2006 GREAT WALL SAFE wheel

CL-9Clutch
Clutch cluster
b) Mount the guide bearing with SST.
Remark: the bearing shall be verified in good running after it
is encased in the flywheel hub.
2. Check whether there is abrasion on the diaphragm spring.
Check the abrasion depth and width of diaphragm spring with
calipers.
Limit value: Max depth: 0.6mm
Max width: 5mm
If the abrasion depth or width of the diaphragm spring exceeds
the limit value, change the diaphragm spring .
3. Check the separation bearing
Exert force in radial direction by hand to rotate the bearing.
If it cannot be rotated or if the resistance is too large, change
the separation bearing.
Remark:
Remark: as this bearing is lubricated permanently, it doesnít
need to be cleaned or lubricated.
Mount of clutch cluster
1. Mount the clutch rib on flywheel;
Mount the clutch rib on flywheel with SST.
2. Mount the clutch pressure plate
a) Align the marks on clutch pressure plate and that on flywheel;
b) Screw up the bolts in even manner around the clutch pressure
plate until pressure plate and the flywheel contact closely,
then tighten the bolts.
Tightening moment: 30 N
m
Remark: tighten the uppermost bolt of the three that is near to
the locating pin.
SST
flywheel sideSST
alignment
mark

MT-5Gearbox
Dismantle of Gear Box
4WD
11. Tear down the wheel-brake cylinder of clutch.
(a) Dismantle the setting bolts of the wheel-brake cylinder of
clutch with spanner.
(b) Hang the wheel-brake cylinder with a thread on the side
of engine without oscillation.
Remark: Do not disconnect the pipeline of the wheel-brake
cylinder.
12. Tear down the pawl washer and bracket of the rear part
of gearbox:
Two-wheel driving:
(a) Dismantle the four bracket bolts (skip over this process
for the wielding structure).
(b) Lift the engine with jack to raise the gearbox a little.
(c) Dismantle the pawl washer from the rear part of gearbox.
Four-wheel driving:
Dismantle the bolts from the pawl washer and bracket of the
rear part of gearbox to tear down the pawl washer and bracket.
13. Insert the wooden plate between the bottom frame and
the beam.

MT-8Gear Box
Mount of Gear Box
4WD:
(a) Mount the bracket and supporter of leg washers of rear
engine in 4WD vehicle;(SF)
(b) Mount and tighten the third beam of 4WD vehicle. (SF)
4. Remove the wooden spill.
5. Mount exhaust pipe.
Mount the exhaust pipe on the branch exhaust pipe.
Tightening moment
(62
3)N
m
6. Mount the wheel-brake cylinder of clutch.
Tightening moment
(18
2)N
m
7. Mount odometer sensor and plugging elements of backup
switch.
8. Connect the drive shaft.
(See page PR-12)
9. Add oil into the gearbox.
Lubricating oil grade: GL-5 85W/90
Volume: 2.4L(dry)
Remark: the Tightening moment of oil filling/draining
plug: (30
50)N
m
4WD
4WD

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-5Transfer Box
Product Description and Simple Maintenance
Transfer Assembly NO. of Manufacturer
product assembly NO.
display
termnumber
displaythe last digit of the year
displaythe specific monthly
manufactuer data
displaythe month numnber
Example display:From January (A) to December (L)
Product instruction and simple maintenanceManufactuer data
Product instruction and simple mainte-
nance
1. Product Introduction
The transfer box adapted by our company is the transfer box
of 45-55 manufactured by Bogeguana, which is two-speed
and time driving, a set of planetary mechanism used is to
obtain the speed-reducing performance, while the driving
force is transmitted to the front driving gear by a highly precise
chain. The planetary gear train and rear output shaft element
of transfer box is lubricated initiatively through oil bath and oil
pump. This transfer box has four gears:

2H-stands for the two high gears
in which, only the two
rear wheel are driven, and the gear ratio of the transfer box
is 1:1


4H-stands for the four high gears, in which , all of the four
wheel are driven, and the gear ratio of the transfer box is
1:1


N- neutral location (this location only exists in the transfer
box of manual gearshift )
No driving force is transmitted
to the wheel when the input shaft and output shaft are
disconnected.

