Great Wall Pegasus (2006 year). Instruction - part 6

TF-20

1

convex plate

groove

2

3

4

5

6

1

2

3

4

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-21

Q

R

N

O

P

NM

S

T

N

U

V

N

O

P

Q

R

S

(d)

All of the following aligning conditions shall be satisfied

when the rear cover assembly is mounted on the transfer

box front housing:

a)

Align the pin hole in the rear cover to the pin on the

housing.

b)

Align the rear output shaft to the inner bearing in

cover rear hole.

c)

Align the blind hole in the rear cover and the shift

guide shaft; ensure the return spring is not tilted.

Check the hole in velocity sensor of the rear cover

with a pen.

d)

Align the shift shaft and the inner bearing in rear

cover.

(e)

Screw up the nine bolts after locating the sign bolts

correctly.

(f)

Encase the gear of odometer in the rear cover assembly

through the spline of the rear output shaft.

(g)

Press the new oil seal in the cover assembly

N

O

P

Q

Transfer Box

 Transfer Box Assembly

1. bolt

2. wire harness

3. magnet

4. return spring

5. shift guide shaft

6. transfer box rear

body assembly

7. sign board

8. driving gear of Odometer

9. oil seal

10. transfer box front housing

1. locating pin

2. output shaft

3. shift shaft

4. return spring

5. shift guide shaft

6. output shaft.

12.

Assembly of Rear Cover

Mount the aforesaid accomplished cover assembly on the

transfer box housing according to the following process:

(a)

Mount the return spring on the shift guide shaft of the

transfer box.

(b)

Mount the magnet in the groove of the housing.

(c)

Coat the Letai glue 598 of 1.6mm on the coupling face of

housing, steer clear of the screwed hole when coating

continuously.

Notice: try to button the rear cover on the transfer box front

housing with the moderate force during the following process.

Not too much force is required when mounting the rear cover

on the front housing when all aligning conditions are satisfied,

in case the rear cover cannot be mounted on the front housing,

take down the rear cover assembly to check the aligning

condition

1. wire harness clip

2. motor assembly

3. bolt

4. sign board

TF-22

1

2

3

4

6

7

8

9

5

2

1

Transfer Box

 Transfer Box Assembly

1. motor assembly

2. shift shaft

1. fixed sensor bracket

2. bolt

3. sensor assembly

4. velocity sensor

5. o-ring

6. motor assembly

7. bolt

8. gasket

9. transfer box rear body

12. Mount the external electric shifting element (for the elec-

tric shift transfer box)

(a)

Locate the motor assembly by aligning the triangle

groove on motor to the shift shaft.

(b)

Move the motor to combine the shift shaft and keep it

close to the rear cover. Then run the motor clockwise

until the motor locates the correct place and the mooting

holes are aligned.

(c)

Mount the O-ring on the velocity sensor and encase the

velocity sensor assembly in rear cover. A clip and three

bolts shall be mounted on the velocity sensor.

Fastening torque

(8
11)N
m

(d)

Mount the bolts and gaskets on the end of motor clip.

Fastening torque

(8
11)N
m

TF-23

5

4

3

1

6

2

Transfer Box

 Transfer Box Assembly

1. transfer box rear body

2. flange

3. oil seal

4. gasket

5. nut

6. oil plug

13. Flange assembly

The parts mount process is as follows:

(a)

Encase the two oil plugs in the rear cover.

(b)

Encase the flange, sealing ring and gasket, and then

screw up the nuts.

Fastening torque

(203
244)N
m

TF-24

Transfer Box 

 Washing, Checking, Up-Keeping and Exchanging (Washing)

1.

Washing

Notice: check the metal rag around the magnet first before washing, large granule or irregular metal

granule shows the disintegratation or similar damage. Small or fine metal granule shows the uneven

or serious wear. If the metal rag is founded, notice shall be taken on damage and wear inspection

during checking the rotating parts and the element matched with the rotating parts.

(a)

Common washing

Wash the parts in cleaning agent to clean away the old lubricant and deposit. Clean away the deposit in oil hole

with brush. Take notice not to scrape the metal coupling face when washing the parts cannot be cleaned with

brush.

(b)

Dry the washed parts by blowing

Dry the washed parts by blowing the low-pressure compressed air (max pressure is 137.9kPa), because cloth

thread may be left during cleaning the parts with cloth. The bearing shall be held by hand to prevent it from

rotating when blowing it.

(c)

Bearing lubrication

The ball bearing and needle bearing shall be lubricated with the lubricant for transfer box after washing. As

the non-lubricated bearing may cause damage when be dry. Cover the lubricated bearing to prevent dust

entering in.

Washing, Inspection, Maintenance or Change

TF-25

(b)

Normal gear grinding trace.

Transfer Box

 Washing, Checking, Up-Keeping and Exchanging (Checking)

Checking

1.

