Great Wall Sailor (2006 year). Instruction - part 5

 

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Great Wall Sailor (2006 year). Instruction - part 5

 

 

TF-4

Transfer Box 

 Troubleshooting

Common troubles

Causes

Resolving approaches

Unsuitable tire pressure.

Noise, which is spread by the transfer
box instead of the clutch, engine or other
parts, occurs at each speed.

Gear noise.
Damage or wear of chain gear or
chain.

Open to check whether there is weary
element or damaged element (including
the odometer gear) and, if any, change
them

Noise occurs in the high-speed or low-
speed four-gear driving.

Open to check whether there is wear or
damage, and if any, adjust the tire pressure
to suitable value.

Oil leakage in transfer box.

Frame Break of transfer box.
Oil leakage of other element.
Ventilation pipe block

Over-added lubricant or lubricant of
unsuitable brand
Looseness of the bolts on sealing
face.
Sealing glue of different brand or
unused sealing glue.
Oil seal wear or damage.

Change the frame.
Check the leakage by wiping dry.
Open and clean it and, if necessary,
change it.
Use the specified lubricant and adjust the
lubricant to suitable volume.
Propel the bolts tightly as requirement.

Use the specified sealing glue and propel
the bolts tightly as required.

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TF-5

Transfer Box 

Product Description and Simple Maintenance

Transfer Assembly NO. of Manufacturer

product assembly NO.

display

termnumber

displaythe last digit of the year
displaythe specific monthly
manufactuer data
displaythe month numnber

Example display:From January (A) to December (L)
Product instruction and simple maintenance

Manufactuer  data

Product instruction and simple mainte-

nance

1.

Product Introduction

The transfer box adapted by our company is the transfer box

of 45-55 manufactured by Bogeguana, which is two-speed

and time driving, a set of planetary mechanism used is to

obtain the speed-reducing performance, while the driving

force is transmitted to the front driving gear by a highly precise

chain. The planetary gear train and rear output shaft element

of transfer box is lubricated initiatively through oil bath and oil

pump. This transfer box has four gears:



2H-stands for the two high gears

in which, only the two

rear wheel are driven, and the gear ratio of the transfer box

is 1:1





4H-stands for the four high gears, in which , all of the four

wheel are driven, and the gear ratio of the transfer box is

1:1





N- neutral location (this location only exists in the transfer

box of instruction gearshift )

No driving force is transmitted

to the wheel when the input shaft and output shaft are

disconnected.



4L-stands for low gears, the four wheels are all driven, and

the gear ratio of transfer box is 2.48:1.

The gearshift of the mechanical gearshift transfer box is

obtained through the shifting-cam-type guide plate that is

operated by the shift rocker arm.

Sign board: which is fastened at the obvious external location

of transfer box, and on which the detailed data are marked.

borgwarner

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TF-6

5D

5D-Oil filling plug
5L-Oil drain plug

5L

2.

Regular lubricant change

(a)

The oil level of lubricant in transfer box shall be checked

when exchanging the engine lubricant or after the vehicle

covers 8000 kilometers, and the lubricant shall be added

as requirement.

(b)

The lubricant shall be changed with the specified one

every year or after the vehicle covers 48000 kilometers.

3.

Lubricant inspection approach

(a)

Clean the oil filling plug and the around area.

(b)

Open the oil-filling plug to check whether the lubricant

can flows out or not.

(c)

if the lubricant can flow out, which means the real

lubricant volume is under the prescribed value, and the

specified lubricant shall be added into the transfer box

until the lubricant can flow from the oil filler hole.

(d)

Propel the oil-filling plug tightly according to the given

Tightening moment.

Tightening moment

(1930)Nm

Notice: The vehicle shall run for a certain time before

checking or exchanging the lubricant so that the

temperature of lubricant in transfer box may be a little

higher. Do not use hammer or other punching tools to

open or propel the oil drain plug or oil filling plug, otherwise,

the thread hole on the frame will be damaged

4.

Lubricant change

(a)

Clean the oil filling plug and oil drain plug and the around

area.

