2006 GREAT WALL DEER Service Manual

MT-30 Gear Box
Countershaft Assembly and Reverse Idle Gear Assembly ( Countershaft Assembly Disassembly, Testing and Assembly)
3. Reverse gear inspection
Measure the diameter of needle bearing with micrometer.
Standard diameter

Shang Chi
26.000mm
Tang Chi
(25.98
26.00)
Limit Diameter

Shang Chi
25.984mm
Tang Chi
25.86mm
4. Check the synchronizing ring
(a) Run the retainer ring for shaft and put it onto the shaft to
check itsstopping performance
(b) Measure the clearance between the rear section of the
synchronizing ring and the spline.
Standard clearance:
Shang Chi
(1.5
1.8)mm
Tang Chi
(1
2)mm
Limit clearance: 0.8mm
5. Measure the clearance of the shift fork and gear sleeve.
Test the clearance of the shift fork and gear sleeve with the
feeler gauge.
Max clearance:
Shang Chi: 0.54mm
Tang Chi:1.0mm
6. Change the bearing
The front bearing of the reverse gear shall be changed when
necessary
(a) Pry down the retainer ring for shaft with a split-ring-type
pliers.

MT-31Gear Box
Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly)
SST
sleeve wrench
front
(b) Press out the bearing with SST.
(c) Press in the bearing, side race and inner race with the
socket spanner.
(d) Select the split ring that leave the radial clearance to
minimum level, and mount it on the shaft.
7. Mount the engagement sleeve of synchronizer, sliding
block and the five-speed spring collar.
Remark: the opens of the spring collar shall be in non-
alignment
Encase the sliding pad into the gear hub and then cover the
gear sleeve.
Mount the spring retainer under the sliding pad.
Notice, the opening direction of the spring retainer shall
not face-to-face.
Mount of Reverse Gear Assembly
1. Check the reverse idle gear
Measure the radial clearance of the reverse idle gear with dial
gauge.
Standard clearance:
Shang Chi
0.05mm; Tang Chi
(0.04
0.08)mm
Max clearance

Shang Chi
0.05mm; Tang Chi
0.13mm

MT-32Gear Box
Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly)
2. Measure the clearance between the reverse idle gear
and gearshift yoke block
Measure the clearance between the reverse idle gear and the
gearshift yoke block with feeler.
Standard clearance:
Shang Chi
0.2mm
Tang Chi
(0.05
0.27)mm
Max clearance

Shang Chi
0.35mm
Tang Chi
0.5mm

MT-33Gearbox
Rear Housing Assembly (Element Drawing, Change of Oil Seal, Change of Shaft Bush)
Rear Housing Assembly
Element drawing
Change of Oil Seal
1. The rear housing oil seal shall be changed where necessary.
(a) Dismantle the oil seal with SST.
(b) Press in the new oil seal with SST
2. The driven oil seal of speedometer shall be changed
where necessary
(a) Pry out the oil seal with SST.
(b) Tap the new oil seal into the shaft bracket with SST.
Change of Shaft Bush
The shaft bush shall be changed where necessary
(a) Tear down the oil seal and dust bush.
(b) Heat the ending parts of extension frame to 80
-100
in
the oil groove.
(c) Tear down the shaft bush with SST and mount on the new
shaft bush.
SST
SST
SST
SST
SST
oil reservoirlocating spring bolts and
spring cylindrical pinrear housing oil seal
assemblyrear housing dust
cover
oil groove
component element
of position-limit
mechanismrear housing
cluster

MT-34Gearbox
Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism)
Inspection on and change of the component
elements of position-limit mechanism
1. Tear down the component elements of position-limit
mechanism
(a) Dismantle the bolts with the torque socket spanner.
(b) Punch out the spring cylindrical pin with the drift punch
and hammer.
(c) Tear the component elements of position-limit mechanism
down.
2. Check the component element of position-limit mechanism.
Run and propel the limit stop and the limit stop can return
to the original location automatically, otherwise, change the
limit stop.
3.
Mount the component element of position-limit mechanism
(a) Mount the component elements of position-limit mecha-
nism in the rear housing.
(b) Tap the spring cylindrical pins in with drift punch and
hammer as shown in the drawing.

MT-35Gearbox
Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism)
(c) Coat the sealing agent on the bolt thread.
(d) Propel the plug with the torque socket spanner.

MT-36Gearbox
Bearing Front Cover Assembly (Element Drawing, Change of Oil Seal)
Bearing Front Cover Assembly
element drawing
bearing front cover
assembly
washerfront cover oil seal
assembly
Change of oil seal
The oil seal of the bearing front cover shall be changed where
necessary
(a) Pry out the oil seal with screwdriver
(b) Press in the new oil seal with SST.
Depth of oil seal:
Upper tooth
9.5mm
Tang tooth
(12.4
0.4)mm
SST

MT-37
Assembly of Gearbox
1. Mount the output shaft in the central link plate
(a) Tap the output shaft in the central link plate while pulling
it, until mounting it in the central link plate.
(b) Mount the stop ring of the rear bearing of output shaft in
with the split-ring-type pliers.
Remarks: The stop ring shall flush with the surface of central
link plate.
2. Mount the input shaft in output shaft
(a) Coat the MP lubricant on the bearing with 13 needle
rollers, and mount the needle rollers in input shaft.
(b) Propel the input shaft in the output shaft and flush the
groove of synchronizing ring with the sliding block.
3. Mount the countershaft in the central link plate
(a) Mount the stop ring on the rear bearing of countershaft
with split-ring-type pliers.
alignment
Gearbox
Assembly of Gearbox