2006 GREAT WALL SO COOL clutch

TF-20
1 convex plate
groove2
3
4
5 6
1234
5
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-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.

AC-5Electric Circuit Diagram of Air
Conditioning System
SF
ST
fusethree-state pressure switch
cold-hot
servomotor circular
servomotor mode
servomotor main air-conditioning
control panel
speed
adjusting
module
air blower
b`r
power resistor
water
valve
Mjjj
M
ACCON
+12V 5
R R 5
5 5 5 5
5
5 PP
P P 3
3
3 3 3 3
3
3
3 1
111
1
1
1 N
N N
1
2 2 2 2
2
22 O O OO
4
44 4
4 4 4Q
Q
Q Q
4
6 6
6 6 6
6S S 6
S6
7
7
7 8
88 9
9
9 10
1010
1111
12
13 14 15 16 17 18 1920
20 21 22 23 2423
ignition switch modular air-door motor cold-hot air-door motor air-in motor
three-stage
pressure switch speed adjusting
modul air conditioning
ignition switchsmall light relay
fusefuse electronic fan
water temperature relay
fuse
compressor relayelectromagnetic
fan relay
compressor clutch
24
Electric circuit diagram of air-conditioning system (continued)
battery
18
5
17
16
3
15
19
14
22
1
13

AC-10Air-conditioning System - Troubleshooting
Troubleshooting
TroubleReparation approachesPage
Lack of cold airNon-pull-in performance of electromagnetic clutch:
(a) Break of ignition switch and fuse;
(b) Trouble of electromagnetic clutch;
(c) Trouble of A/C switch;
(d) Wiring or grounding trouble;
(e) Lack of refrigerant; and
(f) Trouble of pressure switch.
Abnormal operation of compressor:
(a) Looseness or break of driving belt;
(b) Compressor trouble;
Expansion valve trouble;
Systematic leakage;
Liquid tank fusible plug melting or filtering
screen blocking;
Non-work of air blower:
(a) Failure of A/C switch;
(b) Failure of air blower motor, and
(c) Wiring failure.Change the fuse and check to see whether
there is short circuit;
Check the electromagnetic clutch;
Check the A/C switch;
Repair it as requirement;
Check the refrigerant pressure;
Check the pressure switch;
Adjust or change the driving belt;
Check the compressor;
Check the expansion valve;
Conduct lubricating test for the system
Check the liquid tank;
Check the A/C switch;
Check the air blower motor;
Conduct reparation as requirement.
Inconsecutive
cold airElectromagnetic valve slip
Failure of expansion valve;
Wiring or connecting failure;
Over water content in systemCheck the electromagnetic clutch;
Check the expansion valve;
Make reparation as requirement.
Reclaim the water first, then exhaust the
system to vacuum and inflate in the refrigerant.
Cold air occurs in
high-speed conditionBlocking of radiating face of condenser;
Driving belt slip;
Compressor failure;
Insufficient or redundant refrigerant;
Air existing in systemCheck and wash the condenser
Check and change the driving belt;
Check the compressor;
Check the refrigerant quantity;
Vacuumize the system and inflate
the refrigerant;
Insufficient
cold airCondenser blocking;
Driving belt slip;
Electromagnetic clutch failure;
Compressor failure;
Expansion valve failure;
Insufficient or redundant refrigerant;
Air existing in system;
Redundant compressor lubricant;
Liquid tank blockCheck the condenser;
Check and change the driving belt;
Check the electromagnetic clutch;
Check the compressor;
Check the expansion valve;
Check the refrigerant quantity;
Reclaim the air, then vacuumize the sys-
tem and inflate the refrigerant;
Check the compressor lubricant quantity;
Check the liquid tank
Evaporator blocking or frosting
Air leakage in cooling device or air
pipeline;
Air inlet blocking;
Air blower motor failure;Clean the evaporator radiating rib
or filter;
Make reparation as requirement
Make reparation as requirement
Change the air blower motor.
Page AC-4 to 7
Page AC-12
Page AC-4 to 7
Page AC-11
Page AC-13
Page AC-12
Page AC-16
Page AC-14
Page AC-4 to 7
Page AC-12
Page AC-16
Page AC-4 to 7
Page AC-15
Page AC-12
Page AC-12
Page AC-12
Page AC-16
Page AC-11
Page AC-14
Page AC-18
Page AC-20
Possible causes
Page AC-15
Page AC-13
Page AC-12
Page AC-11
Under-speed cold air