(b)

Put down a oil container under the transfer box.

(c)

Open the oil drain plug.

(d)

Open the oil-filling plug.

(e)

Drain the lubricant up.

(f)

Mount the oil drain plug and screw it up according to the

given Tightening moment.

Tightening moment

(1930)Nm

(g)

Add the lubricant through the oil filler hole until the

lubricant overflows. Mount the oil-filling plug and tighten

it according to the Tightening moment.

Tightening moment : (19

30)Nm

Transfer Box 



lubricant grade: ATF--3

Product Description and Simple Maintenance

-------------------------------------------------------------------------------------------------------------------------------------------------------------

TF-7

Transfer Box 

Disassembly and Mount of Transfer Box

Disassembly and Mount of Transfer Box

1.

Transfer Box Disassembly

(a)

Drive the vehicle on the lifting jack.

(b)

Locate the gear of transfer box at the neutral

position, shift the transfer box to the 2H and

extinguish the engine.

(c)

Disconnect the cell cathode.

(d)

Lift the vehicle.

(e)

Put down an oil disc under the transfer box, tear

down the oil drain plug and oil filling plug of the

transfer to drain all the lubricant up, then re-

mount the two plugs.

(f)

Disconnect all wires and wire harnesses that

connected with the transfer box.

(g)

Take apart the hose on the venting valve of

transfer shaft.

(h)

Disconnect the linkage of the front drive shaft

with the front flange of the transfer box.

(i)

Disconnect the linkage of the rear drive shaft

with the rear flange of the transfer box.

(j)

Raise the transfer box up with the jack.

Notice: The transfer box shall be guaranteed to

support by the lifting jack before tearing down

the sets of bolt and nut that connected with the

transfer box and gearbox. The transfer box is

not allowed to hang directly on the gearbox

through spline because such operation will

damage the transfer box parts.

(l)

Tear down the connecting nuts between the

transfer box and gearbox and take down the

transfer box.

(m) Move the transfer box backward directly until

the linkage between the input shaft of transfer

box and the gearbox spline.

(n)

Put down the lifting jack of the transfer box, and

(o)

Tear down the gasket between the transfer box

and gearbox. Clean the gasket or glue on the

coupling face of front body of transfer box with

rear body of the gearbox. Take notice not to

damage the coupling face.

1

2

3

4

5

6

7

8

9

1. input shaft
2. front frame of transfer box
3. rear cover of transfer box
4. flange
5. front output fork flange
6. venting valve
7. gasket
8. rear body of gearbox
9. bolt

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TF-8

Transfer Box 

Disassembly and Mount of Transfer Box

2.

Transfer box mount

a)

Coat the lubricant grease on the output axial

spline of the gearbox with a thin sleeve contain-

ing lubricant grease.

b)

Mount a new gasket on the mounting face of the

transfer box.

c)

Lift the lifting bracket of transfer box and align

it to the same axle with the gearbox.

Notice: The transfer shall be guaranteed to flush

with the gearbox before connecting the spline.

Do not handle it forcefully to press the transfer

box spline into the gearbox. Otherwise, damage

will be caused, run the rear output shaft where

necessary to aim at the spline.

(d)

Move the transfer box forward slowly so that

the spline and pin of the input shaft of gearbox

reach the front body of the transfer box, and the

gasket attaches on the gearbox completely.

(e)

Ensure that the mounting holes of the front

body of transfer box, gasket, and gearbox are in

alignment and then mount the sets of bolt and

nut.

Fastening torque

(35-48)Nm

(f)

Connect the rear drive shaft and the rear output

flange of the transfer box.

(g)

Connect the front drive shaft and the front

output fork flange of the transfer box.

(h)

Connect the venting valve and the soft ventila-

tion pipe.

(i)

Connect the cables of odometer that locates

nearby the transfer box.

(j)

Connect all wire harnesses that connected with

the transfer box, and

(k)

Add the lubricant of right brand.

Notice: when starting the engine, if the lubricant

is added incorrectly or in unsuitable volume,

which may lead the transfer box to damage.

Notice: as for the transfer box mounted on

vehicle, oil pump shall be used when adding oil

for it.

