2006 GREAT WALL HOVER Service Repair Manual

Chapter 6
Drive shaft

Cautions
Do not clamp the drive shaft bushing too tightened by the bench
vice to avoid the deformation.

failure Possible causes Method
Noise The spline of universal-joint fork is worn
The intermediate bearing is worn
The cross-axle bearing is worn or jammed Replace the universal-joint
fork
Replace the intermediate
bearing
Replace the cross-axle bearing
vibration Runout of drive shaft
Unbalance of drive shaft
The rear bearing bushing of transmission
extended housing is worn
The spline of universal-joint fork is jammed Replace the drive shaft
Replace the drive shaft
Replace the bushing
Replace the universal-joint
fork

Front axle propeller shaft (4WD) assembly
Rear axle propeller shaft (4WD) assembly
N m: Specified torque
universal-joint forkfront section of
rear axle propeller
shaft
intermediate sup-
port assembly
universal-
joint fork
shimnut
circlip
cross-axle assembly
rear section assembly of
rear axle propeller shaft
flange forkcirclip
cross-axle assembly
axle tube assembly
front axle drive shaft assembly
N
m: Specified torque
universal-joint fork
circlip
cross-axle
assembly
drive shaft axle
pipe assembly
N
m: Specified torqueflange fork

transmission
drive shaft assemblyrear axle assembly
front axle drive shaft assembly
transmissionrear axle drive
shaft assembly
transfer case
rear axle assembly
Disassembly of drive shaft:
Remove the intermediate support bolt of drive shaft firstly (CC6460KY
is without intermediate support connecting bolt ), then remove the
connecting bolt between the drive shaft and rear axle , lastly, pull out
the drive shaft assembly from the transmission output spline shaft and
remove it in integral.
Installation of drive shaft:
1. Firstly, check the drive shaft for damage, spline for corrosion
and connecting surface for deficiency of damage or sand hole by
itself.
2
Install the connecting spline bushing of drive shaft on the
transmission output spline shaft carefully; then install the drive
shaft intermediate support on the intermediate support bracket
of carriage.
3. Use the special drive shaft bolt, nut and spring shim to connect
the drive shaft to the vehicle axle ring flange and tighten it. The
tightening torque is 78
5Nm
4. Tighten the drive shaft intermediate support nut, the tightening
torque is 63
5Nm (the front and rear drive shaft in
CC6460KY model are the integral and has the installation
content)

Chapter 7
Suspension and vehicle axle
Rear suspension …………………………………112

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

Front wheel alignment
1. Process the following inspection and eliminate
all problems
a. Check the wear condition of tyre and proper inflation.
Tyre inflation pressure: 230kPa
b. Check the wheel bearing of front wheel for loose.
c. Check the front suspension for loose.
d. Check the steering drive device for loose.
e. Process the standard elastic test; check thefrontvibration damper
for normal operation.
3. Install the 4-Wheel alignment instrument
Processed according to the detailed description of equipment
manufacturer.
4. Adjust the wheel angle
Remove the cover of spacing bolt of steering knuckle; check the internal
wheel’s steering angle A.
Internal wheel’s steering angle:
32
Caution: The wheel should not touch the brake hose of car body
when the steering wheel is rotated to limit.
2. Adjust the height of car
A:Adjust the height of car to the standard value for theconvenience of
processing the front wheel alignmentinspection.
B: Front fixed bolt of lower suspension arm
The standard no-load height is: the center of front fixed boltof lower
suspension arm is 295
1mm away form theground.