2006 GREAT WALL SAILOR lock

MT-28Transmission
Output Shaft Assembly(Installation of Output Shaft Assembly)
12. Fix the drive gear of speedometer
(a) Install the locking ball and drive gear.
(b) Install the drive gear of tachometer with plier for shaft
shield ring

MT-29Gear Box
Countershaft Assembly and Reverse Idle Gear Assembly (Element Drawing, Countershaft Assembly Disassembly, Testing and Assembly)
Countershaft Assembly and Reverse Idle Gear Assembly
Element drawing
Disassembly, Testing and Assembly of
Countershaft
1. Tear down the coupling gear, sliding block and the five-
speed spring collar.
Tear down the coupling collar, three sliding blocks and the two
five-speed spring collars with screwdriver.
2. Measure the radial clearance of the reverse idle gear
with dial gauge
Standard clearance:
Shang chi:0.05mm
Tang chi:(0.10~0.30)mm (Tang chi is the close Spline
match, which belongs to radial clearance)
Max clearanle:
Shang chi:0.05mm
Tang chi:(0.10~0.30)mm (Tang chi is the close spline
match, which belongs to radial clearance)
front bearing of
countershaftintermediate-gear shaft
steel ballrear bearing of
countershaftstop ring of the rear bearing
of countershaft
five-speed thrust washerfive-speed needle
bearingsliding block of
synchronize
five-speed clusterengagement sleeve of the
five-speed synchronizer
spring collarsynchronizer tooth
of spring collaraxial pressing plate
for reverse idle gearreverse idle
gear shaft
reverse idle gear
cluster
coupling gear around
the five-speed gear
retainer ring for front
countershaft stop ring for front bearing
of countershaft

MT-31Gear Box
Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly)
SST
sleeve wrench
front
(b) Press out the bearing with SST.
(c) Press in the bearing, side race and inner race with the
socket spanner.
(d) Select the split ring that leave the radial clearance to
minimum level, and mount it on the shaft.
7. Mount the engagement sleeve of synchronizer, sliding
block and the five-speed spring collar.
Remark: the opens of the spring collar shall be in non-
alignment
Encase the sliding pad into the gear hub and then cover the
gear sleeve.
Mount the spring retainer under the sliding pad.
Notice, the opening direction of the spring retainer shall
not face-to-face.
Mount of Reverse Gear Assembly
1. Check the reverse idle gear
Measure the radial clearance of the reverse idle gear with dial
gauge.
Standard clearance:
Shang Chi
0.05mm; Tang Chi
(0.04
0.08)mm
Max clearance

Shang Chi
0.05mm; Tang Chi
0.13mm

MT-32Gear Box
Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly)
2. Measure the clearance between the reverse idle gear
and gearshift yoke block
Measure the clearance between the reverse idle gear and the
gearshift yoke block with feeler.
Standard clearance:
Shang Chi
0.2mm
Tang Chi
(0.05
0.27)mm
Max clearance

Shang Chi
0.35mm
Tang Chi
0.5mm

MT-37
Assembly of Gearbox
1. Mount the output shaft in the central link plate
(a) Tap the output shaft in the central link plate while pulling
it, until mounting it in the central link plate.
(b) Mount the stop ring of the rear bearing of output shaft in
with the split-ring-type pliers.
Remarks: The stop ring shall flush with the surface of central
link plate.
2. Mount the input shaft in output shaft
(a) Coat the MP lubricant on the bearing with 13 needle
rollers, and mount the needle rollers in input shaft.
(b) Propel the input shaft in the output shaft and flush the
groove of synchronizing ring with the sliding block.
3. Mount the countershaft in the central link plate
(a) Mount the stop ring on the rear bearing of countershaft
with split-ring-type pliers.
alignment
Gearbox
Assembly of Gearbox

MT-39
locking ball
socket spanner
Gearbox
Assembly of Gearbox
7. Mount the steel ball and the five-speed thrust washer.
8. Mount the five-speed gear cluster
(a) Coat the gear oil on the needle bearing.
(b) Mount the five-speed gear cluster.
9. Mount the synchronizing ring and the fifth coupling gear
(a) Mount in the synchronizing ring and the fifth coupling
gear.
(b) Dismantle the old central link plate from the table vice.
(c) Put the gearbox straightly as shown in the drawing.
(d) Flush the groove of synchronizing ring with the sliding
block and mount the fifth coupling gear with pressure
machine.
(e) Mount the new central link plate in the table vice.

MT-41Gearbox
Assembly of Gearbox
13. Mount the first gearshift fork axle and first gearshift fork
(a) Coat the MP lubricating on the interlocking guidepost
and mount the interlocking guidepost on the first-second-
speed gearshift fork axle.
(b) Mount the interlocking pin in the central link plate with
the magnetic bar.
(c) Mount first-second gearshift fork axle in the first gear-
shift toggle fork and central link plate.

d) Mount the setting bolts of the first toggle fork and tighten
them.
Tightening moment

Upper tooth
(15
20)N
m
Tang tooth
(13
17)N
m
14. Mount the reverse yoke rod, reverse rocker arm and
reverse yoke block
(a) Mount the reverse yoke rod, reverse rocker arm and
reverse yoke block together.
(b) Mount the reverse rocker arm on the reverse rocker arm
bracket.
(c) Coat the MP lubricant on the interlocking guidepost and
mount the guidepost on the reverse gearshift fork axle.

MT-42Gearbox
Assembly of Gearbox
(d) Mount the interlocking pin in the central link plate with
the magnetic bar.
(e) Mount the reverse gearshift fork axle in the reverse yoke
rod and central link plate.
(f) Mount the spring cylindrical pin with the drift punch and
hammer.
15. Mount the five-speed reverse gearshift guide block and
five-speed reverse gearshift fork axis.
(a) Mount the five-speed reverse gearshift guide block in the
five-speed reverse gearshift guide shaft.
(b) Mount the reverse gearshift fork axle in the next step.
(c) Mount the steel ball in the five-speed gearshift guide
block with the magnetic bar.
(d) Mount the five-speed gearshift fork axle as shown in the
drawing.
(e) Mount the steel ball in the central link plate with mag-
netic bar.
(f) Mount the five-speed gearshift fork axle in the central
link plate.