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

SA-63

Tear down the front long semi-axis and the front minor

half-shaft

Pull out the front long and minor semi-axis from the front

speed reducer with tool.

Tear down the front drive axle shaft sleeve and screw off

the bolts connecting the half-shaft sleeve.

Tear down the oil seal - front half-shaft:

Tear down the oil seal-front half-shaft with the special service

tool.

Change of Axle Shaft Oil Seal

snapping ring

front minor half-shaft

front speed reducer and differential

oil seal-front half-shaft

front long

semi-axis

snapping ring

specified torque

Parts that cannot be reused after being used)

Suspension System Automobile Axle (SF/4WD)

Front Speed Reducer (Change of Axle Shaft Oil Seal)

SA-64

Mount on the upper front drive axle shaft sleeve,

Coat the bolt thread with thread locking agent.

Fastening torque

88N

Mount on the new oil seal-front half-shaft:

Press in the new oil seal with the special service tool until it

flush with the outer ending of the oil seal, coat moderate

lubricant on the lips of the oil seal.

Mount on the front long semi-axis and the front minor

half-shaft.

(a)

Mount the new snapping ring on the half-shaft.

(b)

Mount on the long semi-axis and the minor half-shaft

with the special service tool.

Suspension System Automobile Axle (SF/4WD)

Front Speed Reducer (Change of Axle Shaft Oil Seal)

SA-65

Disassembly and Assembly of Front Speed Reducer

Element figure

front minor half-shaft

snapping ring

bearing 31306

front speed

reducer shell

oil-guard tray

flange and dust cover

driving bevel gear oil seal

jacket

oil seal-front half-shaft

Parts that cannot be reused after being used

specified torque

140-210

bearing 32307

driving bevel gear oil seal

speed reducer cover

adjusting washer

bearing 50KB801

cap-differential
bearing

lock plate

adjusting washer

half axle gear thrust

gasket

planetary gear shaft

half-axle gear

planetary gear stop gasket

planetary gear

axle driven bevel gear

front differential housing

adjusting gasket

70-90

retainer ring

front long semi-axis

bearing B36Z-10

oil seal-front half-shaft

adjusting washer

snapping ring

Suspension System Automobile Axle (SF/4WD)

Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-66

Disassembly of Front Speed Reducer

Tear down the speed reducer cover:

Screw off the eight bolts connecting the speed reducer cover.

Tear down the front long semi-axis and the front minor

half-shaft:

Tear down the front long semi-axis and the front minor half-

shaft from the speed reducer assembly with the special service

tool.

Tear down the front drive axle shaft sleeve

Screw off the four bolts connecting the front drive axle shaft

sleeve.

Tear down the oil seal ó front half-shaft;

Tear down the oil seal ófront half shaft with the special service

tool.

Check the swing difference of the axle driven bevel gear;

Run the flange to measure the axle driven bevel gear with the

dial-indicating lamp.

Swing difference)

0.07mm

Max swing difference: 0.07 mm

In case the swing difference is more than 0.07 mm, change the

compete package of driven bevel gear.

Suspension System Automobile Axle (SF/4WD)

Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-67

Check the teeth-clearance of the driving bevel gear and

the axle driven bevel gear:

(a)

Install the dial-indicating lamp and ensure the axial line

of measuring head is vertical with the contact teeth face.

(b)

Run the flanges, and record the clearance values of

driving bevel gear and the axle driven bevel gear.

Specified clearance range

(0.15-0.25)mm

Remark: the inspection should be conducted at no less than

three equally divided spots on the circumference of the axle

driven bevel gear.

Check the engagement trace of the axle driven bevel

gear.

(See page SA-76)

Tear down the flange and dust cover:

(a)

Loosen the riveted position of main-tooth nut with the

hammer and chisel.

(b)

Lock the main-tooth flange with SST to tear down the

main-tooth nut.

Suspension System Automobile Axle (SF/4WD)

Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

(c)

Tap down the driving bevel gear flange and dust cover

with copper bar.

SA-68

10. Tear down the inner race of bearing 31306 with SST;

If the bearing is damaged, change with a new bearing.

11. Tear down the cap-differential bearing.

12. Take out the differential.

13. Take down the outer race of bearing 50KB801 and mark

clearly the left and right parts to avoid of confusion during

reassembling.

Tear down the driving bevel gear oil seal and the oil-

guard tray:

(a)

Tear down the oil seal from the driving bevel gear with

SST.

(b)

Take out the oil-guard tray.

right

left

Suspension System Automobile Axle (SF/4WD)

Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

14. Tear down the adjusting gaskets and clearly mark the left

and right to avoid of confusion during re-assembling.

right

SA-69

15. Tear down the driving bevel gear.

Inspection on and Change of Front Speed

Reducer

Change the bearing 32307 on driving bevel gear

(a)

Press out the inner race and roller assembly of bearing

32307 with the special service tool.