Common Checking process

Check all parts by visual check to see whether there is damage

or serious or uneven wear (parts needed be substituted by new

parts such as O-ring, oil seal and etc. shall be excluded).

Abandon the damaged or weary parts that will affect on their

performance. The check items are as follows:

 Burr: tips protruded from the material regionally

 Rag: broken small blocks or particles

 Crack: surface thread showing the material is partly or

completely separated.

 Excessive abrasion
Refer to the serious or obvious abra-

sion beyond of application limit.

 Reduction change
Material slip caused by the heavy

pressure on part of it.

 adhesive bonding
Granules of the soft metal are dis-

persed and bonded on the hard metal surface.

 Ditch trance: partial crack or trough that means the material

transfer instead of material loss.

 Pitting corrosion
Damages to the metal surface caused by

pressure, which are displayed due to color change caused

by heat generated by metal friction.

 Step wear
a weary step may be seen or felled between the

neighboring interface or between the non-touching face

due to the excessive wear.

 Uneven wear: Partially, unevenly distributed wear, which

includes holes, bright spots, uneven polishing or other

visual drawbacks.

2.

Gear or Chain sprocket tooth inspection

Check the gear and chain sprocket tooth according to the

following process:

(a)

Normal gear shaving trace.

normal gear shaving trace

normal gear grinding trace

TF-26

Transfer Box

 Washing, Checking, Up-Keeping and Exchanging (Checking)

(e)

Unacceptable side deflective contact area that must be

changed.

(f)

Acceptable side-deflective contact area

(g)

Unacceptable side deflective contact area that must be

changed.

(c)

Ideal engagement contact area

(d)

Acceptable side-deflective contact area

TF-27

Transfer Box

 Washing, Checking, Up-Keeping and Exchanging (Checking)

(h)

Acceptable contact area deflecting to the tooth top.

(i)

Unacceptable contact area deflecting to the tooth top,

which must be changed.

(j)

Acceptable contact area deflecting to tooth root.

(k)

Unacceptable contact area deflecting to tooth root, which

must be changed.

4.

Key tooth inspection

Check the broken or peeled spline teeth. The spline teeth may,

if only small part is peeled off, be repaired in the same way as

that for the gear teeth, and can be reused. In case the spline

tooth is broken, the spline must be abandoned. The contact

type of spline is not the same as that for gear; however, spline

that shows step sliding must be abandoned.

TF-28

Transfer Box

 Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear)

Maintenance or Change of Gear or Chain

Sprocket Gear

1.

Maintenance principle

(a) Conduct the maintenance for the partial, small peel off

with the suitable instruction high-speed grinding tool.

(b) Do not clear away the metal as can as possible when

grinding the matrix metal.

(c) All pointed angles and sides must be repaired as the slip-

pery contour line. Because the pointed angle or edges

may be peeled off again or developed into crack.

(d) Clear away the burr with the suitable grinding stone. Take

notice not to damage the matrix when clearing away the

projecting materials, and

(e) When substituting the non-repaired parts (such as

bearing), if the part is doubted in its re-application

capability, it must be changed.

2.

Cases for gear or chain sprocket maintenance or substi-

tuting

(a)

The gear, being peeled off at the two sides of tooth top in

contact face, may be repaired for reuse.

(b)

The gear, being peeled off at the central tooth top of

contact face, may be repaired for reuse.

(c)

The gear, being peeled off at one side of the non-contact

face, may be repaired for reuse.

TF-29

Transfer Box

 Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear)

(d)

The gear, being peeled off at the center of one side of

contact face, may be repaired for reuse

(e)

The gear, being peeled off in the center of contact area,

shall be changed.

(f)

The gear, being peeled off at two sides of tooth top, shall

be changed.

TF-30

Transfer 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 inspection

All parts with crack, all parts that are bended,

distorted or poor in round bouncing are refused.

All threaded parts

Thread inspection for buckle missing or other

damage

Those parts cannot be threaded or bottomed in

overlap manner shall be refused.

F l a n g e   a n d   f o r k

flange

Please 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

system

Please 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 bearing

Check 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 box

Check 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 box

Check the bearing hole

Refuse to use the assembly that has pitting

corrosion

Odometer gear

Check the gear teeth referring to the Inspection

Paragraph

Refer to the gear or chain sprocket inspection in

inspection paragraph
.

Clutch shell, joint

outer gear sleeve and

joint cover

Check the spline according to the Inspection

paragraph

Refer to the spline inspection of 

inspection

paragraph

Locking sleeve

Check the wear or damage of the toggle fork

groove

Refuse 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 race

Refuse 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 fork

Check 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.

TF-31

Transfer Box

 Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts)

Attachment for Inspection Maintenance or Change of Parts

Parts (items)

Checking items

Acceptance/Refusal

Shift toggle fork as-

sembly

Check the wear and damage of the inserted face

that is combined with gear sleeve;

Check to see whether the contact roller can

rotate freely or is damaged or not

If any step wear or damage is found, the inserted

face shall be refused to use.

