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Great Wall - Hover - Owners Manual - 2009 - 2009 (Italian)
Great Wall - Hover - Workshop Manual - 2010 - 2013
Great Wall - Hover - Parts Catalogue - 2011 - 2011
Summary of Content
Preface With the increase of automobile demand in China, our automobile industry also experiences a rapid development. The trucks including SUV, manufactured by Great Wall Motor Co., Ltd, which are sold all over China, are in the leading place in terms of their sales volume, in order to satisfy the demands of various maintaining staff, technicians and managing staff of Changcheng Co., Ltd, we compile this maintenance manual according to the latest technological data. This manual covers six vehicle models including Deer, Safe, Sailor, Sing, So Cool and Pegasus, its main content includes: Part I is general introduction, which introduces the application index of this manual. Part II introduces the chassis system, which mainly includes the technologies of dismantle, inspection, adjustment, repairing, assembly and mount of the clutch, gear box, transfer box, drive shaft, suspension system and automobile axle, braking system and steering system, etc. each operation approach is illustrated with figure, which not only presents the maintenance procedure, but also clearly describes the technical requirements and application limit. Part III introduces the electric system and air-conditioning system of the automobile body, which mainly covers such items as the location and content of protective box, power supply system, starting system, lighting system, combination instrument, backup radar system, wiping and washing system, center control locking and power window system, acoustical equipment system, full wire harness and air-conditioning system, etc. Electricity diagrams for those electric systems are given in this manual so as to facilitate the maintaining technicians to find out the problem easily and quickly. Part IV introduces the external and internal body decoration, which mainly covers the dismantling, inspecting and assembling requirements of the engine cover, front and rear doors, adhesive strip of body collision avoidance, wheel shield, wrapping angle of wheel-shield and exterior trim panel, front and rear windshields, side-window glass, rear-door glass, rear platform of cargo compartment, rear door, instrument panel, safety belt, seat, tail-fin, luggage rack, and reserve tire bracket etc. The dimensions of vehicle body and frame are also given to maintaining staff for reference during their repairing. During the narrations of each part, items such as troubleshooting, maintenance notice, maintenance data and application limit, fastening torques of bolts and nuts for special purpose, SST, SSM and lubricant materials and so on are also introduced. Various maintenance data are briefed in attachment for reference. Altogether, this manual is comprehensive in content, visual in illustration, clarifying in requirement and plain in language. It can be referred by the maintaining staff, technicians and professional managing staff. Even though we try our best to compile this manual in a strict earnest manner, we cannot guarantee that all contents in this manual are correct. Therefore, users shall not put forward any claim with Great Wall Company according to this manual; we are not in the position to hold the responsibility for the loss caused by usage of this manual. Due to our limited knowledge, it is unavoidable to find error in this manual, any criticism and correction from you is welcomed. The final explanation power for this manual is subject to Great Wall Motor Co., Ltd Compiler May 2006 Service manual for chassis and body General Clutch Gear box Transfer box Drive shaft Suspension system and automobile axle Braking system Steering system Body electric system Air-conditioning system Vehicle body Maintenance and Up-keeping Special Tool IN CL MT TF PR SA BR SR BE AC BO A B IN-1 Introduction Page How to use this manual ................................................. IN-2 Instruction for overall repairing ...................................... IN-4 Body lifting height and support position ........................ IN-5 fk Introduction  How to Use This Manual IN-2 How to use this manual In order to help you to look in this manual, we marked the chapter name and main theme at the top of each page. In order to introduce the repairing items to you, we make the index on the first page of each chapter, and notices need to be taken during all repairing operation are also given in the related chapter. Please read these notices carefully before the repairing work. The troubleshooting form for each system will help you to diagnose the system trouble and its cause. We furnish with the repairing approaches for each possible cause in the repairing approach column, which will help you to acquire the solution in a short time. Repairing approach Most repairing operation can begin with referring to these illustrations. These illustrations can help you identify the parts and their coordination situation Example  snapping ring  oil seal-front semi-axle front minor half-shaft 88  snapping ring front speed reducer and differential N*m specified torque  Parts that cannot be reused after being used front long semi-axis Introduction  How to Use This Manual IN-3 Introductionóhow to use this manual The repairing approaches are described step by step: The illustrations show you what to do and at which position. The theme of repairing operation tell you what you need to do. The detailed instruction show you how to accomplish the repairing and introduce to you other related affairs, such as specification, warning etc.    