2006 GREAT WALL SAFE torque

MT-12Gearbox
Disassembly of Gear Box
11. Grip the central link plate in the table vice,
(a) Use two clutch bolts, washers and suitable nuts as shown
in the drawing.
Remark: mount the washer in the reverse direction, increase
and decrease the washer quantity to flush the bolts terminal
with the external face of the washer.
(b) Grip the central link plate in the table vice.
12. Tear down the locating spring bolts, locating spring and
locking ball,
(a) Dismantle each locating spring bolts with the torque socket
spanner.
(b) Take out the toggle fork axles of the first, second, third,
fourth and reverse as well as the axial locating spring and
locking ball of the fifth-gear toggle fork.
13. Tear down the axial retainer ring of the gearshift fork
Tap the axial retainer ring of gearshift fork lightly with two
screwdrivers and one hammer.

MT-16 Gearbox
Disassembly of Gear Box
22. Tear down the reverse rocker arm bracket
Dismantle the two bolts and the reverse rocker arm bracket.
23. Tear down the reverse idle gear and reverse idle gear
axle
(a) Dismantle the setting bolts of idle gear and the pressing
plate of reverse idle gear axle.
(b) Dismantle the reverse idle gear and the reverse idle gear
shaft.
24. Take down the bearing baffle of the output shaft.
(a) Dismantle the four bolts with torque socket spanner.
(b) Take down the bearing baffle of the output shaft.
25. Dismantle the intermediate-gear shaft.
(a) Pry out the split ring of the rear bearing of the intermediate-
gear shaft with the split-ring-type pliers.

MT-34Gearbox
Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism)
Inspection on and change of the component
elements of position-limit mechanism
1. Tear down the component elements of position-limit
mechanism
(a) Dismantle the bolts with the torque socket spanner.
(b) Punch out the spring cylindrical pin with the drift punch
and hammer.
(c) Tear the component elements of position-limit mechanism
down.
2. Check the component element of position-limit mechanism.
Run and propel the limit stop and the limit stop can return
to the original location automatically, otherwise, change the
limit stop.
3.
Mount the component element of position-limit mechanism
(a) Mount the component elements of position-limit mecha-
nism in the rear housing.
(b) Tap the spring cylindrical pins in with drift punch and
hammer as shown in the drawing.

MT-35Gearbox
Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism)
(c) Coat the sealing agent on the bolt thread.
(d) Propel the plug with the torque socket spanner.

MT-38Gearbox
Assembly of Gearbox
(b) Mount the intermediate-gear shaft in the central link
plate, and mount the backup rear bearing with SST while
holding the intermediate-gear shaft.
4. Mount the baffle of rear bearing of output shaft
Mount and propel the bolts with torque socket spanner.
Tightening moment

Tang tooth
(17
22)N
m
Upper tooth
(12
17)N
m
5. Mount the reverse idle gear and shaft
(a) Mount the reverse idle gear and shaft.
(b) Mount the axial pressing plate of the reverse idle gear,
and then propel the bolts tightly.
Tightening moment
(15
20)N
m
6. Mount the bracket cluster of reverse rocker arm
Mount the reverse rocker arm bracket and propel the two bolts
tightly.
SST

MT-44
sealed material
Gearbox
Assembly of Gearbox
17. Mount the steel ball, locating spring and locating spring
plug
(a) Mount the steel ball and locating spring.
Remarks:
Mount the short spring at the bottom of the central link plate.
(b) Coat the sealing agent on the plug thread.
(c) Mount the plug and tighten them with the torque socket
spanner.
Tightening moment
(17
22)N
m
18. Tear down the central link plate from the table vice
(a) Tear down central link plate from the table vice.
(b) Dismantle the bolts, nuts and washers
19. Mount the gearbox frame
(a) Coat the sealing material on the coupling face of the
gearbox frame as shown in the drawing.
(b) Put down the central link plate straightly as shown in the
drawing.
(c) Mount the gearbox frame on the central link plate as
shown in the drawing.

