2008 GREAT WALL FLORID brake

Downloaded from www.Manualslib.com manuals search engine 117Brake System
9. Examine the front brake disc plate surface runout.
When measuring, tighten the two wheel nut's symmetrical
locations. The front brake disc's brake linings runout on the
two sides should be less than 0.11 mm.
10. Install the brake caliper assembly.
Install the brake caliper on the steering knuckle, and tighten
the bolt according to the set torque.
Tightening torque: 100±10 N·m

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Front Brake Caliper
Components
Disposable parts
Inner and outer brake pad assembly re-
placement
Remark: When applying the brake while driving, if the front
tires makes a continuous screeching sound, inspect the inner
and outer brake pad and friction limit alarm plate. If there
are traces of rubbing from the brake disc on the alarm plate,
the inner and outer brake pad assembly should be replaced.
1. Remove the front wheel.
2. Inspect the inner and outer brake pad's friction material
thickness.
By looking through the caliper's observation ports, inspect
the inner and outer brake pad friction material thickness. If it
is no longer within the specified range, it should be replaced.
Minimum thickness: 2.0 mm
Bleed screw cap
Air bleed screw
Caliper
Rectangular sealing ring
Piston
P iston dust cover
Inner muffler plate subassembly
Alarm plate
Inner brake pad assembly
Outer brake pad assembly
Outer muffler plate subassembly
Guide pin
Guide pin dust cover
Caliper frame
Brake block yoke spring plate
Brake block yoke spring plate
30 ± 5
: Specified torqueN·m
10 ± 2
Q1840820
Rubber grease

Downloaded from www.Manualslib.com manuals search engine 119Brake System
3. Remove the caliper assembly.
(a) Remove the hexagon bolt for flange face connecting
the caliper and caliper frame's lower end.
(b) Lift the caliper assembly and use a rope to hang it up to
protect the brake pipeline.
Remark: Do not unscrew the brake pipeline and bleed screw.
4. Remove the following parts.
(a) The group of inner and outer shims B.
(b) The group of inner and outer shims A.
(c) The group of inner and outer brake discs.
(d) One pair of yoke springs.
5. Measure the brake disc thickness.
(See steering knuckle and hub brake assembly examination and
disassembly step 4).
6. Measure the brake disc radial runout.
(See steering knuckle and hub brake assembly examination and
disassembly step 3).
7. Install the yoke spring.
Install the brake block yoke spring plate to the caliper frame.
Outer shim B
Outer shim AInner brake disc
Warning device
Inner shim B
Inner shim A
Outer brake disc
Yoke spring

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8. Install a new inner and outer brake pad assembly and
inner and outer muffler plate subassembly.
(a) Install inner shim A and B onto the inner brake disc.
(b) Install outer shim A and B onto the outer brake disc.
(c) Install the inner and outer brake pad assembly with
inner muffler plate subassembly onto the caliper frame.
Make the inner brake pad assembly with inner muffler
plate subassembly and alarm plate rest close to the
brake caliper's inner side.
Caution: For the inner and outer brake pad assembly,
the working surface of the brake disc must not have
any grease, oil or paint pollution.
(d) S i p h o n a s m a l l a m o u n t o f b r a k e f l u i d f r o m t h e
reservoir. (Make sure not to let the brake fluid overflow
from the reservoir).
(e) Press in the piston with SST.
9. Install the caliper assembly.
Loosen the rope, remove the caliper assembly, and tighten
the hexagon bolt for flange face.
Tightening torque: 30±5 N·m
Remark: Replace one wheel's brake pad at a time, in order to
avoid the other wheel's piston from springing out.
10. Install the front wheel.
Tightening torque for the wheel retaining nut: 100±5 N·m
Front brake caliper piston removal
1. Remove the brake line.
Remove the brake line, and use a clean container to hold the
brake fluid.
SST
Outer shim B
Outer shim AInner brake disc
Warning device
Inner shim B
Inner shim A
Outer brake disc
Inner muffler plate subassembly
Alarm plate
Inner brake pad assembly
Outer brake pad assembly
Outer muffler plate subassembly

Downloaded from www.Manualslib.com manuals search engine 121Brake System
2. Remove the caliper assembly.
(a) Remove the two hexagon bolts for flange face connecting
the caliper and caliper frame.
(b) Remove the caliper assembly from the caliper frame.
3. Remove the following parts.
(a) The group of inner and outer shims B.
(b) The group of inner and outer shims A.
(c) The group of inner and outer brake discs.
(d) One pair of yoke springs.
4. Remove the piston and piston dust cover from the
caliper.
(a) Place a block in the middle of the caliper.
(b) Use an airgun or air pipe to align the brake pipeline
holes. Remove the piston from the caliper, and at the
same time remove the piston dust cover.
(c) Use a clean rag or other soft cloth to extract the piston.
Warning: When using compressed air, be sure not to
place fingers in front of the piston.
5. Remove the rectangular sealing ring from the caliper.
Use a paperclip to remove the rectangular sealing ring from
the caliper.
Caution: The tools being used should not be sharp, in
order to avoid tearing the rectangular sealing ring.
Inner and outer brake pad assembly exami-
nation
Measure the inner and outer brake pad assembly's thickness.
Standard thickness: 8.5 mm
Minimum thickness: 2.0 mm
If it is smaller than the minimum level of thickness or there
are traces of uneven wear and tear, the brake pad should be
replaced.

