2006 GREAT WALL DEER Body electric

Preface
With the increase of automobile demand in China, our automobile industry also experiences a rapid
development. The trucks including SUV, manufactured by Great Wall Motor Co., Ltd, which are sold all over
China, are in the leading place in terms of their sales volume, in order to satisfy the demands of various maintain-
ing staff, technicians and managing staff of Changcheng Co., Ltd, we compile this maintenance manual accord-
ing to the latest technological data. This manual covers six vehicle models including Deer, Safe, Sailor, Sing, So
Cool and Pegasus, its main content includes:
Part I is general introduction, which introduces the application index of this manual.
Part II introduces the chassis system, which mainly includes the technologies of dismantle, inspection,
adjustment, repairing, assembly and mount of the clutch, gear box, transfer box, drive shaft, suspension system
and automobile axle, braking system and steering system, etc. each operation approach is illustrated with figure,
which not only presents the maintenance procedure, but also clearly describes the technical requirements and
application limit.
Part III introduces the electric system and air-conditioning system of the automobile body, which mainly
covers such items as the location and content of protective box, power supply system, starting system, lighting
system, combination instrument, backup radar system, wiping and washing system, center control locking and
power window system, acoustical equipment system, full wire harness and air-conditioning system, etc. Electric-
ity diagrams for those electric systems are given in this manual so as to facilitate the maintaining technicians to
find out the problem easily and quickly.
Part IV introduces the external and internal body decoration, which mainly covers the dismantling, inspect-
ing and assembling requirements of the engine cover, front and rear doors, adhesive strip of body collision
avoidance, wheel shield, wrapping angle of wheel-shield and exterior trim panel, front and rear windshields,
side-window glass, rear-door glass, rear platform of cargo compartment, rear door, instrument panel, safety belt,
seat, tail-fin, luggage rack, and reserve tire bracket etc. The dimensions of vehicle body and frame are also given
to maintaining staff for reference during their repairing.
During the narrations of each part, items such as troubleshooting, maintenance notice, maintenance data
and application limit, fastening torques of bolts and nuts for special purpose, SST, SSM and lubricant materials
and so on are also introduced. Various maintenance data are briefed in attachment for reference.
Altogether, this manual is comprehensive in content, visual in illustration, clarifying in requirement and
plain in language. It can be referred by the maintaining staff, technicians and professional managing staff.
Even though we try our best to compile this manual in a strict earnest manner, we cannot guarantee that all
contents in this manual are correct. Therefore, users shall not put forward any claim with Great Wall Company
according to this manual; we are not in the position to hold the responsibility for the loss caused by usage of this
manual. Due to our limited knowledge, it is unavoidable to find error in this manual, any criticism and correction
from you is welcomed.
The final explanation power for this manual is subject to Great Wall Motor Co., Ltd
Compiler
May 2006

Service manual for
chassis and body
GeneralIN
ClutchCL
Gear boxMT
Transfer boxTF
Drive shaftPR
Suspension system and automobile axleSA
Braking systemBR
Steering systemSR
Body electric systemBE
Air-conditioning systemAC
Vehicle bodyBO
Maintenance and Up-keepingA
Special ToolB

IN-4
Overall Repairing Description
1. Keep the vehicle clean and prevent it from
damage with guard plate, seat and floor cover
cloth.
2. Put down the dismantled parts in order during
the dismantle process so as to facilitate the re-
assembly
3. Observe the following items:
a) Disconnect the cable cathode from the
accumulator terminal before the electric
operation;.
b) Disconnect the cable from the cathode
connected to the vehicle body when check-
ing or repairing the accumulator where
necessary.
c) In order to avoid the damage of terminal
post of accumulator, loose the bolts first,
then pull up the cable vertically when
dismantling, don
t wring it or prize it.
d) Clean the terminal posts of the accumula-
tor with dishcloth, and do not scrape them
with file or other similar tools to avoid
damage.e) Mount the cable terminal on the post with loosened nut, then
fasten the nut. donít tap the terminal onto the post with
hammer.
f) Be sure to check whether the cover of positive terminal (+) is
well located or not.
4. Check all hoses and wire plugs to verify whether they are
connected solidly and correctly.
5. Parts that cannot be reused after being used.
a) The following parts should be changed with new one regularly:
split pin, sealing washer, O-ring and oil seal, etc.
b) parts that cannot be reused after being used is marked with

