Great Wall Pegasus (2006 year). Instruction - part 7

PR-4

Drive Shaft

 Drive Shaft

Element Drawing(continued)

4WD

front axle drive shaft

front axle drive shaft

74

 5

74

 5

rear axle drive shaft

two-joint type

 snapping ring

 bearing of cross shaft

74

 5

74

 5

 cross shaft

universal joint yoke

rear axle drive shaft

 universal joint flange fork

three-joint type

74

 5

40

 5

 snapping ring

 bearing of cross shaft

center support
bearing

flange

front joint of rear
axle drive shaft

washer

universal joint flange fork

74

 5

74

 5

rear section of
rear axle drive
shaft

universal joint
flange fork

  Parts that cannot be reused after being used

N*m

: specified torque

PR-5

Drive Shaft

 Drive Shaft

(4WD)

Rear axle drive shaft

1.

Take apart the universal joint flange fork of rear axle drive

shaft from the differential flange.

(a)

Label the two flanges with assembly marks.

(b)

Take apart the four sets of bolt and nut.

Disassembly of Drive Shaft

(2WD)

1.

Take apart the universal joint flange fork of the drive shaft

from the differential flange.

(a)

Label the two flanges with assembly remarks.

(b)

Take apart the four sets of bolt and nut.

assembly mark

2.

Take apart the center support bearing from the frame

beam (for the three-joint type)

3.

Take apart the drive shaft from the gearbox

(a)

Pull out the universal joint yoke from the gearbox.

(b)

Insert the SST in gearbox for oil leakage prevention.

2.

Take apart the center support bearing from the frame

beam (three-joint type

SST

assembly mark

PR-6

Drive Shaft

 Drive Shaft

3.

Take apart the drive shaft from the gearbox.

(a)

Pull out the universal joint yoke from the gearbox.

(b)

Insert the SST in gearbox to prevent the oil leakage

Front axle drive shaft

4.

Tear down the front universal joint flange fork of the front

drive shaft.

(a)

Hang he front end of the front axle drive shaft.

(b)

Label the assembly mark on the flange

(c)

Take apart the four sets of bolt and nut.

5.

Disconnect the rear universal joint flange fork from the

front axel drive shaft along the transmission path.

(a)

Label the assembly marks on each flange.

(b)

Take apart the four sets of bolt and nut.

Drive shaft disassembly

1.

Separation of the rear joint of the rear axle drive shaft

from the front joint of rear axle drive shaft

(a)

Label the assembly marks on each flange.

(b)

Take apart the four sets of bolt and nut.

2.

Take apart the center support bearing from the front joint

of the rear axle drive shaft.

(a)

Loosen the riveted nut by chiseling with a chisel and

hammer.

SST

assembly mark

assembly mark

PR-7

Drive Shaft

 Drive Shaft

(b)

Lock the flange with SST tools to tear down the nuts.

(c)

Label the assembly marks on flange and shaft.

SST

SST

assembly mark

assembly mark

(d)

Tear down the flange from the front joint of rear axle

drive shaft with SST tools.

3.

Take apart the universal joint yoke from the rear joint of

rear axle drive shaft.

(a)

Label the universal joint yoke and the shaft with assem-

bly marks.

(b)

Pull out the universal joint yoke from the shaft.

Inspection on Drive Shaft Parts

1.

Cross shaft bearing inspection

Check the wear or damage situation of the cross shaft bearing

and change the weary or damaged bearing where necessary.

2.

Check the wear and damage situation of the central

bearing.

Check the bearing to see whether it can run freely.

In case that the bearing is damaged or wearied or cannot run

freely, change it in time.

PR-8

Drive Shaft

 Drive Shaft

3.

Inspection for the front axle drive shaft

(a)

Check the wear or damage situation of the shaft.

(b)

Check the wear or damage situation of the two universal

joints

grease nozzle

rear axle drive shaft

front axle drive shaft

assembly mark

assembly mark

SST

A

4.

Inspection for the drive shaft lubrication

If the drive shaft is not lubricated completely, add the Lithium

base lubricant grease with SST.

Cross bearing change

1.

Label the shaft and universal joint yoke with assembly

marks.

2.

Take apart the snapping ring.

(a)

Tap in the outer bearing race lightly.

