2006 GREAT WALL DEER Service Manual

TF-31Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts)
Attachment for Inspection Maintenance or Change of Parts
Parts (items) Checking items Acceptance/Refusal
Shift toggle fork as-
semblyCheck the wear and damage of the inserted face
that is combined with gear sleeve;
Check to see whether the contact roller can
rotate freely or is damaged or notIf any step wear or damage is found, the inserted
face shall be refused to use.
If the contact runs difficultly or is damaged, a
new pin-contact roller and new cage assembly
shall be used.
Driving and driven
chain sprocketCheck the sprocket teeth according to
the
inspection
paragraphRefer to the sprocket teeth inspection of

inspection
paragraph
Shift toggle fork as-
semblyCheck the inner diameter that matches with the
output shaftIf any pitting corrosion or damage is found,
refuse to use it.
Driving chain Check the step sliding, looseness or damage of
pin or connecting elementRefuse to use the weary or damaged driving
chain
Filtering screenCheck to see the filtering screen is clean or with
small hole or damageClean it where necessary, and abandon the dam-
aged one.

TF-32Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection
Maintenance or Change of Parts
Pump shell Check to see whether there is pitting corrosion
or step slippingAbandon it in case it is seriously damaged or
worn
Output shaftCheck the spline, check the surface that matches
with bearing and check the distortion according
to
inspection
paragraphRefer to the spline inspection of
inspection

paragraph;
Refuse to use the one with pitting corrosion or
damage;
Refuse to use the one that is bending or poor in
round bouncing.
Deceleration hubCheck the spline of chain sprocket and check the
wear or damage of the location where matches
with the toggle fork according to the

inspection
paragraphRefer to the spline inspection of
inspection

paragraph; refuse to use the one with step slid-
ing or damage.
Front output shaftCheck the surface where matches with the
bearing;
Check the spline according to the
inspection
:
paragraphRefuse to use the one with pitting corrosion or
damage
Input shaft Check the spline according to the
inspection

paragraph
Check the distortionRefer to the spline inspection of
inspection

paragraph;
Refuse the one that is bending or poor in round
bouncing.
Thrust washer and
thrust discCheck the pitting corrosionRefuse to use the one with pitting corrosion or
damage
Sun wheelCheck the gear teeth and spline according to the

inspection
paragraphRefer to the gear teeth inspection and spline
inspection of
inspection
paragraph.
Planetary mechanism
assemblyCheck the gear teeth according to the

inspection
paragraph;
Check the wear and looseness of the planetary
gear pin; check the wear of thrust gasketRefer to the gear teeth inspection of

inspection
paragraph;
If any step sliding or pitting corrosion is found,
refuse to use it
Electric shifting camCheck to see whether there is step slipping or
pitting corrosionIf any step sliding or pitting corrosion is found,
refuse to use it
Shift guide shaftCheck to see whether there is step slipping or
pitting corrosion
Check the distortion situationIf any step sliding or pitting corrosion is found,
refuse to use it
Refuse to use the bending one
Planetary gear ringCheck the match performance of it with the
transfer box housing
Check the gear teeth according to the

inspection
paragraphCheck the transfer box housing assembly to see
whether the gear ring is loose or not in the
housing
Refer to the gear teeth inspection of

inspection

paragraph
Transfer box housingCheck the holes matches with the bearingAbandon the one with pitting corrosion or
damage.

PR-1
Drive shaft
page
Notice .......................................................................... PR-2
Troubleshooting .......................................................... PR-2
Drive shaft ................................................................... PR-3
PR

PR-2Drive Shaft
Notice and Troubleshooting
Notice
Notice: do not grip the drive shaft sleeve too tight with vice
so as to avoid the deformation.
troubleshooting
Trouble Causes Resolving approaches
Noise Wear of universal joint yoke spline;
Wear of central bearing;
Wear or seize-up of cross shaft bearingChange the drive shaft;
Change the central bearing;
Change the bearing of cross shaft
Vibration Oscillation difference of the drive shaft;
Drive shaft imbalance;
Wear of the liner of rear bearing in the lengthening shell of
gear box;
Spline seize-up of the universal joint yokeChange drive shaft
Change drive shaft
Change the liner
Change drive shaft

PR-3
Drive Shaft
Element Drawing
2WD
two-joint type

snapping ring
bearing of cross shaft




universal joint flange fork


rear axle drive shaft
universal joint foke
cross shaft
three-joint type

snapping ring
bearing of cross shaft
universal
joint foke
cross shaftfront joint of rear
axle drive shaftcenter support
bearingflange
washer
washer
74
5
40
5
universal joint
flange fork
74
5
74
5universal joint
flange fork
rear section of
rear axle drive
shaft










N*m: specified torque

Parts that cannot be reused after being used
Drive Shaft
Drive Shaft

PR-4Drive Shaft
Drive Shaft
Element Drawing(continued)
4WD
front axle drive shaft
front axle drive shaft74
5
74
5
rear axle drive shaft
two-joint type

snapping ring
bearing of cross shaft
74
5
74
5

cross shaftuniversal joint yokerear axle drive shaft


universal joint flange fork
three-joint type









74
5
40
5
snapping ring
bearing of cross shaftcenter support
bearing
flange
front joint of rear
axle drive shaftwasher
universal joint flange fork
74
5
74
5
rear section of
rear axle drive
shaft
universal joint
flange fork

Parts that cannot be reused after being used
N*m
: specified torque

PR-5Drive Shaft
Drive Shaft
(4WD)
Rear axle drive shaft
1. Take apart the universal joint flange fork of rear axle drive
shaft from the differential flange.
(a) Label the two flanges with assembly marks.
(b) Take apart the four sets of bolt and nut.
Disassembly of Drive Shaft
(2WD)
1. Take apart the universal joint flange fork of the drive shaft
from the differential flange.
(a) Label the two flanges with assembly remarks.
(b) Take apart the four sets of bolt and nut.
assembly mark
2. Take apart the center support bearing from the frame
beam (for the three-joint type)
3. Take apart the drive shaft from the gearbox
(a) Pull out the universal joint yoke from the gearbox.
(b) Insert the SST in gearbox for oil leakage prevention.
2. Take apart the center support bearing from the frame
beam (three-joint type
SST
assembly mark

PR-6Drive Shaft
Drive Shaft
3. Take apart the drive shaft from the gearbox.
(a) Pull out the universal joint yoke from the gearbox.
(b) Insert the SST in gearbox to prevent the oil leakage
Front axle drive shaft
4. Tear down the front universal joint flange fork of the front
drive shaft.
(a) Hang he front end of the front axle drive shaft.
(b) Label the assembly mark on the flange
(c) Take apart the four sets of bolt and nut.
5. Disconnect the rear universal joint flange fork from the
front axel drive shaft along the transmission path.
(a) Label the assembly marks on each flange.
(b) Take apart the four sets of bolt and nut.
Drive shaft disassembly
1. Separation of the rear joint of the rear axle drive shaft
from the front joint of rear axle drive shaft
(a) Label the assembly marks on each flange.
(b) Take apart the four sets of bolt and nut.
2. Take apart the center support bearing from the front joint
of the rear axle drive shaft.
(a) Loosen the riveted nut by chiseling with a chisel and
hammer.
SST
assembly mark
assembly mark