Notice: In case the transfer box is taken apart for

maintenance or inspection, there will be no

lubricant supplied by oil pump in the oil passage

on the top of transfer box. Therefore, it is not

accurate to control the oil volume by opening the

oil filling plug, in such condition, the oil passage

will be filled with oil once the oil pump runs. If the

wheel can run, such operation can be conducted

on the lifting jack. The oil level shall be rechecked

once the oil pump runs.

(l)

Put down the vehicle after finishing the lubri-

cant inspection, and connect the cell cathode.

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TF-9

5

4

3

1

6

2

1. rear body of transfer box

2. flange

3. oil seal

1. sensor bracket

2. bolt

3. speed sensor

4. o-ring

5. sensor assembly

6. bolt

7. gasket

8. rear body of transfer box

2

1

5

3

4

4

6

7

8

Transfer Box

Disassembly of Transfer Box

4. gasket

5. nut

6. oil plug

Disassembly of Transfer Box

1.

Brief instruction

In case the transfer box is required to be repaired for the

damaged specific element, it shall be taken apart to the degree

on which the damaged element is taken out. And the parts

taken apart from the transfer box, if it doesnít include the

damage element, can exist in the form of sub-assembly or

group instead the individual form, otherwise, the parts will be

taken apart individually.

2.

Transfer Box Disassembly

Put the transfer box on the worktable and ensure the rear part

or the rear cover faces upward. Put the wooden block under the

front part of transfer box to keep the transfer box stands

horizontally. The disassembly process is as follows:

(a)

Fasten the flange with the torque arm typed T-13-54-

002, screw off the nut to take down the gasket, then take

apart the flange and oil seal.

(b)

Take down the two oil plugs from the transfer box body.

As for the electric gearshift transfer box, tear down the

electric shifting element according to the following

disassembly approach:

(a)

Tear down the three bolts, gaskets, sensor and clip for

wire harness.

(b)

Tear down the sensor assembly and take apart the O-

ring.

(c)

Tear down the motor assembly.

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TF-10

1. output shaft

2. shift engagement sleeve assembly

3. locking sleeve

4. return spring

5. engagement sleeve

6. snapping ring

7. shift lock hub

8. clutch assembly

9. fastening snapping ring

10.shift guide shaft

11.toggle fork

Transfer Box

Disassembly of Transfer Box

1. front case of transfer box

2. rear output shaft

3. cluch coil assembly

4. clip

5. bearing

6. nut

7. transfer cover assembly

8. mark plat

9. bolt

10. odometer drave gear

11. oil seal

12. oil seal

13. bearing

14. rear cover of transfer box

15. rolling needle bearing

16. shift guide shaft

17. back spring

18. magnet

19. bundle clip

10

9

8

12

13

14

15

7

7

6

5

4

3

16

17

18

2

1

19

9

11

3. The disassembly approach for rear cover is as follows (above figure)

(a)

Dismantle the nine screws and take down the clip of wire harness and

signboard in the same time.

Notice shall be taken to good keeping for the signboard, which includes the

information for the substitutes to be changed.

(b) Pry the frame lightly so that the sealing glue on the surface disengages, and

then take up the transfer box rear cover assembly directly.

(c) As for the electric gearshift transfer box, tear down the oil seal, bearing and

three nuts and clutch coil assembly.

(d) Tear down the snapping ring, pull out the bearing from the rear cover and

take apart the odometer meanwhile.

(f)

Pull out the oil seal from the rear cover of the transfer box.

(g) Tear down the magnet from the front body of transfer box.

(h) Take apart the return spring from the shift guide shaft

(i)

Clear away the sealing glue on the coupling face of the front housing and

rear cover of transfer box, take notice not to damage the coupling face of

the two housings or cause the materials removed dropping into the transfer

box.

4. Tear down the shifting element connected with the front axle.

Tear down the following parts from the remaining transfer box housing

assembly (electric gearshift).

(a) Electric gearshift assembly, tear down the snapping ring and sliding clutch

sleeve from the shift locking hub.