(b)

Take apart the four snapping rings in the grooves with

two screwdrivers.

3.

Take apart the cross shaft bearing

(a)

Pull out the bearing from the drive shaft with SST tools.

Remarks: Pull up the part A in the drawing to a enough height

so that it cannot contact the bearing.

PR-9

Drive Shaft

 Drive Shaft

SST

(c)

Mount the two outer bearing races that are taken apart on

the cross shaft.

(d)

Pull out the bearing on the universal joint yoke with SST

tool, and

(b)

Grip the outer bearing race with a vice to tap out the drive

shaft lightly with a hammer.

Remarks: Take apart another bearing with the same approach.

4.

Cross shaft bearing mount

(a)

Coat the lithium base grease on the cross shaft and the

bearing.

Remarks: do not over coat the lubricant.

(b)

Align the assembly marks on the universal yoke and on

the shaft.

(e)

Grip the outer bearing race in the vice and tap lightly out

the universal joint yoke with a hammer.

Remarks: the bearing at the other end may be taken apart with

the same approach.

PR-10

Drive Shaft

 Drive Shaft

5.

Snapping ring mount

(a)

Mount two snapping rings with the same thickness.

Remarks: Do not use the used snapping ring.

(b)

Tap the universal joint yoke lightly with a hammer until

there is no clearance between the outer bearing race and

the snapping ring.

6.

Cross shaft bearing inspection

Check the cross shaft bearing to see whether it can run freely

Remarks: the approach for mounting the cross shaft bearing at

the bearing end is the same.

(c)

Encase the new cross shaft in the universal joint yoke.

(d)

Mount the new bearing on the cross shaft with SST tool,

and

SST

(e)

Adjust the two bearings with SST tool so that the widths

of two snapping ring grooves are equal and maximum.

PR-11

Drive Shaft

 Drive Shaft

Drive shaft assembly

1.

Mount the center support bearing on the front joint of rear

axle drive shaft.

Remarks: The notch of the center support bearing shall face

backward when mounting it.

2.

Mount the flange joint on the front joint of rear axle drive

shaft.

(a)

Coat the spline of front joint of rear axle drive shaft with

lithium base grease.

(b)

Mount flange joint on the shaft and align the assembly marks.

Remarks: if the central flange joint or the front joint of the rear

axle drive shaft is required to change, the front and back

universal joint yokes of the rear axle drive shaft shall face in the

same direction when re-assembling.

(c)

Lock the flange joint with SST and screw up the newly-

changed nut to press the bearing in place.

(d)

Loosen the nuts.

(e)

Tighten the nuts again, and

(f)

Rivet the nuts with hammer and punch.

3.

Drive shaft mount

(a)

Align the assembly marks on flanges, and connect the

two flanges with four sets of bolt and nut.

Remarks: if the central flange or the front joint of the rear axle

drive shaft is required to be changed, the front and back

universal joint yokes of the front joint of rear axle drive shaft

shall face in the same direction when reassembling them.

(b)

Screw up the sets of bolt and nut according to the

specified torque.

Fastening torque: (74

 5)N
m

4.

Insert the universal joint yoke in the universal joint yoke

(4WD).

(a)

Coat the lithium base grease on the sliding surfaces of the

drive shaft spline and the universal joint yoke.

(b)

Align the assembly marks on universal joint yoke and

drive shaft.

(c)

Insert the universal joint yoke in drive shaft.

assembly mark

2WD

4WD

forward

assembly mark

SST

assembly mark

PR-12

Drive Shaft

 Drive Shaft

Mount of Drive Shaft

(2WD)

1.

Insert the universal joint yoke in the gearbox.

(a)

Tear down the SST tools.

(b)

Push the universal joint yoke into the gearbox.

2.

Connect the universal joint flange of the rear joint of rear

axle drive shaft and the relative the differential flange.

(a)

Align the assembly marks on the two flanges and connect

the flanges with four sets of bolt and nut.

(b)

Screw up the sets of bolt and nut according to the

specified torque.

Fastening torque

(74 
 5)N
m

3.

Mount the center support bearing on the frame beam

(three-joint type)

(a) Use two bolts to mount the center support bearing on the

frame beam and tighten them instructionly.

