Great Wall. Service manual for chassis and body (2006) - page 6

 

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Great Wall. Service manual for chassis and body (2006) - page 6

 

 

MT-19

Gearbox

Input Shaft Assembly (Bearing Change)

ppq

2.

Mount the new bearing with pressure machine and SST.

3.

Select the retainer ring to obtain the minimum axial clearance

4.

Mount the retainer ring with the split-ring-type pliers.

   5.

Mount the retainer ring with the split-ring-type pliers.

MT-20

Transmission

Output Shaft Assembly (Components Figure)

Output shaft assembly

Components  figure

synchronizer spring

expansion ring

snap ring

synchronizer

slide block

3th,4th gear synchronizer

meshing sleeve

3th gear needle bearing

synchronizer hub of 3rd

and 4th gear

toothed ring of

synchronizer

gear components of 3rd gear

steel ball

synchronizer sliding block

synchronizer meshing sleeve

of 1st and 2nd gear

gear components

of 1st gear

1st gear shaft sleeve

locking ring of output

shaft rear bearing

spring expansion ring

needle bearing of

2nd gear

gear components

of 2th gear

toothed ring of synchronizer

for 1st and 2nd gear

toothed ring of synchro-

nizer for 1st and 2nd gear

needle bearing of 1st gear

rear bearing of

output shaft

gear of 5th gear

odometer drive gear

drive gear snap ring of odometer

output shaft

snap ring of 5th gear

steel ball

MT-21

Transmission

Output Shaft Assembly(Disassembly of Output Shaft Assembly)

Disassembly of output shaft assembly

1.

Remove the drive gear of speedometer

(a)  Pry down the two shield rings with open end ring plier

(b)  Dismantle the drive gear of tachometer.

(c)  Take out the steel ball with magnetic stick.

2.

Remove the 5th gear,rear bearing of output shaft,1st

gear assembly,1st gear shaft sleeve and needle bearing

of 1st gear

(a)  Take down the circlip of 5th gear with two screwdrivers

and one hammer.

(b)  Dismantle the rear bearing of output shaft,1st gear assem-

bly and 1st gear sleeve with press machine.

(c)  Remove the needle bearing of 1st gear.

3. 

Remove the synchronized ring

4.

Take down the steel ball

Take out the steel ball with magnetic rod.

5.

Take down the 1st and 2nd gear synchronizer assembly,

2nd gear assembly,and 2nd gear needle bearing.

(a)  Remove the 1st and 2nd synchronizer assembly and 2nd

gear components.

(b)  Take off the needle bearing of the 2nd gear.

6. 

Take down the meshing sleeve ,sliding block and spring.

Remove the three sliding blocks and two springs from the

synchronizer assembly with one screwdriver.

MT-22

Transmission

Output Shaft Assembly(Disassembly of Output Shaft Assembly)

7. 

Take down the 3rd and 4th gear synchronizer assembly,

3rd gear and needle bearing .

(a)  Remove the snap ring with plier for snap ring.

(b)  Take down the 3rd and 4th gear synchronizer assembly and

3rd gear with press machine.

(c)  Remove the needle bearing .

8.

Take off the meshing sleeve ,sliding block and spring

from 3rd and 4th synchronizer.

Remove the three sliding blocks and spring from the meshing

sleeve  with one screwdriver.

B0-24

Wheel-trims

Wheel-trims of stainless steel

Element mounting position

Vehicle Body

Wheel-Trims

Change of shield of front wheel

1.

Tear down the shield of front wheel;

Tear down the five screws to take down the Wheel-trims;

2.

Mount the shield of front wheel

(a)

Tap the front shield manually to ensure it contact the

body closely.

(b)

Mount the five screws.

shield of front wheel

rear wheel-trims

Dr

Change of rear Wheel-trims

1.

Tear down the rear Wheel-trims.

Tear down the five screws and take down the Wheel-trims.

Prize up the snapping plate of Wheel-trims with screwdriver to

take down the Wheel-trims (SF)

2.

Mount the rear Wheel-trims:

(a)

Tap the rear Wheel-trims manually to ensure it contacts

the body closely.

(b)

Mount the five screws.

Clamp the Wheel-trims with snapping plate. (SF)

B0-25

large wheel trims

Element mounting position

Vehicle Body

Wheel-Trims

shield of front wheel

wrapping angle of

shield of front wheel

rear wheel-trims

SF

Change of shield of front wheel and wrapping angle

1.

Tear down the shield of front wheel and wrapping angle;

Tear down the seven screws and take down the Wheel-trims.

2.

Mount the shield of front wheel:

(a)

Mount the adhesive strip of Wheel-trims first, ensure the adhesive

strip contact the Wheel-trims closely;

(b)

Mount the five screws.

3.

Mount the wrapping angle of the front Wheel-trims.

Mount the wrapping angle on the front bar first, and then fix it with two

screws.

Change of rear wheel-trims

1.

Tear down the rear Wheel-trims

Tear down the five screws and take down the Wheel-trims;

2.

