Great Wall Pegasus (2006 year). Instruction - part 12

 

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Great Wall Pegasus (2006 year). Instruction - part 12

 

 

SA-71

(b)

Tear down the planetary gear shaft to take out the planetary

gear, planetary gear stop gasket, half-axle gear and the

half axle gear thrust gasket

7.

Differential assembly mount

(a)

Clean the differential housing.

(b)

Encase the half-axle thrust gasket in the differential

housing after covering on the half-shaft gear.

(c)

Run the half-axle gear to encase the planetary gear and

planetary gear stop gasket, and put on the planetary gear

shaft.

Remark: The half-axle gear and the planetary gear should run

freely without stagnant.

(d)

Measure the clearance between the half axle gear thrust

gasket and differential housing.

Push the planetary gear to the inside and then measure

the clearance between half-axle gear thrust gasket and

the differential housing with the dial-indicating lamp.

Suitable clearance range: (0.4-0.75)mm

Remark:If the clearance fails to fall within the above-

mentioned range, change the half-axle gear thrust gasket,

and ensure that the thrust gaskets on the both sides are

same thick.

(e)

Tap the pin in the pinhole of differential housing and the

planetary gear shaft with SST, and rivet the hole port so

as to prevent the pin from missing.

Suspension System Automobile Axle (SF/4WD)

Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

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SA-72

(f)

Clean the differential housing surface, mount the axle

driven bevel gear on the differential housing with copper

bar.

Notice: align the assembly marks made when

disassembling when mounting the axle driven bevel

gear, and tap in the driven bevel gear evenly alongside

the direction of circumference.

(g)

Mount on the lock plate and screw on the bolts, then lock

the lock plate with the drift pinch and hammer.

Fastening torque

(70-90)Nm

Notice: the bolts should be screwed up in the diagonal

order in such manner that tighten a little at first, and then

screw up evenly to the specified torque, the lock plate

claw should contact closely the side face of bolt head.

(h)

Press the inner race and roller assembly of bearing

50KB801 in the bearing position at the both sides of

differential housing.

(i)

Put the adjusting gasket in the outer position of the side

bearing of front speed reducer shell.

(j)

Encase another adjusting gasket with the outer race of

bearing 50KB801 in the front speed reducer shell to-

gether with the differential.

Suspension System and Automobile Axle (SF/4WD)

Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

(k)

Mount on the right and left cap-differential bearing, and

screw up the bolts with spanner according to the specified

torque.

Fastening torque

78Nm

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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)

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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)Nm

7.

Measure the preload on the driving bevel gear bearing

with torque tester :

New bearing

(1.2-1.7)Nm

Old bearing

(0.9-1.3)Nm

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)

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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)

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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)Nm

13. Mount on the left and the right cap-differential bearing:

Screw up the bolts with spanner to the specified torque;

Fastening torque

78Nm

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

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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)

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SA-78

18. Mount on the front drive axle shaft sleeve;

Notice: Thread locking agent should be coated on the

bolt thread.

Fastening torque

88Nm

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

47Nm

Suspension System and Automobile Axle (SF/4WD)

Front Speed Reducer (Assembly of Front Speed Reducer)

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SA-79

Rear Axle Shaft

Element figure

rear axle housing

O rubber O-ring seal

rear brake

brake drum

inner oil seal seat of
rear wheel bearing

bearing seat

oil seal of rear
wheel bearing

liner

half-shaft

grooved ball
bearing

rear brake

oil-guard tray

 Parts that cannot be reused after being used

Suspension System and Automobile Axle (rear)

Rear Axle Shaft

flat steel retainer ring for shaft

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SA-80

Dismantle of Rear half  Axle Shaft

1.

Tear down the wheels.

2.

Tear down the rear brake drum.

3.

Tear down the grab end of the bracing wire of hand brake

from the rear brake.

4.

Tear down the half-shaft and the rear brake assembly

from the rear axle housing.

5.

Tear down the flat steel retainer ring for shaft from the

half-shaft;

Tear down the flat steel retainer ring for shaft with the ring

calipers.

6.

Tear down the half-shaft:

Put down a wooden plate on the flat ground, and thrust the end

of spline of half-shaft and rear brake assembly toward the

wooden plate to separate the shaft and the rear brake assembly.

Inspection on and repairing of half-shaft parts

1.

Check the wear, damage and swing difference half-shaft

and the flange.

Max shaft run-out: 2 mm

Max flange run-out: 0.2 mm

In case the half-shaft is damaged, or wearied or the measuring

value of the swing difference is excessive, change the half-

shaft.

2.

Check he oil seal of rear wheel bearing:

Check to see whether there is wear or damage, and change the

oil seal if necessary.

3.

The disassembly of the outer oil seal of rear wheel

bearing;

Tear down the outer oil seal of rear wheel bearing with SST.

Suspension System and Automobile Axle (rear)

 Rear Half Axle Shaft

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SA-81

4.

Check the grooved ball bearing

Check the grooved bearing to see whether there is damage or

wear.

5.

Change the bearing where necessary:

(a)

Press out the grooved ball bearing with SST.

(b)

Press in the new grooved ball bearing with SST.

6.

Mount the new oil seal of rear wheel bearing.

Press in the new oil seal of rear wheel bearing with SST

Coat moderate lithium base grease on the lip open of oil seal.

7.

Check the bearing seat.

Check the wear or damage situation.

8.

Change the bearing seat where necessary:

(a)

Tear down the oil seal of rear wheel bearing and the

grooved ball bearing with SST.

(b)

Tap the bolts with copper bar to tear down the bearing seat.

(c)

Mount the new grooved ball bearing and the oil seal of

rear wheel bearing on the bearing seat

(d)

Press the rear brake, which is put on with bolts, in the

bearing seat.