TF-3Transfer Box
Troubleshooting
Common troubles Causes Resolving approaches
Change the lubricant or supplement the
lubricant volume.
Guarantee the torque of all connecting
elements stand at the specified value.
Open the transfer case to check the
bearing and othe parts whether is weared
or daamaged,if this happened,change
the parts.
Difficulty in mechanic gearshift or
outplace gear engagement
Troubleshooting
Incorrect lubricant or insufficient
lubricant volume.
Looseness of connecting bolt or other
connecting element.
Noise from the transfer box bearing Noise, which is spreader by the transfer
box instead of clutch, engine, drive shaft
and other parts, occurs in each speed. No driving of front wheel in the four-
gear engagementDrive chain breakDisassemble and check the damage of
inner parts, and change the chain. Adjust or repair shift lever.Open the
transfer box to check the toggle fork and
guide shaft, and change the parts as
requirement.Open the transfer box to
check whether the parts is wearied or not,
and, if any, change the weary parts.Open
the transfer box to check whether the
parts is wearied or not, and, if any, change
the weary parts.Open the transfer box to
check whether the parts is wearied or not,
and, if any, change the weary parts. Overlarge loose fit clearance of the
shift toggle fork on the shift guide
shaft.
Wear of the shift toggle fork
assembly including pin and contact
roller.
Wear of the shift cam hub and the
liner.
Attainment of coupling gear Mechanic gearshift seizing at a certain
location Engagement failure of the mechanically
shift transfer boxDamage or unsuitable adjustment of
the shifting mechanism.
Damage or serious wear of the inner
shifting parts, or looseness or
attainment of the shift toggle fork
assembly on the guide shaft.
Unsuitable adjustment of shift lever.Adjust or repair the shift lever mechanism.
Change the seriously wearied parts.
Change the loose or weary parts. Refer to the vehicle manual for correct
operation.
Add the specified oil of given volume.
Open the rear cover of transfer box to check
and changer the damaged parts.
Open the rear cover of the transfer box to
check whether the sliding parts can slide
freely along the axle, if not, dismantle it and
change the damaged parts. Incorrect operation.
Lubricant of inferior quality or
insufficient volume.
Adhesive bonding of shift toggle fork.
Adhesive bonding of the sliding joint
cover, locking sleeve or gear. Mechanic gearshift failure under the
movement of shifting handleBreak or damage of the shift rocker
arm or shift lever.
Damage of the guide plate of shifting
cam;Change the damaged element.
Open the rear cover of the transfer box to
check the damaged element and change
it. Electric gearshift troubleDamage or failure of electrically
controlled element, electric module,
speed sensor, electric motor, electric
clutch, or built-in wire harness.
Damage or worn of shifting cam,
joint cover, locking sleeve, toggle
fork or shift guide axle.Adhesive
bonding shiftRefer to the vehicle usage manual to
diagnose the failure element and change
it as requirement.
Dismantle the weary or damaged parts
and change it as requirement.
Dismantle and check the free movement
of sliding element, and change it as
requirement

TF-8Transfer Box
Disassembly and Mount of Transfer Box
2. Transfer box mount
a) Coat the lubricant grease on the output axial
spline of the gearbox with a thin sleeve contain-
ing lubricant grease.
b) Mount a new gasket on the mounting face of the
transfer box.
c) Lift the lifting bracket of transfer box and align
it to the same axle with the gearbox.
Notice: The transfer shall be guaranteed to flush
with the gearbox before connecting the spline.
Do not handle it forcefully to press the transfer
box spline into the gearbox. Otherwise, damage
will be caused, run the rear output shaft where
necessary to aim at the spline.
(d) Move the transfer box forward slowly so that
the spline and pin of the input shaft of gearbox
reach the front body of the transfer box, and the
gasket attaches on the gearbox completely.
(e) Ensure that the mounting holes of the front
body of transfer box, gasket, and gearbox are in
alignment and then mount the sets of bolt and
nut.
Fastening torque
(35-48)N
m
(f) Connect the rear drive shaft and the rear output
flange of the transfer box.
(g) Connect the front drive shaft and the front
output fork flange of the transfer box.(h) Connect the venting valve and the soft ventila-
tion pipe.
(i) Connect the cables of odometer that locates
nearby the transfer box.
(j) Connect all wire harnesses that connected with
the transfer box, and
(k) Add the lubricant of right brand.
Notice: when starting the engine, if the lubricant
is added incorrectly or in unsuitable volume,
which may lead the transfer box to damage.
Notice: as for the transfer box mounted on
vehicle, oil pump shall be used when adding oil
for it.
Notice: In case the transfer box is taken apart for
maintenance or inspection, there will be no
lubricant supplied by oil pump in the oil passage
on the top of transfer box. Therefore, it is not
accurate to control the oil volume by opening the
oil filling plug, in such condition, the oil passage
will be filled with oil once the oil pump runs. If the
wheel can run, such operation can be conducted
on the lifting jack. The oil level shall be rechecked
once the oil pump runs.
(l) Put down the vehicle after finishing the lubri-
cant inspection, and connect the cell cathode.