2006 GREAT WALL SO COOL oil

MT-2Gear Box
Notice
Notice
Notice for disassembly and assembly of gearbox
Notice shall be taken during the gear disassembly and assembly on the soft handle for the parts, especially
for the coupling faces so as to avoid the collision; each part shall be put down in order to avoid the missing
or mistaking.
Notice shall not only be taken in the aforesaid aspects, but also in the following items
1. Wash all parts before assembly (rubber fittings and washers excluded).
2. Various oil seals, retainer rings for shafts, spring-type pins shall not be reused.
3. Lubricating oil shall be coated on the friction surfaces, and lubricating grease shall be coated on the lips
of oil seals.
4. Rolling elements shall not be used to transfer the pressure during the various bearing assembly.
5. Lip-type oil seal must not be sloping when assembling it.
6. The openness at the two ends of the spring collar shall be misfit when assembling the component
elements of the synchronizing instrument, and
7. No part is allowed to leak the lubricating oil when the gearbox locating at its working place.

MT-3
Troubleshooting
Gear Box
Troubleshooting
Non-use of clutch
Non-full separation of clutch
Severely warned tooth rings of synchronizing
fittings
Over-hard locating springUse the right driving approach
Checking for adjustment
Change
Change Difficulty in gear engagement
Over-low oil level
Lubricating oil of inferior quality
Non-timely oil change
Unsuitable axial location or clearance of gears
Bearing damage
Burr or collision on gearAdd oil to the specified level
Change it with the specified oil
Change the oil and damaged parts
Check for adjustment
Change
Repair or change the gear
Oil leakage, oil penetration Oil added above the specified level
Loss or missing of bolts
Vent plug trouble
Sealing element damageAdjust oil to the given level
Reassembling or fasten the bolt according to
the specified torque
Change
Change
Damage of synchronizer Overexert in gear shift
Non-use of clutch
Damage on spring collar of synchronizer
Incorrect mounting of drive shaftChange
Use the right driving approach
Change
Check for adjustment
Non-engagement of gear Trouble in controlling mechanism
Incorrect assembling the locating spring or
steel ball
Invalidation of locating spring
Severely worn gear sleeve or fork groove
Seriously worn toggle forkCheck for adjustment
Reassembly
Change
Change
Change
Burning bearing, burning gear Over-low oil level
Inferior lubricating grease
Non-timely oil change, over-dirty oil
Inter-use of differential oil or usage of
additiveChange damaged parts and add oil
Change the damaged parts and lubricating oil
Change damaged parts and lubricating oil
Change damaged parts and lubricating oil
Difficult in gear disengagement Spring invalidation of synchronizer
Warn inner groove of tooth ring of synchronizer
Tooth ring of synchronizer choked on conical
face
Toggle fork deformation or toggle fork axle
deformation
Severely worn toggle forkChange
Change
Change
Change
Change
Methods for troubleshooting
Over-loud or abnormal noise
Common Failures Causes

MT-4Gearbox
Dismantle of Gear Box
3. Tear down the shifting ball of gear change lever
Loose the locking nuts by dextroroting the ball.
4. Tear down the glove box
Dismantle the four bolts of the glove box and put the glove box
into the suitable place.
5. Tear down the dust cover.
6. Tear down the gear change lever.
7. Raise the vehicle to discharge the oil in gearbox.
Warning: the reliability of vehicle shall be verified.
8. Tear down the drive shaft.
(See page PR-5)
9. Tear down the odometer sensor and the plugging
elements of backup switch
10. Tear down the vent pipe.
Tear down the heading exhaust pipe from branch exhaust pipe
Dismantle of gearbox
1. Disconnect the cathode wire from the cathode of storage
cell.
2. Tear down the setting bolts of fan cover.
Tear down 4

MT-8Gear Box
Mount of Gear Box
4WD:
(a) Mount the bracket and supporter of leg washers of rear
engine in 4WD vehicle;(SF)
(b) Mount and tighten the third beam of 4WD vehicle. (SF)
4. Remove the wooden spill.
5. Mount exhaust pipe.
Mount the exhaust pipe on the branch exhaust pipe.
Tightening moment
(62
3)N
m
6. Mount the wheel-brake cylinder of clutch.
Tightening moment
(18
2)N
m
7. Mount odometer sensor and plugging elements of backup
switch.
8. Connect the drive shaft.
(See page PR-12)
9. Add oil into the gearbox.
Lubricating oil grade: GL-5 85W/90
Volume: 2.4L(dry)
Remark: the Tightening moment of oil filling/draining
plug: (30
50)N
m
4WD
4WD

