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

SA-31

Mount on the inner race and roller assembly of front hub

bearing (outer).

After coating 4 to 5 mm lithium base grease on the outer race

of bearing, put in the inner race and roller assembly of front hub

bearing (outer), and then plaster the lubricant.

Mount the front wheel hub and front brake disc on the

steering knuckle.

Coat a little lubricant on the steering knuckle where the oil seal

locates, and mount the front wheel hub and front brake disc on

the steering knuckle, then mount on the stop washer.

Adjust the preload

(a)

Mount on the steering knuckle nut and screw up them

according to the specified torque.

Tighten torque: (100-120)N

(b)

Run the front wheel hub about 1/4-1/3 round, and seat the

bearing.

(c)

Loosen the steering knuckle nut to ensure the front brake

disc can run freely. Screw up the steering knuckle nut

again according to the specified torque.

Fastening torque

25N

(d)

Mount on the lock plate and another steering knuckle nut.

Tighten torque

60N

(e)

Hold the front wheel hub bolts with a spring-tension

meter and drag the meter slowly in the direction of the

tangent line of this spot.

Suitable tension range: (29-54)N

The nuts should be retightened until falls within the suitable

range if the tension force is overlarge or over small.

(f)

Check the bearing and ensure that the clearance, which is

not larger than 0.05 mm, is not excessive.

(g)

Measure the bouncing value of the front brake disc face.

Bouncing value should not be above o.11mm.

Suspension System and Automobile Axle (SF/2WD)

Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-32

(h)

Bend one tooth of the lock plate inside and other teeth

outside to lock the steering knuckle nut.

Mount on the liner and the steering knuckle outer flange

cap.

Fastening torque

(23-29)N

Mount the brake caliper

(a)

Mount the brake caliper on the steering knuckle and

screw up the bolts according to the specified torque.

Fastening torque

123N

(b)

Connect the Bundy tube.

Fastening torque

(20-22)N

Check the height of the brake liquid level and add the

brake liquid as requirement, exhaust the gas in the

braking system.

Steering knuckle

Dismantle of Steering Knuckle

Tear down the brake caliper, front wheel and the front

brake disc.

Tear down the dust cover, and the brake shell.

Tear down the steering knuckle arm from the steering

knuckle.

Suspension System and Automobile Axle (SF/2WD)

Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-33

Tear down the vibration damper from the lower arm.

Tear down the transverse stabilizer rod from the lower

arm.

Tear down the steering knuckle;

(a)

Tear down the split pin and groove nut of upper ball stud.

(b)

Take apart the steering knuckle from the upper ball stud

with special service tool.

(c)

Tear down the split pin and groove of the lower ball stud.

(d)

Take apart the steering knuckle from the lower ball stud

with special service tool.

(e)

Press down the lower arm to tear down the steering

knuckle.

Suspension System and Automobile Vehicle (SF/2WD)

Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-34

Tear down the lower ball stud assembly from the steering

knuckle.

Inspection on and Change of Steering

Knuckle

Check the steering knuckle.

Check the steering knuckle with the dye penetration agent to

see whether there is crack or not.

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

Mount of Steering Knuckle

Mount the lower ball stud on the steering knuckle.

Connect the lower ball stud and steering knuckle with bolts,

which are tightened according to the specified torque.

Fastening torque

(70-90)N

Mount on the steering knuckle

(a)

Press down the lower arm to mount on the steering

knuckle.

(b)

Mount on the lower ball stud, groove nut and screw up the

nuts according to the specified torque and then mount on

the split pin.

Fastening torque

(132-152)N

Suspension System and Automobile Axle (SF/2WD)

Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-35

(c)

Mount on the upper ball stud and the groove nut that are

screwed up according to the specified torque, and then

split pin.

Fastening torque

(132-152)N

Mount the stabilizer rod on the lower arm.

Fastening torque

(20-26)N

Mount the vibration damper on the lower arm.

Fastening torque

(127-147)N

Mount the steering knuckle arm and the brake oil pipe

bracket on the steering knuckle.

Coat the sealing agent 1271 on the bolt thread.

Fastening torque

180N

Mount the dust cover and brake shell, and align the

locating hole of the dust cover with the groove of the

steering knuckle to ensure that the dust cover is concen-

tric with the steering knuckle.

Fastening torque

(25-29)N

Mount the front wheel hub and the front brake disc as well

as the brake caliper.

Check the height of brake liquid level and add the brake

liquid as requirement, then exhaust the gas in the brak-

ing system.