(b) Tear down the shift-locking hub from the rear output shaft.

(c) Tear down the shift engagement sleeve assembly and shift toggle fork from

the rear output shaft and shift guide shaft. Separate the assemblies one

another and tear down the shift guide shaft.

(d)

Disassemble the shift engagement sleeve assembly by taking apart the

snapping ring, engagement sleeve, return spring, and locking sleeve.

(e)

A plastic toggle fork that substitutes the metal toggle fork assembly and a

independent contact roller in earlier time.

1

9

8

7

6

5

Q

3

2

10

11

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TF-11

5.

Tear down the Chain drive system

Take apart the following parts from the transfer box housing

assembly.

(a)

Take apart the snapping ring and washer from the front

output shaft.

(b)

Take apart the driving chain sprocket, driven chain

sprocket and drive chain together from the two output

shafts.

(c)

Separate the chain sprocket from the chain.

1

2

3

4

5

6

7

1. output shaft

2. driving chain sprocket

3. driven chain sprocket

4. washer

1

2

3

4

5

6

7

6.

Oil pump assembly

Take apart the shaft and pump assembly, pipe clip, oil pipe and

filter from the remaining transfer box housing assembly.

1

2

7

6

3

4

5

8

1. deceleration gear hub

2. inserted face of Shift

    toggle fork

3. plastic sleeve

4. contact roller

5. pin

6. pin, contact roller and sleeve assembly

7. deceleration shift toggle fork

8. deceleration shift toggle fork assembly

7.

Deceleration shifting element disassembly

Tear down the following parts from the remaining transfer box

housing assembly.

(a)

Take apart the deceleration hub, and deceleration shift

fork assembly from the housing.

(b)

Take apart two plastic inserted faces from the decelera-

tion shift fork assembly

(c)

Disassembly the deceleration shift fork assembly only if

it were broken.Cut the plastic cover,and take out the pin

and truckle.

Transfer Box

Disassembly of Transfer Box

1. output shaft

2. driving chain sprocket

3. driven chain sprocket

4. washer

5. snapping ring

6. transmission chain

7. front output shaft

5. snapping ring

6. transmission chain

7. front output shaft

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TF-12

1

10

9

8

6

5

4

3

2

11

15

14

13

12

17

18

19

20

7

16

Transfer Box

Disassembly of Transfer Box

1. fork-type flange

2. dust cover

3. fork-type flange assembly

4. transfer box front housing

8.

Take apart the following parts from the remaining trans-

fer box housing assembly

(a)

Fasten the front fork-type flange with the torque arm of

T-13-54-002 and screw off the nuts to take apart the

gasket, pull out the front fork-type flange assembly and

sealing ring.

(b)

The dust cover may also be pressed down from the front

fork-type flange where necessary, and

(c)

Take apart the front output shaft.

1. planetary mechanism

assembly

2. gasket

3. snapping ring

4. thrust disc

5. sun wheel

6. planetary bracket

7. input shaft assembly

8. input shaft

9. needle bearing

10. bearing shell

11. transfer box front

body assembly

9.

Tear down the front body, input shaft assembly and

planetary mechanism assembly

Tear down the following parts from the remaining transfer box

housing assembly

(a)

Take apart the venting valve.

(b)

Take apart the six bolts to separate the front body from

the transfer box housing and take down the front body

(take notice not to damage the front-end cover and the

transfer housing).

(c)

Take apart the front body assembly, input shaft assembly

and planetary mechanism assembly in grouping manner

(loose the snapping ring to take apart the input shaft from

the front end cover).

(d)

Hold one end of the input shaft on the worktable while

open the long end of the snapping ring, press the front

body tightly to disassemble the front body assembly from

the remaining assembly.

(e)

Take apart the snapping ring and oil seal from the front

body, the pin is only be taken apart where change is

necessary.

(f)

Take apart the bearing and gasket from the input shaft

assembly after the bearing gripping loop is taken apart;

and take apart the input shaft assembly from the planetary

mechanism assembly.