9.

Check the wear or damage of the inner oil seal of the rear

wheel bearing.

10. Change the rear wheel bearing where necessary:

(a)

Tear down the oil seal of rear wheel bearing with SST.

Suspension System and Automobile Axle (rear)

Rear half Axle Shaft

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SA-82

11. Mount the new inner oil seal of rear wheel bearing.

Coat the hyperbolic gear oil on the axle housing where matches

with the oil seal; and plaster the moderate lithium base grease

on the lip open of the oil seal, then put them on the pressure

head and press them in.

Mount of Rear Axle Shaft

1.

Press the rear brake and the bearing seat assembly on

the haft shaft.

2.

Press the heated inner oil seal seat of rear wheel bearing

on he half shaft;

Notice: the face at the chamfering end of inner oil seal of

rear bearing should contact the oil seal closely, do not

mount it at the incorrect position.

Requirement for heat mount: heat the inner oil seal seat into the

22# oil (GB443-1989) to 100

, after the part is heated

completely, take it out for mount.

3.

Mount on the flat steel retaining ring with the ring calipers.

4.

Encase the half-shaft rear brake in the axle housing,

screw on the self-locking nut.

Tightening moment

(63-79)Nm

Notice: protect the oil seal lip open, bracing wire assembly

and the oil-guard sleeve.

5.

Mount on the hand brake wire and the brake pipe.

6.

Mount on the liner and rear brake drum;

7.

Make a trial gas exhaust on the braking system, and

8.

Mount on the rear wheels.

Suspension System and Automobile Axle (rear) 

Rear Half Axle Shaft

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SA-83

Rear speed reducer

Element figure

column bolt

bearing7306E

oil-guard tray

oil seal

flange and dust
cover assembly

flat washer



adjusting ring

bearing 200719E

speed reducer housing and
differential bearing cover

stop gasket

80-110

18-26

washer

adjusting washer

driving bevel gear

Bearing 7607E

jacket

adjusting washer

65-95

=

lock plate

differential housing

axle driven

bevel gear

 Parts that cannot be reused after being used

:specified  torque

N

M

Suspension System and Automobile Axle (Rear) 

Rear Speed Reducer

double-eared stop washer

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SA-84

On-vehicle Change of main-teeth oil seal

1.

Disconnect the drive shaft from the speed reducer:

(a)

Mark the assembly mark on the two flanges;

(b)

Tear down the four sets of bolt and nut.

2.

Tear down the flange and dust cover assembly.

3.

Tear down the oil seal.

Tear down the oil seal with SST.



4.

Mount on the new oil seal:

(a)

Coat the lithium base grease on the lips of oil seal;

(b)

Tap in the new oil seal with SST.

Remark: tap the new oil seal until it is in place.

5.

Mount the flange and dust cover assembly.

6.

Screw up the nut to the specified torque.

Specified torque: (140-160)N

m

7.

Rivet the nut.

8.

Connect the drive shaft flange with the speed reducer

flange:

Align the assembly mark and connect the flanges with bolts.

Tightening moment

(69-79)Nm

9.

Check the oil level of the speed reducer.

Change the gear oil where necessary.

Oil brand: heavy-duty oil of grade 

GL-5

Oil volume: add the oil until it overflows from the oil filler

outlet.

Viscosity: SAE 85W/90

Suspension System and Automobile Axle (Rear) 

Rear Speed Reducer

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SA-85

Dismantle of Rear Speed Reducer

1.

Take out the oil drain plug to drain the oil in the speed

reducer up.

2.

Tear down the rear axle shaft.

3.

Disconnect the drive shaft from the speed reducer.

4.

Tear down the nuts on the bolts that connect the rear axle

housing and the speed reducer.

5.

Tear down the rear speed reducer.

Disassembly of Rear Speed Reducer

Remark: in case the noise is over loud, the following item

should be checked before taking apart it to find out the causes.

If the speed reducer has serious drawback, take it apart for

repairing where necessary.

1.

Check the play between the axle driven bevel gear;

In case the play value fails to be within the specified range,

adjust the preload of bearing 200719E or repair it where

necessary.

(see page SA-91)

Standard play: (0.13-0.25)mm

2.

Check the teeth engagement of the driving bevel gear

with the axle driven bevel gear.

(See Page SA-92)

Record the teeth engagement positions.

3.

Check the clearance between the half-shaft gear thrust

gasket and the differential housing.

Check the clearance between the half-shaft gear thrust gasket

and the differential housing with the feeler.

Standard clearance

(0.45-0.75)mm

Remark: in case the clearance value fails to fall within the

above range, change the half-shaft gear stop gasket, and

ensure the half-shaft gear stop gaskets on the left and right

sides are same in thickness.

(See Page SA-95)

Suspension System and Automobile Axle (Rear)

(Dismantle of Rear Speed Reducer)

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SA-86

4.

Tear down the differential and the axle driven bevel gear:

(a)

Mark the assembly marks on the differential bearing

cover and the speed reducer housing.

(b)

Tear down the stop gasket and take down the adjusting

ring.

(c)

Loosen the double-stop washer and screw off the nut to

take down the differential bearing cover.

(d)

Tear down the differential and axle driven bevel gear

from the rear speed reducer.

(e)

Tear down the outer race of bearing 200719E.

5.

Tear down the flange and dust cover assembly:

(a)

Loosen the riveted part of the nut with hammer and

chisel;

(b)

Lock the flange with SST to tear down the nuts.

Notice: those nuts should not be reuse.



left

right

(c)

Tear down the flange and dust cover assembly with

copper bar.

Suspension System and Automobile Axle (Rear) 

(Dismantle of Rear Speed Reducer)

Remark: mark the label on the parts to clarify the position for

re-assembling

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