(b)

Press in the new inner race and roller assembly of bearing

32307 with SST.

Change the outer race of bearing 32307:

(a)

Tap down the outer race of bearing 32307 with the copper

bar and hammer.

(b)

Press in the new outer race of bearing 32307 with the

SST.

Suspension System Automobile Axle (SF/4WD)

Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-70

Tear down the inner race and roller assembly of the two

bearings 50KB801 from the differential housing.

Tear down the inner race and roller assembly of bearing

50KB801 with SST.

Tear down the axle driven bevel gear:

Tear down the bolts and lock plate by tapping lightly the axle

driven bevel gear with the copper until tear them down.

Change the outer race of bearing 31306:

(a)

Tap down the outer race of bearing 31306 with copper bar

and hammer.

(b)

Press in the new outer race of bearing 31306 with SST.

Remark: the inner race of the bearing should be changed with

the outer race together.

Differential disassembly

(a)

Tap out the pin with SST.

Suspension System Automobile Axle (SF/4WD)

Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-71

(b)

Tear down the planetary gear shaft to take out the planetary

gear, planetary gear stop gasket, half-axle gear and the

half axle gear thrust gasket

Differential assembly mount

(a)

Clean the differential housing.

(b)

Encase the half-axle thrust gasket in the differential

housing after covering on the half-shaft gear.

(c)

Run the half-axle gear to encase the planetary gear and

planetary gear stop gasket, and put on the planetary gear

shaft.

Remark: The half-axle gear and the planetary gear should run

freely without stagnant.

(d)

Measure the clearance between the half axle gear thrust

gasket and differential housing.

Push the planetary gear to the inside and then measure

the clearance between half-axle gear thrust gasket and

the differential housing with the dial-indicating lamp.

Suitable clearance range: (0.4-0.75)mm

Remark:If the clearance fails to fall within the above-

mentioned range, change the half-axle gear thrust gasket,

and ensure that the thrust gaskets on the both sides are

same thick.

(e)

Tap the pin in the pinhole of differential housing and the

planetary gear shaft with SST, and rivet the hole port so

as to prevent the pin from missing.

Suspension System Automobile Axle (SF/4WD)

Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-72

(f)

Clean the differential housing surface, mount the axle

driven bevel gear on the differential housing with copper

bar.

Notice: align the assembly marks made when

disassembling when mounting the axle driven bevel

gear, and tap in the driven bevel gear evenly alongside

the direction of circumference.

(g)

Mount on the lock plate and screw on the bolts, then lock

the lock plate with the drift pinch and hammer.

Fastening torque

(70-90)N

Notice: the bolts should be screwed up in the diagonal

order in such manner that tighten a little at first, and then

screw up evenly to the specified torque, the lock plate

claw should contact closely the side face of bolt head.

(h)

Press the inner race and roller assembly of bearing

50KB801 in the bearing position at the both sides of

differential housing.

(i)

Put the adjusting gasket in the outer position of the side

bearing of front speed reducer shell.

(j)

Encase another adjusting gasket with the outer race of

bearing 50KB801 in the front speed reducer shell to-

gether with the differential.

Suspension System and Automobile Axle (SF/4WD)

Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

(k)

Mount on the right and left cap-differential bearing, and

screw up the bolts with spanner according to the specified

torque.

Fastening torque

78N

SA-73

(l)

Run the flange to check the swing difference of axle

driven bevel gear.

Max swing difference

0.07mm

Remark: if the requirement is not satisfied, tear down the axle

driven bevel gear from the differential, and then screw up the

bolts again.

Change the bearing of the long semi-axis:

(a)

Take down the retainer ring with the calipers.

(b)

Tear down the grooved ball bearing from the long semi-

axis.

(c)

Mount on the new grooved ball bearing on the long semi-

axis

(d)

Mount on the retainer ring with calipers.

Suspension System and Automobile Axle (SF/4WD)

Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer)

SA-74

Select the adjusting washer ñdriving bevel gear accord-

ing to the experience, and cover it on the driving bevel

gear; and mount the inner race and roller assembly of

bearing 32307 on the driving bevel gear by pressing.

Mount the adjusting washer and sleeve on the driving

bevel gear, and encase it in the front speed reducer cell

through the flange along with the spline, and screw on

the nuts.

Screw up the main-tooth nuts to the specified torque with

the SST.

Fastening torque

(175

35)N

Measure the preload on the driving bevel gear bearing

with torque tester :

New bearing

(1.2-1.7)N

Old bearing

(0.9-1.3)N

Assembly of Front Speed Reducer

Clean the front speed reducer shell; press the outer

races of bearing 31306 and bearing 32307 to mount

them in the speed reducer shell.

Mount he inner race and roller assembly of bearing

31306 as well as the oil-guard tray in the front speed

reducer shell, then press on the driving bevel gear oil

seal with SST.

