2006 GREAT WALL HOVER oil

Replacement of front reducer assembly oil seal
1. Remove the front drive axle assembly
(Refer to “Removal of Front Reducer Assembly”)
2. Remove the left and right front drive shaft assem-
bly from the front drive axle assembly.
3. Remove and replace the lower oil seal according to
the removal and installation procedure of front drive
shaft assembly and install the new side oil seal on
the front drive shaft, then install them in the front
reducer assembly.
(Refer to “Removal and Installation of Front Drive Shaft
Assembly”)
Replacement of oil seal and major semiaxle oil seal of front reducer assembly
major semiaxle oil seal
major semiaxle pressing assembly
circlip
mechanical wheel of separator
Pregummed component N
m: Specified torque

Replacement of major semiaxle oil seal
1. Make the electric clutch is in the 4WD status,
them stop the engine and remove the front drive
axle assembly (see the disassembly of front reducer
assembly)
2. Use the wrench to screw off the bolt which fix the
front axle vent tube connectorassemblyonventtubeb
racket bolt
3. Disconnect the connector between vent tube of
electric clutch housing and front drive axle vent tube
connector assembly
4. Disconnect the connector between the vent tubes
on the electric clutch and vent tube connector
assembly.
5. Remove the bolt which is used to fix the electric
clutch housing and front axle tube flange; use the
brass bar to open the electric clutch housing and take
out the mechanical wheel of separator.
Caution: The lubrication oil will flow out when sepa-
rate the electric clutch housing from the front axle
flange. It should use the container to hold it.
mechanical wheel of separator
disconnect the place
disconnect the place

circlip
circlip pliers
special tools
8. Use the special tools to remove the major semiaxle
oil seal.
Caution: Do not scratch the inner surface of flange.6
Use the circlip pliers to remove the circlip
which clamp the major semiaxle bearing outer race.
7
Use the special tools to remove the major
semiaxle and bearing, circlip assembly.
liftout bolt
bolt pin
Pad
special tools

9. Remove the sealant on the matching surface
between the flange and electric clutch housing by
knife.
Caution: Do not scratch the matching surface.
10. Use the special tools to knock the new seal in the
oil seal position in flange.
Caution: Before install the new oil seal, it should
coat the lip with thin lithium base grease, and the oil
seal should be in alignment position.
11. Insert the spline of small end of major semiaxle
in the spline of front reducer half axle gear slightly,
then use the brass bar and hand hammer to knock it
in.
Caution: When knock in the major semiaxle, must
not damage the inside needle bearing of large end
spline of major semiaxle.
12. Use the circlip pliers to install the circlip in the
flange and clamp the bearing outer race.
Caution: The circlip should be replaced if it has
serious deformation.
13. Use the clean cloth to wipe the matching surface
of flange and electric clutch housing respectively.

14. Align the spline of mechanical wheel of separator
with the spline in front drive shaft and separator
shift fork sleeve, and install it in the front drive
shaft and separator shift fork sleeve.
15. Coat the flange matching surface with the 1596
silicon rubber plane sealant uniformly and level it by
plate.
Caution: Ensure the continuity of sealant and avoid
the sealant enter into the screw hole.
16. Align the shift fork bush with the spline on the
major semiaxle to make the mechanical wheel of
separator enters into the major semiaxle, then use
the bolt to connect the electric clutch housing and
front axle pipe flange and tighten it to the specified
torque. In which the bolt should be precoated with
the screw locking agent (drip one or two drops on the
middle of screw).
specified torque : 90-110Nm
Caution: Prevent the foreign material from entering into the
front drive axle during assembly.
17. Use the wrench to tighten the bolt of vent tube
bracket to tightening torque.
Tightening force: 23-26Nm
18. Screw off the oil filling plug on the electric clutch
housing, remove the washer and fill it with the gear
lubrication oil until flush with the bottom of oil
filling port.
Number of lubrication oil: GL-5
19. Place the washer of oil filling plug, tighten the oil
filling plug to specified torque.
Specified torque: 140-150N.m

Disassembly and assembly of front reducer assembly and electric clutch
adjusting shim
bearing gland
differential housing
driven bevel gear
front drive axle housing
washer
oil filling plug
vent tube
clip
front axle vents tube
connector assembly
major semiaxle
needle bearingelectric clutch
location pin
vent tube
mechanical wheel of separator
declutch shift sleeve
electric clutch housing
oil filling plug
circlip
major semiaxle oil seal
half axle gear thrust plate
half axle gear
planetary gear shaft
planetary gear
bolt clump
weight bracketclump weight and bush
assembly
clump weight bracket
welded assembly
front reducer
housing
adjusting washerspacer
drive bevel gear
small bearingoil sealfront drive gear flange and
dustproof cover assembly
drive bevel gearadjusting washer
Pregummed component
N m: Specified torque
Used component which
can not be used any more.bearing
circlip
big bearing

Disassembly of front reducer assembly
1. Remove the front drive axle and left and right
front drive shaft assembly.
(Refer to “Removal of Front Reducer Assembly”
and “Removal of Front Drive Shaft Assembly”)
2. Disconnect three interface positions of front drive
axle vent tube connector assembly.
3. Use the flat screwdriver to pry off the clip fixed
the vent tube connector assembly and take out
the vent tube connector assembly.
4. Screw off the bolt fixed the electric clutch and use
the brass bar to knock down the electric clutch.
5. Use the wrench to remove the oil filling plug;
remove the washer and pull out the vent tube.
6. Use the wrench to remove the bolt connected to
the electric clutch housing and front axle tubeflange;
take out the shift fork sleeve and mechanical wheel
of separator.
Caution: The leaked gear oil during disassembly
should be stored in the container to avoid the
pollution for environment.
disconnected in
this place
disconnected in this place
disconnected in this place

7. Use the circlip pliers to remove the circlip fixed
the major semiaxle bearing outer race.
8. Use the special tools to pull out the major semiaxle
and major semiaxle bearing with the major semiaxle
inner race circlip.
(Refer to “Replacement of Major Semiaxle Oil Seal”)
9. Use the special tools to remove the major semiaxle
oil seal.
(Refer to “Replacement of Major Semiaxle Oil Seal”)
10. Pull out the vent tube on the front axle tube.
11. Use the circlip pliers to remove the circlip. Fasten
the major semiaxle bearing inner race.
12. Press out the major semiaxle bearing on press
machine. (Or knocked out by hand hammer)
Caution: Don’t damage the end spline of major
semiaxle.
13. Use the special tools to pull out the needle bear-
ing in major semiaxle.
Caution: It should use the pad when use the vise to
clamp the major semiaxle.
14. Use the wrench to remove the bolt which is used
to fix the clump weight and axle bush assembly, take
off the clump weight and axle bush assembly.
special tools