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Front brake caliper assembly installation
1. Preparations
Make sure all parts are clean and free of foreign materials
before installation.When installing, apply an appropriate
amount of rubber grease to the guide pin and piston's
working surface, as well as the rectangular sealing ring and
the piston protective cover's working surface.
2. Install the rectangular sealing ring to the caliper.
(a) Screw the bleed screw into the caliper's vent holes.
Tightening torque: 10±2 N·m
(b) After applying an appropriate amount of rubber grease
on the rectangular sealing ring's working surface, install
them into the caliper's seal groove.
3. Install the piston with piston dust cover on the caliper.
(a) Place the piston dust cover on the piston.
(b) Stretch the piston dust cover, until its card holder
exposes the bottom of the piston. Use tools (for
example, about Ф2 mm of iron wire) to assist by
stuffing the card holder into the cylinder bore card
holder's groove.
Caution: The tools being used should not be sharp, as
to avoid tearing the dust cover.
(c) Then manually press the piston into the bottom of the
cylinder bore.
4. Install the guide pin and guide pin dust cover onto the
caliper frame.
(a) Install the guide pin dust cover onto the guide pin.
(b) Screw the guide pin into the caliper frame.
Caution: Do not damage the guide pin dust cover.
5. Install an inner and outer brake pad assembly and
inner and outer muffler plate subassembly.
6. Install the brake block yoke spring plate as well as the
inner and outer brake pad assembly and inner and
outer muffler plate subassembly on the caliper frame.
Guide pin
Guide pin dust cover
Caliper frameBrake block yoke spring plate
Air bleed screw cap
Air bleed screw Caliper
Inner muffler plate subassembly
Alarm plate
Inner brake pad assembly
Outer brake pad assembly
Outer muffler plate subassembly

Downloaded from www.Manualslib.com manuals search engine 123Brake System
7. Install the caliper assembly.
(a) Install the caliper assembly.
(b) Install and tighten the hexagon bolt for flange face.
Tightening torque: 30±5 N·m
8. Connect the brake line.
Connect the brake pipeline to the caliper.
Tightening torque: 40±4 N·m
9. Fill the brake reservoir up with brake fluid and exhaust
the air from the brake system.
10. Check for leaking brake fluid.
Caution: Bleed the air after replacing.

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual124
Rear Brake
Components
4. Remove the rear brake drum.
Remark: If it is difficult to remove the rear brake drum,
follow the steps below:
Method one:
(a) Remove the rubber plug of the adjuster's observation
port, and insert a slotted screwdriver into the brake's
back plate assembly hole, and pry off the adjusting
paddle from the adjusting clearance wheel.
(b) Use another slotted screwdriver to toggle the adjusting
clearance wheel and loosen the brake's leading and
trailing shoe assembly's tension on the rear brake drum.
Disposable parts
Dust cover
Brake leading shoe assembly
Pressure spring
Pressure spring cap
Brake shoe tension spring
Rear brake drum
Lever rotating shaft
Retainer spring
Locking cap
Split ring
Brake lever
Brake trailing shoe assembly
Brake back plate assembly
Pressure spring bar
Rubber plug of the adjuster's observation port
Rubber plug of the observation port gap
Washer
Bleed screw cap
Bleed screwPiston
Ring cup
Piston spring
Wheel cylinder
Adjusting clearance shaft head
Adjusting clearance wheel
Adjusting clearance screw rod
Return springAdjusting paddle
Pin
Side spring
Dust cover
Piston
Ring cup
Rubber grease
: Specified torqueN·m
7.8-11.8
High temperature resistant grease
Rear brake removal
1. Inspecting the brake's friction plate thickness.
Remove the rubber plug of the observation port gap and
examine the friction plate thickness via the observation port.
If it's smaller than the minimum value, the brake's leading
and trailing shoe assemblies should be replaced.
Minimum thickness: 1.0 mm
2. Remove the rear wheel.
3. Release the brake fluid.
Caution: Be sure not to spill the brake fluid onto the
paint's surface. Otherwise it must be immediately
cleaned.