Suspension System and Automobile Axle (SF/2WD)

Front Wheel Hub and Steering Knuckle (Steering Knuckle)

SA-36

Front Suspension

Elemtents figures

Suspension System and Automobile Axle(SF/2WD)

Front Suspension

upper swing arm
shaft

upper arm

transverse
stabilizer rod

vibration
damper

lower arm shaft bush
pinch-off gasket(small)

lower arm

: specified torque

Parts that cannot be reused after being used

178

225

142

137

142

upper arm shaft
bush(short)

upper arm shaft bush and tube(long)

torsion bar yoke

upper arm shaft bush
pinch-off gasket(large)

upper arm shaft bush pinch-off
gasket(small)

upper ball stud

eccentric

gasket

lower arm shaft bush

and tube

lower ball
stud

lower arm shaft bush
pinch-off gasket(large)

SA-37

Ball Stud

Inspection on Ball Stud

Check the lower ball stud to see whether it is excessively

loose:

(a)

Raise the vehicle with a jack and then support it with the

bracket.

(b)

Press down the brake pedal after verifying that the front

wheel is straightly forward.

(c)

Move the arm vertically to check whether the clearance

of lower ball stud is over large.

(Max vertical clearance): 0.5 mm

Check whether the upper ball stud is loose excessively;

Move the wheel vertically to check whether the clearance of

the ball stud is over large.

(Max vertical clearance): 0.5 mm

Check the rotating performance of the ball stud:

(a)

Tear down the ball stud;

(b)

Shake the ball stud column several times before mount-

ing on the nut, as shown in the drawing.

(c)

Rotate the nut continuously with the torsion meter at the

speed of one round each 2 to 4 seconds, read the meter

reading at the fifth round.

Fastening torque(running)

lower ball stud

(0.1-4)N

Upper ball stud: (0.1-4)N

Disassembly of Ball Stud

Tear down the steering knuckle, steering knuckle arm

and the lower ball stud assembly.

Tear down the ball stud from the steering knuckle;

Tear down the ball stud from the upper ball stud.

Suspension System and Automobile Axle (SF/2WD)

Front Suspension (Ball Stud)

SA-38

Mount of Ball Stud

Mount the upper ball stud on the upper arm;

Fastening torque

(27

Mount the lower ball stud on the steering knuckle;

Fastening torque

(80

0)N

Mount on the steering knuckle and hub brake disc

assembly

(See Page SA-34)

Suspension System and Automobile Axle (SF/2WD)

Front Suspension (Ball Stud

Torsion Rod Spring)

Torsion Rod Spring

(see Page SA-19)

SA-39

Lower arm and Vibration Damper

Disassembly of Lower Arm

Tear down the transverse stabilizer rod;

Tear down the vibration damper;

Disconnect the lower arm ball stud seat and the lower

ball stud;

Remove the cotter pin and the groove nut.

Tear down the lower arm

(a)

Make a mark on the mounting position of the eccentric

gasket.

(b)

Tear down the lower arm.

Suspension System and Automobile Axle (SF/2WD)

Front Suspension (Lower Arm and Vibration Damper)

SA-40

Change of Lower Arm Shaft Bush and Tube

Tear down the lower arm shaft bush and shaft tube:

(a)

Tear down the large and small pinch-off gaskets of the

lower arm shaft bush first.

(b)

Tear down the lower arm shaft bush and tube.

Mount the lower arm shaft bush and tube.

(a)

Press down the lower arm shaft bush and tube.

(b)

Press down the large and small pinch-off gaskets of the

lower arm shaft bush.

Mount of Lower Arm

Mount on the lower arm

Align the marks on the eccentric gasket and on the frame, and

then screw up the lower arm bolt.

Connection for lower ball stud and lower arm:

Mount the lower ball stud and the lower arm ball stud seat

together.

Fastening torque

(142

0)N

Vibration damper mount

Mount the vibration damper on the lower arm bracket;

Fastening torque

(137

0)N

Suspension System and Automobile Axle (SF/2WD)

Front Suspension (Lower Arm and Vibration Damper)

SA-42

Upper Arm

Dismantle of Upper Arm

Tear down the torsion rod spring:

(See page SA-19)

Tear down the upper ball stud:

(a)

Support the upper arm with a jack.

(b)

Tear down the four sets of bolt and nut.

Upper arm dismantle

Tear down the bolts to take down the upper arm.

Change of the Upper Arm Shaft Bush

(Short) and the Upper Arm Shaft Bush

and Tube

Tear down the upper arm shaft bush (short) and the

upper arm shaft bush and tube (long)

(a)

Tear down the torsion bar yoke, the nuts as well as the

large and small pinch-off gaskets of the upper arm shaft

bush.

(b)

Push out the upper arm shaft bush (short) and upper arm

shaft bush and tube.

