2006 GREAT WALL SAILOR Gear box

TF-19
1
9
8
7
6
5
4
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10
11
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345
6 7
Transfer Box
Transfer Box Assembly
9. Assembly of driving chain
The parts assembly process is as follows:
(a) Put the driving chain sprocket at the rear end of the output
shaft, and the driven chain sprocket is put at the rear end
of the front output shaft on the worktable after the transfer
box housing assembly mount.
(b) Mount the chain on the sprocket.
(c) Holding the two chain sprockets parallel with the transfer
box in the space that the chain on the two sprockets are
straightened, and encase the chain and sprocket assembly
through the output shaft, it is required to run the chain
sprocket slowly to ensure that they engage with the front
output shaft and the spline.
(d) Mount the gasket and snapping ring on the front output
shaft.
10. Shift locking element assembly
The parts mounting process is as follows (for the electric shift
transfer box):
(a) Mount the return spring and locking hub on the locking
sleeve and fasten them with snapping ring to finish the
2W-4W locking sleeve assembly.
(b) Encase the shift guide shaft in the blind hole of the
housing through the deceleration toggle fork assembly
that is already assembled.
(c) Mount the shift toggle fork on the 2W-4W locking sleeve
assembly, which will slide through the shift guide shaft
and rear output shaft.
(d) Joint the combined external gear sleeve spline and the
rear output shaft spline as well as the 2W-4W locking
sleeve.
1. output shaft
2. driving chain sprocket
3. driven chain sprocket
4. washer
5. snapping ring
6. transmission chain
7. front output shaft
1. output shaft
2. shift engagement
sleeve assembly
3. locking sleeve
4. return spring
5. engagement sleeve6. snapping ring
7. shift lock hub
8. clutch assembly
9. fastening snapping ring
10. shift guide shaft
11. toggle fork

TF-20
1 convex plate
groove2
3
4
5 6
1234
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6
7
1. electric shift convex plate
2. torsion spring
3. shift shaft
4. gear down shift fork assembly
5. shift fork
6. gear shifting shaft
Transfer Box
Transfer Box Assembly
1. clutch washer assembly
2. snapping ring
3. ball bearing
4. transfer box rear body
5. nut
6. oil seal
7. bearing
8. needle bearing
11. Rear cover Assembly
Mount the parts into the rear cover according to the following
process:
(a) Locate the rear cover on the suitable press machine, the
coupling face of the rear cover shall face upward and
parallel with the work face of the press machine.
(b) Locate the needle bearing, of which the marked end
facing upward, and press it in the rear cover until the
upper end of needle bearing is 40.47
40.97 lower than
the coupling face of the rear cover that matches with the
front housing.
(c) Press the ball bearing in the rear cover and mount the
snapping ring well.
(d) As for the electric shift transfer box, the parts shall be
encased according to the following process:
(1) Confirm the four O-rings are set on the clutch
washer assembly (one O-ring is located on the coil,
the other three on studs).
Mount on the clutch coil assembly, of which the
wire and stud shall protrude out the rear cover, take
notice not to damage the wire when screwing up the
nuts.
Fastening torque
(8
11)N
m
(2) Encase the motor bearing and oil seal in the rear
cover. (e) As for the electric shift transfer box, encase the as-
sembled electric shifting cam group and clutch shell in
the process as follows:
(1) Put down the electric shifting cam group as shown in
the drawing.
(2) Hold the shift guide shaft downward and raise lightly
the toggle fork assembly. Run the electric shifting
cam group in place, so that the contact roller on
deceleration toggle fork assembly enters in the groove
of shifting cam, and the projecting part of lock
toggle fork is at the rear end of the shifting cam, and
then take reduce the component elements in the
transfer box housing, meanwhile, joint the shift
shaft on the pin in transfer box housing.
(3) Locate the clutch shell well through the shift exter-
nal gear sleeve and mount on the snapping ring.
8