AC-12Air-Conditioning System
Compressor
Installation of manifold gauge
Remark: Connect the manifold gauge to the auxiliary valve of
compressor.
1. Turn off the manual valve of manifold gauge.
2. Mount the packing hose of manifold gauge on the packing
valve.
Mount the LP hose to the LP packing valve and the HP hose to
HP packing valve. Then screw up the nuts for hose joint by
hand.
Remark: Do not coat the compressor lubricant on the connec-
tion positions.
packing hose
efrigeration system
connected to mani-
fold gauge
connect to compressor
turn offturn offCompressor
On vehicle inspection
1. Mount the manifold gauge;
(see manifold gauge mount)
2. Run the engine at the speed of 1500 r/m or so;
3. Check the compressor according to the following items:
(a) The HP gauge readings under the normal system should
satisfy the specified value of (1.4-1.7)MPa , that of LP
gauge should meet the specified value of (0.15-0.2)MPa .
(b) Whether there is abnormal sound;
(c) Whether there is leakage at the shaft oil seal.
If any problem is found, repair or change the compressor.
4. Check the electromagnetic clutch:
(a) Check to see whether there is lubricant trace on the
pressing plate and rotor;
(b) Check to see whether there is noise or lubricant leakage
at the clutch bearing;
(c) Measure the resistance between the stator coils that is set
between the clutch lead and the grounding lead with the
ohmn meter.
Standard resistance:
SL SK SJ
(3.2
.2)
Ω
Dr SF SY
(3.5
.2)Ω
In case the requirement is not satisfied, change the compressor.

AC-13Air-Conditioning System
Compressor
Disassemble of compressor
1. Run the engine in the idle status for ten minutes under
the air-conditioning situation;
2. Turn off the engine;
3. Disconnect the cathode lead from the storage cell;
4. Disconnect the electromagnetic clutch lead from the
matching wire;
5. Exhaust the refrigerant from the refrigeration system;
6. Disconnect the two hoses from the auxiliary valve of
compressor;
Cover the opening joint with cork right away to prevent the wet
gas entering in to the system.
7. Tear down the compressor:
(a) Tear down the fan cover;
(b) Loosen the driving belt;
(c) Tear down the fixing bolts of compressor bracket and the
compressor.
Mount of compressor
1. Mount the compressor with fixing bolts;
Tightening moment
(25-30)N
m
2. Mount the driving belt correctly;
Requirement for belt tension: the tension belt is allowed
to reduce (9-13)mm under 98N after the compressor
runs for five minutes;
3. Connect the two hoses to the auxiliary valve of
compressor;
Tightening moment
(see page AC-8)
4. Connect the clutch lead to the matching wire;
5. Connect the cathode lead of storage cell to the storage
cell, and
6. Vacuumize the system and inflate the refrigerant:
Vacuum time:
Dr SL SK SF SJ
Vacuumize for 20min and main-
tain the pressure for 30min;
SY
Vacuumize for 30min and maintain for 30min
Inflated refrigerant quantity:
Dr
(600-650)g
SL
700
0g
SK SJ
560
0g
SF
(700-720)g
SY
850
0gcorrect incorrect incorrect
98N

A-1
Specifications of Maintenance
and Up-keeping
page
Clutch .......................................................................... A-2
Gear box ..................................................................... A-2
Transfer box ................................................................ A-3
Drive shaft ................................................................... A-4
Suspension system and automobile axle .................... A-4
Braking system ............................................................ A-5
Steering system .......................................................... A-6
A

A-2
Clutch
Specification
Item Specification
Fastening torque for clutch tube on master cylinder
Fastening torque for clutch tube on wheel-brake cylinder
Fastening torque for clutch pressure plate160
190-200
5-15
0.3
0.8
0.2
0.6
5
Max misplacement
0.5 Pedal height (calculated from front wall
Pedal free stroke
Min depth of clutch-facing rivet
Max radial swing difference of clutch rib
Max radial swing difference of flywheel
Max width of wear of diaphragm spring
Max width of wear of diaphragm spring
Alignment degree of diaphragm spring endApplicable vehicle model
Dr SF
SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Torsion moment
Fastening location (N*m)
15-17
15-17
30 Applicable Vehicle model
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Dr SF SL SK SY SJ
Gearbox
Three-grade maintenance for gearbox
1. Grade I maintenance for gear box
Grade I maintenance: Check the lubricant level to see whether the lubricant level is in alignment with the lower edge of oil
filler; if the lubricant is lower than the oil filler lower edge, add the lubricant; or the insufficient lubricant will lead to the poor
lubrication or burn-out of bearing and teeth; while the over-high lubricant will cause the overheating and oil leakage.
2. Grade II maintenance for gear box
Grade II maintenance: The gear box of a new vehicle should be maintained by exchanging the lubricant during the
first grade II maintenance and should be washed with kerosene; and the lubricant quality should be checked in the
grade II maintenance in later time, if the lubricant is diluted, gumming or over-dirty, it should be changed.
3. Grade III maintenance
The gearbox should be disassembled for inspection, washing and oil change.
Notice: As the new vehicle is in the running-in status, the gearbox should be maintained by exchanging lubricant
after the vehicle covers 1500 km,
Lubricant Type
GL-5 SAE80W/90
Torsion moment of relative connecting elements
Tung Teeth: Tang tooth(5DYA4TWD
5DYA8FWD)
Unit
ãã Specification of Maintenance and Up-Keeping
Clutch and Gearbox
Locating screw of fork axle at first and second gear
Locating screw of yoke block
Screw on baffle of rear bearing of output shaft
Screw of reverse idler shaft
Bolt of gearshift cover
Bolt of front cover
Bolt of rear body
Bolt of clutch shell
Bolt of locating spring13
17
15
20
17
22
17
20
15
20
15
20
30
45
30
45
17
22 Fastening location N*m