(g)

Take apart the needle bearing and bearing shell from the

input shaft assembly, and

(h)

Take apart the snapping ring, thrust disc and sun wheel

from the planetary assembly, and

(i)

Do not try to disassemble the planetary bracket.

4

2

1

5

6

7

8

3

5. front output shaft

6. oil seal

7. washer

8. nut

12. oil seal

13. locating pin

14. transfer box front

body

15. snapping ring

16. transfer box front

housing

17. bearing

18. bearing gripping

loop

19. bolt

20. vent

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TF-13

1

2

3

4

5

7

6

5

4

3

2

1

Transfer Box

Disassembly of Transfer Box

10. Take apart the shift convex plate parts (for the electric

shift transfer box)

(a)

Take apart the integrated electric shifting cam from the

transfer box housing.

(b)

Take apart the electric shifting cam from the shift guide

shaft.

(c)

Grip the end of shift guide shaft with soft-jaw vices, and

tap the shaft with a screwdriver until the torsion spring

drops off.

1. front body of transfer box housing

2. shift guide shaft

3. torsion spring

4. electric gearshift

5. gasket

1. transfer box front housing assembly

2. gear ring

3. oil seal

4. transfer box front housing

5. locating pin

6. ball bearing

7. snapping ring

11. Disassemble the transfer box housing assembly

Disassemble the transfer box housing assembly in the manner

as follows.

(a)

Take apart the oil seal.

(b)

Take apart the snapping ring, and pull out the bearing.

(c)

The locating pin may only be taken apart from the transfer

box front housing in the case that the pin is loose or

damaged, and

(d) Where the gear ring needs to be changed, it may be

pressed out from the transfer box housing.

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TF-14

7

6

5

4

3

2

1

1. transfer box front housing assembly

2. gear ring

3. oil seal

4. transfer box front housing

5. locating pin

6. ball bearing

7. snapping ring

NMR

2

3

4

1

1. oil seal

2. transfer box front housing

3. gear ring

4. locating pin

Transfer Box

Transfer Box Assembly

Transfer box assembly

1.

Introduction

Please refer to the given instruction of this chapter during

assembly process. And the following items shall be taken

notice on:

(a)

In case that the torque of the threaded parts is required,

torque spanner shall be used to screw up the parts.

(b)

The small parts shall be coated with the lubricant grease

during the mounting process, so that they are immobilized

at the mounting locations.

(c)

SST such as thimble of T-13-54-001 shall be used to press

the oil seal and bearing during the oil seal mount and

bearing mount, do not use the hammer to strike the oil seal

or bearing directly.

2.

Lubricating during assembling

All inner parts without lubricant shall be lubricated with the

suitable lubricant before mounting, so that they can be as-

sembled easily and can supply the original lubricant

performance.

(a)

If the O-ring and oil seal were not lubricated before

mounting, they may be damaged.

(b)

Be sure that the bearing or liner is lubricated completely

before mounting. Because the bearing or liner may be

leaded into damage even though they are run for a very

short time.

(c)

The lips of oil seal and the metal elements that match with

lips shall be lubricated before mounting.

3.

Transfer box housing assembly

Parts taken apart from the transfer box shall be mounted

according to the following approaches:

(a)

If the gear ring needs to be changed, the tooth-type saddle

rear of new gear ring shall be flushed with the gullet of the

transfer box front housing when pressing the new gear

ring. Press in the gear ring as shown in the left bottom

drawing, in which, the chamfering end is firstly pressed

in. if it is ensured the gear ring is not tilted, then fasten the

gear ring tightly on the housing.

(b)

In case there are two locating pins taken apart, mount two

new locating pins into the housing.

(c)

Press the bearing into the transfer box front housing and

mount the snapping ring correctly, and

(d)

Put down the new oil seal as shown in the left bottom

drawing and press it into the housing.

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TF-15

1

2

3

4

1. shift guide shaft

2. torsion spring

3. electric shift convex plate

4. gasket

1

2

3

1. torsion spring

2. gasket

3. shift shaft

Transfer Box

Transfer Box Assembly

1

2

3

1. torsion spring

2. gasket

3. shift shaft

4.

