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

TF-12

Transfer Box

Disassembly of Transfer Box

1. fork-type flange

2. dust cover

3. fork-type flange assembly

4. transfer box front housing

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

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.

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

TF-13

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.

TF-14

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

1. oil seal

2. transfer box front housing

3. gear ring

4. locating pin

Transfer Box

Transfer Box Assembly

Transfer box assembly

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.

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.

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.

TF-15

1. shift guide shaft

2. torsion spring

3. electric shift convex plate

4. gasket

1. torsion spring

2. gasket

3. shift shaft

Transfer Box

Transfer Box Assembly

1. torsion spring

2. gasket

3. shift shaft

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.

TF-16

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

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.

TF-17

1.25-1.75mm

12.70mm

(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

(27

46)N

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

(203

244)N

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

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

Transfer Box

Transfer Box Assembly

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

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

TF-19

Transfer Box

Transfer Box Assembly

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

TF-20

convex plate

groove

1. electric shift convex plate

2. torsion spring

3. shift shaft

4. gear down shift fork assembly

5. shift fork

6. gear shifting shaft

Transfer Box

Transfer Box Assembly

1. clutch washer assembly

2. snapping ring

3. ball bearing

4. transfer box rear body

5. nut

6. oil seal

7. bearing

8. needle bearing

11. Rear cover Assembly

Mount the parts into the rear cover according to the following

process:

(a)

Locate the rear cover on the suitable press machine, the

coupling face of the rear cover shall face upward and

parallel with the work face of the press machine.

(b)

Locate the needle bearing, of which the marked end

facing upward, and press it in the rear cover until the

upper end of needle bearing is 40.47

40.97 lower than

the coupling face of the rear cover that matches with the

front housing.

(c)

Press the ball bearing in the rear cover and mount the

snapping ring well.

(d)

As for the electric shift transfer box, the parts shall be

encased according to the following process:

(1)

Confirm the four O-rings are set on the clutch

washer assembly (one O-ring is located on the coil,

the other three on studs).

Mount on the clutch coil assembly, of which the

wire and stud shall protrude out the rear cover, take

notice not to damage the wire when screwing up the

nuts.

Fastening torque

11)N

(2)

Encase the motor bearing and oil seal in the rear

cover.

(e)

As for the electric shift transfer box, encase the as-

sembled electric shifting cam group and clutch shell in

the process as follows:

(1) Put down the electric shifting cam group as shown in

the drawing.

(2) Hold the shift guide shaft downward and raise lightly

the toggle fork assembly. Run the electric shifting

cam group in place, so that the contact roller on

deceleration toggle fork assembly enters in the groove

of shifting cam, and the projecting part of lock

toggle fork is at the rear end of the shifting cam, and

then take reduce the component elements in the

transfer box housing, meanwhile, joint the shift

shaft on the pin in transfer box housing.

(3) Locate the clutch shell well through the shift exter-

nal gear sleeve and mount on the snapping ring.

TF-21

(d)

All of the following aligning conditions shall be satisfied

when the rear cover assembly is mounted on the transfer

box front housing:

Align the pin hole in the rear cover to the pin on the

housing.

Align the rear output shaft to the inner bearing in

cover rear hole.

Align the blind hole in the rear cover and the shift

guide shaft; ensure the return spring is not tilted.

Check the hole in velocity sensor of the rear cover

with a pen.

Align the shift shaft and the inner bearing in rear

cover.

(e)

Screw up the nine bolts after locating the sign bolts

correctly.

(f)

Encase the gear of odometer in the rear cover assembly

through the spline of the rear output shaft.

(g)

Press the new oil seal in the cover assembly

Transfer Box

Transfer Box Assembly

1. bolt

2. wire harness

3. magnet

4. return spring

5. shift guide shaft

6. transfer box rear

body assembly

7. sign board

8. driving gear of Odometer

9. oil seal

10. transfer box front housing

1. locating pin

2. output shaft

3. shift shaft

4. return spring

5. shift guide shaft

6. output shaft.

12.

Assembly of Rear Cover

Mount the aforesaid accomplished cover assembly on the

transfer box housing according to the following process:

(a)

Mount the return spring on the shift guide shaft of the

transfer box.

(b)

Mount the magnet in the groove of the housing.

(c)

Coat the Letai glue 598 of 1.6mm on the coupling face of

housing, steer clear of the screwed hole when coating

continuously.

Notice: try to button the rear cover on the transfer box front

housing with the moderate force during the following process.

