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

PR-12

Drive Shaft

Mount of Drive Shaft

(2WD)

Insert the universal joint yoke in the gearbox.

(a)

Tear down the SST tools.

(b)

Push the universal joint yoke into the gearbox.

Connect the universal joint flange of the rear joint of rear

axle drive shaft and the relative the differential flange.

(a)

Align the assembly marks on the two flanges and connect

the flanges with four sets of bolt and nut.

(b)

Screw up the sets of bolt and nut according to the

specified torque.

Fastening torque

(74

5)N

Mount the center support bearing on the frame beam

(three-joint type)

(a) Use two bolts to mount the center support bearing on the

frame beam and tighten them manually.

(b) Check the bearing seat, which shall be vertical with the

drive shaft, and change it where necessary.

that the central lines of the central bearing and the bear-

ing seat shall be the same when the vehicle is in the non-

loaded stage. And adjust the bearing seat only it is

necessary.

(d) Screw up the mounting bolts according to the specified

torque.

Fastening torque

(40

5)N

(4WD)

Connect the universal joint flange fork of the front axle

drive shaft with the flange that matches with the transfer

box.

Align the assembly marks and use four sets of bolt and nut to

connect the flange fork with the flange, screw up the sets of bolt

and nut according to the specified torque.

Fastening torque

(74

5)N

forward

SST

assembly mark

PR-13

Drive Shaft

Mount on the front axle drive shaft.

Mount on it and screw up the four bolts according to the

specified torque.

Fastening torque

(74

5)N

Connect the universal joint flange fork of the rear axle

drive shaft on the relative differential flange.

(a)

Align the assembly marks on flanges and connect the

flanges with four sets of bolt and nut, and

(b)

Tighten the sets of bolt and nut according to the specified

torque.

Fastening torque

(74

5)N

Mount the center support bearing on the frame beam

(three joint type)

(a)

Use two mounting bolts to mount the center support

bearing on the frame beam and screw up them manually.

(b)

Check the bearing seat, which shall be vertical with the

drive shaft, and adjust the bearing seat when necessary.

(c)

Check the central line of the central bearing. The central

line of the central bearing shall be the same with that of

the bearing seat when vehicle is in the non-loaded stage.

(d)

Adjust the bearing seat if necessary, and

(e)

Screw up the mounting bolts according to the specified

torque.

Fastening torque

(40

5)N

assembly mark

forward

SA-1

Suspension System and Automobile Axle

Page

Troubleshooting .......................................................... SA-2
Alignment of Front Wheel ............................................ SA-3
(Dr/2WD)
Front Wheel Hub and Steering Knuckle ...................... SA-10

Front Wheel Hub ..................................................... SA-11
Steering Knuckle ..................................................... SA-14

Front Suspension ........................................................ SA-16

Ball Stud .................................................................. SA-17
Torsion bar .............................................................. SA-19
Lower Arm and Vibration Damper ........................... SA-21
Upper Arm ............................................................... SA-24
Guide Level ............................................................. SA-26
Lateral Stabilizer ..................................................... SA-27

(SF/2WD)
Front Wheel Hub and Steering Knuckle ...................... SA-28

Front Wheel Hub ..................................................... SA-29
Steering Knuckle ..................................................... SA-32

Front Suspension ......................................................... SA-36

Ball Stud ................................................................... SA-37
Torsion bar ............................................................... SA-38
Lower Arm and Vibration Damper ............................ SA-39
Upper Arm ................................................................ SA-42
Guide Level .............................................................. SA-43
Lateral Stabilizer ....................................................... SA-43

(SF/4WD)
Front Wheel Hub and Steering Knuckle ....................... SA-44

Front Wheel Hub ...................................................... SA-45
Steering Knuckle ..................................................... SA-49

Constant Speed Drive Shaft ........................................ SA-54
Front Speed Reducer .................................................. SA-57

