damper

oil seal  

front vibration damper

hanger plank 

L

front drive shaft assembly

front drive axle vent tube connector assembly

circlip

circlip

Pregummed component

N 

m: specified trque

circlip

6. Use the wrench to screw off the bolt on the vent tube

bracket, which is used to fix the vent tube connector.

7. Disconnect the connection between the front drive

shaft assembly and steering knuckle front hub

assembly.

a.

Screw off the connecting bolt which is used to fix the front

hub cover; remove the front hub cover.

b.

Use the circlip pliers to remove the circlip from the front drive

shaft and remove the adjusting washer.

c.

Remove the steering knuckle of both sides and separate it

form the front drive shaft assembly.

1. Support the front of the car; remove two front

wheels and the beam under the front reducer

assembly.

2. Drain the lubrication oil in the front reducer

assembly.

3. Remove the flange of front reducer assembly from

the drive shaft

Caution: Make the assembly mark on the flange of

front reducer assembly and drive shaft before discon-

nect them.

4. Disconnect the connector of power wire of electric

clutch

5. Disconnect three rubber connectors on the front

drive axle vent tube connector assembly.

assembly mark

disconnect three connectors in this place

8. Use the jack to support the front reducer assembly

9. Remove the lifting bolt of front drive axle hanger

plank and carriage.

10. Remove the front drive axle assembly

Caution: Do not damage the drive shaft and front drive

shaft jacket

11. Remove the front drive shaft assembly of both sides

from the front drive axle assembly.

12. Use the wrench to remove the bolt and nut which is

used to fix the front reducer housing.

13. Remove the clump weight assembly and clump

weight bracket welded assembly

(Refer to “Disassembly of Front Reducer Assembly”)

electric clutch connector

N 

m:   specified torque

Replacement of front reducer assembly oil seal

1. Remove the front drive axle assembly

(Refer to “Removal of Front Reducer Assembly”)

2. Remove the left and right front drive shaft assem-

bly from the front drive axle assembly.

3. Remove and replace the lower oil seal according to

the removal and installation procedure of front drive

shaft assembly and install the new side oil seal on

the front drive shaft, then install them in the front

reducer assembly.

(Refer to “Removal and Installation of Front Drive Shaft

Assembly”)

Replacement of oil seal and major semiaxle oil seal of front reducer assembly

major semiaxle oil seal

major semiaxle pressing assembly

circlip

mechanical wheel of separator

 Pregummed component

 N 

m:  Specified torque

Replacement of major semiaxle oil seal

1. Make the electric clutch is in the 4WD status,

them stop the engine and remove the front drive

axle assembly (see the disassembly of front reducer

assembly)

2. Use the wrench to screw off the bolt which fix the

front axle vent tube connectorassemblyonventtubeb

racket bolt

3. Disconnect the connector between vent tube of

electric clutch housing and front drive axle vent tube

connector assembly

4. Disconnect the connector between the vent tubes

on the electric clutch and vent tube connector

assembly.

5. Remove the bolt which is used to fix the electric

clutch housing and front axle tube flange; use the

brass bar to open the electric clutch housing and take

out the mechanical wheel of separator.

Caution: The lubrication oil will flow out when sepa-

rate the electric clutch housing from the front axle

flange. It should use the container to hold it.

mechanical wheel of separator

disconnect the place

disconnect the place