(b) Check the bearing seat, which shall be vertical with the

drive shaft, and change it where necessary.

(c) Check the central line of the central bearing and ensure

that the central lines of the central bearing and the bear-

ing seat shall be the same when the vehicle is in the non-

loaded stage. And adjust the bearing seat only it is

necessary.

(d) Screw up the mounting bolts according to the specified

torque.

Fastening torque

(40 
 5)N
m

(4WD)

1.

Connect the universal joint flange fork of the front axle

drive shaft with the flange that matches with the transfer

box.

Align the assembly marks and use four sets of bolt and nut to

connect the flange fork with the flange, screw up the sets of bolt

and nut according to the specified torque.

Fastening torque

(74 
 5)N
m

forward

SST

assembly mark

assembly mark

PR-13

Drive Shaft

 Drive Shaft

2.

Mount on the front axle drive shaft.

Mount on it and screw up the four bolts according to the

specified torque.

Fastening torque

(74 
 5)N
m

3.

Connect the universal joint flange fork of the rear axle

drive shaft on the relative differential flange.

(a)

Align the assembly marks on flanges and connect the

flanges with four sets of bolt and nut, and

(b)

Tighten the sets of bolt and nut according to the specified

torque.

Fastening torque

(74 
 5)N
m

4.

Mount the center support bearing on the frame beam

(three joint type)

(a)

Use two mounting bolts to mount the center support

bearing on the frame beam and screw up them instructionly.

(b)

Check the bearing seat, which shall be vertical with the

drive shaft, and adjust the bearing seat when necessary.

(c)

Check the central line of the central bearing. The central

line of the central bearing shall be the same with that of

the bearing seat when vehicle is in the non-loaded stage.

(d)

Adjust the bearing seat if necessary, and

(e)

Screw up the mounting bolts according to the specified

torque.

Fastening torque

(40 
 5)N
m

assembly mark

forward

SA-1

Suspension System and Automobile Axle

Page

Troubleshooting .......................................................... SA-2
Alignment of Front Wheel ............................................ SA-3
(Dr/2WD)
Front Wheel Hub and Steering Knuckle ...................... SA-10

Front Wheel Hub ..................................................... SA-11
Steering Knuckle ..................................................... SA-14

Front Suspension ........................................................ SA-16

Ball Stud .................................................................. SA-17
Torsion bar .............................................................. SA-19
Lower Arm and Vibration Damper ........................... SA-21
Upper Arm ............................................................... SA-24
Guide Level ............................................................. SA-26
Lateral Stabilizer ..................................................... SA-27

(SF/2WD)
Front Wheel Hub and Steering Knuckle ...................... SA-28

Front Wheel Hub ..................................................... SA-29
Steering Knuckle ..................................................... SA-32

Front Suspension ......................................................... SA-36

Ball Stud ................................................................... SA-37
Torsion bar ............................................................... SA-38
Lower Arm and Vibration Damper ............................ SA-39
Upper Arm ................................................................ SA-42
Guide Level .............................................................. SA-43
Lateral Stabilizer ....................................................... SA-43

(SF/4WD)
Front Wheel Hub and Steering Knuckle ....................... SA-44

Front Wheel Hub ...................................................... SA-45
Steering Knuckle ..................................................... SA-49

Constant Speed Drive Shaft ........................................ SA-54
Front Speed Reducer .................................................. SA-57

Change of Oil Seal of Driving Bevel Gear Of
 Front Speed Reducer ............................................. SA-57
Dismantle of Front Speed Reducer ......................... SA-61
Change of Axle Shaft Oil Seal ................................. SA-63
Disassembly and Assembly of Front Speed Reducer .... SA-65
Assembly of Front Speed Reducer ......................... SA-74

(Back)
Rear Axle Shaft ........................................................... SA-79
Rear Speed Reducer .................................................. SA-83

On-vehicle Change of Oil Seal of Main Teeth ......... SA-84
Dismantle of Rear Speed Reducer .......................... SA-85
Disassembly of Rear Speed Reducer ..................... SA-85
Assembly of Rear Speed Reducer .......................... SA-89
Mount of Rear Speed Reducer and
 Differential Assembly .............................................. SA-94

