2006 GREAT WALL HOVER roof

Reducer
Replace the oil seal on the car
1. Disconnect the reducer from the drive shaft.
a. Make the assembly mark on two flanges.
b. Remove four bolts and nuts.
2. Remove the flange and dustproof cover assembly
3. Remove the oil seal
Use the special tools to remove the oil seal.
bearing spacer
adjusting washer
rear bearing
drive bevel gear
adjusting ring
side bearingdriven bevel gear
differential housing
locking plate
plain washer
flange
dustproof cover
oil seal
oil baffle disc
front bearingbearing glandstop plate
lock washer with
double ears
N m: Specified torque
Used component which can not be used any more.
assembly mark

4. Install the new oil seal
a. Coat the lip of oil seal with the HP-R grease.
b. Use the special tools to knock in the new oil seal.
Insertion depth of oil seal: 1.0mm
5. Install the flange and dustproof cover assembly
6. Rivet the drive bevel gear nut.
7. Connect the drive shaft flange to the reducer
flange Align the assembly mark ; then connect them
by bolt.
Tightening force: 785Nm
8. Check the oil level of reducerReplace the hyperbolic
gear oil if necessary.
Oil number : GL-5 hyperbolic gear
Viscosity : SAE80W/90
Amount: Filled with oil until the oil flows out form oil filling
port.
Removal of reducer
1.Remove the oil drain plug; drain the oil from the
reducer
2. Remove the rear axle
(Refer to Step 2 in “Disassembly of Rear Axle”)
3. Disconnect the drive shaft from the reducer
(Refer to step 1 in “Replace the Oil Seal on Car”)
4Remove the assembly of reducer.
special tools
insertion depth: 1mm
assembly mark
assembly mark

Remarks: Mark the label on the removed components to indi-
cate the position of reassembly.
7. Remove the flange and dustproof cover assembly
a.Use the hammer and chisel to loose the riveted part of nut.
b.Use the special tools to clamps the flange; then remove the nut.
Caution: The used nut can not be used any more.
c.Remove the flange and dustproof cover assembly.
8. Remove the oil seal
Use the tools to pry out the oil seal.
9. Remove the drive bevel gear and spacer
Remove the drive bevel gear, bearing and spacer from the reducer
housing.
10. Remove the oil baffle disc and front bearing inner
race
11. Replace the rear bearing of drive bevel gear
a. Use the press machine and special tools to pull out the rear
bearing from the drive bevel gear.
special tools
special tools

2. Install the rear bearing of drive bevel gear and ad
justing washer
a. Select the proper adjusting washer according to “Meshing Condi
tion of Drive Bevel Gear and Driven Bevel Gear”.
b. Install the rear bearing and selected adjusting washer by press
machine.
3. Install the spacer.
a.Select the adjusting washer between the rear bearing and spacer
based on the experience.
b.Install the spacer.
4. Install the front bearing inner race, oil baffle disc
and oil seal of drive bevel gear
a. Place the front bearing inner race in the reducer housing; place the
oil baffle disc.
b. Coat the position of reducer housing oil seal and lip of oilseal
with grease uniformly; place the oil seal in position. Start the
press machine for installation.
5. Install the drive bevel gear, flange and dustproof
cover assembly
a. Install the flange and dustproof cover assembly in the reducer
housing, Press it to level by hand.
b. Insert the drive bevel gear installed with the spacer, rear bearing
and adjusting washer into the flange through the spline; screw on
the nut.
c. Use the nut to tighten the flange, plain washer and drive gear.
special tools
level
special tools

Brake-3
Troubleshooting (continued)

failure caus e Inspection content


The brake generates the
crack clatter during
operation. (drum brake)
The brake shoe is blocked in the rear apron flange
The rear apron flange is worn
The brake shoe pull-out piece spring is loose or lost
The fixed bolt of rear apron is loose (disc brake )
Brake block support plate is loose or lost
Installation bolt is loose
Filled with lubricated oil
Replace the lubricant flange
Replace
tighten
replace
tighten