Mechanic shift convex plate assembly (for electric shift

transfer box)

The mounting process for the electric shifting element is as

follows:

(a)

Insert the gasket into the inside of free end of the torsion

spring.

(b)

Slide the torsion spring and gasket along with the shift

shaft to the driving tongue and put down the first spring

ring at the left side of the driving tongue (from the

direction of free end of shift shaft).

(c)

Twist the second spring ring of the torsion spring on shift

shaft to the right side of the driving tongue.

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TF-16

1

10

9

8

6

5

4

3

2

11

15

14

13

12

17

18

19

20

7

16

1

2

3

Transfer Box

Transfer Box Assembly

1. torsion spring

2. gasket

3. shift shaft

1. planetary mechanism

assembly

2. gasket

3. snapping ring

4. thrust disc

5. sun wheel

6. planetary bracket

7. input shaft assembly

8. input shaft

9. needle bearing

10. bearing shell

11. transfer box

frontbody assembly

12. oil seal

13. locating pin

14. transfer box front body

15. snapping ring

16. transfer box housing

17. bearing

18. bearing gripping loop

19. bolt

20. vent

(d)

Push the torsion spring and gasket backward together as

can as possible

(e)

Mount the electric shifting cam on the shift shaft in such

way that the free end of the driving tongue of the cam is

put in first, fasten the cam driving tongue, which shall be

between the two spring ring of two torsion spring, under

the driving tongue of shift shaft and put it innermost as

can as possible.

(f)

After mounting the toggle fork, then mount the electric

shifting cam assembly in the transfer box housing assembly

5.

Assemble for front body, input shaft assembly and plan-

etary component element.

Mount the following element on the worktable:

(a)

Put the planetary bracket assembly on worktable, and the

end with snapping ring groove shall face upward.

(b)

Mount in the sun wheel and let the part with projecting

end upward, run the gear of the planetary bracket assem-

bly until it completely engages with the sun wheel.

(c)

Flush the projecting teeth, and then mount the thrust disc

into the planetary bracket assembly.

(d)

Mount in the snapping ring to complete the whole plan-

etary bracket assembly.

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TF-17

1.25-1.75mm

2

3

1

12.70mm

1

3

2

4

4

2

1

5

6

7

8

3

(e)

In the case that the input shaft is taken apart, what need

to do is to fill the needle bearing as shown in the drawing

and press it in the input shaft, meanwhile, press the new

sliding bearing to complete the whole input shaft assembly.

(f)

Raise the planetary mechanism assembly to mount it into

the input shaft assembly; encase the thrust gasket and

press in the bearing through the input shaft end. Encase

the fixed bearing in the snapping ring groove of the input

shaft with a snapping ring.

(g)

If the transfer box front body is taken apart, press the new

located pin in the front body, and the pressing dimensions

are shown in the drawing.

(h)

Put down the oil seal as the drawing shows, and press it

in the front body according to the dimensions shown in

the drawing.

(i)

Put down the front body assembly on two wooden blocks

in the way that the coupling face of the front body and the

housing faces upward, so that there is clearance left

between the input shaft assembly and the worktable. Put

down the input shaft and planetary mechanism assembly

in the front body, in which the input shaft shall be

downward. Open the long ends of the snapping ring to

encase input shaft and planetary mechanism assembly

until the snapping ring enters into the external snapping

ring groove of the bearing.

(j)

Coat the sealing glue of 1.6mm on the coupling locations

of the front end cover and transfer box assembly, The

glue shall be coated continuously without break and steer

clear of the screwed hole.

(k)

Screw up the six bolts.

Fastening torque

(2746)Nm

6.

Assembly  of front output shaft

Mount the following parts:

(a)

If the dust cover is taken apart, mount it by pressing.

(b)

Encase the input shaft, sealing ring, gasket and nuts in the

transfer front housing.

(c)

Insert the torque arm of T-13-54-002 in the flange hole to

screw up the nuts.