Rear Differential .......................................................... SA-95
Rear Suspension ......................................................... SA-97

SA

SA-2

Troubleshooting

Suspension System and Automobile Axle

 Troubleshooting

Change the tire or inflate to the proper pressure

Balance the wheels

Change vibration damper

Check Alignment of Front Wheel

Change or adjust the wheel bearing

Check ball joint) or liner

Tighten or change steering linkage

Adjust or repair the steering device

Discharge the oil and change with new one

Check the wandering clearance

Check the gears

Change the bearing

Change the bearing

Tighten or change the bearing

Trouble

Causes

Inspection items

Body wandering/body

dragging

Tire wear or improper air inflation

Incorrect alignment of front wheel

Over-tightened wheel bearing

Part looseness or damage of front/rear sus-

pension

Wear or looseness of steering rod system

Poor connection or damage of steering de-

vice

Inflate the tire to the proper pressure or change

the tire.

Check the situation of alignment of front wheel

Adjust the wheel bearing

Tighten or change the suspension element

Tighten or change the steering rod system

Adjust or repair the steering device

Body sink

Overloaded vehicle

Wear of vibration damper

Poor spring performance

Check the loading mass

Change vibration damper

Change spring

Left-right vibration/up-

down bouncing

Improper air inflation

Bending or damaged lateral stabilizer

Vibration damper wear

Inflate the tire to suitable pressure

Change stabilizer

Change vibration damper

Front wheel vibration

Tire wear or improper air inflation

Imbalance of wheels

Vibration damper wear)

Improper Alignment of Front Wheel

Wheel bearing wear or improper adjustment

Ball joint or liner wear

Steering linkage looseness or wear

Poor adjustment or damage of steering mecha-

nism

Abnormal tire wear

Improper air inflation

Vibration damper wear

Poor Alignment of Front Wheel

Suspension system wear

Inflate the tire to the proper pressure

Change vibration damper

Check the Alignment of Front Wheel

Change suspension element

Speed reducer leakage

Over-high oil level or improper oil quality

Oil seal wear or damage

Flange looseness or damage

Discharge the oil for change

Change oil seal

Tighten or change the flange

Noise inside the

axleNoise inside the axle

Over-low oil level or inferior oil quality

Over-large wandering clearance between

driving bevel gear and driven bevel gear

Wear and disintegration of driving bevel

gear and driven bevel gear

Bearing wear of driving bevel gear

Bearing wear of rear axle shaft

Bearing looseness or wear of speed reducer

SA-3

Suspension System and Automobile Axle

 Alignment of Front Wheel (Dr SL SK SY SJ)

Alignment of Front Wheel

(Dr SL SK SY SJ)

1.

Inspection should be conducted for the following items to

remove the trouble

(a)

Check the tire abrasion and air inflation situation

Tire inflation pressure:

Front  (220

 0)kPa

Back   (240

 0)kPa

(b)

Check the front wheel bearing to see whether it is loose.

(c)

Check the front suspension to see whether it is loose.

(d)

Check the steering driving device to see whether it is

loose, and

(e)

Check the front vibration damper work to see whether it

is loose.

2.

Measure the ground clearance of the chassis.

Chassis ground clearance:

Dr

295

0

+5

mm

SL SK

(255 
 2)mm

SY

(310 
 2)mm

SJ

(295 
 1)mm

If the chassis ground clearance of the vehicle is sub-standard,

push down the body or raise it for a trial adjustment, if fails,

check the spring or suspension element to see whether they are

normal.

Remarks: adjust the chassis ground clearance to a specified

value before checking the Alignment of Front Wheel

parameters.

3.

Mount on the four-wheel locating device.

The mount should be conducted according to the manufacturerís

instructions.

SA-4

Suspension System and Automobile Axle

 Alignment of Front Wheel (Dr SL SK SY SJ)

5.

Adjustment for inner tilt angle of kingpin, outer tilt angle

of front wheel and back tilt angle of kingpin

Item

Inner tilt
angle of
kingpin

Outer tilt
angle of
front
wheel

Applicable vehicle type

Dr SL SK SY

SJ

M e c h a n i c
steering

Dr SL SK SY

Power
steering

Dr

SL SK SY

SJ

Back tilt
angle of
kingpin

M e c h a n i c
steering

Dr SL SK SY

Power steer-
ing

Dr SL SK SY

SJ

9

30
 45

14

52

0

30
 20

0

10
 10

0

20
 10

0

30
 15

2

45
 15

3

 15

Location parameter

4.