Change of Oil Seal of Driving Bevel Gear Of
Front Speed Reducer ............................................. SA-57
Dismantle of Front Speed Reducer ......................... SA-61
Change of Axle Shaft Oil Seal ................................. SA-63
Disassembly and Assembly of Front Speed Reducer .... SA-65
Assembly of Front Speed Reducer ......................... SA-74

(Back)
Rear Axle Shaft ........................................................... SA-79
Rear Speed Reducer .................................................. SA-83

On-vehicle Change of Oil Seal of Main Teeth ......... SA-84
Dismantle of Rear Speed Reducer .......................... SA-85
Disassembly of Rear Speed Reducer ..................... SA-85
Assembly of Rear Speed Reducer .......................... SA-89
Mount of Rear Speed Reducer and
Differential Assembly .............................................. SA-94

Rear Differential .......................................................... SA-95
Rear Suspension ......................................................... SA-97

SA-2

Troubleshooting

Suspension System and Automobile Axle

Troubleshooting

Change the tire or inflate to the proper pressure

Balance the wheels

Change vibration damper

Check Alignment of Front Wheel

Change or adjust the wheel bearing

Check ball joint) or liner

Tighten or change steering linkage

Adjust or repair the steering device

Discharge the oil and change with new one

Check the wandering clearance

Check the gears

Change the bearing

Tighten or change the bearing

Trouble

Causes

Inspection items

Body wandering/body

dragging

Tire wear or improper air inflation

Incorrect alignment of front wheel

Over-tightened wheel bearing

Part looseness or damage of front/rear sus-

pension

Wear or looseness of steering rod system

Poor connection or damage of steering de-

vice

Inflate the tire to the proper pressure or change

the tire.

Check the situation of alignment of front wheel

Adjust the wheel bearing

Tighten or change the suspension element

Tighten or change the steering rod system

Adjust or repair the steering device

Body sink

Overloaded vehicle

Wear of vibration damper

Poor spring performance

Check the loading mass

Change vibration damper

Change spring

Left-right vibration/up-

down bouncing

Improper air inflation

Bending or damaged lateral stabilizer

Vibration damper wear

Inflate the tire to suitable pressure

Change stabilizer

Change vibration damper

Front wheel vibration

Tire wear or improper air inflation

Imbalance of wheels

Vibration damper wear)

Improper Alignment of Front Wheel

Wheel bearing wear or improper adjustment

Ball joint or liner wear

Steering linkage looseness or wear

Poor adjustment or damage of steering mecha-

nism

Abnormal tire wear

Improper air inflation

Vibration damper wear

Poor Alignment of Front Wheel

Suspension system wear

Inflate the tire to the proper pressure

Change vibration damper

Check the Alignment of Front Wheel

Change suspension element

Speed reducer leakage

Over-high oil level or improper oil quality

Oil seal wear or damage

Flange looseness or damage

Discharge the oil for change

Change oil seal

Tighten or change the flange

Noise inside the

axleNoise inside the axle

Over-low oil level or inferior oil quality

Over-large wandering clearance between

driving bevel gear and driven bevel gear

Wear and disintegration of driving bevel

gear and driven bevel gear

Bearing wear of driving bevel gear

Bearing wear of rear axle shaft

Bearing looseness or wear of speed reducer

SA-3

Suspension System and Automobile Axle

Alignment of Front Wheel (Dr SL SK SY SJ)

Alignment of Front Wheel

(Dr SL SK SY SJ)

Inspection should be conducted for the following items to

remove the trouble

(a)

Check the tire abrasion and air inflation situation

Tire inflation pressure:

Front (220

0)kPa

Back (240

0)kPa

(b)

Check the front wheel bearing to see whether it is loose.

(c)

Check the front suspension to see whether it is loose.

(d)

Check the steering driving device to see whether it is

loose, and

(e)

Check the front vibration damper work to see whether it

is loose.

Measure the ground clearance of the chassis.

Chassis ground clearance:

295

SL SK

(255

2)mm

(310

2)mm

(295

1)mm

If the chassis ground clearance of the vehicle is sub-standard,

push down the body or raise it for a trial adjustment, if fails,

check the spring or suspension element to see whether they are

normal.

