2006 GREAT WALL SAILOR check oil

SA-80
Dismantle of Rear half Axle Shaft
1. Tear down the wheels.
2. Tear down the rear brake drum.
3. Tear down the grab end of the bracing wire of hand brake
from the rear brake.
4. Tear down the half-shaft and the rear brake assembly
from the rear axle housing.
5. Tear down the flat steel retainer ring for shaft from the
half-shaft;
Tear down the flat steel retainer ring for shaft with the ring
calipers.
6. Tear down the half-shaft:
Put down a wooden plate on the flat ground, and thrust the end
of spline of half-shaft and rear brake assembly toward the
wooden plate to separate the shaft and the rear brake assembly.
Inspection on and repairing of half-shaft parts
1. Check the wear, damage and swing difference half-shaft
and the flange.
Max shaft run-out: 2 mm
Max flange run-out: 0.2 mm
In case the half-shaft is damaged, or wearied or the measuring
value of the swing difference is excessive, change the half-
shaft.
2. Check he oil seal of rear wheel bearing:
Check to see whether there is wear or damage, and change the
oil seal if necessary.
3. The disassembly of the outer oil seal of rear wheel
bearing;
Tear down the outer oil seal of rear wheel bearing with SST. Suspension System and Automobile Axle (rear)
Rear Half Axle Shaft

SA-81
4. Check the grooved ball bearing
Check the grooved bearing to see whether there is damage or
wear.
5. Change the bearing where necessary:
(a) Press out the grooved ball bearing with SST.
(b) Press in the new grooved ball bearing with SST.
6. Mount the new oil seal of rear wheel bearing.
Press in the new oil seal of rear wheel bearing with SST
Coat moderate lithium base grease on the lip open of oil seal.
7. Check the bearing seat.
Check the wear or damage situation.
8. Change the bearing seat where necessary:
(a) Tear down the oil seal of rear wheel bearing and the
grooved ball bearing with SST.
(b) Tap the bolts with copper bar to tear down the bearing seat.
(c) Mount the new grooved ball bearing and the oil seal of
rear wheel bearing on the bearing seat
(d) Press the rear brake, which is put on with bolts, in the
bearing seat.
9. Check the wear or damage of the inner oil seal of the rear
wheel bearing.
10. Change the rear wheel bearing where necessary:
(a) Tear down the oil seal of rear wheel bearing with SST. Suspension System and Automobile Axle (rear)
Rear half Axle Shaft

SA-84
On-vehicle Change of main-teeth oil seal
1. Disconnect the drive shaft from the speed reducer:
(a) Mark the assembly mark on the two flanges;
(b) Tear down the four sets of bolt and nut.
2. Tear down the flange and dust cover assembly.
3. Tear down the oil seal.
Tear down the oil seal with SST.



4. Mount on the new oil seal:
(a) Coat the lithium base grease on the lips of oil seal;
(b) Tap in the new oil seal with SST.
Remark: tap the new oil seal until it is in place.
5. Mount the flange and dust cover assembly.
6. Screw up the nut to the specified torque.
Specified torque: (140-160)N
m
7. Rivet the nut.
8. Connect the drive shaft flange with the speed reducer
flange:
Align the assembly mark and connect the flanges with bolts.
Tightening moment
(69-79)N
m
9. Check the oil level of the speed reducer.
Change the gear oil where necessary.
Oil brand: heavy-duty oil of grade
GL-5
Oil volume: add the oil until it overflows from the oil filler
outlet.
Viscosity: SAE 85W/90 Suspension System and Automobile Axle (Rear)
Rear Speed Reducer

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-94
Mount of Rear Speed Reducer and
Differential Assembly
1. Mount the speed reducer and differential assembly on
the rear axle housing.
Tightening moment
(18-26)N
m
Remark: in case the sealing gasket is mounted, it should be
checked to see whether it is damaged before mounting, if
damaged, change with the new sealing gasket, and the dam-
aged sealing gasket should be clear away; if no sealing gasket
is mounted, no mount is required to mount. Clean the contact
face of the mounted axle housing and coat it with silicon-
rubber plain sealing agent.
2. Connect the drive shaft and flange well and be careful to
align the assembly marks marked when disassembling.
Tightening moment
(69-79)N
m
Screw up the oil drain plug with the Tightening moment
of (140-150)N
m
Mount on the half-shaft and the brake assembly to adjust the
brake oil path so that the wheel brake pump is filled with brake
liquid.
3. Inject in the heavy-duty oil.
Oil brand: heavy-duty oil graded GL-5;
Viscosity: SAE 85W/90
Oil volume: add the oil until it overflows from the oil filler
outlets.
Screw up the oil-filling plug.
Tightening moment
(140-150)N
m
Suspension System and Automobile and Axle (Rear)
Rear speed reducer (Mount of Rear Speed Reducer and Differential Assembly)

