Great Wall Pegasus (2006 year). Instruction - part 9

SA-23

3.

Mount the guide lever on the lower arm

Fastening torque

(96 
 0)N
m

4.

Link the transverse stabilizer rod with the lower arm.

Fastening torque

(23 
 3)N
m

5.

Mount the vibration damper.

6.

Mount the ending part of the drag rod:

(a)

Link the drag rod end to the steering knuckle arm, mount

and screw up the nuts according to the specified torque.

Fastening torque

(91 
 0)N
m

(b)

Lock the nut with the new split pin.

7.

Mount the torsion rod spring.

8.

Check the Alignment of Front Wheel.

(See the page SA-3)

Suspension System and Automobile Axle (Dr/2WD) 

 Front Suspension (Lower Arm and Vibration Damper)

SA-24

Upper Arm

Dismantle of Upper Arm

1.

Take apart the ball stud from the upper arm:

(a)

Support the upper arm with a jack.

(b)

Take apart the four sets of bolt and nut.

2.

Take apart the upper arm

(a)

Tear down the bolts and adjusting gasket.

(b)

Take apart the upper arm.

Remark: Do not lose the adjusting gasket. Write down the

gasket thickness so that it can be mounted on the original place.

Change of the rubber liner of Upper arm

shaft

1.

Tear down the rubber liner of the upper arm.

(a)

Tear down the bolts and the pinch-off gasket of the upper

arm shaft bush.

(b)

Push out the rubber liner of upper arm with tools.

2.

Mount the upper arm rubber liner.

(a)

Push in the rubber liner of the upper arm with tools.

(b)

Mount on the pinch-off gasket of the upper arm shaft

bush and tighten the bolts instructionly.

Remark: it is not required to screw up the bolts according to the

specified torque.

Mount of Upper Arm

1.

Screw up the axle bolts of the upper arm according to

the specified torque,

Fastening torque

(100 
 0)N
m

Suspension System and Automobile Axle (Dr/2WD) 

 Front Suspension (Upper Arm)

SA-25

2.

Mount the upper arm

(a)

Mount on the upper arm and the regulating gasket.

(b)

Screw up the bolts according to the specified torque.

Fastening torque

(96 
 0)N
m

Remark: Mount back the gaskets of the same thickness in the

same number on the original locations.

3.

Connect the upper ball stud and upper arm together.

Fastening torque

26N
m

4.

Check the Alignment of Front Wheel

(See page SA-3)

Suspension System and Automobile Axle (Dr/2WD) 

 Front Suspension (Upper Arm)

SA-26

Suspension System and Automobile Axle (Dr/ 2WD)

 Front Suspension (Guide Lever)

Guide Lever

Disassembly of Guide Lever

1.

Mark the assembly mark on the guide lever.

2.

Tear down the front fixing nuts from the guide lever.

3.

Tear down the guide lever from the lower arm.

Tear down the nuts that fix the guide lever on the lower

swimming arm, and then tear down the guide lever.

Mount of Guide Lever

1.

Mount on the front fixing nuts

Mount on the front fixing nuts and meanwhile align the

assembly marks on the guide lever.

4.

Screw up the fixing nuts according to the specified torque,

(a)

Dismantle the bracket so that make the vehicle bounce

sever times to put the suspension in balance.

(b)

Screw up the front fixing nut.

5.

Check the Alignment of Front Wheel

(See Page SA-3)

2.

Mount the guide lever on the bracket

(a)

Mount the washer and liner on the guide lever, and then

mount the guide lever on bracket.

(b)

Mount the sleeve ring, the liner and the washer on the

guide lever.

(c)

Screw up the fixing nuts with finger.

3.

Mount the guide lever on the lower swing arm.

Screw up the fixing nuts according to the specified torque.

Fastening torque

(96 
)N
m

assembly mark

assembly mark

SA-27

Suspension System and Automobile Axle (Dr/2WD)

 Front Suspension (Transverse Stabilizer Rod)

Transverse stabilizer rod

Dismantle of Transverse Stabilizer Rod

1.

Tear down the torsion rod spring

2.