Remarks: adjust the chassis ground clearance to a specified

value before checking the Alignment of Front Wheel

parameters.

Mount on the four-wheel locating device.

The mount should be conducted according to the manufacturerís

instructions.

SA-4

Suspension System and Automobile Axle

Alignment of Front Wheel (Dr SL SK SY SJ)

Adjustment for inner tilt angle of kingpin, outer tilt angle

of front wheel and back tilt angle of kingpin

Item

Inner tilt
angle of
kingpin

Outer tilt
angle of
front
wheel

Applicable vehicle type

Dr SL SK SY

M e c h a n i c
steering

Dr SL SK SY

Power
steering

SL SK SY

Back tilt
angle of
kingpin

M e c h a n i c
steering

Dr SL SK SY

Power steer-
ing

Dr SL SK SY

Location parameter

Adjust the wheel angle

Take apart the limit bolts of the steering knuckle to check the

steering angle A of inner wheel.

Inner wheel steering angle

Dr SL SK SY

( 36

)

( 32

)

Remark: The wheel should not contact the body or brake hose

when the steering wheel reaches the limit position.

In case the steering angle of inner wheel doesnít conform to the

standard value, adjust the wheel angle through adjusting the

limit bolts of the steering knuckle.

Fastening torque

(90

0)N

m(SJ)

If the wheel angle fails to be adjusted within the standard value,

change the weary or damaged parts of steering system.

If the tilt angle fails to fall within the specified values, make an

adjustment through adding or reducing the gaskets on the

location of upper arm.

Gasket thickness: 3.0, 2.0 and 1.0mm

Once the gasket thickness increases by 1mm, the outer tilt

angle of wheel will change by 7', while the back tilt angle of

kingpin will change 20'.

After the wheel outer tilt angle and the back tilt angle of kingpin

are adjusted, if the inner tilt angle of kingpin still fails to the

specified value, check the steering knuckle or front wheel to

see whether they are bending or loose.

-20

adjusting bolt

outer tilt

angle of

front wheel

inner tilt angle of kingpin

back tilt angle of

kingpin

front

HPM

SA-5

Check the sliding measuring situation.

Check the sliding situation with the sliding measuring tester.

Sliding measuring value:

.5m/km

push forward the vehicle;

forward

A=B

Wheel toe-in adjustment

(a)

Verify that each wheel has been located forward in a line.

(b)

Mark the tire center at the bearing height on the tread of

left and right tire, and measure the distance between the

marks on left and right treads.

(c)

Push forward the vehicle until the mark on the back tread

of tire moves to the front.

Remark: the toe-in measurement should be conducted from the

same spot at the same height.

(d)

Measure the distance between the two marks on the front

of two treads.

Toe-in value: (0-2)mm

(e)

Loosen the clamping bolts of connecting pipe.

(f)

Adjust the toe-in angle through the approach according to

which rotate the left and right drag rod tube by a same

angle.

Remark: check the lengths of the two drag rods to see whether

the two rods are same in length.

Length error of the left and right drag rod should not

be larger than 2.0mm.

(g)

Tighten the clamping bolts.

Fastening torque

(20

) N

(h)

Locate the split pin well.

Suspension System and Automobile Axle

Alignment of Front Wheel (Dr SL SK SY SJ)

SA-6

Suspension System and Automobile Axle

Alignment of Front Wheel

Alignment of Front Wheel (SF)

Alignment of Front Wheel

(SF)

The following items should be checked to remove the

troubles.

(a)

Check the tire abrasion and the air inflation to see it is

suitable or not.

Tire inflation pressure: (250

0)kPa

(b)

Check the front wheel bearing to see whether it is loose.

(c)

Check the front suspension to see whether it is loose.

(d)

Check the steering driving device to see whether it is

loose, and

(e)

Check the front vibration through elastic force test to see

whether it is normal in performance.

Height adjustment of vehicle

Adjust the vehicle height to the standard value so as to make

the Alignment of Front Wheel inspection.

