2006 GREAT WALL DEER Service Manual

SA-66
Disassembly of Front Speed Reducer
1. Tear down the speed reducer cover:
Screw off the eight bolts connecting the speed reducer cover.
2. Tear down the front long semi-axis and the front minor
half-shaft:
Tear down the front long semi-axis and the front minor half-
shaft from the speed reducer assembly with the special service
tool.
3. Tear down the front drive axle shaft sleeve
Screw off the four bolts connecting the front drive axle shaft
sleeve.
4. Tear down the oil seal ó front half-shaft;
Tear down the oil seal ófront half shaft with the special service
tool.
5. Check the swing difference of the axle driven bevel gear;
Run the flange to measure the axle driven bevel gear with the
dial-indicating lamp.
Swing difference)
0.07mm
Max swing difference: 0.07 mm
In case the swing difference is more than 0.07 mm, change the
compete package of driven bevel gear.
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-67
6. Check the teeth-clearance of the driving bevel gear and
the axle driven bevel gear:
(a) Install the dial-indicating lamp and ensure the axial line
of measuring head is vertical with the contact teeth face.
(b) Run the flanges, and record the clearance values of
driving bevel gear and the axle driven bevel gear.
Specified clearance range
(0.15-0.25)mm
Remark: the inspection should be conducted at no less than
three equally divided spots on the circumference of the axle
driven bevel gear.
7. Check the engagement trace of the axle driven bevel
gear.
(See page SA-76)
8. Tear down the flange and dust cover:
(a) Loosen the riveted position of main-tooth nut with the
hammer and chisel.
(b) Lock the main-tooth flange with SST to tear down the
main-tooth nut.
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)
(c) Tap down the driving bevel gear flange and dust cover
with copper bar.

SA-68
10. Tear down the inner race of bearing 31306 with SST;
If the bearing is damaged, change with a new bearing.
11. Tear down the cap-differential bearing.
12. Take out the differential.
13. Take down the outer race of bearing 50KB801 and mark
clearly the left and right parts to avoid of confusion during
reassembling. 9. Tear down the driving bevel gear oil seal and the oil-
guard tray:
(a) Tear down the oil seal from the driving bevel gear with
SST.
(b) Take out the oil-guard tray.
right
left
left
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)
14. Tear down the adjusting gaskets and clearly mark the left
and right to avoid of confusion during re-assembling.
right

SA-69
15. Tear down the driving bevel gear.
Inspection on and Change of Front Speed
Reducer
1. Change the bearing 32307 on driving bevel gear
(a) Press out the inner race and roller assembly of bearing
32307 with the special service tool.
(b) Press in the new inner race and roller assembly of bearing
32307 with SST.
2. Change the outer race of bearing 32307:
(a) Tap down the outer race of bearing 32307 with the copper
bar and hammer.
(b) Press in the new outer race of bearing 32307 with the
SST.
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)
.

SA-70
4. Tear down the inner race and roller assembly of the two
bearings 50KB801 from the differential housing.
Tear down the inner race and roller assembly of bearing
50KB801 with SST.
5. Tear down the axle driven bevel gear:
Tear down the bolts and lock plate by tapping lightly the axle
driven bevel gear with the copper until tear them down. 3. Change the outer race of bearing 31306:
(a) Tap down the outer race of bearing 31306 with copper bar
and hammer.
(b) Press in the new outer race of bearing 31306 with SST.
Remark: the inner race of the bearing should be changed with
the outer race together.
6. Differential disassembly
(a) Tap out the pin with SST.
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-71
(b) Tear down the planetary gear shaft to take out the planetary
gear, planetary gear stop gasket, half-axle gear and the
half axle gear thrust gasket
7. Differential assembly mount
(a) Clean the differential housing.
(b) Encase the half-axle thrust gasket in the differential
housing after covering on the half-shaft gear.
(c) Run the half-axle gear to encase the planetary gear and
planetary gear stop gasket, and put on the planetary gear
shaft.
Remark: The half-axle gear and the planetary gear should run
freely without stagnant.
(d) Measure the clearance between the half axle gear thrust
gasket and differential housing.
Push the planetary gear to the inside and then measure
the clearance between half-axle gear thrust gasket and
the differential housing with the dial-indicating lamp.
Suitable clearance range: (0.4-0.75)mm
Remark:If the clearance fails to fall within the above-
mentioned range, change the half-axle gear thrust gasket,
and ensure that the thrust gaskets on the both sides are
same thick.
(e) Tap the pin in the pinhole of differential housing and the
planetary gear shaft with SST, and rivet the hole port so
as to prevent the pin from missing.
Suspension System Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-72
(f) Clean the differential housing surface, mount the axle
driven bevel gear on the differential housing with copper
bar.
Notice: align the assembly marks made when
disassembling when mounting the axle driven bevel
gear, and tap in the driven bevel gear evenly alongside
the direction of circumference.
(g) Mount on the lock plate and screw on the bolts, then lock
the lock plate with the drift pinch and hammer.
Fastening torque
(70-90)N
m
Notice: the bolts should be screwed up in the diagonal
order in such manner that tighten a little at first, and then
screw up evenly to the specified torque, the lock plate
claw should contact closely the side face of bolt head.
(h) Press the inner race and roller assembly of bearing
50KB801 in the bearing position at the both sides of
differential housing.
(i) Put the adjusting gasket in the outer position of the side
bearing of front speed reducer shell.
(j) Encase another adjusting gasket with the outer race of
bearing 50KB801 in the front speed reducer shell to-
gether with the differential.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)
(k) Mount on the right and left cap-differential bearing, and
screw up the bolts with spanner according to the specified
torque.
Fastening torque
78N
m

SA-73
(l) Run the flange to check the swing difference of axle
driven bevel gear.
Max swing difference
0.07mm
Remark: if the requirement is not satisfied, tear down the axle
driven bevel gear from the differential, and then screw up the
bolts again.
8. Change the bearing of the long semi-axis:
(a) Take down the retainer ring with the calipers.
(b) Tear down the grooved ball bearing from the long semi-
axis.
(c) Mount on the new grooved ball bearing on the long semi-
axis
(d) Mount on the retainer ring with calipers.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)