It has the rustle or rattler
when use the brake The brake shoe gasket or brake block is worn
The brake caliper and wheel or rotor are disturbed
mutually
The dustproof cover and rotor, rear apron and brake
drum are disturbed mutually
Failure of other brake system component
Tyre generates the abrasion with the tyre and chassis Replace, if the scratch is heavy,
then fine machine the brake drum or
rotor again
Replace it according to requirement
Correct or replace
Repair or replace it according to
requirement
Check or maintain
It has the squeak, continuous
scream, rattler or vibration
noise when use the brake .
Caution: The abrasion
material in the brake will
generate the inherent noise
and heat during the
abrasion, then emit the
heat. So it is normal that
generate the squeak by
accident. The condition
will be serious in extreme
environment, such as cold,
hot, high humidity,
snowing, saliferous and
mud. The accident squeak
will not cause the fatal
failure of the brake, and
will not reduce the effective
performance of the brake. The brake drum and brake shoe gasket, rotor and
brake block is worn or scratched.
The brake pad or block is dirty, with oil or smoothed.
The brake pedal or assistor push bar is adjusted
incorrectly
(dis c brake )
The brake block silencing plate is lost or damaged.
The abrasion of the brake block makes the brake
block abrasion indication plate contacts the rotor
The brake ca lip er has burr or is corrosive
(drum brake)
The pull-out piece spring of brake shoe is soft,
damaged or improper. The pull-out piece spring pin
and spring of brake shoe is loose or damaged; and
rear apron flange has crack Check, repair or replace
clean or replace
check, replace
check and adjust
replace
replace
clean or remove the flash
check, repair or replace

Brake-9
Front brake
front brake oil pipe
cliper bracket
outer silencing plate combination
lower circlip of
brake block
brake block assembly
lower circlip of brake block
wear limitation alarm plate of brake block
lnner silencing plate combination
Inner brake block
silencing plate
upper circlip of brake block (I)upper circlip of brake block (II)
piston
dustproof cover
guide pin dustproof cover
guide pin rubber covercooper washer
tong
air-bleed
bolt cover
location pin
guide pin dustproof coversquare seal ring
N
m: Specified torque
Piston
Replacement of brake block
Remarks:
When brake during the travel process, if the front wheel has the
continuous screams noise, then it should check the wear limitation
alarm plate of brake block. If the alarm plate has the abrasion
mark with brake disc, then it should replace the brake block .
1. Remove the front wheel
2. Check the thickness of abrasion material of brake block.
Check the thickness of abrasion material of brake block by the watch
hole on the tong.
Replace it if is not within specified range.
Min. thickness : 2.0mm

Brake-14
Assembly of brake pump
1. Preparation work
All components should be washed, dried by wind and without foreign
material before the assembly. During the assembly, cost the guide pin
and location pin with proper vacuum silicon based grease; coat the
working surface of piston and square gasket with proper rubber
lubricant.
2. Install the piston gasket in the tong body.
a. Screw the bleed screw into the bleed hole;
tightening torque 7
10Nm.
b. Install the square gasket in the sealing groove of two cylinders of
pump respectively after coat its working surface with proper
rubber lubricant.
3. Install the piston with dustproof cover in the tong
a. Cover the dustproof cover on the piston.
b. Lengthen the dustproof cover to expose the bottom of piston
from the dustproof cover clip ring; use the tool (for example: steel
wire about
2mm ) to assist insert the clip ring into the cylinder
hole clip ring groove.
Caution: The used tools must not be sharp to prevent the damage
of dustproof cover.
c. Press the piston to the bottom of cylinder hole by hand.
4. Pre Install the guide pin and location pin on the tong bracket.
a. Install the guide pin dustproof cover on the guide pin and location
pin respectively.
b. Screw the guide pin and location pin in the tong bracket
respectively.
Caution: Do not damage the guide pin dustproof cover.

Brake-16
Rear brake (Disk-and-drum type)
tong bracket
pin rubber cover
brake caliper locking bolt 100
silencing plate
combination
outside brake block
inside brake block
brake block wearing
indication plate
cylinder hole
dustproof cover
wire clip
rectangle seal ring
piston
tong body (left)
copper washer
brake oil pipe fastening blot 55
location pin 2530
bleed screw
bleed screw dustproof cover
guide pin 2530
rear brake oil pipeline
N
m: specified torque
peepholesilencing
plate
Replacement of brake block
Remarks: if the rear wheel generates the cheep during the braking,
it should check the abrasion indication plate of brake block. If the
indication plate has the abrasion mark with brake disc, then it
should replace the brake block .
1. Remove the rear wheel
2. Check the thickness of brake block bush.
Measure the thickness of the brake block bush (abrasion material)
from the eyehole of tong. If the thickness is not within the specified
range, then it should replace the brake block.
minimum thickness: 2.0mm.