Example: Topic:what to do ? PMãã Check and adjust the flange bounce (a) Attach the dial indicator seat to the reducer housing, and touch the flange face with the measuring head of dial indicator, run the flange and observe the pendular range of the indicator carefully. Full bounce tolerance of face : 0.10mm Specification Detailed introductionz;How to do? This formula can help the experienced technicians find out the failure causes in short time. Overhauling staff can browse the operation theme and refer to the detailed description thereunder where necessary; important specifications and warnings are written out in boldface. Illustration: what to do and at which position Specification The corresponding specifications are given in boldface in each repairing approach of this manual, which allows the overhauling staff to check the specification while keeping on repairing work. Warning, Notice and Remark    Warning written out in boldface means there is possibility of selfinjury or harm to others. Notice written out in boldface means there is possibility of damage to parts under repairing. Remarks singled out independently, but not in boldface, serve as supplementary descriptions to help you accomplish the work more efficiently. Vehicle Code There are six vehicle models in this manual, the model codes are as follows: Deer modelDr Sailor modelSL SO COOL modelSK Safe modelSF Sing modelSY PEGASUS modelSJ Abbreviation used in this manual A/Cair-conditioner ECUelectronic controller unit SSTspecial service tool 2WDtwo-wheel drive 4WDfour-wheel drive Introduction  Overall Repairing Rescription IN-4 Overall Repairing Description 1. Keep the vehicle clean and prevent it from e) Mount the cable terminal on the post with loosened nut, then damage with guard plate, seat and floor cover fasten the nut. donít tap the terminal onto the post with hammer. cloth. 2. Put down the dismantled parts in order during the dismantle process so as to facilitate the reassembly 3. Observe the following items: a) Disconnect the cable cathode from the accumulator terminal before the electric f) Be sure to check whether the cover of positive terminal (+) is well located or not. 4. Check all hoses and wire plugs to verify whether they are connected solidly and correctly. 5. Parts that cannot be reused after being used. operation;. b) Disconnect the cable from the cathode a) The following parts should be changed with new one regularly: split pin, sealing washer, O-ring and oil seal, etc. connected to the vehicle body when check- b) parts that cannot be reused after being used is marked with  in the element figure. ing or repairing the accumulator where necessary. 6. Pre-coated parts c) In order to avoid the damage of terminal post of accumulator, loose the bolts first, The pre-coated parts including the bolt and nut are coated with locking seal glue in factory. then pull up the cable vertically when a) In case the pre-coated parts are moved due to its fastening, loosening or other causes, they must be coated again with the dismantling, dont wring it or prize it. d) Clean the terminal posts of the accumulator with dishcloth, and do not scrape them with file or other similar tools to avoid specified seal glue. b) Coating procedure of pre-coated parts 1) Clear away the former seal glue from the screw thread of the said parts. damage. 2) Dry the parts with compressed air. 3) Coat the screw thread of the parts with the specified tighten seal glue locking seal glue. c) The pre-coated parts are marked with the  in element figure. 7. When necessary, sealing agent or sealing ring to prevent the leakage. 8. Each specification shall be followed strictly. And the torque spanners should be used. 9. Determine the necessity of using the special service tools (SST) or special service materials (SSM) according to the real situation. SST and SSM must be used where necessary and the repairing should be in accordance with the repairing approach. SST list and SSM list are attached to this manual. 10. Be sure to check whether the rated current of the new fuse is correct when changing the fuse. The fuse rated current should not larger than that of securing fitting and the fuse of smaller rated current must not be used. 11. Be careful to hang or support the vehicle on the suitable place when propping up or raising it. a) In case prop up the vehicle at the front or back part, the wheels must be blocked to guarantee the safety work. Introduction  Body Lifting Height and Supporting Position IN-5 b) The raised vehicle must be supported with the bracket; it is dangerous to conduct the repairing work on the vehicle propped up with one jack, even though such repairing can be finished in short time. 12. The following items shall be taken notice to avoid the parts damage: a) Do not open the covers of ECU and various computers where not necessary absolutely. (if the IC terminal is