Fastening torque

(203244)Nm

Transfer Box

Transfer Box Assembly

1. needle bearing

2. bearing roller

3. input shaft

1. locating pin

2. oil seal

3. front body of transfer box

4. snapping ring

1. fork-type flange

2. dust cover

3. fork-type flange assembly

4. transfer box housing

5. output shaft

6. oil seal

7. washer

8. nut

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TF-18

1. deceleration gear

2. output shaft

3. insert face of toggle fork

4. deceleration toggle fork assembly

5. pin, contact roller and sleeve assembly

6. deceleration shift toggle fork

7. plastic sleeve

8. contact roller

9. pin

1

2

6

7

8

9

3

N

O

P

Q

R

S

T

Transfer Box

Transfer Box Assembly

7.

Deceleration shift parts assembly

The mounting process is as follows:

(a)

If the parts are taken apart for change, assemble the shift

toggle fork assembly with a new pin-contact roller

assembly. Press the pin-contact roller in the deceleration

fork hole until the detent passes the hole completely and

seizes the right location. Ensure that the contact roller can

run freely.

(b)

Mount two inserted faces of toggle fork on the decelera-

tion toggle fork assembly.

(c)

Engage the deceleration fork assembly and deceleration

gear sleeve and put them in the housing, and the decelera-

tion gear sleeve shall be put in the planetary mechanism

assembly that is assembled already. Mount the rear

output shaft and joint the bearings at the ends of output

shaft and input shaft as well as the spline of the gear

sleeve.

Remarks: the output shaft assembly can be delayed until the oil

pump is mounted on the output shaft. The oil pump may be

dipped into the lubricant through the oil pump screen, turn the

output shaft in clockwise from the output shaft direction to see

whether there is lubricant pumped out so as to check whether

the oil pump can work normally or not. The parts mounted

readily may be encased in the transfer box housing as an

assembly

8.

Oil pump assembly

 Ensure the parts of oil pump are completely lubricated when

assembling, and the oil can be pumped out from the conical

hole of the oil pump front cover. The mount of oil pump is as

follows:

(a)

Mount the pin on the rear output shaft.

(b)

Slide the oil pump assembly on the rear output shaft

along with the pin.

(c)

Put the gripping hoop at the end of oil pipe that is

mounted on the oil nozzle of the pump housing, screw up

the gripping hoop.

1. filter

2. oil pump hose

3. gripping hoop

4. oil pump assembly

5. output shaft

6. pump pin

7. output shaft and pump assembly

5

4

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Transfer Box

Transfer Box Assembly

9.

Assembly of driving chain

The parts assembly process is as follows:

(a)

Put the driving chain sprocket at the rear end of the output

shaft, and the driven chain sprocket is put at the rear end

of the front output shaft on the worktable after the transfer

box housing assembly mount.

(b)

Mount the chain on the sprocket.

(c)

Holding the two chain sprockets parallel with the transfer

box in the space that the chain on the two sprockets are

straightened, and encase the chain and sprocket assembly

through the output shaft, it is required to run the chain

sprocket slowly to ensure that they engage with the front

output shaft and the spline.

(d)

Mount the gasket and snapping ring on the front output

shaft.

10. Shift locking element assembly

The parts mounting process is as follows (for the electric shift

transfer box):

(a)

Mount the return spring and locking hub on the locking

sleeve and fasten them with snapping ring to finish the

2W-4W locking sleeve assembly.

(b)

Encase the shift guide shaft in the blind hole of the

housing through the deceleration toggle fork assembly

that is already assembled.

(c)

Mount the shift toggle fork on the 2W-4W locking sleeve

assembly, which will slide through the shift guide shaft

and rear output shaft.

(d)

Joint the combined external gear sleeve spline and the

rear output shaft spline as well as the 2W-4W locking

sleeve.

1. output shaft

2. driving chain sprocket

3. driven chain sprocket

4. washer

5. snapping ring

6. transmission chain

7. front output shaft

1. output shaft

2. shift engagement

sleeve assembly

3. locking sleeve

4. return spring

5. engagement sleeve

6. snapping ring

7.  shift lock hub

8. clutch assembly

9. fastening snapping ring

10. shift guide shaft

11. toggle fork

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