2006 GREAT WALL HOVER lock

c.Use the special pneumatic pliers to lock the large and small clip of
outer jacket.
d.Ensure the jacket of both sides does not be prolonged or shortened
when the front drive shaft has the standard length.
Standard length: 400.5mm
If only need to replace the outer components of front drive
shaft assembly on car, it can remove the left and right steer-
ing knuckle of car, then disconnect the inner trumpet con-
nector of front drive shaft assembly, then take out the three-
pin section assembly and shaft from the inner trumpet con-
nector for replacement.
Installation of constant-speed drive shaft assem-
bly on front drive axle
1. Insert the hanger plank into the drive shaft, inserted
with oil seal; use the circlip pliers to install the inner
circlip.
Caution: It should replace the oil seal if damaged.
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circlip pliers
support the lower end

Use the special tools to knock bearing in slightly.
Caution: Support the lower end of the drive shaft assembly
when knock the bearing in. The lower end must not slide out.
3. Use the circlip pliers to install the outer circlip on
the front drive shaft assembly.
4. Repeat the previous method to install the hanger
plank, oil seal, circlip, bearing and circlip on another
end.
5. Insert the spline of connecting end of drive shaft
and reducer into the differential halfaxle gear spline
hole of electric clutch and reducer slowly.
6. Drip 1-2 drop of screw lock agent on the middle of
screw of connecting bolt of hanger plank andreducer.
7. Use the wrench to tighten the connecting bolt of
hanger plank and drive axle to specified torque.
specified torque : 90-110N
m
Caution: It should screw on all bolts before tighten
them, then tighten them in diagonal direction.
Check the hanger plank for levelness after tightened
the bolt to the specified torque. Remove the hanger
plank and reinstall it if is not planished.
8. Install the vent tube connector assembly; connect
all ports to front drive axle.
(Refer to “Assembly of Front Reducer Assembly”)
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support the lower end

Specified torque : 200-220Nm
Caution: Drip 1-2 drop of screw lock agent on the middle front
part of the lifting bolt
10Use the bolt to connect the front drive axle flange
and drive shaft according to the mark mage before
disassembly and tighten it to the specified torque.
specified torque: 73-83N.m
11. Install the beam under the front drive axle.
Tighten the beam connecting bolt to the specified
torque.
specified torque: 73-83N.m

5. Remove the drive gear flange and dustproof cover
assembly
a. Use the hand hammer and chisel to loose the riveted part on
nut.
b. Use the special tools to clamp the drive gear flangeandremove
the drive gear nut.
c. Use the cooper bar to knock down the drive gear flange and
dustproof cover assembly.
6. Remove the drive gear oil seal
Use the special tools to remove the oil seal; do not
damage the inner wall of reducer housing.
7. Install the new drive gear oil seal
a. Use the special tools to knock into the new oil seal.
b. The top of the oil seal is level to the top of reducer housing.
Caution: Coat the oil seal lip with the lithium base grease and
the oil seal should be in correct position.
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rotate the wrench in clockwise.
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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

15. Use the wrench to remove the bolt fixed the
clump weight bracket welded assembly.
16. Use the wrench to remove the bolt and nut used
to fix the front reducer assembly and front axle
housing.
17. Use the brass rod or hand hammer to knock the
front reducer housing to separate it from the front
drive axle housing.
18. Check the run-out of driven bevel gear.
Rotate the flange; use the dial indicator to measure
the run-out of driven bel gear.
Max. Runout: 0.07mm
It should replace the drive and driven bevel gear totally if the run-
out is more than 0.07mm.
19Check the running clearance of drive and
driven bevel gear.
a. Install the dial indicator and ensure the side axis is vertical to
contact tooth surface.
b. Hold the drive gear flange and rotate the driven bevel gear in
clockwise and anticlockwise to measure the clearance.
Specified range of clearance: 0.15-0.25mm
Remarks: Check three average points on circumference of driven
bevel gear at least.

25. Use the special tools to remove the small
bearing inner race, and then reverse the reducer
to slide out the spacer.
Remarks: The bearing should be replaced by new
one if damaged.
26. Use the wrench to remove two bearing glands.
Remarks: It should distinguish the left and right of
the bearing gland when remove it to avoid the
confusion.
Remove the side bearing outer race and marked
with L and R.
29. Remove the left and right adjusting washer; mea-
sure its thickness; marked with left and right. 27. Use the brass rod to vibrate the differential
assembly upwardly, then take out the differential
assembly.
holding
pliers
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rotate the wrench in clockwise
24. Use the special tools to remove the drive gear oil
seal.

b. Knock out the planetary gear shaft, rotate the half axle gear to
take out the planetary gear, then take out the half axle gear
and thrust plate.
7. Assembly of differential assembly.
a. Wash the differential housing.
b. Cover the half axle gear thrust plate with the half axle gear,
then installs it in the differential housing.
c. Rotate the half axle gear; install the planetary gear in rolling
and insert the planetary gear shaft.
d. Use the special tools to hit the pin to fix the planetary gear
shaft, and rivet the inserted hole to prevent the loose of pin.
Remarks: The rotation of half axle gear and planetary gear
should be smooth and without block; push the planetary gear
to inside, then use the dial indicator to measure the clearance
between the half axle gear thrust plate and differential
housing.
Rational clearance range: 0.4-0.75mm
It is necessary to replace the half axle gear thrust plate if the
clearance is beyond the previous range, at the same time ensure the
thrust plate in left and right side has the same thickness.
e. Check the clearance between the half axle gear thrust plate and
differential housing.
special tools