2006 GREAT WALL HOVER Service Repair Manual

Disassembly of reducer
Remarks: If the noise of differential is loud, process the follow-
ing inspection before disassembles the differential to determine
its reason. When the differential has serious problems, it can be
disassembled for repair if necessary.
1. Check the internal clearance of driven bevel gear.
If the clearance is beyond the specified range; adjust the preapplied
load of bearing or repair if necessary.
(Refer to step 13 “Assembly of Reducer”)
Standard internal clearance: 0.15-0.25mm
2. Check the intertooth contact of drive bevel gear
and driven bevel gear.
(Refer to Step 14 in “Assembly of Reducer”)
Record the contact position of tooth.
3. Check the clearance between the thrust plate of
axle shaft gear and differential housing.
Use the feeler to measure the clearance between the thrust plate
of axle shaft gear and differential housing.
Standard clearance: 0.45-0.75mm
It should be replaced by the proper thrust washer if the clearance
is beyond the specified range.
(Refer to Step 2 in “Replacement of Differential Components”)
4. Measure the pre-applied load of drive bevel gear
Use the torsion meter to measure the pre-applied load on the
internal clearance between the drive small gear and driven bevel
gear.
Pre-applied load: 0.4-0.6N
m
5. Total pre-applied load
Use the torsion meter to measure the total pre-applied load.
Pre-applied load : 0.9-1.3N
m
6. Remove the differential and driven bevel gear
a. Make the assembly mark on the differential bearing gland and
reducer housing.
b.Remove two stop plates.
c.Remove two bearing glands and two adjusting rings.
d.Remove the bearing outer race.
e.Remove the differential form the reducer housing.

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

b.Use the press machine and special tools to install the reused
adjusting washer and new rear bearing on the drive bevel gear.
12. Replacement of front and rear bearing outer race
of drive bevel gear.
a. Use the hammer and brass bar to knock out the front and rear
bearing.
b. Use the press machine and special tools to install the new
bearing outer race by press.
13. Remove the side bearing form the differential
housing.
Use the special tools to pull out the side bearing from the differ
ential housing.
14. Remove the driven bevel gear
a.Remove the connecting bolt and lock plate of driven bevel gear.
b.Make the assembly mark on the driven bevel gear and differen
tial housing.
c.Use the rubber hammer or brass rod to knock down the driven
bevel gear.
Assembly of reducer
1. Install the bearing outer race of drive bevel gear.
(Refer to Step 12 in “Disassembly of Reducer”)
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

6Use the special tools to clamp the flange; use the
torque wrench to tighten the nut.
Tightening force: 140160Nm
7. Measure the rotation pretightening force of bearing
For new bearing : 1.21.7Nm
For reused bearing : 0.4
0.6Nm
If does not meet the requirement, replace the adjusting washer
under the spacer until meet the requirement.
Tightening torque : 0-3.5N
m
a. Reduce the thickness of adjusting washer if the measured value
is less than standard value;
b. Increase the thickness of adjusting washer if the measured value
is more than standard value.
8. Install the driven bevel gear on the differential
housing.
a. Use the bolt and lock plate to connect the driven bevel gear to the
differential housing.
b. Screw on for three rounds at least by hand; then use the pneu
matic wrench to tighten it properly.
c. Use the torque wrench to tighten it.
Tightening force: 65-95N
m
Caution: Tighten the bolt in diagonal .
Use the hand hammer and flat head punch to lock the lock plate.
Special tools

9. Install the differential side bearing by press.
Use the press machine and special tools to install the side bearing
on the differential housing by press.
10. Install the differential assembly
a.Remove the bearing gland. Do not mix the left up with right.
b.Install the differential assembly in the reducer housing.
11.Install the adjusting ring
Use the adjusting ring to press the bearing outer race in position;
tighten it properly. Adjust the clearance between the drive and
driven gear to the proper dimension.
12. Install the bearing gland
a. Align the assembly mark on the bearing cover with that on re
ducer housing; Press down the press cover by hand.
b. Install the lock washer with double ears and nut; tighten the
hexagon nut by pneumatic wrench properly.
13. Adjust the engagement clearance between the drive
and driven gear.
a. Use the torque wrench to tighten four bolts on bearing cover by
torque wrench.
Tightening force: 78-115N
m
special tools
special tools
assembly mark

b. Adhere the measuring meter base on the end surface of reducer
housing; the measuring head contacts the tooth surface; rotate
the driven gear by hand and measure the engagement clearance be
tween the drive and driven gear.
c. If the engagement clearance does not meet the requirement, use
the special tools to adjust the left and right adjusting ring until it
meets the requirement.
d. Recheck the engagement clearance between the drive and driven
gear.
Engagement clearance: 0.13-0.18mm
14. Check the meshing mark of drive and driven bevel
gear.
a. Paint 3-4 teeth with the red lead in three different positions of
driven bevel gear.
b. Rotate the driven bevel gear in clockwise and anticlockwise by
hand.Check the engagement of gear.

sound contacttoe contact
dedendum contact
arge end contact
small end contact select the shim which can make the small drive gear
close to the driven bevel gear
select the shim which can make the small drive gear away from the driven bevel gear
Select the proper washer from the table for correction if the intertooth
contacting status is bad. The thickness tolerance of washer is
0.01mm.
15. Install the stop washer and stop plate
a. If the drive and driven gear engagement mark meets the requirement,
then use the hand hammer and punch to lock the stop washer.
b. Install the stop plate, spring shim and bolt; tighten the bolt.
Tightening force: 18-25N
m
c. Use the punch and hand hammer to knock the lower end of stop
plate in the adjusting ring hole.
Set NO. Thickness Set NO. Thickness
16. Measure the total pre-applied load
Pre-applied load : 1.8-2.4Nm
If the pre-applied load is beyond the specified; it should replace the
shim between the spacer and rear bearing until meet the requirement.
a. It should replace the adjusting washer if the pre-applied load is
more than specified value.
b. If the pre-applied load is less than specified value, it can retighten
the nut slowly and the torque should be no more than 160N
m.
Caution: When tighten the nut, if is beyond the Max. torque, re-
place the adjusting washer and repeat the pre-applied load process.
Do not reduce the pre-applied load by the method of screw off the
drive gear nut to loose.
washerrear bearing