2006 GREAT WALL SAILOR Gear box

TF-31Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts)
Attachment for Inspection Maintenance or Change of Parts
Parts (items) Checking items Acceptance/Refusal
Shift toggle fork as-
semblyCheck the wear and damage of the inserted face
that is combined with gear sleeve;
Check to see whether the contact roller can
rotate freely or is damaged or notIf any step wear or damage is found, the inserted
face shall be refused to use.
If the contact runs difficultly or is damaged, a
new pin-contact roller and new cage assembly
shall be used.
Driving and driven
chain sprocketCheck the sprocket teeth according to
the
inspection
paragraphRefer to the sprocket teeth inspection of

inspection
paragraph
Shift toggle fork as-
semblyCheck the inner diameter that matches with the
output shaftIf any pitting corrosion or damage is found,
refuse to use it.
Driving chain Check the step sliding, looseness or damage of
pin or connecting elementRefuse to use the weary or damaged driving
chain
Filtering screenCheck to see the filtering screen is clean or with
small hole or damageClean it where necessary, and abandon the dam-
aged one.

TF-32Transfer Box
Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection
Maintenance or Change of Parts
Pump shell Check to see whether there is pitting corrosion
or step slippingAbandon it in case it is seriously damaged or
worn
Output shaftCheck the spline, check the surface that matches
with bearing and check the distortion according
to
inspection
paragraphRefer to the spline inspection of
inspection

paragraph;
Refuse to use the one with pitting corrosion or
damage;
Refuse to use the one that is bending or poor in
round bouncing.
Deceleration hubCheck the spline of chain sprocket and check the
wear or damage of the location where matches
with the toggle fork according to the

inspection
paragraphRefer to the spline inspection of
inspection

paragraph; refuse to use the one with step slid-
ing or damage.
Front output shaftCheck the surface where matches with the
bearing;
Check the spline according to the
inspection
:
paragraphRefuse to use the one with pitting corrosion or
damage
Input shaft Check the spline according to the
inspection

paragraph
Check the distortionRefer to the spline inspection of
inspection

paragraph;
Refuse the one that is bending or poor in round
bouncing.
Thrust washer and
thrust discCheck the pitting corrosionRefuse to use the one with pitting corrosion or
damage
Sun wheelCheck the gear teeth and spline according to the

inspection
paragraphRefer to the gear teeth inspection and spline
inspection of
inspection
paragraph.
Planetary mechanism
assemblyCheck the gear teeth according to the

inspection
paragraph;
Check the wear and looseness of the planetary
gear pin; check the wear of thrust gasketRefer to the gear teeth inspection of

inspection
paragraph;
If any step sliding or pitting corrosion is found,
refuse to use it
Electric shifting camCheck to see whether there is step slipping or
pitting corrosionIf any step sliding or pitting corrosion is found,
refuse to use it
Shift guide shaftCheck to see whether there is step slipping or
pitting corrosion
Check the distortion situationIf any step sliding or pitting corrosion is found,
refuse to use it
Refuse to use the bending one
Planetary gear ringCheck the match performance of it with the
transfer box housing
Check the gear teeth according to the

inspection
paragraphCheck the transfer box housing assembly to see
whether the gear ring is loose or not in the
housing
Refer to the gear teeth inspection of

inspection

paragraph
Transfer box housingCheck the holes matches with the bearingAbandon the one with pitting corrosion or
damage.

PR-2Drive Shaft
Notice and Troubleshooting
Notice
Notice: do not grip the drive shaft sleeve too tight with vice
so as to avoid the deformation.
troubleshooting
Trouble Causes Resolving approaches
Noise Wear of universal joint yoke spline;
Wear of central bearing;
Wear or seize-up of cross shaft bearingChange the drive shaft;
Change the central bearing;
Change the bearing of cross shaft
Vibration Oscillation difference of the drive shaft;
Drive shaft imbalance;
Wear of the liner of rear bearing in the lengthening shell of
gear box;
Spline seize-up of the universal joint yokeChange drive shaft
Change drive shaft
Change the liner
Change drive shaft

PR-5Drive Shaft
Drive Shaft
(4WD)
Rear axle drive shaft
1. Take apart the universal joint flange fork of rear axle drive
shaft from the differential flange.
(a) Label the two flanges with assembly marks.
(b) Take apart the four sets of bolt and nut.
Disassembly of Drive Shaft
(2WD)
1. Take apart the universal joint flange fork of the drive shaft
from the differential flange.
(a) Label the two flanges with assembly remarks.
(b) Take apart the four sets of bolt and nut.
assembly mark
2. Take apart the center support bearing from the frame
beam (for the three-joint type)
3. Take apart the drive shaft from the gearbox
(a) Pull out the universal joint yoke from the gearbox.
(b) Insert the SST in gearbox for oil leakage prevention.
2. Take apart the center support bearing from the frame
beam (three-joint type
SST
assembly mark