touched, it be leaded into static damage) . b) Pull the hose at its ends when dismantling it, do not pull it at the center section. c) Pull the wire joint instead of the wire when pulling the joint wrong away. correct d) Take notice to avoid of the drop of electric parts such as the sensors or repeaters. In case those parts drop to the hard ground, they must be changed instead of being reused. e) Do not use the striking spanner to dismantle or mount the thermostatic switch or thermostatic sensor. f) Plug the needles of the multi-meter into the wire connector carefully when checking its conductance and do not bend the terminals. g) Do not sheath the hose of the vacuum gauge into the very large connector when using the gauge, instead, the stage joint shall be used because once the hose expands, it is possible to lead into the leakage. Body lifting height and supporting position front 123456 123456 123456 123456 Jack lifting position ........................................................................................................... 123456 Front......the front the beam center Rear.....rear differential Supporting position  12345 12345 12345 safety bracket ............................................................................................. 12345 CL-1 Clutch Page Troubleshooting .......................................................... CL-2 Inspection and adjustment of clutch pedal ................... CL-3 Air exhausting of clutch ................................................ CL-3 Clutch master cylinder ................................................ CL-4 Clutch wheel-brake cylinder ......................................... CL-6 Clutch cluster ............................................................... CL-7 CL Clutch  Troubleshooting CL-2 Troubleshooting Trouble Causes Overlarge free stroke of clutch pedal There is air in clutch pipe Failure of clutch brake-wheel cylinder Difficulty in gearshift Failure of clutch master cylinder or non-gearshift Overlarge clutch pendulum difference due to incorrect mounting, the friction liner is stained with oil or is breaking There is dirty or adhesive materials on spline of input shaft or clutch rib Failure of clutch pressure plate Repairing approaches Adjust the free stroke of pedal Exhaust the air in clutch pipe Change the clutch brake-wheel cylinder Change the master cylinder Check the clutch rib Repair according to requirement Change the clutch pressure plate Disengagement of gear box or clutch slip Abrasion of clutch guide shaft Insufficient free stroke of clutch pedal The friction liner of clutch rib is stained with oil or is worn Failure of clutch pressure plate Seize up of separation fork Change the guide shaft Adjust the free stroke of pedal Check the clutch rib Change the clutch pressure plate Check the separation fork Clutch seize-up or shaking The friction liner of clutch rib is stained with oil or is worn Failure of clutch pressure plate Looseness of engine seat Check the clutch rib Change the clutch pressure plate Repair according to requirement Looseness of clutch pedal There is air in clutch pipe Failure of clutch brake-wheel cylinder Failure of clutch master cylinder Exhaust the air in clutch pipe Change the clutch brake-wheel cylinder Change the master cylinder Seize up of separation fork; Abrasion or stained spot of separation bearing Over-loud clutch noise Abrasion of guide bearing Parts looseness in clutch pressure plate Repair according to requirement Change the separation bearing Change the guide bearing Change the clutch pressure plate Clutch  Inspection and Adjustment of Clutch Pedal, Air Exhausting of Clutch CL-3 Inspection on and adjustment of clutch pedal 1. Check whether the pedal height is correct Pedal height that begins from front wall board: Dr SF(165  5)mm SL SK SY SJ(190-200)mm adjusting spot in pedal height pedal height 2. Adjust the pedal height where necessary Loosen the locking nut and screw off the adjusting bolts until the pedal height is correct. Then screw up the locking nut. Pedal free stroke 3. Check whether the pedal free stroke is correct Press the pedal lightly until the resistance generated by clutch occurs. pedal free stroke: (5-15)mm 4. Adjust the pedal free stroke where necessary; a) Loosen the locking nut and rotate the push-rod until the stroke is correct; b) Screw up the locking nuts; pedal free stroke c) Check the pedal height after the adjustment of pedal free stroke. Air-exhausting of clutch Remark: in case operation needs to be conducted for the clutch system or if there is air in clutch, exhaust the air. Notice : Do not stain the painted surface with brake liquid, if any brake liquid is left, wash it away immediately. 1. Fill the brake liquid into the oil cup of clutch master cylinder; The oil cup of master cylinder shall often be checked and, if necessary, added with brake liquid. 2. Connect the ethene resin pipe to the air-exhausting valve. Insert the other end of the pipe into the container, half of which is filled with brake liquid. 