2006 GREAT WALL DEER Service Manual

CL-8Clutch
Clutch Cluster
Inspection on clutch parts
1. Check whether there is abrasion or damage of clutch rib;
Measure the depth of the rivet head with calipers.
Min depth of rivet head: 0.3mm
If the depth of rivet head exceeds the limit value, change the
clutch rib.
2. Check the radial pendulum difference of the clutch
Check the radial pendulum difference of the clutch rib with
multi-meter.
Max radial pendulum difference: 0.8mm
If the radial pendulum difference exceeds the max value,
change the clutch rib.
3. measure the rdial pendulum difference of the flywheel;
Check the radial pendulum difference of flywheel with multi-
meter;
Max radial pendulum difference: 0.2mm
If the radial pendulum difference exceeds the max value,
change the flywheel.
4. Check the guide bearing
Exert the force in radial direction to rotate the bearing by hand.
If the guide bearing doesn
t run or if there is great resistance,
change the guide bearing.
Remark: as this bearing is lubricated permanently, it needs not
to be cleaned or lubricated.
5. Change the guide bearing where necessary.
a) Tear down the guide bearing with SST;
SST

CL-9Clutch
Clutch cluster
b) Mount the guide bearing with SST.
Remark: the bearing shall be verified in good running after it
is encased in the flywheel hub.
2. Check whether there is abrasion on the diaphragm spring.
Check the abrasion depth and width of diaphragm spring with
calipers.
Limit value: Max depth: 0.6mm
Max width: 5mm
If the abrasion depth or width of the diaphragm spring exceeds
the limit value, change the diaphragm spring .
3. Check the separation bearing
Exert force in radial direction by hand to rotate the bearing.
If it cannot be rotated or if the resistance is too large, change
the separation bearing.
Remark:
Remark: as this bearing is lubricated permanently, it doesnít
need to be cleaned or lubricated.
Mount of clutch cluster
1. Mount the clutch rib on flywheel;
Mount the clutch rib on flywheel with SST.
2. Mount the clutch pressure plate
a) Align the marks on clutch pressure plate and that on flywheel;
b) Screw up the bolts in even manner around the clutch pressure
plate until pressure plate and the flywheel contact closely,
then tighten the bolts.
Tightening moment: 30 N
m
Remark: tighten the uppermost bolt of the three that is near to
the locating pin.
SST
flywheel sideSST
alignment
mark

CL-10Clutch
Clutch Cluster
3. Check the alignment of the diaphragm spring end.
Check the alignment of diaphragm spring end with SST.
Max dislocation: 0.5mm
if the difference is more than the specified value, adjust the
alignment of diaphragm spring end with SST.
4. Coat the lithium base grease;
Coat the lithium base grease on the following parts:

Contact spot of separation fork and bearing

Contact spot of separation fork and push-rod;

Support spots of separation fork

Spline of clutch rib
5. Encase the dust cover, separation fork, separation bearing
seat and bearing into the gearbox;
6. Mount the gearbox.
SST

MT-1
Gear box
page
Notice ........................................................................... MT-2
Troubleshooting ........................................................... MT-3
Dismantle of Gear Box ................................................. MT-4
Mount of Gear Box ....................................................... MT-7
Disassembly of Gear Box ............................................. MT-10
Input Shaft Assembly ................................................... MT-18
Element Drawing ...................................................... MT-18
Inspection on Synchronizing Ring ............................ MT-18
Bearing Change ....................................................... MT-18
Output Shaft Assembly ................................................. MT-20
Element Drawing ...................................................... MT-20
Disassembly of Output Shaft Assembly .................... MT-21
Inspection on Output Shaft Assembly ...................... MT-23
assembly of Output Shaft Assembly ......................... MT-25
Countershaft Assembly And Reverse Idle Gear
Assembly ...................................................................... MT-29
Element Drawing ...................................................... MT-29
Disassembly Inspection and Assembly of
Countershaft Assembly ............................................. MT-29
Assembly of Reverse Gear ...................................... MT-31
Rear Housing assembly ............................................... MT-33
Element Drawing ...................................................... MT-33
Change of Oil Seal ................................................... MT-33
Change of Shaft Bush .............................................. MT-33
Inspection on and change of Position-Limit
Mechanism Cluster ................................................... MT-34
Front Cover of Bearing ................................................. MT-36
Element Drawing ...................................................... MT-36
Change of Oil Seal ................................................... MT-36
Assembly of Gear Box ................................................. MT-37
MT