TF-21
QR
NOP
NMSTN
UV
NOPQ
RS
(d) All of the following aligning conditions shall be satisfied
when the rear cover assembly is mounted on the transfer
box front housing:
a) Align the pin hole in the rear cover to the pin on the
housing.
b) Align the rear output shaft to the inner bearing in
cover rear hole.
c) Align the blind hole in the rear cover and the shift
guide shaft; ensure the return spring is not tilted.
Check the hole in velocity sensor of the rear cover
with a pen.
d) Align the shift shaft and the inner bearing in rear
cover.
(e) Screw up the nine bolts after locating the sign bolts
correctly.
(f) Encase the gear of odometer in the rear cover assembly
through the spline of the rear output shaft.
(g) Press the new oil seal in the cover assembly
NO
P
Q
Transfer Box
Transfer Box Assembly
1. bolt
2. wire harness
3. magnet
4. return spring
5. shift guide shaft
6. transfer box rear
body assembly
7. sign board
8. driving gear of Odometer
9. oil seal
10. transfer box front housing
1. locating pin
2. output shaft
3. shift shaft4. return spring
5. shift guide shaft
6. output shaft.12. Assembly of Rear Cover
Mount the aforesaid accomplished cover assembly on the
transfer box housing according to the following process:
(a) Mount the return spring on the shift guide shaft of the
transfer box.
(b) Mount the magnet in the groove of the housing.
(c) Coat the Letai glue 598 of 1.6mm on the coupling face of
housing, steer clear of the screwed hole when coating
continuously.
Notice: try to button the rear cover on the transfer box front
housing with the moderate force during the following process.
Not too much force is required when mounting the rear cover
on the front housing when all aligning conditions are satisfied,
in case the rear cover cannot be mounted on the front housing,
take down the rear cover assembly to check the aligning
condition
1. wire harness clip
2. motor assembly
3. bolt
4. sign board

TF-25
(b) Normal gear grinding trace.
Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Checking)
Checking
1. Common Checking process
Check all parts by visual check to see whether there is damage
or serious or uneven wear (parts needed be substituted by new
parts such as O-ring, oil seal and etc. shall be excluded).
Abandon the damaged or weary parts that will affect on their
performance. The check items are as follows:

Burr: tips protruded from the material regionally

Rag: broken small blocks or particles

Crack: surface thread showing the material is partly or
completely separated.

Excessive abrasion
Refer to the serious or obvious abra-
sion beyond of application limit.

Reduction change
Material slip caused by the heavy
pressure on part of it.

adhesive bonding
Granules of the soft metal are dis-
persed and bonded on the hard metal surface.

Ditch trance: partial crack or trough that means the material
transfer instead of material loss.

Pitting corrosion
Damages to the metal surface caused by
pressure, which are displayed due to color change caused
by heat generated by metal friction.

Step wear
a weary step may be seen or felled between the
neighboring interface or between the non-touching face
due to the excessive wear.

Uneven wear: Partially, unevenly distributed wear, which
includes holes, bright spots, uneven polishing or other
visual drawbacks.
2. Gear or Chain sprocket tooth inspection
Check the gear and chain sprocket tooth according to the
following process:
(a) Normal gear shaving trace.
normal gear shaving trace
normal gear grinding trace

TF-27Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Checking)
(h) Acceptable contact area deflecting to the tooth top.
(i) Unacceptable contact area deflecting to the tooth top,
which must be changed.
(j) Acceptable contact area deflecting to tooth root.
(k) Unacceptable contact area deflecting to tooth root, which
must be changed.
4. Key tooth inspection
Check the broken or peeled spline teeth. The spline teeth may,
if only small part is peeled off, be repaired in the same way as
that for the gear teeth, and can be reused. In case the spline
tooth is broken, the spline must be abandoned. The contact
type of spline is not the same as that for gear; however, spline
that shows step sliding must be abandoned.