3. Air-exhausting in clutch system a) Move the clutch pedal up and down slowly for several times. b) Loosen the air-exhausting valve when pressing the pedal increasingly until there is brake liquid overflowing, then tighten the air-exhausting valve. c) Repeat this operation until the bubble in brake liquid disappears. Clutch  Clutch Master Cylinder CL-4 Clutch Master Cylinder Element drawing oil cup of clutch master cylinder spring pin with groove  ring pipe piston clutch master cylinder spring 18  2 19  1 open pin of nut nut open ring push-rod U-clamp gasket N*m pin dust cover specified torque  Parts that cannot be reused after using. Disassembly of master cylinder SST 1. Tear down the pin of push-rod 2. Tear down the clutch pipe Disconnect the jointed pipe nuts with SST 3. Tear down the master cylinder a) Tear down the fixing nuts; b) Pull out the master cylinder. Clutch  Clutch Master Cylinder CL-5 Disassembly of oil cup of master cylinder 1. Tear down the oil cup a) Use the pinch and hammer to tap out the spring pin with groove; b) Tear down the oil cup and ring pipe. Assembly of master cylinder 1. Mount the oil cup a) Mount the oil cup and the new ring pipe. b) Use the pinch and hammer to tap in the spring pin with groove. Mount of master cylinder 1. Mount the master cylinder Mount the fixing nuts and screw them up. 2. Connect the clutch pipes; Connect the clutch pipes with SST 3. Connect the push-rod and mount the pin; Encase the pin of push-rod with clamping pliers. 4. Exhaust the air in clutch system and adjust the clutch pedal. Clutch  Clutch Brake-Wheel Cylinder CL-6 Clutch brake-wheel cylinder Element drawing air-exhausting plug clutch brake-wheel cylinder 18  2 19  1 push-rod spring N*m piston dust cover specified torque Disassembly of brake-wheel cylinder 1. Tear down the clutch pipeline. Remove the pipeline with SST 2. Tear down the two bolts to take down the clutch brake-wheel cylinder mount of brake-wheel cylinder 1. Mount the brake-wheel cylinder with two bolts; 2. Connect the clutch pipeline; Connect the pipeline with SST; 3. Exhaust the air in clutch system. Clutch  Clutch Cluster CL-7 Clutch cluster Element drawing flywheel clutch rib clutch pressure plate 30 clamp separation fork dust cover N*m separation bearing specified torque Disassembly of clutch cluster 1. Tear down the gear box; Remark: do not leave the gear oil in drying 2. Tear down the clutch pressure plate and the clutch rib a) Make aligning marks on the clutch pressure plate and the flywheel. b) Loosen the fixing bolts gradually until the spring tension is released; c) Tear down the fixing bolts to pull out the clutch pressure plate and clutch rib. 3. Tear down the bearing and separation fork from the gear box; a) Tear down the clamp to pull out the bearing; b) Tear down the separation fork and dust cover. Clutch  Clutch Cluster CL-8 Inspection on clutch parts 1. Check whether there is abrasion or damage of clutch rib; Measure the depth of the rivet head with calipers. Min depth of rivet head: 0.3mm If the depth of rivet head exceeds the limit value, change the clutch rib. 2. Check the radial pendulum difference of the clutch Check the radial pendulum difference of the clutch rib with multi-meter. Max radial pendulum difference: 0.8mm If the radial pendulum difference exceeds the max value, change the clutch rib. 3. measure the rdial pendulum difference of the flywheel; Check the radial pendulum difference of flywheel with multimeter; Max radial pendulum difference: 0.2mm If the radial pendulum difference exceeds the max value, change the flywheel. 4. Check the guide bearing Exert the force in radial direction to rotate the bearing by hand. If the guide bearing doesn t run or if there is great resistance, change the guide bearing. Remark: as this bearing is lubricated permanently, it needs not to be cleaned or lubricated. 5. Change the guide bearing where necessary. a) Tear down the guide bearing with SST; SST Clutch  Clutch cluster CL-9 b) Mount the guide bearing with SST. Remark: the bearing shall be verified in good running after it SST is encased in the flywheel hub. 2. Check whether there is abrasion on the diaphragm spring. Check the abrasion depth and width of diaphragm spring with calipers. Limit value: Max depth: 0.6mm Max width: 5mm If the abrasion depth or width of the diaphragm spring exceeds the limit value, change the diaphragm spring . 3. Check the separation bearing Exert force in radial direction by hand to rotate the bearing. If it cannot be rotated or if the resistance is too large, change the separation bearing. Remark: Remark: as this bearing is lubricated permanently, it doesnít need to be cleaned or lubricated. SST Mount of clutch cluster 1. Mount the clutch rib on flywheel; Mount the clutch rib on flywheel with SST. flywheel side 2. alignment mark Mount the clutch pressure plate a) Align the marks on clutch pressure plate and that on flywheel; b) Screw up the bolts in even manner around the clutch pressure plate until pressure plate and the flywheel contact closely, then tighten the bolts. Tightening moment: 30 Nm Remark: tighten the uppermost bolt of the three that is near to the locating pin. Clutch  Clutch Cluster CL-10 3. Check the alignment of the diaphragm spring end. Check the alignment of diaphragm spring end with SST. Max dislocation: 0.5mm if the difference is more than the specified value, adjust the alignment of diaphragm spring end with SST. SST 4. Coat the lithium base grease; Coat the lithium base grease on the following parts: Contact spot of separation