MT-2Gear Box
Notice
Notice
Notice for disassembly and assembly of gearbox
Notice shall be taken during the gear disassembly and assembly on the soft handle for the parts, especially
for the coupling faces so as to avoid the collision; each part shall be put down in order to avoid the missing
or mistaking.
Notice shall not only be taken in the aforesaid aspects, but also in the following items
1. Wash all parts before assembly (rubber fittings and washers excluded).
2. Various oil seals, retainer rings for shafts, spring-type pins shall not be reused.
3. Lubricating oil shall be coated on the friction surfaces, and lubricating grease shall be coated on the lips
of oil seals.
4. Rolling elements shall not be used to transfer the pressure during the various bearing assembly.
5. Lip-type oil seal must not be sloping when assembling it.
6. The openness at the two ends of the spring collar shall be misfit when assembling the component
elements of the synchronizing instrument, and
7. No part is allowed to leak the lubricating oil when the gearbox locating at its working place.

MT-3
Troubleshooting
Gear Box
Troubleshooting
Non-use of clutch
Non-full separation of clutch
Severely warned tooth rings of synchronizing
fittings
Over-hard locating springUse the right driving approach
Checking for adjustment
Change
Change Difficulty in gear engagement
Over-low oil level
Lubricating oil of inferior quality
Non-timely oil change
Unsuitable axial location or clearance of gears
Bearing damage
Burr or collision on gearAdd oil to the specified level
Change it with the specified oil
Change the oil and damaged parts
Check for adjustment
Change
Repair or change the gear
Oil leakage, oil penetration Oil added above the specified level
Loss or missing of bolts
Vent plug trouble
Sealing element damageAdjust oil to the given level
Reassembling or fasten the bolt according to
the specified torque
Change
Change
Damage of synchronizer Overexert in gear shift
Non-use of clutch
Damage on spring collar of synchronizer
Incorrect mounting of drive shaftChange
Use the right driving approach
Change
Check for adjustment
Non-engagement of gear Trouble in controlling mechanism
Incorrect assembling the locating spring or
steel ball
Invalidation of locating spring
Severely worn gear sleeve or fork groove
Seriously worn toggle forkCheck for adjustment
Reassembly
Change
Change
Change
Burning bearing, burning gear Over-low oil level
Inferior lubricating grease
Non-timely oil change, over-dirty oil
Inter-use of differential oil or usage of
additiveChange damaged parts and add oil
Change the damaged parts and lubricating oil
Change damaged parts and lubricating oil
Change damaged parts and lubricating oil
Difficult in gear disengagement Spring invalidation of synchronizer
Warn inner groove of tooth ring of synchronizer
Tooth ring of synchronizer choked on conical
face
Toggle fork deformation or toggle fork axle
deformation
Severely worn toggle forkChange
Change
Change
Change
Change
Methods for troubleshooting
Over-loud or abnormal noise
Common Failures Causes

MT-4Gearbox
Dismantle of Gear Box
3. Tear down the shifting ball of gear change lever
Loose the locking nuts by dextroroting the ball.
4. Tear down the glove box
Dismantle the four bolts of the glove box and put the glove box
into the suitable place.
5. Tear down the dust cover.
6. Tear down the gear change lever.
7. Raise the vehicle to discharge the oil in gearbox.
Warning: the reliability of vehicle shall be verified.
8. Tear down the drive shaft.
(See page PR-5)
9. Tear down the odometer sensor and the plugging
elements of backup switch
10. Tear down the vent pipe.
Tear down the heading exhaust pipe from branch exhaust pipe
Dismantle of gearbox
1. Disconnect the cathode wire from the cathode of storage
cell.
2. Tear down the setting bolts of fan cover.
Tear down 4

MT-5Gearbox
Dismantle of Gear Box
4WD
11. Tear down the wheel-brake cylinder of clutch.
(a) Dismantle the setting bolts of the wheel-brake cylinder of
clutch with spanner.
(b) Hang the wheel-brake cylinder with a thread on the side
of engine without oscillation.
Remark: Do not disconnect the pipeline of the wheel-brake
cylinder.
12. Tear down the pawl washer and bracket of the rear part
of gearbox:
Two-wheel driving:
(a) Dismantle the four bracket bolts (skip over this process
for the wielding structure).
(b) Lift the engine with jack to raise the gearbox a little.
(c) Dismantle the pawl washer from the rear part of gearbox.
Four-wheel driving:
Dismantle the bolts from the pawl washer and bracket of the
rear part of gearbox to tear down the pawl washer and bracket.
13. Insert the wooden plate between the bottom frame and
the beam.