Tear down the transverse stabilizer rod from the lower

swing arm,

(a)

Tear down the nuts and cushion blocks that support the

two sides of the stabilizer rod from the lower swing arm

so as to disconnect the stabilizer rod.

(b)

Tear down the liner and bracket of the stabilizer rod and

then tear down the stabilizer rod.

Mount of Transverse Stabilizer Rod

1.

Put the transverse stabilizer rod on the frame,

Lay the stabilizer rod in place, and mount the stabilizer rod

liner on the bracket, then mount the bracket on frame, finally

screw up the bolts with fingers.

2.

Connect the transverse stabilizer rod to the lower swing arm.

Connect the two ends of stabilizer to two lower swing arm with

bolts, cushion blocks and new nuts.

As shown in the drawing, tighten the nuts according to the

specified torque.

Fastening torque

(29 
)N
m

3.

Screw up the locating bolts according to the specified

torque,

Fastening torque

(29 
)N
m

4.

Mount on the torsion rod spring.

SA-28

Suspension System and Automobile Axle(SF/2WD)

 Front Suspension

locking ring

cushion block

nut

locking ring

cushion block

upper arm

transverse stabilizer rod

bolt

transverse stabilizer rod gasket

rubber
snubber washer

restrictor tube

Brake

caliper

steering knuckle

brake oil pipe bracket

steering

knuckle arm

brake shell

dust cover

 oil seal -front hub

front wheel

bearing(inner)

front wheel hub and

front brake disc

stop washer

lock plate

front hub bearing

(outer)

steering knuckle nut

liner

lower

ball stud

 Parts that cannot be reused after being used

:specified torque

N

m

135-155

23

 29

25

 29

70-90

132-152

20-26

180

127-147

132

 152

123

shock absorber

steering knuckle

outer flange cap

Front  wheel hub and steering knuckle

Element figures

SF2WD

stabilizer rod gasket

stabilizer rod gasket

rubber snubber
washer

stabilizer rod gasket

stabilizer rod gasket

SA-29

Front Wheel Hub

Disassembly of Front Wheel Hub

1.

Tear down the brake caliper.

(a)

Tear down the brake Bundy tube from the brake caliper,

and block the Bundy tube line with a cork.

(b)

Tear down the brake caliper from the steering knuckle.

2.

Tear down the steering knuckle outer flange cap.

3.

Tear down the front wheel hub and brake disc.

(a)

Open the lock plate with a screwdriver.

(b)

Tear down the steering knuckle nut with the SST tools to

take out the. lock plate

(c)

Tear down the other steering knuckle nut with SST tools

to take out the stop washer and the steering knuckle outer

bearing.

(d)

Tear down the front wheel hub and the brake disc

assembly.

4.

Tear down the front hub, oil seal, front hub bearing

(inner) inner race and roller assembly.

(a)

Pry out the oil seal.

Notice: the deformed oil seal should not be reused.

(b)

Take out the front hub bearing (inner) inner race and

roller assembly.

Suspension System and Automobile Axle (SF/2WD)

 Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-30

5.

Front hub bearing outer race inspection and change

(a)

Check each bearing

Wash the inner and outer races of each bearing, and check

them whether they are wearied or damaged.

(b)

Tear down the outer race of each bearing.

Tap out the bearing outer race with copper bar and

hammer.

Notice: bind the dismantled inner and outer races of

bearing together to prevent from mixing.

6.

Front brake disc inspection and change

(a)

Check the wear situation of front brake disc.

(b)

Tear down the bolts that connect the front wheel hub and

front brake disc.

(c)

Connect the front wheel hub and front brake disc and

screw up the bolts with moment spanner to the specified

torque diagonally

Fastening torque

(70-80)N
m

(d)

Conduct the dynamic balance test on the dynamic balancer,

the amplitude value displayed should not be above 13.5g

under the condition that the measuring rotating velocity

is 796 r/m and the locking rotating velocity 786 r/m,

otherwise, tap in the counter balanced clip, which is 4g

each, at the corresponding location, the number of the

clip should not be more than 4.

(e)

Tap in the new bearing outer race with the special service

tool.