Mount the rear Wheel-trims

(a)

Mount the adhesive strip of Wheel-trims first, ensure the adhesive

strip contact the Wheel-trims closely;

(b)

Mount the five screws

MT-23

Inspection of output shaft assembly

1.

Check the axial clearance of every gear:

For the transmission made by Shang Chi:(0.15

0.33)

mm(1st,2nd,and 3rd gear position)

For the transmission made by Tang Chi:(0.1

0.25)mm

(1st gear position)(0.09

0.26)mm,(2nd and 3rd gear

position)

2. 

Measure the idle clearance of every gear.

Check the radial clearance of every gear with micrometer.

Standard clearance:

For the transmission made by Shang Chi:0.05mm

(1st,2nd,and 3rd gear position)

For the transmission made by Tang Chi:

(0.009

0.033)mm(2nd and 3rd gear position)

(0.009

0.032)mm(1st gear position)

Max clearance

For the transmission made by Shang Chi:0.05mm

For the transmission made by Tang Chi:0.033mm

(2nd,and 3rd gear position);0.032(1st gear position)

If the clearance value exceeds the limit above , the gear,

needle bearing or shaft should be changed

.

PK

Inspection for output shaft and 1st gear shaft sleeve

(a)  Measure the thickness of output shaft flange with callipers

Min thickness

 For the transmission made by Shang Chi:4.75mm

 For the transmission made by Tang Chi:4.65mm

(b)  Measure the thickness of flange of 1st gear shaft sleeve

with callipers

Min thickness

  For the transmission made by Shang Chi:3.87mm

  For the transmission made by Tang Chi:3.795mm

(c)  Measure the outside diameter of the journal of output shaft

with micrometer.

Min diameter:19.216mm

Gear of 2nd gear:37.984mm

Gear of 3rd gear:34.984mm

Transmission

Output Shaft Assembly(Inspection of Output Shaft Assembly)

1st gear position

2nd gear position

3rd gear position

MT-24

(d)  Measure the outside diameter of the gear sleeve of 1st gear

with micrometer.

Min diameter:38.984mm.

(e)  Measure the radial run out torlerance of the shaft with

micrometer.

Max radial run out torlerance

  For the transmission made by Shang Chi:0.015mm

  For the transmission made by Tang Chi:0.05mm

4.

Check the synchronized ring

(a)  Turn the ring ,and put it into to check the brake action.

(b)  Measure the gap between the rear of the synchronized ring

and gear end.

Standard clearance:

  For the transmission made by Shang Chi:(1.5

1.8)mm

  For the transmission made by Tang Chi:(1.2

0.4)mm

Limit clearance:0.8mm

5.

Measure the clearance between the gear shifting fork

and meshing sleeve

Check the clearance between the gear sleeve and gear shifting

fork with feeler gauge.

Max clearance

  For the transmission made by Shang Chi: 0.54mm

  For the transmission made by Tang Chi: 0.7mm

Transmission

Output Shaft Assembly(Inspection of Output Shaft Assembly)

MT-25

Transmission

Output Shaft Assembly(Assembly of Output Shaft Assembly)

Assembly of output shaft assembly

1.

Assembly of synchronizer

(a)   Insert the synchronizer hub and sliding block into the gear

sleeve.

(b)  Install the spring expansion ring under the  sliding block.

Note:The openings of spring expansion ring should be

staggered during installation .

2.

Install the gear components of 3rd gear and synchronizer

of 3rd and 4th gear on the output shaft.

(a)   Smear the gear oil on the shaft and the needle bearing of

3rd gear.

(b)   Put the synchronized ring on the components of gear of 3rd

gear, and align the notch of synchronized ring and sliding

block.

(c)   Install the needle bearing into gear components of 3rd gear.

(d)   Assembly the gear components of 3rd gear and synchro-

nizer of 3rd and 4th gear with pressing machine.

3.

Assembly of snap ring for shaft

To choose one snap ring which make the axial clearance be

Min, and install it on the shaft.

3/4 gear posititon

1/2gear posititon

front

front side

MT-26

Transmission

Output Shaft Assembly(Assembly of Output Shaft Assembly)

Standard clearance:

 For the transmission made by Shang Chi

(0.15

0.33)mm

 For the transmission made by Tang Chi:

(0.09

0.33)mm

5.

Assembly for the gear components of 2nd and

synchronizer of 1st and 2nd gear

(a)   Smear the gear oil on the needle bearing of gear of 2nd

gear.

(b)   Put the synchronized ring on the gear,and align the notch

and shift key.

(c)   Install the needle bearing into the gear components of 2nd

gear.

(d)   Assembly the gear components of 2nd gear and meshing

sleeve of synchronzer of 1st and 2nd gear with pressing

machine.

6.

Check the axial clearance of gear components of 2nd

gear

Measure the axial clearance of gear components of 2nd gear

with feeler gauge.

Standard clearance:

For the transmission made by Shang Chi:(0.15

0.33)mm

For the transmission made by Tang Chi:(0.09

0.33)mm

7.

Assembly the locking ball and gear components of 1st

gear

(a)   Install the locking ball into the shaft.

 

 

 

 

 

 

 

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