2006 GREAT WALL SO COOL 4WD

PR-11Drive Shaft
Drive Shaft
Drive shaft assembly
1. Mount the center support bearing on the front joint of rear
axle drive shaft.
Remarks: The notch of the center support bearing shall face
backward when mounting it.
2. Mount the flange joint on the front joint of rear axle drive
shaft.
(a) Coat the spline of front joint of rear axle drive shaft with
lithium base grease.
(b)
Mount flange joint on the shaft and align the assembly marks.
Remarks: if the central flange joint or the front joint of the rear
axle drive shaft is required to change, the front and back
universal joint yokes of the rear axle drive shaft shall face in the
same direction when re-assembling.
(c) Lock the flange joint with SST and screw up the newly-
changed nut to press the bearing in place.
(d) Loosen the nuts.
(e) Tighten the nuts again, and
(f) Rivet the nuts with hammer and punch.
3. Drive shaft mount
(a) Align the assembly marks on flanges, and connect the
two flanges with four sets of bolt and nut.
Remarks: if the central flange or the front joint of the rear axle
drive shaft is required to be changed, the front and back
universal joint yokes of the front joint of rear axle drive shaft
shall face in the same direction when reassembling them.
(b) Screw up the sets of bolt and nut according to the
specified torque.
Fastening torque: (74
5)N
m
4. Insert the universal joint yoke in the universal joint yoke
(4WD).
(a) Coat the lithium base grease on the sliding surfaces of the
drive shaft spline and the universal joint yoke.
(b) Align the assembly marks on universal joint yoke and
drive shaft.
(c) Insert the universal joint yoke in drive shaft.
assembly mark
2WD 4WD
forward
assembly mark
SST
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

SA-1
Suspension System and Automobile Axle
Page
Troubleshooting .......................................................... SA-2
Alignment of Front Wheel ............................................ SA-3
(Dr/2WD)
Front Wheel Hub and Steering Knuckle ...................... SA-10
Front Wheel Hub ..................................................... SA-11
Steering Knuckle ..................................................... SA-14
Front Suspension ........................................................ SA-16
Ball Stud .................................................................. SA-17
Torsion bar .............................................................. SA-19
Lower Arm and Vibration Damper ........................... SA-21
Upper Arm ............................................................... SA-24
Guide Level ............................................................. SA-26
Lateral Stabilizer ..................................................... SA-27
(SF/2WD)
Front Wheel Hub and Steering Knuckle ...................... SA-28
Front Wheel Hub ..................................................... SA-29
Steering Knuckle ..................................................... SA-32
Front Suspension ......................................................... SA-36
Ball Stud ................................................................... SA-37
Torsion bar ............................................................... SA-38
Lower Arm and Vibration Damper ............................ SA-39
Upper Arm ................................................................ SA-42
Guide Level .............................................................. SA-43
Lateral Stabilizer ....................................................... SA-43
(SF/4WD)
Front Wheel Hub and Steering Knuckle ....................... SA-44
Front Wheel Hub ...................................................... SA-45
Steering Knuckle ..................................................... SA-49
Constant Speed Drive Shaft ........................................ SA-54
Front Speed Reducer .................................................. SA-57
Change of Oil Seal of Driving Bevel Gear Of
Front Speed Reducer ............................................. SA-57
Dismantle of Front Speed Reducer ......................... SA-61
Change of Axle Shaft Oil Seal ................................. SA-63
Disassembly and Assembly of Front Speed Reducer.... SA-65
Assembly of Front Speed Reducer ......................... SA-74
(Back)
Rear Axle Shaft ........................................................... SA-79
Rear Speed Reducer .................................................. SA-83
On-vehicle Change of Oil Seal of Main Teeth ......... SA-84
Dismantle of Rear Speed Reducer .......................... SA-85
Disassembly of Rear Speed Reducer ..................... SA-85
Assembly of Rear Speed Reducer .......................... SA-89
Mount of Rear Speed Reducer and
Differential Assembly .............................................. SA-94
Rear Differential .......................................................... SA-95
Rear Suspension ......................................................... SA-97
SA

SA-44
Front Wheel Hub and Steering Knuckle
Element Figure
Suspension System and Automobile Axle (SF/4WD)
Front Wheel Hub and Steering Knuckle
lock ring
cushion block nut
lock ring
cushion
block
shock
absorberupper arm
transverse stabilizer rod
bolt
transverse stabilizer
rod gasket

rubber snubber
washer
stabilizer rod limit tubebrake
caliper rubber
snubber
washer
constant speed
drive shaft needle
bearingsteering knuckle
steering knuckle
small sleeve
retainer ring
washer-spline of
steering knuckle
shaft thrust plate-
steering knuckle

inner oil
seal- drive shaft
brake oil pipe bracket
steering
knuckle arm
brake shell
dust cover

oil seal -
front hub
front hub bearing
(inner)
front wheel hub and
front brake discstop washer
lock plate
front hub bearing
(out)
steering knuckle
big nut
free wheel hub
noumenongasket
free wheel
hub cap
gasket


liner
lower ball stud








Parts that cannot be reused after being used
specified torque
N
m
135-155
6-12 25-29