Notice: the inner and outer races of bearing should be

changed in set.

Assembly of Front Wheel Hub

1.

Mount on the inner race and roller assembly of front hub

bearing (inner) as well as the front hub oil seal.

Coat the lithium base grease of 4 to 5 mm on the inside surface of

the bearing outer race and front wheel hub, and plaster the

lubricant in the front hub bearing (inner) and the roller assembly.

Coat a little lubricant on the lips of oil seal of front wheel hub, and

then tap the oil seal of front hub in place with special service tool.

Notice: do not coat the lubricant on the front brake disc face.

Suspension System and Automobile Axle (SF/2WD)

 Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-31

2.

Mount on the inner race and roller assembly of front hub

bearing (outer).

After coating 4 to 5 mm lithium base grease on the outer race

of bearing, put in the inner race and roller assembly of front hub

bearing (outer), and then plaster the lubricant.

3.

Mount the front wheel hub and front brake disc on the

steering knuckle.

Coat a little lubricant on the steering knuckle where the oil seal

locates, and mount the front wheel hub and front brake disc on

the steering knuckle, then mount on the stop washer.

4.

Adjust the preload

(a)

Mount on the steering knuckle nut and screw up them

according to the specified torque.

Tighten torque: (100-120)N

m

(b)

Run the front wheel hub about 1/4-1/3 round, and seat the

bearing.

(c)

Loosen the steering knuckle nut to ensure the front brake

disc can run freely. Screw up the steering knuckle nut

again according to the specified torque.

Fastening torque

25N
m

(d)

Mount on the lock plate and another steering knuckle nut.

Tighten torque

60N
m

(e)

Hold the front wheel hub bolts with a spring-tension

meter and drag the meter slowly in the direction of the

tangent line of this spot.

Suitable tension range: (29-54)N

The nuts should be retightened until falls within the suitable

range if the tension force is overlarge or over small.

(f)

Check the bearing and ensure that the clearance, which is

not larger than 0.05 mm, is not excessive.

(g)

Measure the bouncing value of the front brake disc face.

Bouncing value should not be above o.11mm.

Suspension System and Automobile Axle (SF/2WD)

 Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-32

(h)

Bend one tooth of the lock plate inside and other teeth

outside to lock the steering knuckle nut.

5.

Mount on the liner and the steering knuckle outer flange

cap.

Fastening torque

(23-29)N
m

6.

Mount the brake caliper

(a)

Mount the brake caliper on the steering knuckle and

screw up the bolts according to the specified torque.

Fastening torque

123N
m

(b)

Connect the Bundy tube.

Fastening torque

(20-22)N
m

7.

Check the height of the brake liquid level and add the

brake liquid as requirement, exhaust the gas in the

braking system.

Steering knuckle

Dismantle of Steering Knuckle

1.

Tear down the brake caliper, front wheel and the front

brake disc.

2.

Tear down the dust cover, and the brake shell.

3.

Tear down the steering knuckle arm from the steering

knuckle.

Suspension System and Automobile Axle (SF/2WD) 

 Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-33

4.

Tear down the vibration damper from the lower arm.

5.

Tear down the transverse stabilizer rod from the lower

arm.

6.

Tear down the steering knuckle;

(a)

Tear down the split pin and groove nut of upper ball stud.

(b)

Take apart the steering knuckle from the upper ball stud

with special service tool.

(c)

Tear down the split pin and groove of the lower ball stud.

(d)

Take apart the steering knuckle from the lower ball stud

with special service tool.

(e)

Press down the lower arm to tear down the steering

knuckle.

Suspension System and Automobile Vehicle (SF/2WD)

 Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-34

7.

Tear down the lower ball stud assembly from the steering

knuckle.

Inspection on and Change of Steering

Knuckle

1.

Check the steering knuckle.

Check the steering knuckle with the dye penetration agent to

see whether there is crack or not.

If crack is found, the steering knuckle is required to be changed.

Mount of Steering Knuckle

1.

Mount the lower ball stud on the steering knuckle.

Connect the lower ball stud and steering knuckle with bolts,

which are tightened according to the specified torque.