A-B-58 5mm

A: The height of steering knuckle shaft center.

B: The center height of the adjusting cam bolt at front end

The standard value for the unloaded height is: the

difference of the center height of drive shaft climax and

the front adjusting cam bolt is 58.5mm.

Mount on the four wheel locating device

This approach should be conducted according to the detailed

instruction of the equipment manufacturer.

Adjust the outer tilt angle of front wheel and the back tilt

angle of kingpin

The outer tilt angle of front wheel: 0

The back tilt angle of kingpin: 2

Outer inclination of front wheel:

the outer tilt angle of
front wheel

the back tilt angle
of kingpin

front

SA-7

Suspension System and Automobile Axle

Alignment of Front Wheel

Alignment of Front Wheel (SF)

In case the outer tilt angle of front wheel or the back tilt angle

of kingpin fails to conform to the specified value, adjust the

cam forward or backward may amend them.

Wheel angel adjustment

Take apart the limit bolt cap of the steering knuckle to check

the inner wheel steering angle A.

The inner wheel steering angle: =32

Notice:The wheel should not touch the body brake hose

when the steering wheel is rotated to the bottom.

In case the max steering angle is not in the conformity with the

standard value, adjust the wheel angle through the limit bolts

of steering knuckle.

In case the wheel angle still fails to fall within the standard

range, make a inspection and change the weary and damaged

steering mechanism parts.

Wheel toe-in adjustment

Adjust the wheel toe-in according to the following approach

(a)

Raise or reduce the vehicle until the suspension stands in

balance.

(b)

Push the vehicle on the ground 5 meters forward under

the condition that the front wheels locate forward in a

line.

front cam adjustment

rear cam adjustment

reduce

increase

reduce

front

SA-8

Suspension System and Automobile Axle

Alignment of Front Wheel (SF)

(c)

Mark the center of the back of front wheel, and measure

the distance ìBî between the remarks on the left and right

tires.

(d)

Push the vehicle forward so that the mark on the back of

tire moves to the measuring height of the instrument.

Remark: if the tire moves too far, repeat the approach (b).

(e)

Measure the distance ìAî between the marks on the front

of tire.

(f)

Measure the wheel toe-in.

Toe-in = B-A

Inspection standard: (0-2)mm

In case the toe-in fails to conform to the specified value, it can

be amended through adjusting the left and right drag rods.

(g)

Loosen the clamping bolt and nut.

(h)

Adjust the toe-in situation by the approach of rotating the

left and right drag rod by a same angle.

(i)

Ensure the left and the right drag rods are same in length.

forward

move the vehicle forward

front

A=B

SA-10

Front wheel hub and steering knuckle

Element Drawing

front wheel hub snap ring

25-28

front wheel hub oil seal

brake caliper

plain washer

bearing 32007

front wheel hub and
front brake disc

bearing 30205

locking nut

front wheel hub cap

stop washer

dust cover

steering knuckle arm

steering knuckle

85-105

98-118

100-120

132-152

Used component which can not be used any more

: specific torque

front brake shell

Suspension System and Automobile Axle (Dr/2WD)

Front Wheel Hub and Steering Knuckle

SA-11

Take apart the front wheel hub oil seal, the inner race and

roller assembly of bearing 32007.

(a)

Pry out the oil seal.

(b)

Take out the bearing inner race and roller assembly.

Front Wheel Hub

Disassembly of Front Wheel Hub

Take apart the brake caliper.

Take apart the front wheel hub cap.

Take apart the front wheel hub and front brake disc:

(a)

Take apart the split pin to take down the lock cover.

(b)

Screw off the lock nuts of the hub bearing with spanner

and take down the stop washer.

(c)

Take apart the front wheel hub and front brake disc with

the bearing 30205 together.

Disassembly the wheel hub and suspend it with tightwire.

Remark: Donít dismantle the brake hose and brake metal pipe

Takeapart the front wheel hub cap from the gap between the

front wheel hub cap and the front wheel hub.

