2006 GREAT WALL HOVER Service Repair Manual

1. Place the car in the middle of repair platform or
trench, support the front of the car steadily(support
on the carriage) then remove the left and right
front wheel. (make the car in 2WD status before
the disassembly)
2. Remove the beam on the lower of front drive axle
assembly.
3. Disconnect the connection of front drive axle
flange and drive shaft and make the assembly
mark
4. Drain the lubrication oil in reducer.
bolt
front hub cover
circlip
adjusting washer set
flange
disconnect three ports in this position
N m: specified torque

9. Use the wrench to screw off the bolt which fixes
the lower segment assembly of front drive axle
vent tube on the vent tube bracket.
10. Support the front drive axle by the jack; screw
off the lifting bolt of hanger plank and carriage.
11. Remove the complete drive axle.
12. Screw off the connecting bolt of hanger plank and
front drive axle assembly.
13. Pull out the left and right front drive shaft
assembly with the oil seal, hanger plank and
bearing.
se the circlip pliers to remove the outside circlip
of bearing.
15. Use the special tools pull out the bearing.
16. Use the circlip pliers to remove the circlip on
another side of bearing.
Caution: During the disassembly, support the lower end of
drive shaft and prevent the drive shaft from sliding out from
the inner jacket, meanwhile, it could not damage the inner
and outer jacket.
wrench
circlip pliers
support the lower end
hold
special tools
shim
support the lower end
supporting position

Constant-speed drive shaft assembly
pliers
Disassembly of constant-speed drive shaft
assembly
1. Check the front drive shaft assembly
a. Check the inner trumpet connector; it could slide in axial
direction smoothly.
b. Check the universal-joint position; it should be without the
clear clearance in radius direction.
c. Check the inner and outer jacket for damage.
Caution: It should use the pad when clamp the front drive
shaft to avoid the damage of it.
2. Remove the large clip of inner jacket
Caution: Do not damage the inner and outer jacket
inner trumpet connector
circlip
three-pin section assembly
large clip of inner jacket
inner jacket
small clip of inner jacketsmall clip of outer jacket
outer jacket
large clip of outer jacket
outer trumpet connector
dustproof cover

a. Make the assembly mark on the inner trumpet connector and
three-pin section assembly.
Caution: remove the grease in the connector before make the
mark and don’t make the mark by the hard object such as
punch.
b. Remove the inner trumpet connector.
4. Disassembly of three-pin section assembly
a. Use the circlip pliers to remove the circlip.
b. Use the adz and hand hammer to make the assembly mark on
the shaft and three-pin section assembly.
c. Use the cooper bar and hand hammer to remove the three-pin
section.
Caution: Remove the cooper chip on the shaft or three-pin
section assembly if has.
5. Remove the inner jacket
a. Use the pliers to disassemble the small clip of inner jacket.
b. Pull out the inner jacket.
Caution: Remove the grease in the jacket and maintain the
clean field.
6. Use the straight screwdriver to disassemble the
large and small clip of outer jacket.
assembly mark
assembly mark

7. Remove the outer jacket
Caution: Clean the protective jacket and remove the grease on
the outer trumpet connector. Do not disassemble the outer
trumpet connector.
8. Use the screwdriver and hand hammer to remove
the dustproof cover.
Assembly of constant-speed drive shaft assembly
1. Use the hand hammer and screwdriver to install
the dustproof cover
Caution: The dustproof cover should be replaces when
itisdeformed heavily.
2. Install the large clip of outer jacket, outer jacket
and small clip of outer jacket.
Caution: The outer jacket should be replaced when it is
damaged or aged heavily and warp the end of the shaft with the
plastic band and coat with small grease before insert it.
3. Insert the small clip of inner jacket, inner jacket
and large clip of inner jacket.
Caution: The inner jacket should be replaced when it is
damaged or aged heavily.

4. Install the three-pin section assembly on the front
drive shaft.
a.Let the end of three-pin section assembly with chamfer faces the
shaft inner direction.
Caution: The three-pin section assembly should be replaced if
its needle bearing position is damaged.
b.Align the assembly mark made before disassembly.
c. Use the hand hammer and copper bar to install the three-pin sec
tion assembly to the front drive shaft.
d.Use the circlip pliers to install the new circlip.
5Install the outer jacket on the outertrump etconn
ector.
Fill the jacket with the grease supplied with the jacket before
install the jacket.
(Recommend used grease is CAPLEX or KY1)
Grease using amount: About 110g
with chamfer

6Install the inner trumpet connector on the front
drive shaft
a. Fill the inner trumpet connector and inner jacket with the
grease supplied with the jacket
(Recommend used grease is CAPLEX or KY1). Amount About140g
b. Align the assembly mark made during disassembly; covered
with inner trumpet connector.
c. Cover the inner jacket on the inner trumpet connector.
7Use the inner and outer jacket clip pliers to
clamp the inner and outer jacket.
a. Use the special non-ear clip pliers to lock the large clip of
inner jacket.
b. Use the nutcracker to lock the small clip of inner jacket.
Caution: Ensure the large and small connecting place of jacket
is in the corresponding groove of trumpet connector and shaft.
assembly mark
outer jacket clip
inner jacket clip
non-ear clip pliers
nutcracker

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.
special tools
circlip pliers
support the lower end