Not too much force is required when mounting the rear cover

on the front housing when all aligning conditions are satisfied,

in case the rear cover cannot be mounted on the front housing,

take down the rear cover assembly to check the aligning

condition

1. wire harness clip

2. motor assembly

3. bolt

4. sign board

TF-22

Transfer Box

Transfer Box Assembly

1. motor assembly

2. shift shaft

1. fixed sensor bracket

2. bolt

3. sensor assembly

4. velocity sensor

5. o-ring

6. motor assembly

7. bolt

8. gasket

9. transfer box rear body

12. Mount the external electric shifting element (for the elec-

tric shift transfer box)

(a)

Locate the motor assembly by aligning the triangle

groove on motor to the shift shaft.

(b)

Move the motor to combine the shift shaft and keep it

close to the rear cover. Then run the motor clockwise

until the motor locates the correct place and the mooting

holes are aligned.

(c)

Mount the O-ring on the velocity sensor and encase the

velocity sensor assembly in rear cover. A clip and three

bolts shall be mounted on the velocity sensor.

Fastening torque

11)N

(d)

Mount the bolts and gaskets on the end of motor clip.

Fastening torque

11)N

TF-23

Transfer Box

Transfer Box Assembly

1. transfer box rear body

2. flange

3. oil seal

4. gasket

5. nut

6. oil plug

13. Flange assembly

The parts mount process is as follows:

(a)

Encase the two oil plugs in the rear cover.

(b)

Encase the flange, sealing ring and gasket, and then

screw up the nuts.

Fastening torque

(203

244)N

TF-24

Transfer Box

Washing, Checking, Up-Keeping and Exchanging (Washing)

Washing

Notice: check the metal rag around the magnet first before washing, large granule or irregular metal

granule shows the disintegratation or similar damage. Small or fine metal granule shows the uneven

or serious wear. If the metal rag is founded, notice shall be taken on damage and wear inspection

during checking the rotating parts and the element matched with the rotating parts.

(a)

Common washing

Wash the parts in cleaning agent to clean away the old lubricant and deposit. Clean away the deposit in oil hole

with brush. Take notice not to scrape the metal coupling face when washing the parts cannot be cleaned with

brush.

(b)

Dry the washed parts by blowing

Dry the washed parts by blowing the low-pressure compressed air (max pressure is 137.9kPa), because cloth

thread may be left during cleaning the parts with cloth. The bearing shall be held by hand to prevent it from

rotating when blowing it.

(c)

Bearing lubrication

The ball bearing and needle bearing shall be lubricated with the lubricant for transfer box after washing. As

the non-lubricated bearing may cause damage when be dry. Cover the lubricated bearing to prevent dust

entering in.

Washing, Inspection, Maintenance or Change

TF-25

(b)

Normal gear grinding trace.

Transfer Box

Washing, Checking, Up-Keeping and Exchanging (Checking)

Checking

Common Checking process

Check all parts by visual check to see whether there is damage

or serious or uneven wear (parts needed be substituted by new

parts such as O-ring, oil seal and etc. shall be excluded).

Abandon the damaged or weary parts that will affect on their

performance. The check items are as follows:

Burr: tips protruded from the material regionally

Rag: broken small blocks or particles

Crack: surface thread showing the material is partly or

completely separated.

Excessive abrasion

Refer to the serious or obvious abra-

sion beyond of application limit.

Reduction change

Material slip caused by the heavy

pressure on part of it.

adhesive bonding

Granules of the soft metal are dis-

persed and bonded on the hard metal surface.

Ditch trance: partial crack or trough that means the material

transfer instead of material loss.

Pitting corrosion

Damages to the metal surface caused by

pressure, which are displayed due to color change caused

by heat generated by metal friction.

Step wear

a weary step may be seen or felled between the

neighboring interface or between the non-touching face

due to the excessive wear.

Uneven wear: Partially, unevenly distributed wear, which

includes holes, bright spots, uneven polishing or other

visual drawbacks.

Gear or Chain sprocket tooth inspection

Check the gear and chain sprocket tooth according to the

following process:

(a)

Normal gear shaving trace.

normal gear shaving trace

normal gear grinding trace

TF-27

Transfer Box

Washing, Checking, Up-Keeping and Exchanging (Checking)

(h)

Acceptable contact area deflecting to the tooth top.

(i)

Unacceptable contact area deflecting to the tooth top,

which must be changed.

(j)

Acceptable contact area deflecting to tooth root.

(k)

Unacceptable contact area deflecting to tooth root, which

must be changed.

Key tooth inspection

Check the broken or peeled spline teeth. The spline teeth may,

if only small part is peeled off, be repaired in the same way as

that for the gear teeth, and can be reused. In case the spline

tooth is broken, the spline must be abandoned. The contact

type of spline is not the same as that for gear; however, spline

that shows step sliding must be abandoned.

Great Wall. Service manual for chassis and body (2006) - page 9