If the contact runs difficultly or is damaged, a

new pin-contact roller and new cage assembly

shall be used.

Driving and driven

chain sprocket

C h e c k   t h e   s p r o c k e t   t e e t h   a c c o r d i n g   t o

the 

inspection
 paragraph

Refer to the sprocket teeth inspection of

inspection
 paragraph

Shift toggle fork as-

sembly

Check the inner diameter that matches with the

output shaft

If any pitting corrosion or damage is found,

refuse to use it.

Driving chain

Check the step sliding, looseness or damage of

pin or connecting element

Refuse to use the weary or damaged driving

chain

Filtering screen

Check to see the filtering screen is clean or with

small hole or damage

Clean it where necessary, and abandon the dam-

aged one.

TF-32

Transfer Box

 Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection

Maintenance or Change of Parts

Pump shell

Check to see whether there is pitting corrosion

or step slipping

Abandon it in case it is seriously damaged or

worn

Output shaft

Check the spline, check the surface that matches

with bearing and check the distortion according

to 

inspection
 paragraph

Refer to the spline inspection of 

inspection

paragraph;

Refuse to use the one with pitting corrosion or

damage;

Refuse to use the one that is bending or poor in

round bouncing.

Deceleration hub

Check the spline of chain sprocket and check the

wear or damage of the location where matches

with the toggle fork according to the

inspection
 paragraph

Refer to the spline inspection of 

inspection

paragraph; refuse to use the one with step slid-

ing or damage.

Front output shaft

Check the surface where matches with the

bearing;

Check the spline according to the 

inspection
:

paragraph

Refuse to use the one with pitting corrosion or

damage

Input shaft

Check the spline according to the 

inspection

paragraph

Check the distortion

Refer to the spline inspection of 

inspection

paragraph;

Refuse the one that is bending or poor in round

bouncing.

Thrust washer and

thrust disc

Check the pitting corrosion

Refuse to use the one with pitting corrosion or

damage

Sun wheel

Check the gear teeth and spline according to the

inspection
 paragraph

Refer to the gear teeth inspection and spline

inspection of 

inspection
 paragraph.

Planetary mechanism

assembly

Check the gear teeth according to the

inspection
 paragraph;

Check the wear and looseness of the planetary

gear pin; check the wear of thrust gasket

R e f e r   t o   t h e   g e a r   t e e t h   i n s p e c t i o n   o f

inspection
 paragraph;

If any step sliding or pitting corrosion is found,

refuse to use it

Electric shifting cam

Check to see whether there is step slipping or

pitting corrosion

If any step sliding or pitting corrosion is found,

refuse to use it

Shift guide shaft

Check to see whether there is step slipping or

pitting corrosion

Check the distortion situation

If any step sliding or pitting corrosion is found,

refuse to use it

Refuse to use the bending one

Planetary gear ring

Check the match performance of it with the

transfer box housing

Check the gear teeth according to the

inspection
 paragraph

Check the transfer box housing assembly to see

whether the gear ring is loose or not in the

housing

R e f e r   t o   t h e   g e a r   t e e t h   i n s p e c t i o n   o f

inspection
 paragraph

Transfer box housing

Check the holes matches with the bearing

Abandon the one with pitting corrosion or

damage.

PR-1

Drive shaft

page

Notice .......................................................................... PR-2

Troubleshooting .......................................................... PR-2

Drive shaft ................................................................... PR-3

PR

PR-2

Drive Shaft

 Notice and Troubleshooting

Notice

Notice: do not grip the drive shaft sleeve too tight with vice

so as to avoid the deformation.

 troubleshooting

Trouble

Causes

Resolving approaches

Noise

Wear of universal joint yoke spline;

Wear of central bearing;

Wear or seize-up of cross shaft bearing

Change the drive shaft;

Change the central bearing;

Change the bearing of cross shaft

Vibration

Oscillation difference of the drive shaft;

Drive shaft imbalance;

Wear of the liner of rear bearing in the lengthening shell of

gear box;

Spline seize-up of the universal joint yoke

Change drive shaft

Change drive shaft

Change the liner

Change drive shaft

PR-3

Drive Shaft

 Element Drawing

2WD

two-joint type

 snapping ring

 bearing of cross shaft

universal joint flange fork

rear axle drive shaft

universal joint foke

 cross shaft

three-joint type

 snapping ring

 bearing of cross shaft

universal
joint foke

 cross shaft

front joint of rear
axle drive shaft

center support
bearing

flange

washer

washer

74

 5

40

 5

universal joint
flange fork

74

 5

74

 5

universal joint
flange fork

rear section of
rear axle drive
shaft

N*m

: specified torque

  Parts that cannot be reused after being used

Drive Shaft

 Drive Shaft