Notice: coat a little lubricant on the lip open of the oil seal

before encasing it, and the oil seal that is encase in the

front speed reducer shell should be 1.5 mm away from

housing faces.

Encase the flange and dust cover in the front speed

reducer through the lip open of oil seal and press it by

hand.

Suspension System and Automobile Axle (SF/4WD) Front Speed Reducer (Assembly of Front Speed Reducer)

SA-75

Encase in the differential:

(a)

Put the adjusting gasket in the outer position of bearing

at the side of the front speed reducer shell, and then

Encase the differential in the front speed reducer shell, be

sure there is a play between the driving gear and the

driven gear.

(b)

Tap the axle driven bevel gear with the rubber hammer,

so that the bearing 50KB801 on the differential, together

with the adjusting gasket, contact the mounting part of

the side face of speed reducer closely.

Measure the clearance between the axle driven bevel

gear and the driving bevel gear with the dial indicator to

select the adjusting gasket that satisfy the reasonable

play of (0.15-0.25)mm.

10. Select the adjusting washer for the other side:

The thickness of adjusting gasket should eliminate the clear-

ance between the bearing 50KB801 and the front speed re-

ducer shell, on the other side, the adjusting gasket should not

be over thick because the over-thick gasket will lead in too

large pre-tightening force on the bearing 50KB801 of

differential.

11. Tear down the adjusting gasket and differential, and

encase the new adjusting gasket in the front speed

reducer shell, and another adjusting gasket, together

with the differential housing, should be encased in the

front speed reducer shell correctly.

Suspension System and Automobile Axle (SF/4WD)

Front Speed Reducer (Assembly of Front Speed Reducer)

SA-76

12. Measure the clearance between the axle driven bevel

gear and the driving bevel gear with dial indicating lamp.

Clearance: 0.15-0.25mm

Remark: if the play fails to fall within the specified range,

change with the adjusting gasket of other thickness to satisfy

the requirement under the precondition there is no clearance

between the adjusting gasket and the differential.

14. Measure the total preload of the front speed reducer with

torque tester;

Fastening torque

(1.8-2.4)N

13. Mount on the left and the right cap-differential bearing:

Screw up the bolts with spanner to the specified torque;

Fastening torque

78N

15. Check the teeth engagement between the axle driven

bevel gears:

(a)

Coat three or four teeth at three different positions of the

axle driven bevel gear in red

(b)

Hold the flange tightly while rotating the axle driven

bevel gear.

(c)

Check the teeth engagement situation.

Remark: the trace of the teeth of axle driven bevel gear should

satisfy this requirement. Otherwise, select the suitable adjust-

ing washer for correcting according to the situation of poor

teeth engagement;

Select the adjusting gasket that makes the main teeth apart

from the axle driven bevel gear.

convex surface of gear

Suspension System and Automobile Axle (SF/4WD)

Front Speed Reducer (Assembly of Front Speed Reducer)

concave surface of gear

SA-77

heel end engagement

tooth top engagement

Select the adjusting gasket that make the main teeth contact

closer with the axle driven bevel gear.

toe end engagement

tooth top engagement

Select the adjusting gasket that make the main teeth contact farther with the axle driven bevel gear.

(d)

Tear down the bearing 32307 from the driving bevel gear

and change the adjusting washer.

(e)

Re-measure the total preload of the front speed reducer

and the situation of teeth engagement until they satisfy

the requirement.

16. Rivet the main-tooth nut;

17. Mount on the new oil seal ó front half-shaft;

Press in the new oil seal with the SST until it flush with the

outer face of the oil seal, coat the moderate lubricant on the

position of oil seal and on the lip open of oil seal.

Suspension System and Automobile Axle (SF/4WD)

Front Speed Reducer (Assembly of Front Speed Reducer)

SA-78

18. Mount on the front drive axle shaft sleeve;

Notice: Thread locking agent should be coated on the

bolt thread.

Fastening torque

88N

19. Mount on the front long semi-axis and the front minor

half-shaft.

(a)

Mount the new snapping ring on half-shaft.

(b)

Mont on the front semi-axis and the front minor half-

shaft.

20. Mount the front speed reducer shell assembly:

(a)

Clear the front speed reducer shell and the contact face of

front speed reducer shell;

(b)

Coat the glue line with diameter of 2-3 mm, and the glue

line should be even and without fracture.

Remark: The front speed reducer shell should be mounted

ready within 15 min after coating the glue.

(c)

The bolts, before screwed up, should be coated with

thread locking sealing agent and screwed up to the

specified torque.

Fastening torque

47N

Suspension System and Automobile Axle (SF/4WD)

Front Speed Reducer (Assembly of Front Speed Reducer)

Great Wall. Service manual for chassis and body (2006) - page 15