Fastening torque

(70-90)N
m

2.

Mount on the steering knuckle

(a)

Press down the lower arm to mount on the steering

knuckle.

(b)

Mount on the lower ball stud, groove nut and screw up the

nuts according to the specified torque and then mount on

the split pin.

Fastening torque

(132-152)N
m

Suspension System and Automobile Axle (SF/2WD)

 Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-35

(c)

Mount on the upper ball stud and the groove nut that are

screwed up according to the specified torque, and then

split pin.

Fastening torque

(132-152)N
m

3.

Mount the stabilizer rod on the lower arm.

Fastening torque

(20-26)N
m

4.

Mount the vibration damper on the lower arm.

Fastening torque

(127-147)N
m

5.

Mount the steering knuckle arm and the brake oil pipe

bracket on the steering knuckle.

Coat the sealing agent 1271 on the bolt thread.

Fastening torque

180N
m

6.

Mount the dust cover and brake shell, and align the

locating hole of the dust cover with the groove of the

steering knuckle to ensure that the dust cover is concen-

tric with the steering knuckle.

Fastening torque

(25-29)N
m

7.

Mount the front wheel hub and the front brake disc as well

as the brake caliper.

8.

Check the height of brake liquid level and add the brake

liquid as requirement, then exhaust the gas in the brak-

ing system.

Suspension System and Automobile Axle (SF/2WD)

 Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-36

Front Suspension

Elemtents figures

Suspension System and Automobile Axle(SF/2WD)

 Front Suspension

upper swing arm
shaft

upper arm

transverse
stabilizer rod

vibration
damper

lower arm shaft bush
pinch-off gasket(small)

lower arm

: specified torque

 Parts that cannot be reused after being used

N

M

178

 15

225

 5

89

 7

27

 2

142

 10

137

 10

23

 3

142

 10

142

 10

23

 3

SF

upper arm shaft
bush(short)

upper arm shaft bush and tube(long)

torsion bar yoke

upper arm shaft bush
pinch-off gasket(large)

upper arm shaft bush pinch-off
gasket(small)

upper ball stud

eccentric

gasket

lower arm shaft bush

and tube

lower ball
stud

lower arm shaft bush
pinch-off gasket(large)

SA-37

Ball Stud

Inspection on Ball Stud

1.

Check the lower ball stud to see whether it is excessively

loose:

(a)

Raise the vehicle with a jack and then support it with the

bracket.

(b)

Press down the brake pedal after verifying that the front

wheel is straightly forward.

(c)

Move the arm vertically to check whether the clearance

of lower ball stud is over large.

(Max vertical clearance): 0.5 mm

2.

Check whether the upper ball stud is loose excessively;

Move the wheel vertically to check whether the clearance of

the ball stud is over large.

(Max vertical clearance): 0.5 mm

3.

Check the rotating performance of the ball stud:

(a)

Tear down the ball stud;

(b)

Shake the ball stud column several times before mount-

ing on the nut, as shown in the drawing.

(c)

Rotate the nut continuously with the torsion meter at the

speed of one round each 2 to 4 seconds, read the meter

reading at the fifth round.

Fastening torque(running)

lower ball stud

(0.1-4)N
m

Upper ball stud: (0.1-4)N

m

Disassembly of Ball Stud

1.

Tear down the steering knuckle, steering knuckle arm

and the lower ball stud assembly.

2.

Tear down the ball stud from the steering knuckle;

3.

Tear down the ball stud from the upper ball stud.

Suspension System and Automobile Axle (SF/2WD)

 Front Suspension (Ball Stud)

SA-38

Mount of Ball Stud

1.

Mount the upper ball stud on the upper arm;

Fastening torque

(27 
)N
m

2.

Mount the lower ball stud on the steering knuckle;

Fastening torque

(80 
 0)N
m

3.

Mount on the steering knuckle and hub brake disc

assembly

(See Page SA-34)

Suspension System and Automobile Axle (SF/2WD)

 Front Suspension (Ball Stud
Torsion Rod Spring)

Torsion Rod Spring

 (see Page SA-19)