2006 GREAT WALL HOVER Service Repair Manual

Brake-19
Removal of brake pump
1.Remove the brake pipeline
Remove the brake pipeline. Use a container to contain the brake fluid.
2. Remove the pump form the bracket
a. Remove the location pin and guide pin.
b. Remove the tong.
3. Remove the brake block
a. Two pieces of brake block
b. Two pieces of silencing plate
c. Two pieces of silencing plate combination
d. One piece of brake block bush abrasion indicating plate
e. Two brake block circlips
Disassembly of brake pump
1. Remove the piston form the tong
a. Insert the cleaning cloth or other soft cloth into the place between
piston and tong.
b. Use the compressed air to remove the piston and cylinder hole
dustproof cover from the tong.
Warning: it must not place the finger in front of the piston when
use the compressed air.
2. Remove the piston gasket form the tong
Use the screwer to remove the piston gasket.

Brake-20
Check the components of rear brake
1. Measure the thickness of the brake block bush.
Standard thickness: 8.0mm
Minimum thickness: 2.0mm
It should replace the brake block if less than minimum thickness or
has uneven abrasion.
2. Measure the thickness of brake disc.
standard thickness: 18.0mm
minimum thickness: 16.0mm
It should repair or replacement brake disc if it is scratched or worn or
its thickness is less than minimum thickness.
3. Measure the circular runout of brake disc.
Remarks: It should ensure that the rear bearing is adjusted
correctly before the measurement.
Maximum circular runout : 0.11mm
4. Replace the brake disc if necessary.
a. Remove the bracket form the rear axle flange.
b. Remove the rear brake disc and install the new brake disc .
c. Install the bracket and tighten the fastening brake caliper bolt.
Tightening force: 100
5Nm

Brake-21
Assembly of pump
1. During the assembly, coat the guide pin with the proper vacuum
sili con based grease; coat the operating surface of piston and
square gasket with proper rubber lubricant.
2. Install the piston gasket and piston in the tong
3. Install the cylinder hole dustproof cover and wire clip in the
tong.
4. Install the rubber pin cover on the tong bracket.
Installation of brake caliper
1. Install the brake block

Brake-22
2. Install the piston gasket in the tong body.
a. Screw the bleed screw into the bleed hole;
b. Install the square gasket in the sealing groove of two cylinders of
pump respectively after coat its working surface with proper
rubber lubricant.
Tightening torque 7
10Nm.
3. Connect the brake pipeline
Connect the brake oil pipe to the tong.
Tightening force: 50
5Nm
4. Fill up the brake system with the brake fluid and drain the air
in the brake system.
5. Check for leakage of brake fluid.
Rear parking brake
pull-out piece
spring draw bar
hand brake
stay wire
front brake shoe
lower tension spring
clearance-adjusting bolt
clearance-adjusting gear
clearance-adjusting
bolt head
pull-out piece
spring seat
pulling arm pin
rear brake shoe
brake shoe pulling arm
saddle type washer
push pedal
push pedal
release spring
stopper
upper release spring
rear brake disc
Used component which can not be used any more.
Removal of rear brake
Remarks: When the brake torque of the hand brake cannot meet
the brake requirement, the thickness of the brake shoe gasket
shall be tested. If it is less than the minimum value of brake show
gasket, the brake shoe shall be replaced.
minimum thickness: 1.0mm

Brake-23
1. Remove the rear wheel
2. Remove the rear brake caliper
3. Remove the rear brake disc
Remarks: If the brake disc is difficult to remove, remove the
adjust ment spout plug, insert the screwdriver into the adjust
ment spout of the rear brake bedplate, Release the brake shoe
adjustment device through twisting the clearance-adjusting gear.
4. Remove the shoe plate, pull-out the piece spring , pull-out piece
spring seat, pull-out piece spring draw bar
5. Remove the lower tension spring and clearance-adjusting device
Use clipper to remove the extension spring, release the clearance
adjusting device and remove it.
6. Remove the two upper extension springs
7. Remove the brake shoe
a. Remove the brake shoe, baffle, baffle return spring.
b. Remove the band brake stay wire from the stay and brake pulling
arm.

Brake-24
8. Remove the parking brake pulling arm
Use the screw driver to remove the parking brake pulling arm
Check and maintain the components of brake
1. Check the dismantled components
Check to se whether the dismantled components are wearing, rusted
or damaged.
2. Measure the internal diameter of the brake disc
Standard inter diameter: 210mm
maximum internal diameter: 212mm
3. Measure the thickness of the brake shoe
standard thickness: 4.0mm
minimum thickness: 1.0mm
If the thickness of the brake shoe is less than the minimum value, or
there is uneven wearing, the brake shoe shall be replaced.
Remarks: If any one of the brake shoes needs to be replaced, all
the brake shoes need to be replaced to keep the even brake
performance.
4. Check whether the contact between the brake shoe gasket and
brake disc is sound.
If the contact between the brake shoe gasket and brake disc is bad, it
should use the brake shoe grinding device to repair or replace the
brake shoe assembly.

Brake-25
1. Install the clearance-adjusting device assembly
Insert the clearance-adjusting shaft head into the clearance-adjusting
wheel; screw the clearance-adjusting screw rod into the clearance
adjusting wheel.
Remarks:The screw direction of left clearance-adjusting screw
rod is the left hand.
The screw direction of right clearance-adjusting
screw rod is the right hand.
2. Coat the following components with the proper anti-high tem
perature grease :
a. Contact position of brake soleplate and brake shoe.
b. Contacting surface of push plate and shoe plate; contacting sur-
face of clearance-adjusting device assembly and shoe plate.
Assembly of rear parking brake
Remarks: Assemble the component according to the direction shown in figure;
It is prohibited strictly that the working surface of brake drum and abrasion disk is polluted by the paint and grease. It
should be removed by the fine abrasive paper if the abrasion disk has little dirty. The brake shoe should be replaced when
the polluted area is large, otherwise it will cause the serious effect of insufficient brake force.
left wheel
frontright wheel
front

Brake-26
2. Install the parking brake pulling arm
Install the parking brake pulling arm and use a new saddle washer.
3. Install the rear brake shoe
a. Install the parking brake pull wire on the parking brake pulling
arm.
b. Insert the end of rear brake shoe into the support pin of brake
soleplate.
Insert the pull-out piece spring pull bar into the brake soleplate and
brake shoe assembly, then insert the pull-out piece spring and pull-
out piece spring base. Use the pull-out piece spring fork to rotate
the pull-out piece spring base in position.
4. Install the front brake shoe
install the front shoe plate; insert one of its ends into the fixed pin of
soleplate.
Insert the pull-out piece spring pull bar into the brake soleplate and
brake shoe assembly, then insert the pull-out piece spring and pull-
out piece spring base. Use the pull-out piece spring fork to rotate the
pull-out piece spring base in position.
5. Install the brake push plate
Insert the push plate release spring into the push plate; then install
the push plate on the place between the front and rear brake shoe
assemblies.