 in the element figure.
6. Pre-coated parts
The pre-coated parts including the bolt and nut are coated with
locking seal glue in factory.
a) In case the pre-coated parts are moved due to its fastening,
loosening or other causes, they must be coated again with the
specified seal glue.
b) Coating procedure of pre-coated parts
1) Clear away the former seal glue from the screw thread of
the said parts.
2) Dry the parts with compressed air.
3) Coat the screw thread of the parts with the specified
locking seal glue.
c) The pre-coated parts are marked with the
 in element
figure.
7. When necessary, sealing agent or sealing ring to prevent the
leakage.
8. Each specification shall be followed strictly. And the torque
spanners should be used.
9. Determine the necessity of using the special service tools (SST)
or special service materials (SSM) according to the real situation.
SST and SSM must be used where necessary and the repairing
should be in accordance with the repairing approach. SST list
and SSM list are attached to this manual.
10. Be sure to check whether the rated current of the new fuse is
correct when changing the fuse. The fuse rated current should
not larger than that of securing fitting and the fuse of smaller
rated current must not be used.
11. Be careful to hang or support the vehicle on the suitable place
when propping up or raising it.
a) In case prop up the vehicle at the front or back part, the wheels
must be blocked to guarantee the safety work. Introduction
Overall Repairing Rescription
tighten seal glue

IN-5
Body lifting height and supporting position
wrong correct
Introduction
Body Lifting Height and Supporting Position
Jack lifting position
...........................................................................................................
Front......the front the beam center
Rear.....rear differential
Supporting position

safety bracket .............................................................................................
front
123456
123456
123456
123456
123456
12345
12345
12345
12345
b) The raised vehicle must be supported with the bracket; it is
dangerous to conduct the repairing work on the vehicle propped
up with one jack, even though such repairing can be finished in
short time.
12. The following items shall be taken notice to avoid the parts damage:
a) Do not open the covers of ECU and various computers where not
necessary absolutely. (if the IC terminal is touched, it be leaded
into static damage) .
b) Pull the hose at its ends when dismantling it, do not pull it at the
center section.
c) Pull the wire joint instead of the wire when pulling the joint
away.
d) Take notice to avoid of the drop of electric parts such as the
sensors or repeaters. In case those parts drop to the hard ground,
they must be changed instead of being reused.
e) Do not use the striking spanner to dismantle or mount the
thermostatic switch or thermostatic sensor.
f) Plug the needles of the multi-meter into the wire connector
carefully when checking its conductance and do not bend the
terminals.
g) Do not sheath the hose of the vacuum gauge into the very large
connector when using the gauge, instead, the stage joint shall be
used because once the hose expands, it is possible to lead into
the leakage.

TF-9
5 4
3
1
6 2
1. rear body of transfer box
2. flange
3. oil seal
1. sensor bracket
2. bolt
3. speed sensor
4. o-ring
5. sensor assembly
6. bolt
7. gasket
8. rear body of transfer box2 1
5 3
4
4
6
7
8
Transfer Box
Disassembly of Transfer Box
4. gasket
5. nut
6. oil plug
Disassembly of Transfer Box
1. Brief instruction
In case the transfer box is required to be repaired for the
damaged specific element, it shall be taken apart to the degree
on which the damaged element is taken out. And the parts
taken apart from the transfer box, if it doesnít include the
damage element, can exist in the form of sub-assembly or
group instead the individual form, otherwise, the parts will be
taken apart individually.
2. Transfer Box Disassembly
Put the transfer box on the worktable and ensure the rear part
or the rear cover faces upward. Put the wooden block under the
front part of transfer box to keep the transfer box stands
horizontally. The disassembly process is as follows:
(a) Fasten the flange with the torque arm typed T-13-54-
002, screw off the nut to take down the gasket, then take
apart the flange and oil seal.
(b) Take down the two oil plugs from the transfer box body.
As for the electric gearshift transfer box, tear down the
electric shifting element according to the following
disassembly approach:
(a) Tear down the three bolts, gaskets, sensor and clip for
wire harness.
(b) Tear down the sensor assembly and take apart the O-
ring.
(c) Tear down the motor assembly.