BR-3
Troubleshooting (continued)
Braking System
Notice and Troubleshooting
Trouble Causes Inspection items
There is clatter noise when using
the brake(Drum-type brake)
The brake shoe is seized on the flange of rear baffle;
The flange of rear baffle is worn;
The pressure spring of brake shoe is loose or missing;
The fixed bolts of brake bottom plate is loose;
(disc type brake)
The brake pad support plate is loose or missing
The mounting bolts are loose;Add lubricant
Change the lubricating flange
Change
Tightening it
Change
Tightening it
There is hoarse noise or quack-
quack when using the brakeThe brake shoe or brake pad is worn;
The brake caliper, the wheel or the rotator interferes each
other.
There is friction between the dust cover and brake disc,
the brake bottom plate and the brake drum;
The other braking part has trouble
There is friction between the tire and bodyChange the part, and re-process
precisely the brake drum or
rotator if the abrasion is serious;
Make change according to real
situation;
repair or change
Make repairing according to
real situation;
Change
Check or maintain the part
There is such noise as
continuous screaming, quack-
quack, oscillating sound, etc.
Notice: the braking materials
may generate the natural noise
and heat during friction, and
thus emit the energy. Therefore,
it is normal to have the
screaming noise. These
phenomena will be more serious
under the condition of frigidity,
torridity, and over humidity,
snowing and mud. the
screaming noise occurring
occasionally will not lead the
fatal brake trouble nor reduce
the effective properties of the
brake.The brake drum, brake liner, liner or brake pad is worn
or scraped
The brake liner or brake pad is dirty or with oil stain or
polished.
The brake liner or brake pad is improperly used.
The brake pedal or vacuum booster drag rod is unsuitably
adjusted.
(disc type brake)
The brake pad silent pad is loss or damaged;
The brake pad is worn to the degree that the abrasion-
indicating lamp of brake pad has friction with the rotator.
There is burr or rust on the brake caliper.
(Drum type brake)
The pressure spring of brake shoe is soft in rigidity, or is
damaged or unsuitable.
The pressure spring pin or spring of brake shoe is loose
or damaged;
There is crack on the brake bottom plate flangeCheck, repair or change
Clean or change
Check or change
Check for adjustment
Change
Change
Clean or polish the burr
Check, repair or change
Check, repair or change
Check, repair or change

BR-6
Operation test of vacuum booster
Remark: check the operation of vacuum booster with the
vacuum booster tester if workable.
1.Operation inspection
(a) Before starting the engine, tread down the brake pedal
several times, and check the pedal reservation distance to
ensure there is no change occurs.
(b) Tread down the brake pedal and start the engine. If the
treaded pedals continue to move downward, which means
the operation is normal.
1. Inspection on Air-tight
(a) Start the engine for 1-2 min and then turn it off. Then
tread down the brake pedal slowly for several times, if the
pedal move downward continuously in the first, but
return gradually in the second or third time, which means
the vacuum booster has a good air-tight.
(b) Tread down the brake pedal when the engine is working,
then stop the engine, but tread the pedal down. If the
reservation distance doesnít change within the 30 seconds,
which shows the air tight of vacuum booster is good.
Air-bleeding of braking system
Remark: air-bleeding is required if any operation for braking
system is conducted or the pipe line is doubted to have air.
1. Fill the oil cup with the brake liquid
Check the liquid level of oil cup after the air in each wheel
brake pump is exhausted. If necessary, add the brake liquid.
2. Connect the vinyl resin pipe with the vent screws.
Insert the other end of pipe into the container with half brake
liquid.
Remark: the air-bleeding shall begin from the longest pipe line
when the wheel-brake cylinder is exhausting the air.
3. Air exhaust of the pipe line in braking system
(a) Tread down brake pedal slowly several times.
(b) Loosen the vent screws until the brake liquid flows out
while letting the assistant tread down the pedal. Then
screw up the vent screws.
(c) Repeat this approach until there is no air in the liquid.
4. Repeat the approach for the wheel-brake cylinder.
normal
abnormal
the third time
the second time
the first time
Braking System
Inspection and Adjustment

BR-9Braking System
Master Cylinder
Mount of Master Cylinder
1. Adjust the length of vacuum booster pushrod before
mounting the master cylinder;
2. Mount the master cylinder:
Mount the master and sealing washer on the vacuum booster
with four nuts.
3. Connect the two pipelines of braking system;
Mount the brake pipeline on the master cylinder with SST and
screw up the nuts.
Fastening torque

Dr SF
(18
2)N
m
SL SK SY SJ
(19
1)N
m
4. Connect the alarm switch joint for liquid level;
5. Fill the oil cup with brake liquid and exhaust the air in
the brake pipeline;
6. Check to see whether there is brake liquid leakage;
7. Check and adjust the brake pedal.
SST
SST