25-29 70-90
132-152
20-26
180 127-147132-152123
SF 4WD
transverse stabilizer rod gasket

transverse stabilizer rod gasket

transverse stabilizer
rod gasket

transverse stabilizer
rod gasket

SA-45
2. Tear down the free hub.
3. Tear down the retainer ring and the axle spine of washer-
steering knuckle:
Tear down the retainer ring with the pliers for retainer ring, and
take down the axle spline of washer-steering knuckle by hand.
4. Tear down the front wheel hub and front brake disc:
(a) Prize up the lock plate with screwdriver.
(b) Tear down the steering knuckle nut with special service
tool to take out the lock plate.
(c) Tear down another steering knuckle nut with special
service tool to take out the stop washer.
(d) Tear down the front wheel hub and the front brake disc.
Front Wheel Hub
Disassembly of Front Wheel Hub
1. Tear down the brake caliper:
(a) Tear down the Bundy tube from the brake caliper and
block the pipeline of Bundy tube with cork.
(b) Tear down the brake caliper from the steering knuckle.
Suspension System and Automobile Axle (SF/4WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-46
5. Tear down the front hub, the oil seal and the inner race
of front hub bearing (inner)
(a) Prize out the oil seal.
(b) Take out the inner race of front hub bearing (inner).
6. Inspection on and change of the outer race of front hub
bearing
(a) Check each bearing:
Wash the inner and outer races of each bearing to check
their wear or damage situation.
(b) Tear down the outer race of each bearing:
Tap out the outer bearing race with copper bar and hammer.
Notice: bind the inner and outer races of the same
bearing together to prevent from mixing.
7. Inspection and change for front brake disc
(a) Check the wear situation of the front brake disc.
(b) Tear down the bolts that connect the front wheel hub and
the front brake disc.
(c) Connect the front wheel hub and the front brake disc with
bolts, which are tightened diagonally with moment span-
ner according to the specified torque.
Fastening torque
(70-80)N
m
(d) Make the dynamic balance test on the dynamic balancer,
and the amplitude value displayed should not be smaller
than 13.5g under the condition that the measuring rotat-
ing velocity is 796 r/m and the locking rotating velocity
of 786 r/m, otherwise, tap the counter balanced clip,
which is 4g each, in the corresponding position, the clip
number should not be more than 4.
(e) Tap in the new bearing outer race carefully with the
special service tool.
Notice: the inner and outer races of the same bearing
should be changed in one time.
Suspension System and Automobile Axle (SF/4WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-47
Assembly of Front Wheel Hub
1. Mount on the inner race and roller assembly of front hub
bearing as well as the oil seal of front hub.
Coat the lithium base grease of (4-5)mm on the inside surfaces
of the bearing outer race and the front wheel hub, put in the
inner race and roller assembly of front hub bearing (inner),
then plaster the lubricant. Plaster a little lubricant on the lips of
front wheel hub oil seal, and finally tap the front hub in place
with special service tool.
Notice: Do not plaster the lubricant on the face of front
brake disc.
2. Mount the inner race of front hub bearing (outer) and
roller assembly
Coat 4
5 mm of lithium base grease on the outer race of
bearing, and then put the inner race of front hub bearing (outer)
and roller assembly in it, finally plaster with lubricant.
(c) Loosen the steering knuckle nut to ensure the front brake
disc can run freely. Screw up the steering knuckle nut
again to the specified torque.
Fastening torque
25N
m
(d) Mount on the lock plate and mount on another steering
knuckle nut.
Fastening torque
60N
m 3. Mount the front wheel hub on the steering knuckle
Coat a little lubricant on the oil seal of steering knuckle, and
then mount the front wheel hub and front brake disc on the
steering knuckle, finally mount on the stop washer.
4. Adjust preload:
(a) Mount on the steering knuckle nut and screw it up
according to the specified torque.
Fastening torque
(100-120)N
m
(b) Run the front wheel hub by 1/4-1/3 round so as to seat the
bearings.
Suspension System and Automobile Axle (SF/4WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-48
(e) Hold the bolt of front wheel hub with the spring-tension meter
and drag slowly in the direction of the spot tangent line.
Suitable tension range
(29-54)N
The nut should be screwed up again within the suitable range if the
tension value is overlarge or over small.
(f) Check the bearing to ensure it cannot leap excessively (the
axial clearance should not be more than 0.05mm).
(g) Measure the bouncing value of the front brake disc, which
should not be more than 0.11mm, and
5. Mount the liner and the free hub:
(a) Tear down the free wheel hub cap firstly.
(b) Mount the liner and the free hub on the front wheel hub.
Fastening torque
(25-29)N
m
(c) Mount on the free wheel hub cap.
Fastening torque
(6-12)N
m
6. Mount the brake caliper:
(a) Mount the brake caliper on the steering knuckle and screw
up the bolts according to the specified torque.
Fastening torque
123N
m
(b) Connect the Bundy tube.
Fastening torque
20-22N
m
7. Check the height of brake liquid level and, if required, add
the brake liquid, exhaust the gas from the brake system.
Suspension System and Automobile Axle (SF/4WD)
Front Wheel Hub and Steering Knuckle (Front Wheel Hub)
(h) Bend one tooth of lock plate inside and other teeth outside
so as to lock the steering knuckle nut.