Adjust the wheel angle

Take apart the limit bolts of the steering knuckle to check the

steering angle A of inner wheel.

Inner wheel steering angle

Dr SL SK SY

 ( 36
40
)

SJ

 ( 32
34
)

Remark: The wheel should not contact the body or brake hose

when the steering wheel reaches the limit position.

In case the steering angle of inner wheel doesnít conform to the

standard value, adjust the wheel angle through adjusting the

limit bolts of the steering knuckle.

Fastening torque

(90 
 0)N
m(SJ)

If the wheel angle fails to be adjusted within the standard value,

change the weary or damaged parts of steering system.

If the tilt angle fails to fall within the specified values, make an

adjustment through adding or reducing the gaskets on the

location of upper arm.

Gasket thickness: 3.0, 2.0 and 1.0mm

Once the gasket thickness increases by 1mm, the outer tilt

angle of wheel will change by 7', while the back tilt angle of

kingpin will change 20'.

After the wheel outer tilt angle and the back tilt angle of kingpin

are adjusted, if the inner tilt angle of kingpin still fails to the

specified value, check the steering knuckle or front wheel to

see whether they are bending or loose.

1

50

-20

adjusting bolt

outer tilt

angle of

front wheel

inner tilt angle of kingpin

back tilt angle of

kingpin

front

A

B

A

B

HPM

SA-5

7.

Check the sliding measuring situation.

Check the sliding situation with the sliding measuring tester.

Sliding measuring value: 

.5m/km

push forward the vehicle;

forward

A=B

B

A

6.

Wheel toe-in adjustment

(a)

Verify that each wheel has been located forward in a line.

(b)

Mark the tire center at the bearing height on the tread of

left and right tire, and measure the distance between the

marks on left and right treads.

(c)

Push forward the vehicle until the mark on the back tread

of tire moves to the front.

Remark: the toe-in measurement should be conducted from the

same spot at the same height.

(d)

Measure the distance between the two marks on the front

of two treads.

Toe-in value: (0-2)mm

(e)

Loosen the clamping bolts of connecting pipe.

(f)

Adjust the toe-in angle through the approach according to

which rotate the left and right drag rod tube by a same

angle.

Remark: check the lengths of the two drag rods to see whether

the two rods are same in length.

Length error of the left and right drag rod should not

be larger than 2.0mm.

(g)

Tighten the clamping bolts.

Fastening torque

(20 
) N
m

(h)

Locate the split pin well.

Suspension System and Automobile Axle

 Alignment of Front Wheel (Dr SL SK SY SJ)

SA-6

Suspension System and Automobile Axle

 Alignment of Front Wheel 
 Alignment of Front Wheel (SF)

Alignment of Front Wheel

(SF)

1.

The following items should be checked to remove the

troubles.

(a)

Check the tire abrasion and the air inflation to see it is

suitable or not.

Tire inflation pressure: (250

 0)kPa

(b)

Check the front wheel bearing to see whether it is loose.

(c)

Check the front suspension to see whether it is loose.

(d)

Check the steering driving device to see whether it is

loose, and

(e)

Check the front vibration through elastic force test to see

whether it is normal in performance.

2.

Height adjustment of vehicle

Adjust the vehicle height to the standard value so as to make

the Alignment of Front Wheel inspection.

A-B-58 5mm

A: The height of steering knuckle shaft center.

B: The center height of the adjusting cam bolt at front end

The standard value for the unloaded height is: the

difference of the center height of drive shaft climax and

the front adjusting cam bolt is 58.5mm.

3.

Mount on the four wheel locating device

This approach should be conducted according to the detailed

instruction of the equipment manufacturer.

4.

Adjust the outer tilt angle of front wheel and the back tilt

angle of kingpin

The outer tilt angle of front wheel: 0

5' 
 0'

The back tilt angle of kingpin: 2

0' 
 0'

Outer inclination of front wheel:

B

A

the outer tilt angle of
front wheel

the back tilt angle
of kingpin

front