Bearing outer race inspection and tear-down

(a)

Inspect the bearings

Clean each bearing and check them to see whether there is wear

or damage.

(b)

Take apart the bearing outer race

Tap out the bearing outer race with copper bar and hammer.

Notice: bind the disassembled inner and outer bearing

race together to avoid of mixing.

Suspension System and Automobile Axle (Dr/2WD)

Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-12

Inspection and replacement for front brake disc

(a)

Check the wear situation of the front brake disc. (see Dr

the brake caliper).

(b)

Use the spanner to tear down the bolts that connect the

front wheel hub and the front brake disc.

(c)

Connect the front wheel hub and the front brake disc with

bolt and spring washer, and screw up the bolts with a

moment spanner to the specified torque in the diagonal

order.

Fastening torque

(60-79)N

(d)

Conduct the equilibrium test on the dynamic balancer,

the amplitude value displayed should not be larger than

13.5g under the condition that the measuring rotating

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

786 r/m, when the amplitude value is larger than 13.5 g,

encase the counter balanced clip, which is 4 g each, at the

corresponding phase, the number of the clip encased

should not be more than four.

Bearing outer race change

Press in the new bearing outer space with the special service

tools.

Notice: the bearing inner and outer races should be changed at

one time.

Assembly of Front Wheel Hub

Mount on the Bearing 32007 inner race and roller assem-

bly as well as the front wheel hub oil seal.

Coat the lithium base grease of (4-5)mm on the inner surfaces

of bearing outer race and the front wheel hub, encase the

Bearing 32007 inner race and roller assembly, plaster the

lubricant again. Coat a little lubricant on the lips of front wheel

hub oil seal and then tap it in place.

Notice: do not make the lubricant contact the front brake

disc face.

Mount on the Bearing 32007 inner race.

After coating the bearing outer race with the lithium base

grease of 4-5 mm, encase the inner race and roller assembly of

Bearing 30205, and plaster the lubricant again.

Suspension System and Automobile Axle (Dr/2WD)

Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-13

Mount the front wheel hub on the steering knuckle.

Coat a little lubricant at the position of the steering knuckle

where the oil seal locates, mount the front wheel hub and front

brake disc on the steering knuckle, and then mount on the stop

washer.

Preload adjustment

(a)

Mount on the lock nut and screw up according to the

specified torque.

Fastening torque

(130-150)N

(b)

Run the front wheel hub about 1/4-1/3 of circle, and

combine it with the bearing seat.

(c)

Loosen the locking nut to ensure the front brake disc run

freely, and then screw up the nuts to the specified torque.

Fastening torque

(25-35)N

(d)

Hook the front wheel hub with the spring-tension meter

and pull the spring-tension meter slowly in the tangential

direction of this spot.

The reasonable range of tension force: (16-33)N.

Remark: if the tension force is larger or smaller of the reason-

able range, screw up the nuts again until the tension force falls

within the reasonable range.

(e)

Measure the bouncing value of the front brake disc,

which should not be larger than 0.11mm.

Mount on the lock cover and the split pin

Suspension System and Automobile Axle (Dr/2WD)

Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-14

Tap in the front wheel hub with a rubber hammer

Mount the brake caliper on the steering knuckle.

Fastening torque

(85-105)N

Steering Knuckle

Disassembly of Steering Knuckle

Take apart the brake caliper, the front wheel hub and the

front brake disc.

Take apart the front brake shell:

(a)

Tear down the two bolts (M8X16).

(b)

Tear down the two split pins, grooved nuts, washer and

bolts that connect the steering knuckle arm.

Tear down the steering knuckle

(a)

Support the lower arm with jack;

(b)

Tear down the two split pins and the grooved nuts

(c)

Disconnect the steering knuckle from the upper and

lower ball studs and take apart it.

Inspection on Steering Knuckle

Check the steering knuckle

Check the steering knuckle with the dye penetration agent to

see whether the steering knuckle has a crack or not.

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

changed.

Suspension System and Automobile Axle (Dr/2WD)

Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

Great Wall. Service manual for chassis and body (2006) - page 11