2006 GREAT WALL HOVER weight

Troubleshooting
Failure Cause Repair cont ent
Floating/pulling The t yre is worn or charged improperly.

The front wheel alignment is incorrect.

The wheel bearing is adjusted too tightened.
The front /rear suspension components is loose or
damaged
The steering linkage is loose or worn
The steering device is connect ed unsound or worn. Charge the t yre to the prop er pressur e or
repla ce the t yre.
Check the condition of front wheel
alignment.
Adjust the wheel bearing
Tighten or replace the suspension
partTighten or replace the steering
linkage
Adjust or replace the steering device
Subsidence of vehicle body Overload of vehicle
vibration damper is worn
spring is weak Check the load weight
Replace the vibration damper
Replace the spring
Left-right swing/up-down
bounce The t yre is charged improperly
The stabilizer bar is bend or damaged
The vibration damper is worn Charge the t yre to the prop er pressur e
Replace the stabilizer bar
Replace the vibration damper
Front wheel vibration The t yre is worn or is charged improperly

Unbalance of each wheel
The vibration damper is worn
The front wheel alignment is incorrect

The wheel bearing is worn or adjusted badly
The ball joint or bushing is worn
The steering system is loose or worn
The steering mechanism is adjusted badly or damaged Repla ce the t yr e or char ge it to the prop er
pressure.
Balance all wheels
Replace the vibration damper
Check the condition of front wheel
alignment
Replace or adjust the wheel bearing
Check the ball joint or bushing
Tighten or replace the steering linkage
Adjust or repair the steering device
Abnormal abrasion of tyre The t yre is charged improperly
The vibration damper is worn
The front wheel alignment is badly

The suspension part is worn Charge the t yre to the prop er pressur e
Replace the vibration damper
Check the condition of front wheel
alignment
Replace the suspension part
Oil leakage of differential High oil level or incorrect oil grade

The oil seal is worn or damaged
The matching flange is loose or damaged Drain the oil to the specified level or
repla ce the oil
Replace the oil seal
Tighten or replace the flange
The axle has the nois e The oil grade is low or incorrect

The clearance of the pinion, ring gear or side gear is
large.
The ring, pinion gear or side gear is worn or broken
The pinion gear bearing is worn
The b earing of rear axle half shaft is worn.
The differential b earing is loos e or worn Fill with the lubrication oil or replace the
oil according to the specification
Check the clearance

Check each gear
Replace the bearing
Replace the bearing
Tighten or replace the bearing

8. Use the jack to support the front reducer assembly
9. Remove the lifting bolt of front drive axle hanger
plank and carriage.
10. Remove the front drive axle assembly
Caution: Do not damage the drive shaft and front drive
shaft jacket
11. Remove the front drive shaft assembly of both sides
from the front drive axle assembly.
12. Use the wrench to remove the bolt and nut which is
used to fix the front reducer housing.
13. Remove the clump weight assembly and clump
weight bracket welded assembly
(Refer to “Disassembly of Front Reducer Assembly”)
electric clutch connector
N
m: specified torque

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

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

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.

23. Use the bolt coated with screw lock agent toconnect
the clump weight bracket welded assembly to the front
reducer housing and tighten it to the specified torque.
Specified torque : 20-26Nm
24.Use the bolt coated with screw lock agent to
connect the clump weight assembly to the clump
weight bracket assembly and tighten it to the speci-
fied torque.
Specified torque : 20-26Nm
The amount of screw lock agent could cover the screw.
25.Use the pneumaticto screw two studs on the correspon
ding screw hole on the front axle housing until the
limitation.
26. Coat the plane of front axle housing with the
continuous 1596 silicon rubber plane sealant, scrape
it to level by plate.
Caution: Avoid the screw hole when paint the sealant; prevent
the sealant enters into the screw hole.
27. Install the front reducer assembly on the front
drive axle housing and screw on the hexagon bolt and
spring washer combination; cap the spring washer on
the stud, tighten the nut to the specified torque.
(The screw of all bolts should be precoated with screw lock agent)
The specified tightening force of hexagon bolt and spring washer
combination, stud and nut should be: 18-25N
m
Caution: The bolt should be tightened in diagonal sequence
evenly; check the reducer housing and axle housing contacting
surface for gap; check the sealant from break. It should
remove the reducer for reinstallation if has the gap or break.
28. Screw the oil filling plug with washer on the front
drive axle.
Caution: Do not tighten it.
29. Screw the oil drain plug on the front drive axle.
Specified torque : 30-35Nm
30. Use the special tools to install the major semiaxle
oil seal in the front axle tube.
Caution: Precoat the lip of oil seal with thin lithium base grease
and the oil seal should be installed in position.
(It should coat the screw of the stud which is screwed
in the front axle housing with the screw lock agent, and
the amount should be just can cover the screw which is
screw in the front axle housing)
Caution: The position of stud should consist with that before
disassembly.