Mount on the upper arm shaft bush (short) and the upper

arm shaft bush and tube (long):

(a)

Press the upper arm shaft bush and tube (long) in the

upper arm, and encase the upper swing arm shaft, and

then encase the upper arm shaft bush (short).

(b)

Mount on the large and small pinch-off gaskets of upper

arm shaft bush and screw up the nuts.

Fastening torque

(225

(c)

Mount on the torsion bar yoke.

Notice: the notch of torsion bar yoke should face

downward;

Fastening torque

(89

Suspension System and Automobile Axle (SF/2WD)

Front Suspension (Upper Arm)

SA-43

Mount of Upper Arm

Screw up the axle nut of upper arm according to the

specified torque;

Fastening torque

(225

Mount on the upper arm;

Screw up the three bolts of the upper swing arm shaft according

to the specified torque;

Fastening torque

(178

5)N

Connect the upper arm ball stud with the upper arm;

Use four sets of bolt and nut to connect the upper arm ball stud

and the upper arm.

Fastening torque

(27

Mount the torsion rod spring;

Check the Alignment of Front Wheel:

(See Page SA-6)

Suspension System and Automobile Axle (SF/2WD)

Front Suspension \(Lower arm, Guide Lever and Transverse Stabilizer Rod)

Guide Lever

(See page SA-26)

Transverse Stabilizer rod

(See page SA-27)

SA-44

Front Wheel Hub and Steering Knuckle

Element Figure

Suspension System and Automobile Axle (SF/4WD)

Front Wheel Hub and Steering Knuckle

lock ring

cushion block

nut

lock ring

cushion
block

shock
absorber

upper arm

transverse stabilizer rod

bolt

transverse stabilizer
rod gasket

rubber snubber
washer

stabilizer rod limit tube

brake
caliper

rubber
snubber
washer

constant speed
drive shaft

needle
bearing

steering knuckle

steering knuckle
small sleeve

retainer ring

washer-spline of
steering knuckle
shaft

thrust plate-
steering knuckle

inner oil

seal- drive shaft

brake oil pipe bracket

steering
knuckle arm

brake shell

dust cover

oil seal -

front hub

front hub bearing
(inner)

front wheel hub and
front brake disc

stop washer

lock plate

front hub bearing
(out)

steering knuckle
big nut

free wheel hub
noumenon

gasket

free wheel
hub cap

gasket

liner

lower ball stud

Parts that cannot be reused after being used

specified torque

135-155

6-12

25-29

70-90

132-152

20-26

180

127-147

132-152

123

SF 4WD

transverse stabilizer rod gasket

transverse stabilizer
rod gasket

SA-45

Tear down the free hub.

Tear down the retainer ring and the axle spine of washer-

steering knuckle:

Tear down the retainer ring with the pliers for retainer ring, and

take down the axle spline of washer-steering knuckle by hand.

Tear down the front wheel hub and front brake disc:

(a)

Prize up the lock plate with screwdriver.

(b)

Tear down the steering knuckle nut with special service

tool to take out the lock plate.

(c)

Tear down another steering knuckle nut with special

service tool to take out the stop washer.

(d)

Tear down the front wheel hub and the front brake disc.

Front Wheel Hub

Disassembly of Front Wheel Hub

Tear down the brake caliper:

(a)

Tear down the Bundy tube from the brake caliper and

block the pipeline of Bundy tube with cork.

(b)

Tear down the brake caliper from the steering knuckle.

Suspension System and Automobile Axle (SF/4WD)

Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

SA-46

Tear down the front hub, the oil seal and the inner race

of front hub bearing (inner)

(a)

Prize out the oil seal.

(b)

Take out the inner race of front hub bearing (inner).

Inspection on and change of the outer race of front hub

bearing

(a)

Check each bearing:

Wash the inner and outer races of each bearing to check

their wear or damage situation.

(b)

Tear down the outer race of each bearing:

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

Notice: bind the inner and outer races of the same

bearing together to prevent from mixing.

Inspection and change for front brake disc

(a)

Check the wear situation of the front brake disc.

(b)

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

bolts, which are tightened diagonally with moment span-

ner according to the specified torque.

Fastening torque

(70-80)N

(d)

Make the dynamic balance test on the dynamic balancer,

and the amplitude value displayed should not be smaller

than 13.5g under the condition that the measuring rotat-

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

of 786 r/m, otherwise, tap the counter balanced clip,

which is 4g each, in the corresponding position, the clip

number should not be more than 4.

(e)

Tap in the new bearing outer race carefully with the

special service tool.

Notice: the inner and outer races of the same bearing

should be changed in one time.

Suspension System and Automobile Axle (SF/4WD)

Front Wheel Hub and Steering Knuckle (Front Wheel Hub)

Great Wall. Service manual for chassis and body (2006) - page 13