4L-stands for low gears, the four wheels are all driven, and
the gear ratio of transfer box is 2.48:1.
The gearshift of the mechanical gearshift transfer box is
obtained through the shifting-cam-type guide plate that is
operated by the shift rocker arm.
Sign board: which is fastened at the obvious external location
of transfer box, and on which the detailed data are marked.
borgwarner

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.

TF-12
110
9
8
6
5
4
3
2
11
15
14
13
12
17
18
19
207
16
Transfer Box
Disassembly of Transfer Box
1. fork-type flange
2. dust cover
3. fork-type flange assembly
4. transfer box front housing
8. Take apart the following parts from the remaining trans-
fer box housing assembly
(a) Fasten the front fork-type flange with the torque arm of
T-13-54-002 and screw off the nuts to take apart the
gasket, pull out the front fork-type flange assembly and
sealing ring.
(b) The dust cover may also be pressed down from the front
fork-type flange where necessary, and
(c) Take apart the front output shaft.
1. planetary mechanism
assembly
2. gasket
3. snapping ring
4. thrust disc
5. sun wheel
6. planetary bracket
7. input shaft assembly
8. input shaft
9. needle bearing
10. bearing shell
11. transfer box front
body assembly
9. Tear down the front body, input shaft assembly and
planetary mechanism assembly
Tear down the following parts from the remaining transfer box
housing assembly
(a) Take apart the venting valve.
(b) Take apart the six bolts to separate the front body from
the transfer box housing and take down the front body
(take notice not to damage the front-end cover and the
transfer housing).
(c) Take apart the front body assembly, input shaft assembly
and planetary mechanism assembly in grouping manner
(loose the snapping ring to take apart the input shaft from
the front end cover).
(d) Hold one end of the input shaft on the worktable while
open the long end of the snapping ring, press the front
body tightly to disassemble the front body assembly from
the remaining assembly.
(e) Take apart the snapping ring and oil seal from the front
body, the pin is only be taken apart where change is
necessary.
(f) Take apart the bearing and gasket from the input shaft
assembly after the bearing gripping loop is taken apart;
and take apart the input shaft assembly from the planetary
mechanism assembly.
(g) Take apart the needle bearing and bearing shell from the
input shaft assembly, and
(h) Take apart the snapping ring, thrust disc and sun wheel
from the planetary assembly, and
(i) Do not try to disassemble the planetary bracket.
4
2
1
5 6
7
83
5. front output shaft
6. oil seal
7. washer
8. nut
12. oil seal
13. locating pin
14. transfer box front
body
15. snapping ring
16. transfer box front
housing
17. bearing
18. bearing gripping
loop
19. bolt
20. vent

TF-16
110
9
8
6
5
4
3
2
11
15
14
13
12
17
18
19
207
16
1
2
3
Transfer Box
Transfer Box Assembly
1. torsion spring
2. gasket
3. shift shaft
1. planetary mechanism
assembly
2. gasket
3. snapping ring
4. thrust disc
5. sun wheel
6. planetary bracket
7. input shaft assembly
8. input shaft
9. needle bearing
10. bearing shell11. transfer box
frontbody assembly
12. oil seal
13. locating pin
14. transfer box front body
15. snapping ring
16. transfer box housing
17. bearing
18. bearing gripping loop
19. bolt
20. vent(d) Push the torsion spring and gasket backward together as
can as possible
(e) Mount the electric shifting cam on the shift shaft in such
way that the free end of the driving tongue of the cam is
put in first, fasten the cam driving tongue, which shall be
between the two spring ring of two torsion spring, under
the driving tongue of shift shaft and put it innermost as
can as possible.
(f) After mounting the toggle fork, then mount the electric
shifting cam assembly in the transfer box housing assembly
5. Assemble for front body, input shaft assembly and plan-
etary component element.
Mount the following element on the worktable:
(a) Put the planetary bracket assembly on worktable, and the
end with snapping ring groove shall face upward.
(b) Mount in the sun wheel and let the part with projecting
end upward, run the gear of the planetary bracket assem-
bly until it completely engages with the sun wheel.
(c) Flush the projecting teeth, and then mount the thrust disc
into the planetary bracket assembly.
(d) Mount in the snapping ring to complete the whole plan-
etary bracket assembly.