2006 GREAT WALL HOVER Service Repair Manual

Disassembly of front reducer assembly
1. Remove the front drive axle and left and right
front drive shaft assembly.
(Refer to “Removal of Front Reducer Assembly”
and “Removal of Front Drive Shaft Assembly”)
2. Disconnect three interface positions of front drive
axle vent tube connector assembly.
3. Use the flat screwdriver to pry off the clip fixed
the vent tube connector assembly and take out
the vent tube connector assembly.
4. Screw off the bolt fixed the electric clutch and use
the brass bar to knock down the electric clutch.
5. Use the wrench to remove the oil filling plug;
remove the washer and pull out the vent tube.
6. Use the wrench to remove the bolt connected to
the electric clutch housing and front axle tubeflange;
take out the shift fork sleeve and mechanical wheel
of separator.
Caution: The leaked gear oil during disassembly
should be stored in the container to avoid the
pollution for environment.
disconnected in
this place
disconnected in this place
disconnected in this place

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.

20. Check the engaging mark of drive and driven
bevel gear.
(Refer to “Assembly of Front Reducer Assembly”)
21. Measure the pre-applied load of drive bevel gear
bearing.
Use the torque measuring meter to measure the preapplied
load on the gap between the drive and drivenbevel gear.
Range of pre-applied load: 1.2-1.7N.m
22. Measure the total pre-applied load of drive bevel
gear.
23 Remove the drive gear flange and dustproof cover
assembly.
a. Use the hand hammer and chisel to loose the riveted part of
drive gear nut.
b. Use the special tools to clamp the drive gear flange and
remove the drive gear nut.
c. Use the brass rod to knock down the drive gear flange and
dustproof cover assembly.

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
special tools
rotate the wrench in clockwise
24. Use the special tools to remove the drive gear oil
seal.

30. Remove the drive bevel gear, then take out the
adjusting washer under spacer.
Check and replacement of reducer
1. Replace the big bearing of drive bevel gear .
a. Use the special tools to press out the big bearing of drive
bevel gear.
Caution: It should replace the drive and driven bevel gear in
pair before replace the big bearing if the drive bevel gear is
damaged.
special
special
specialb. Install the washer on the drive bevel gear, Use the special
tools to install the new big bearing .
2. Replace the big bearing outer race of drive bevel
gear.
a. Use the brass bar and hand hammer to knock down the big
bearing outer race.
b. Use the special tools to press in the new big bearingouter race.
Special tools

3. Replace the small bearing of drive bevel gear.
a. Use the brass rod and hand hammer to knock down the small
bearing outer race of drive bevel gear.
b. Use the special tools to press in the new bearing outer race.
c. Replace it by the new bearing inner race when installs the
small bearing..
4Remove two side bearing inner races from the
differential housing.
a Use the special tools to remove the side bearing inner race on
the side of differential assembly with bolt.
b. It should pay attention to does not damage the driven bevel
gear when use the vice for clamping to remove the bearing
inner race on another side.
5. Use the wrench to remove the bolt fastened the
driven bevel gear
Caution: It should make the assembly mark on the
driven bevel gear and differential housing before
disassembly.
6
Disassembly of differential assembly
a. Use the hand hammer and special tools to knock out the pin
after remove the driven bevel gear.
special tools
rubber pad
assembly mark
rubber pad
special tools

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