TF-10
1. output shaft
2. shift engagement sleeve assembly
3. locking sleeve
4. return spring
5. engagement sleeve
6. snapping ring
7. shift lock hub
8. clutch assembly
9. fastening snapping ring
10.shift guide shaft
11.toggle fork
Transfer Box
Disassembly of Transfer Box
1. front case of transfer box
2. rear output shaft
3. cluch coil assembly
4. clip
5. bearing
6. nut
7. transfer cover assembly
8. mark plat
9. bolt
10. odometer drave gear
11. oil seal
12. oil seal
13. bearing
14. rear cover of transfer box
15. rolling needle bearing
16. shift guide shaft
17. back spring
18. magnet
19. bundle clip10
9
8
12
13
14
157 7
6
5
4
3
16
17
18 2
1
19
911
3. The disassembly approach for rear cover is as follows (above figure)
(a) Dismantle the nine screws and take down the clip of wire harness and
signboard in the same time.
Notice shall be taken to good keeping for the signboard, which includes the
information for the substitutes to be changed.
(b) Pry the frame lightly so that the sealing glue on the surface disengages, and
then take up the transfer box rear cover assembly directly.
(c) As for the electric gearshift transfer box, tear down the oil seal, bearing and
three nuts and clutch coil assembly.
(d) Tear down the snapping ring, pull out the bearing from the rear cover and
take apart the odometer meanwhile.
(f) Pull out the oil seal from the rear cover of the transfer box.
(g) Tear down the magnet from the front body of transfer box.
(h) Take apart the return spring from the shift guide shaft
(i) Clear away the sealing glue on the coupling face of the front housing and
rear cover of transfer box, take notice not to damage the coupling face of
the two housings or cause the materials removed dropping into the transfer
box.
4. Tear down the shifting element connected with the front axle.
Tear down the following parts from the remaining transfer box housing
assembly (electric gearshift).
(a) Electric gearshift assembly, tear down the snapping ring and sliding clutch
sleeve from the shift locking hub.
(b) Tear down the shift-locking hub from the rear output shaft.
(c) Tear down the shift engagement sleeve assembly and shift toggle fork from
the rear output shaft and shift guide shaft. Separate the assemblies one
another and tear down the shift guide shaft.
(d) Disassemble the shift engagement sleeve assembly by taking apart the
snapping ring, engagement sleeve, return spring, and locking sleeve.
(e) A plastic toggle fork that substitutes the metal toggle fork assembly and a
independent contact roller in earlier time.
1
9
8
7
6
5
Q
32
10
11

TF-13
1
234
5
7
6
5
4
3
21
Transfer Box
Disassembly of Transfer Box
10. Take apart the shift convex plate parts (for the electric
shift transfer box)
(a) Take apart the integrated electric shifting cam from the
transfer box housing.
(b) Take apart the electric shifting cam from the shift guide
shaft.
(c) Grip the end of shift guide shaft with soft-jaw vices, and
tap the shaft with a screwdriver until the torsion spring
drops off.
1. front body of transfer box housing
2. shift guide shaft
3. torsion spring
4. electric gearshift
5. gasket
1. transfer box front housing assembly
2. gear ring
3. oil seal
4. transfer box front housing
5. locating pin
6. ball bearing
7. snapping ring
11. Disassemble the transfer box housing assembly
Disassemble the transfer box housing assembly in the manner
as follows.
(a) Take apart the oil seal.
(b) Take apart the snapping ring, and pull out the bearing.
(c) The locating pin may only be taken apart from the transfer
box front housing in the case that the pin is loose or
damaged, and
(d) Where the gear ring needs to be changed, it may be
pressed out from the transfer box housing.

TF-16
110
9
8
6
5
4
3
2
11
15
14
13
12
17
18
19
207
16
1
2
3
Transfer Box
Transfer Box Assembly
1. torsion spring
2. gasket
3. shift shaft
1. planetary mechanism
assembly
2. gasket
3. snapping ring
4. thrust disc
5. sun wheel
6. planetary bracket
7. input shaft assembly
8. input shaft
9. needle bearing
10. bearing shell11. transfer box
frontbody assembly
12. oil seal
13. locating pin
14. transfer box front body
15. snapping ring
16. transfer box housing
17. bearing
18. bearing gripping loop
19. bolt
20. vent(d) Push the torsion spring and gasket backward together as
can as possible
(e) Mount the electric shifting cam on the shift shaft in such
way that the free end of the driving tongue of the cam is
put in first, fasten the cam driving tongue, which shall be
between the two spring ring of two torsion spring, under
the driving tongue of shift shaft and put it innermost as
can as possible.
(f) After mounting the toggle fork, then mount the electric
shifting cam assembly in the transfer box housing assembly
5. Assemble for front body, input shaft assembly and plan-
etary component element.
Mount the following element on the worktable:
(a) Put the planetary bracket assembly on worktable, and the
end with snapping ring groove shall face upward.
(b) Mount in the sun wheel and let the part with projecting
end upward, run the gear of the planetary bracket assem-
bly until it completely engages with the sun wheel.
(c) Flush the projecting teeth, and then mount the thrust disc
into the planetary bracket assembly.
(d) Mount in the snapping ring to complete the whole plan-
etary bracket assembly.