2006 GREAT WALL SAILOR differential

SA-73
(l) Run the flange to check the swing difference of axle
driven bevel gear.
Max swing difference
0.07mm
Remark: if the requirement is not satisfied, tear down the axle
driven bevel gear from the differential, and then screw up the
bolts again.
8. Change the bearing of the long semi-axis:
(a) Take down the retainer ring with the calipers.
(b) Tear down the grooved ball bearing from the long semi-
axis.
(c) Mount on the new grooved ball bearing on the long semi-
axis
(d) Mount on the retainer ring with calipers.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-75
8. Encase in the differential:
(a) Put the adjusting gasket in the outer position of bearing
at the side of the front speed reducer shell, and then
Encase the differential in the front speed reducer shell, be
sure there is a play between the driving gear and the
driven gear.
(b) Tap the axle driven bevel gear with the rubber hammer,
so that the bearing 50KB801 on the differential, together
with the adjusting gasket, contact the mounting part of
the side face of speed reducer closely.
9. Measure the clearance between the axle driven bevel
gear and the driving bevel gear with the dial indicator to
select the adjusting gasket that satisfy the reasonable
play of (0.15-0.25)mm.
10. Select the adjusting washer for the other side:
The thickness of adjusting gasket should eliminate the clear-
ance between the bearing 50KB801 and the front speed re-
ducer shell, on the other side, the adjusting gasket should not
be over thick because the over-thick gasket will lead in too
large pre-tightening force on the bearing 50KB801 of
differential.
11. Tear down the adjusting gasket and differential, and
encase the new adjusting gasket in the front speed
reducer shell, and another adjusting gasket, together
with the differential housing, should be encased in the
front speed reducer shell correctly.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Assembly of Front Speed Reducer)

SA-76
12. Measure the clearance between the axle driven bevel
gear and the driving bevel gear with dial indicating lamp.
Clearance: 0.15-0.25mm
Remark: if the play fails to fall within the specified range,
change with the adjusting gasket of other thickness to satisfy
the requirement under the precondition there is no clearance
between the adjusting gasket and the differential.
14. Measure the total preload of the front speed reducer with
torque tester;
Fastening torque
(1.8-2.4)N
m 13. Mount on the left and the right cap-differential bearing:
Screw up the bolts with spanner to the specified torque;
Fastening torque
78N
m
15. Check the teeth engagement between the axle driven
bevel gears:
(a) Coat three or four teeth at three different positions of the
axle driven bevel gear in red
(b) Hold the flange tightly while rotating the axle driven
bevel gear.
(c) Check the teeth engagement situation.
Remark: the trace of the teeth of axle driven bevel gear should
satisfy this requirement. Otherwise, select the suitable adjust-
ing washer for correcting according to the situation of poor
teeth engagement;
Select the adjusting gasket that makes the main teeth apart
from the axle driven bevel gear.
convex surface of gear
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Assembly of Front Speed Reducer)
concave surface of gear

SA-83
Rear speed reducer
Element figure
column bolt
bearing7306E
oil-guard tray

oil seal
flange and dust
cover assembly
flat washer

adjusting ring
bearing 200719Espeed reducer housing and
differential bearing coverstop gasket80-110
18-26

washer
adjusting washer
driving bevel gear
Bearing 7607E jacketadjusting washer
65-95
=
lock plate
differential housing
axle driven
bevel gear

Parts that cannot be reused after being used:specified torque
N
M
Suspension System and Automobile Axle (Rear)
Rear Speed Reducer
double-eared stop washer

SA-85
Dismantle of Rear Speed Reducer
1. Take out the oil drain plug to drain the oil in the speed
reducer up.
2. Tear down the rear axle shaft.
3. Disconnect the drive shaft from the speed reducer.
4. Tear down the nuts on the bolts that connect the rear axle
housing and the speed reducer.
5. Tear down the rear speed reducer.
Disassembly of Rear Speed Reducer
Remark: in case the noise is over loud, the following item
should be checked before taking apart it to find out the causes.
If the speed reducer has serious drawback, take it apart for
repairing where necessary.
1. Check the play between the axle driven bevel gear;
In case the play value fails to be within the specified range,
adjust the preload of bearing 200719E or repair it where
necessary.
(see page SA-91)
Standard play: (0.13-0.25)mm
2. Check the teeth engagement of the driving bevel gear
with the axle driven bevel gear.
(See Page SA-92)
Record the teeth engagement positions.
3. Check the clearance between the half-shaft gear thrust
gasket and the differential housing.
Check the clearance between the half-shaft gear thrust gasket
and the differential housing with the feeler.
Standard clearance
(0.45-0.75)mm
Remark: in case the clearance value fails to fall within the
above range, change the half-shaft gear stop gasket, and
ensure the half-shaft gear stop gaskets on the left and right
sides are same in thickness.
(See Page SA-95)
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)

SA-86
4. Tear down the differential and the axle driven bevel gear:
(a) Mark the assembly marks on the differential bearing
cover and the speed reducer housing.
(b) Tear down the stop gasket and take down the adjusting
ring.
(c) Loosen the double-stop washer and screw off the nut to
take down the differential bearing cover.
(d) Tear down the differential and axle driven bevel gear
from the rear speed reducer.
(e) Tear down the outer race of bearing 200719E.
5. Tear down the flange and dust cover assembly:
(a) Loosen the riveted part of the nut with hammer and
chisel;
(b) Lock the flange with SST to tear down the nuts.
Notice: those nuts should not be reuse.


leftright
(c) Tear down the flange and dust cover assembly with
copper bar.
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)
Remark: mark the label on the parts to clarify the position for
re-assembling

SA-88
10. Change for the bearing 7306E and the outer race of
bearing 7607E:
(a) Tap out the bearing outer race with hammer and copper
bar.
(b) Press in the new bearing outer race with pressure ma-
chine and SST.
12. Tear down the axle driven bevel gear.
(a) Tear down the lock plate and bolts on the axle driven
bevel gear.
(b) Mark the assembly marks on the axle driven bevel gear
and the differential housing.
(c) Tap down the axle driven bevel gear with rubber hammer
and copper bar.
11. Tear down the inner race and roller assembly of bearing
200719E from differential.
Pull out the inner race and roller assembly of bearing 200719E
from the differential housing with SST. Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)

SA-90
5. Mount the axle driven bevel gear on the differential housing:
(a) Mount on the lock plate and screw up the bolts to the
specified torque.
Tightening moment
(65-95)N
m
Notice: screw up the bolts diagonally.
(b) Tighten the lock plate with hand hammer and flat head
pinch.
6. Mount the inner race and roller assembly of bearing
200719E;
Mount the bearing inner race and roller assembly in differen-
tial housing with the pressure machine and SST.
7. Mount the differential assembly;
Mount the differential in the speed reducer housing.
When mounting the differential that hasnít changed the inner
race and roller assembly of bearing 200719E, ensure the outer
race of the left and the right bearings that has disassembled
should match with their inner racers respectively.
8. Mount the adjusting ring;
Adjust the clearance between the driving bevel gear and the
axle driven bevel gear to the moderate size. And press the
bearing outer race to flatten it with adjusting ring, and then
screw up moderately.
Notice: the two adjusting rings should be adjusted
synchronically in the movement of same direction.
Suspension System and Automobile Axle (Rear)
(Dismantle of Rear Speed Reducer)