MT-11Gearbox
Disassembly of Gear Box
(c) Dismantle the nuts of the four-gear driven extension fram.
(d) Tap the extension frame lightly with rubber hammer to tear
down the selective gearshift shaft and selective rocker
arm.
8. Tear down front cover.
Dismantle the eight bolts and front cover and axial oil seal.
9. Tear down the input shaft, axial/bearing open ring and
countershaft bearing open ring.
10. Dismantle the gearbox frame from the central link plate,
(a) Put the gearbox straightly as shown in the drawing.
(b) Tap out the gearbox frame out carefully with the rubber
hammer. And
(c) Pull out the gearbox frame out from the central link plate
as the drawing shows
4WD

MT-25Transmission
Output Shaft Assembly(Assembly of Output Shaft Assembly)
Assembly of output shaft assembly
1. Assembly of synchronizer
(a) Insert the synchronizer hub and sliding block into the gear
sleeve.
(b) Install the spring expansion ring under the sliding block.
Note:The openings of spring expansion ring should be
staggered during installation .
2. Install the gear components of 3rd gear and synchronizer
of 3rd and 4th gear on the output shaft.
(a) Smear the gear oil on the shaft and the needle bearing of
3rd gear.
(b) Put the synchronized ring on the components of gear of 3rd
gear, and align the notch of synchronized ring and sliding
block.
(c) Install the needle bearing into gear components of 3rd gear.
(d) Assembly the gear components of 3rd gear and synchro-
nizer of 3rd and 4th gear with pressing machine.
3. Assembly of snap ring for shaft
To choose one snap ring which make the axial clearance be
Min, and install it on the shaft.
3/4 gear posititon
1/2gear posititon
front
front side

MT-26Transmission
Output Shaft Assembly(Assembly of Output Shaft Assembly)
Standard clearance:
For the transmission made by Shang Chi
(0.15
0.33)mm
For the transmission made by Tang Chi:
(0.09
0.33)mm
5. Assembly for the gear components of 2nd and
synchronizer of 1st and 2nd gear
(a) Smear the gear oil on the needle bearing of gear of 2nd
gear.
(b) Put the synchronized ring on the gear,and align the notch
and shift key.
(c) Install the needle bearing into the gear components of 2nd
gear.
(d) Assembly the gear components of 2nd gear and meshing
sleeve of synchronzer of 1st and 2nd gear with pressing
machine.
6. Check the axial clearance of gear components of 2nd
gear
Measure the axial clearance of gear components of 2nd gear
with feeler gauge.
Standard clearance:
For the transmission made by Shang Chi:(0.15
0.33)mm
For the transmission made by Tang Chi:(0.09
0.33)mm
7. Assembly the locking ball and gear components of 1st
gear
(a) Install the locking ball into the shaft.

MT-27Transmissio
Output Shaft Assembly(Assembly of Output Shaft Assembly)
SST
SST
(b) Smear the gear oil on the needle bearing of gear of 1st gear.
(c) Assembly the gear components of 1st gear,synchronized
ring,needle bearing and sleeve of gear of 1st gear.
(d) Install the assembly on the output shaft,and align the notch
of synchronized ring and sliding block .
(e) Turn the sleeve of 1st gear shaft to align the it with the
locking ball.
8. Installation for rear bearing of output shaft
Fix the bearing of output shaft to the output shaft with SST and
pressing machine, make the notch of locking ring of output
shaft rear bearing expose to the tail.
Remark: Hold the sleeve of gear of 1st gear and don
t let it fall
off.
9. Install the gear of 5th gear
Fix the gear of 5th gear with SST and pressing machine.
10. Assembly the snap ring of shaft
(a) To choose one snap ring which make the axial clearance
be Min, and install it on the shaft.
Max clearance
0.1mm

(b) Knock the snap ring of shaft of 5th gear tightly with
screwdriver and hammer.
11. Measure the axial clearance of gear of 1st gear
Measure the axial clearance of gear of 1st gear with feeler
gauge
Standard clearance:

For the transmission made by Shang Chi:(0.15
0.33)mm
For the transmission made by Tang Chi:(0.09
0.33)mm