2006 GREAT WALL SO COOL 4WD

SA-73
(l) Run the flange to check the swing difference of axle
driven bevel gear.
Max swing difference
0.07mm
Remark: if the requirement is not satisfied, tear down the axle
driven bevel gear from the differential, and then screw up the
bolts again.
8. Change the bearing of the long semi-axis:
(a) Take down the retainer ring with the calipers.
(b) Tear down the grooved ball bearing from the long semi-
axis.
(c) Mount on the new grooved ball bearing on the long semi-
axis
(d) Mount on the retainer ring with calipers.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-74
4. Select the adjusting washer ñdriving bevel gear accord-
ing to the experience, and cover it on the driving bevel
gear; and mount the inner race and roller assembly of
bearing 32307 on the driving bevel gear by pressing.
5. Mount the adjusting washer and sleeve on the driving
bevel gear, and encase it in the front speed reducer cell
through the flange along with the spline, and screw on
the nuts.
6. Screw up the main-tooth nuts to the specified torque with
the SST.
Fastening torque
(175
35)N
m
7. Measure the preload on the driving bevel gear bearing
with torque tester :
New bearing
(1.2-1.7)N
m
Old bearing
(0.9-1.3)N
m
Assembly of Front Speed Reducer
1. Clean the front speed reducer shell; press the outer
races of bearing 31306 and bearing 32307 to mount
them in the speed reducer shell.
2. Mount he inner race and roller assembly of bearing
31306 as well as the oil-guard tray in the front speed
reducer shell, then press on the driving bevel gear oil
seal with SST.
Notice: coat a little lubricant on the lip open of the oil seal
before encasing it, and the oil seal that is encase in the
front speed reducer shell should be 1.5 mm away from
housing faces.
3. Encase the flange and dust cover in the front speed
reducer through the lip open of oil seal and press it by
hand.
Suspension System and Automobile Axle (SF/4WD) Front Speed Reducer (Assembly of Front Speed Reducer)

SA-75
8. Encase in the differential:
(a) Put the adjusting gasket in the outer position of bearing
at the side of the front speed reducer shell, and then
Encase the differential in the front speed reducer shell, be
sure there is a play between the driving gear and the
driven gear.
(b) Tap the axle driven bevel gear with the rubber hammer,
so that the bearing 50KB801 on the differential, together
with the adjusting gasket, contact the mounting part of
the side face of speed reducer closely.
9. Measure the clearance between the axle driven bevel
gear and the driving bevel gear with the dial indicator to
select the adjusting gasket that satisfy the reasonable
play of (0.15-0.25)mm.
10. Select the adjusting washer for the other side:
The thickness of adjusting gasket should eliminate the clear-
ance between the bearing 50KB801 and the front speed re-
ducer shell, on the other side, the adjusting gasket should not
be over thick because the over-thick gasket will lead in too
large pre-tightening force on the bearing 50KB801 of
differential.
11. Tear down the adjusting gasket and differential, and
encase the new adjusting gasket in the front speed
reducer shell, and another adjusting gasket, together
with the differential housing, should be encased in the
front speed reducer shell correctly.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Assembly of Front Speed Reducer)

SA-76
12. Measure the clearance between the axle driven bevel
gear and the driving bevel gear with dial indicating lamp.
Clearance: 0.15-0.25mm
Remark: if the play fails to fall within the specified range,
change with the adjusting gasket of other thickness to satisfy
the requirement under the precondition there is no clearance
between the adjusting gasket and the differential.
14. Measure the total preload of the front speed reducer with
torque tester;
Fastening torque
(1.8-2.4)N
m 13. Mount on the left and the right cap-differential bearing:
Screw up the bolts with spanner to the specified torque;
Fastening torque
78N
m
15. Check the teeth engagement between the axle driven
bevel gears:
(a) Coat three or four teeth at three different positions of the
axle driven bevel gear in red
(b) Hold the flange tightly while rotating the axle driven
bevel gear.
(c) Check the teeth engagement situation.
Remark: the trace of the teeth of axle driven bevel gear should
satisfy this requirement. Otherwise, select the suitable adjust-
ing washer for correcting according to the situation of poor
teeth engagement;
Select the adjusting gasket that makes the main teeth apart
from the axle driven bevel gear.
convex surface of gear
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Assembly of Front Speed Reducer)
concave surface of gear

SA-77
heel end engagement tooth top engagement
Select the adjusting gasket that make the main teeth contact
closer with the axle driven bevel gear.
toe end engagement tooth top engagement
Select the adjusting gasket that make the main teeth contact farther with the axle driven bevel gear.
(d) Tear down the bearing 32307 from the driving bevel gear
and change the adjusting washer.
(e) Re-measure the total preload of the front speed reducer
and the situation of teeth engagement until they satisfy
the requirement.
16. Rivet the main-tooth nut;
17. Mount on the new oil seal ó front half-shaft;
Press in the new oil seal with the SST until it flush with the
outer face of the oil seal, coat the moderate lubricant on the
position of oil seal and on the lip open of oil seal.
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Assembly of Front Speed Reducer)

SA-78
18. Mount on the front drive axle shaft sleeve;
Notice: Thread locking agent should be coated on the
bolt thread.
Fastening torque
88N
m
19. Mount on the front long semi-axis and the front minor
half-shaft.
(a) Mount the new snapping ring on half-shaft.
(b) Mont on the front semi-axis and the front minor half-
shaft.
20. Mount the front speed reducer shell assembly:
(a) Clear the front speed reducer shell and the contact face of
front speed reducer shell;
(b) Coat the glue line with diameter of 2-3 mm, and the glue
line should be even and without fracture.
Remark: The front speed reducer shell should be mounted
ready within 15 min after coating the glue.
(c) The bolts, before screwed up, should be coated with
thread locking sealing agent and screwed up to the
specified torque.
Fastening torque
47N
m
Suspension System and Automobile Axle (SF/4WD)
Front Speed Reducer (Assembly of Front Speed Reducer)

B-2
Disassembling and as-
sembling tools for lock-
ing nut of steering
knuckle3916001



Press fitting tool for in-
ner bearing of front wheel
hub3916002
3916003
3916004
3916005
3916006
3916007
3916008
3916009
3916010 Press fitting tool for outer
bearing of front wheel
hub
Disassembling tool of
ball stud
Fixing tool of main teeth
flange of needle bearing
Press fitting tool for steer-
ing knuckle oil seal
Disassembling tool of
shorter liner of lower arm
Mounting tool of shorter
liner of lower arm
Mounting and disassem-
bling tool of long liner of
lower arm
Disassembling tool of
upper arm liner

























SST Special Service tool
Diagram Tool name tool number Remark
SST Special Tool
Special Service Tool
Application position
Front axle
Rear axle
2WD 4WD

B-3
Application position
Front axle
Rear axle
2WD 4WD
3916011

3916012
3916013
3916014
3916015
3916016
3916017
3916018
3916019
3916020 Press fitting tool of up-
per arm liner
Disassembling and as-
sembling tools of wheel
brake cylinder of front
brake caliper
Disassembling tool of
front drive shaft bearing
Pneumatic caliper of
outer sleeve of front drive
shaft
Press fitting casing of
front drive shaft bearing
Disassembling tool of
main teeth oil seal
Press fitting tool of main
teeth oil seal
Disassembling tool of
long semi-axis
Electric cutch tester
Disassembling tool of oil
seal and needle bearingOil seal of long semi-
axis of front axle
Inner oil seal of rear axle
shaft
Needle bearing of long
semi-axis
SST Special tool
Diagram Tool Name tool number Remark
SST Special Tool
Special Service Tool