PR-6Drive Shaft
Drive Shaft
3. Take apart the drive shaft from the gearbox.
(a) Pull out the universal joint yoke from the gearbox.
(b) Insert the SST in gearbox to prevent the oil leakage
Front axle drive shaft
4. Tear down the front universal joint flange fork of the front
drive shaft.
(a) Hang he front end of the front axle drive shaft.
(b) Label the assembly mark on the flange
(c) Take apart the four sets of bolt and nut.
5. Disconnect the rear universal joint flange fork from the
front axel drive shaft along the transmission path.
(a) Label the assembly marks on each flange.
(b) Take apart the four sets of bolt and nut.
Drive shaft disassembly
1. Separation of the rear joint of the rear axle drive shaft
from the front joint of rear axle drive shaft
(a) Label the assembly marks on each flange.
(b) Take apart the four sets of bolt and nut.
2. Take apart the center support bearing from the front joint
of the rear axle drive shaft.
(a) Loosen the riveted nut by chiseling with a chisel and
hammer.
SST
assembly mark
assembly mark

PR-12Drive Shaft
Drive Shaft
Mount of Drive Shaft
(2WD)
1. Insert the universal joint yoke in the gearbox.
(a) Tear down the SST tools.
(b) Push the universal joint yoke into the gearbox.
2. Connect the universal joint flange of the rear joint of rear
axle drive shaft and the relative the differential flange.
(a) Align the assembly marks on the two flanges and connect
the flanges with four sets of bolt and nut.
(b) Screw up the sets of bolt and nut according to the
specified torque.
Fastening torque
(74
5)N
m
3. Mount the center support bearing on the frame beam
(three-joint type)
(a) Use two bolts to mount the center support bearing on the
frame beam and tighten them manually.
(b) Check the bearing seat, which shall be vertical with the
drive shaft, and change it where necessary.
(c) Check the central line of the central bearing and ensure
that the central lines of the central bearing and the bear-
ing seat shall be the same when the vehicle is in the non-
loaded stage. And adjust the bearing seat only it is
necessary.
(d) Screw up the mounting bolts according to the specified
torque.
Fastening torque
(40
5)N
m
(4WD)
1. Connect the universal joint flange fork of the front axle
drive shaft with the flange that matches with the transfer
box.
Align the assembly marks and use four sets of bolt and nut to
connect the flange fork with the flange, screw up the sets of bolt
and nut according to the specified torque.
Fastening torque
(74
5)N
m
forward
SST
assembly mark
assembly mark

SR-9Steering System
Manual Steering Gear
Manual steering gear
Disassembly and mount of manual steering gear
steering drive shaft
manual steering gear box
swing arm
N
m
specified torque
245
25(Dr)
assembly mark
SSTPoints on disassembly and mount
1. Disassemble the steering drive shaft:
(a) Loosen the fixing bolts at upper part of steering column;
(b) Tear down the connecting bolts of steering drive shaft;
(c) Mark the assembly marks on the steering drive shaft and
worm shaft;
(d) Slide the shaft backward to tear it down from the worm shaft.
2. Tear down the swing arm from the steering gear:
(a) Loosen the fixing nuts of swing arm;
(b) Tear down the swing arm from the steering gear with SST.
96
10(Dr SL SK SY)
worm shaft

BE-9Body Electric System
Protective Box Position and Content
fuse relay
1. Small lamp 10A A. electromagnetic fan relay
2. Brake 5A B. lasher
3. Ceiling lamp 5A C. electromagnetic fan relay
4. Central control lock 15A D. small lamp relay
5. Electric rocker gear 30A E. electric window relay
6. Dual flasher 10A
7. Cigarette lighter 15A
8. Rear vision mirror 5A (1) plugging elements of ceiling lamp wire harness
9. Unload (2) plugging elements of wire harness at front left door
10. Acoustic device 15A (3)plugging elements of wire harness in engine room
11. Rear window 20A
12. Electromagnetic fan 10A
13. Instrument 5A
14. Back-up lamp 5A
15. Rain brush 10A
16. Steering 5A
17. Unload
18. Unload




A
B
C
E D
123 456
78 9 101112
13 14 15
16 1718
SF
Protective bos I (continued)