TF-28Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear)
Maintenance or Change of Gear or Chain
Sprocket Gear
1. Maintenance principle
(a) Conduct the maintenance for the partial, small peel off
with the suitable manual high-speed grinding tool.
(b) Do not clear away the metal as can as possible when
grinding the matrix metal.
(c) All pointed angles and sides must be repaired as the slip-
pery contour line. Because the pointed angle or edges
may be peeled off again or developed into crack.
(d) Clear away the burr with the suitable grinding stone. Take
notice not to damage the matrix when clearing away the
projecting materials, and
(e) When substituting the non-repaired parts (such as
bearing), if the part is doubted in its re-application
capability, it must be changed.
2. Cases for gear or chain sprocket maintenance or substi-
tuting
(a) The gear, being peeled off at the two sides of tooth top in
contact face, may be repaired for reuse.
(b) The gear, being peeled off at the central tooth top of
contact face, may be repaired for reuse.
(c) The gear, being peeled off at one side of the non-contact
face, may be repaired for reuse.

TF-29Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear)
(d) The gear, being peeled off at the center of one side of
contact face, may be repaired for reuse
(e) The gear, being peeled off in the center of contact area,
shall be changed.
(f) The gear, being peeled off at two sides of tooth top, shall
be changed.

TF-30Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts)
Change the parts and fittings as requirement
Attachment for Inspection Maintenance or Change of Parts
Checking items
Acceptance/Refusal
Parts (items)
All parts (including
all springs)Crack inspection, distortion inspection and ero-
sion inspectionAll parts with crack, all parts that are bended,
distorted or poor in round bouncing are refused.
All threaded partsThread inspection for buckle missing or other
damageThose parts cannot be threaded or bottomed in
overlap manner shall be refused.
Flange and fork
flangePlease refer to the paragraph of
inspection
to
check the spline.Please refer to the
inspection paragraph
for
spline inspection.
Velocity sensor, mo-
tor assembly
Parts of electric clutch
systemPlease refer to the part of electric appliance
Sliding bearing Inside surface inspection for the sliding bearing In the case that the bearing has pitting corrosion
or other damage, refuse it.
Ball bearingCheck visually the ball and track of the ball
bearing to see whether there is damage such as
adhesive bonding, pitting corrosion, etc.
Ensure that the bearing are all lubricated, run the
outer race of the bearing while holding the inner
one to feel whether there is poor running or
corrosion, the bearing shall be run smoothly
without excessive clearance.Refuse to use the damaged bearing;
Refuse to use the damaged or loose bearing; or
Check the axial clearance to see whether it
exceeds 0.23mm.
Needle bearing Check the bearing needle roller and track to see
whether there is damage such as adhesive
bonding, pitting corrosion, etc.Refuse to use the damaged bearing.
The rear cover, front
body and front hous-
ing of transfer boxCheck to see whether there is burr on the cou-
pling face or other damage that impedes assem-
bling or sealing.Clear away the burr according to the paragraph
of
inspection
, otherwise, change the dam-
aged element
Rear cover of trans-
fer boxCheck the bearing holeRefuse to use the assembly that has pitting
corrosion
Odometer gear Check the gear teeth referring to the Inspection
ParagraphRefer to the gear or chain sprocket inspection in

inspection paragraph
.
Clutch shell, joint
outer gear sleeve and
joint coverCheck the spline according to the Inspection
paragraphRefer to the spline inspection of
inspection
paragraph

Locking sleeveCheck the wear or damage of the toggle fork
grooveRefuse the parts with step slipping or damage.
Shift guide shaft Check the deformation situation
Check the burr or other damage on outer race
Check the wear of outer raceRefuse to use the bend shaft; clear away the burr
according to the
inspection
paragraph, oth-
erwise refuse to use.
Refuse to use the shaft with step slipping or
other damage.
Shift toggle forkCheck whether there is wear or damage at the
location where the toggle fork combines with
the shifting cam and gear sleeve.If any step slipping or damage is found, refuse
to use it.