2006 GREAT WALL DEER Service Manual

BR-30
Assembly of Rear Brake
remark: assemble the parts according to the
direction in the drawing;
left wheel
right wheel forward
1. Assemble the wheel-brake cylinder:
(a) Coat moderate lithium soap base glycol grease on the
piston cup;
(b) Assemble the wheel-brake cylinder:

Mount the two piston cups on two piston;

Encase the spring and two pistons in the wheel cylinder
body and

Mount the two dust covers
Remark: Assembly shall be conducted correctly according to
the direction shown in the drawing.
2. Mount the wheel-brake cylinder:
(a) Use two bolts to fix the wheel-brake cylinder on the rear
bottom plate.
Coat moderate sealing glue (Glue 704) on the position where
the wheel-brake cylinder connects with the bottom plate.
Fastening torque
(16
20)N
m
(c) Connect the brake pipeline on the wheel-brake cylinder.
Fastening torque
18N
m
3. Coat the following parts with moderate lubricant that
resistant high temperature (do not pollute the friction
plates);
(a) The upper plain of the hex convex platform where the
bottom plate connects the brake shoe;
(b) Contact face of the brake shoe and the top lever of wheel
cylinder;
(c) Contact face of the brake shoe with the support pin. Braking System
Rear Brake (DR)
Assembly of Rear Brake
forward

BR-31
(d) Adjusting bolts
(e) Contact position where the clearance adjuster and the
brake shoe.
4. Mount the parking brake drag arm;
Mount the new split pin with pliers to mount the parking brake
drag arm.
5. Mount the rear brake shoe:
(a) Mount the parking brake bracing wire on the parking
brake drag arm.
(b) Mount the rear brake shoe in such way that its end is
inserted into the cylinder rod. Encase the pressure spring
drag rod in the brake bottom plate and the brake shoe
assembly in turn and then insert it in the pressure seat ,
pressure spring, pressure spring seat, finally rotate the
pressure spring in place with the pressure spring fork.
6. Mount the parking brake pull plate and the front brake shoe:
(a) Mount the pull plate and the spring.
(b) Mount the front brake shoe, of which, the end is inserted
in the piston rod, and mount the pull plate. Insert the
pressure spring drag rod in the brake bottom plate and
brake shoe assembly in turn, then encase it in the pressure
spring seat, pressure spring and pressure spring, finally
rotate the pressure spring in place with the pressure
spring.
7. Mount the tension spring;
Mount the tension spring with pliers. Braking System
Rear Brake (DR)

BR-32
8. Mount on the adjuster;
Poke the brake shoes with the screwdriver and then mount the
adjuster.
9. Mount the brake shoe retainer ring, bracing wire of
guide seat, self clearance-adjusting bracing wire and
the return spring.
(a) Mount the brake shoe retainer ring, then the front return
spring.
(b) Mount the return spring ,and then mount the forward
return spring.
10. Mount the self-clearance toggle plate:
(a) Mount the toggle plate bracing wire torsion spring on the
rear brake shoe.
(b) Mount the clearance self-adjusting toggle plate and hook
It with the clearance-adjusting bracing wire.
(9) Hook the self clearance-adjusting toggle plate with the
bracing wire torsion spring
11. Check the operation of self-adjusting mechanism.
(a) Drag the clearance-adjusting bracing wire backward as
shown in the drawing, then release it. Check the clear-
ance-adjusting bolts to see whether it is rotating. If not,
check the rear brake to verify which part has problem.
(b) Adjust the clearance adjuster to shorten its length as
possible as can.
(c) Mount the brake drum
forward
Braking System
Rear Brake (DR)

BR-33
12. Check the clearance between the brake shoe and the
brake drum:
(a) Tear down the brake drum;
(b) Measure the inner diameter of the brake drum and the
outer diameter of brake shoe to check whether the differ-
ence of the two diameters falls within the standard
clearance range.
Shoe clearance: 0.6mm
If it is not correct, check the parking brake system.
13. Mount the brake drum and the rear wheel; screw up
the nuts of rear wheel hub.
Fastening torque
(145
10)N
m
14. Fill the liquid container with brake liquid and exhaust
the air in braking system.
15. Check to see whether there is leakage of brake liquid.
Braking System
Rear Brake (DR)

BR-34
Rear brake
Element figure

Parts that cannot be reused after using.wheel-brake cylinder cluster
observation hole cork

claming pin
observation hole cork

front brake shoe
pressure spring caplower tension springupper tension spring clearance adjuster
rear brake shoe
brake lever
toggle plate

open retainer ring
clearance-adjusting spring
brake drum pressure spring
Disassembly of Rear Brake
1. Check the thickness of the brake shoe liner:
Tear down the observation hole cork I and measure the thickness
of brake shoe liner through the observation hole. If the thickness
if less than the min thickness, change the brake shoe.
Min thickness
1.0mm
2. Tear down the rear wheel.
3. Tear down the brake drum;
Remark: if the brake cannot be tear down easily, the following
steps shall be adapted:
(a) Tear down the observation hole cork II by inserting the
screwdriver in the hole of brake bottom plate, and poke
the toggle plate from the self-adjusting screw arbor.
(b) Loosen the brake shoe clearance adjuster with another
screwdriver by screwing the self-adjusting screw arbor. SF
Braking System
Rear Brake (SF)

BR-35
4. Tear down the front brake shoe:
(a)Tear down the tension spring from the front brake shoe;
(b) Tear down the pressure spring cap of brake shoe, the
pressure spring and claming pin.
(c) Tear down the lower tension spring from the front shoe
and the shoe pads.
(d) Tear down the lower tension spring from the rear shoe.
5. Tear down the rear brake shoe:
(a) Tear down the shoe pressure spring cap, pressure spring
and claming pin.
(b) Tear down the upper tension spring from the shoe pad.
(c) Tear down the rear brake shoe and the clearance adjuster.
(d) Tear down the parking brake bracing wire from the brake
shoe.
6. Tear down the clearance adjuster from the rear brake shoe:
(a) Tear down the clearance-adjusting spring.
(b) Tear down the clearance adjuster.
Braking System
Rear Brake (SF)

BR-36
7. Tear down the toggle plate and the brake lever:
(a) Tear down the open retainer ring;
(b) Tear down the toggle plate;
(c) Tear down the pin clip;
(d) Tear down the brake lever.
8. Tear down the wheel-brake cylinder:
(a) Tear down the brake pipeline. And block the pipeline
with a clean cork.
(b) Tear down the two bolts to take apart the wheel-brake
cylinder.
9. Tear down the following parts:
(a) Two dust covers;
(b) Two pistons;
(c) Two piston cups
(d) Spring. Braking System
Rear Brake (SF)

BR-37
Check and Repair the Brake Parts
1. Check the disassembled parts;
Check the disassembled parts to see whether there is abrasion,
rust or damage.
2. Measure the inner diameter of the brake drum;
Inner diameter
295.0mm
Max diameter
297.0mm
3. Measure the thickness of brake shoe liner;
Standard thickness
6.5mm
Min thickness
1.5mm
In case the thickness of brake shoe liner is less than the min
thickness or there is uneven abrasion, change the brake shoe.
Remark: if either brake shoe is required to change, all rear
brake shoes shall be changed to maintain the even braking
properties.
4. Check the brake shoe liner and the brake drum to see
whether there is close contact;
If there is poor contact between the brake shoe liner or brake
drum, repair or change the brake shoe cluster with the grinding
devices. Braking System
Rear Brake (SF)