fork and bearing     Contact spot of separation fork and push-rod; Support spots of separation fork Spline of clutch rib 5. Encase the dust cover, separation fork, separation bearing seat and bearing into the gearbox; 6. Mount the gearbox. MT-1 Gear box page Notice ........................................................................... MT-2 Troubleshooting ........................................................... MT-3 Dismantle of Gear Box ................................................. MT-4 Mount of Gear Box ....................................................... MT-7 Disassembly of Gear Box ............................................. MT-10 Input Shaft Assembly ................................................... MT-18 Element Drawing ...................................................... MT-18 Inspection on Synchronizing Ring ............................ MT-18 Bearing Change ....................................................... MT-18 Output Shaft Assembly ................................................. MT-20 Element Drawing ...................................................... MT-20 Disassembly of Output Shaft Assembly.................... MT-21 Inspection on Output Shaft Assembly ...................... MT-23 assembly of Output Shaft Assembly ......................... MT-25 Countershaft Assembly And Reverse Idle Gear Assembly ...................................................................... MT-29 Element Drawing ...................................................... MT-29 Disassembly Inspection and Assembly of Countershaft Assembly ............................................. MT-29 Assembly of Reverse Gear ...................................... MT-31 Rear Housing assembly ............................................... MT-33 Element Drawing ...................................................... MT-33 Change of Oil Seal ................................................... MT-33 Change of Shaft Bush .............................................. MT-33 Inspection on and change of Position-Limit Mechanism Cluster ................................................... MT-34 Front Cover of Bearing ................................................. MT-36 Element Drawing ...................................................... MT-36 Change of Oil Seal ................................................... MT-36 Assembly of Gear Box ................................................. MT-37 MT MT-2 Gear Box  Notice Notice Notice for disassembly and assembly of gearbox Notice shall be taken during the gear disassembly and assembly on the soft handle for the parts, especially for the coupling faces so as to avoid the collision; each part shall be put down in order to avoid the missing or mistaking. Notice shall not only be taken in the aforesaid aspects, but also in the following items 1. Wash all parts before assembly (rubber fittings and washers excluded). 2. Various oil seals, retainer rings for shafts, spring-type pins shall not be reused. 3. Lubricating oil shall be coated on the friction surfaces, and lubricating grease shall be coated on the lips of oil seals. 4. Rolling elements shall not be used to transfer the pressure during the various bearing assembly. 5. Lip-type oil seal must not be sloping when assembling it. 6. The openness at the two ends of the spring collar shall be misfit when assembling the component elements of the synchronizing instrument, and 7. No part is allowed to leak the lubricating oil when the gearbox locating at its working place. Gear Box  Troubleshooting MT-3 Troubleshooting Common Failures Difficulty in gear engagement Causes Methods for troubleshooting Non-use of clutch Non-full separation of clutch Severely warned tooth rings of synchronizing fittings Over-hard locating spring Use the right driving approach Checking for adjustment Change Over-loud or abnormal noise Over-low oil level Lubricating oil of inferior quality Non-timely oil change Unsuitable axial location or clearance of gears Bearing damage Burr or collision on gear Add oil to the specified level Change it with the specified oil Change the oil and damaged parts Check for adjustment Change Repair or change the gear Oil leakage, oil penetration Oil added above the specified level Loss or missing of bolts Vent plug trouble Sealing element damage Adjust oil to the given level Reassembling or fasten the bolt according to the specified torque Change Change Damage of synchronizer Overexert in gear shift Non-use of clutch Damage on spring collar of synchronizer Incorrect mounting of drive shaft Change Use the right driving approach Change Check for adjustment Non-engagement of gear Trouble in controlling mechanism Incorrect assembling the locating spring or steel ball Invalidation of locating spring Severely worn gear sleeve or fork groove Seriously worn toggle fork Check for adjustment Reassembly Burning bearing, burning gear Over-low oil level Inferior lubricating grease Non-timely oil change, over-dirty oil Inter-use of differential oil or usage of additive Change damaged parts and add oil Change the damaged parts and lubricating oil Change damaged parts and lubricating oil Change damaged parts and lubricating oil Difficult in gear disengagement Spring invalidation of synchronizer Warn inner groove of tooth ring of synchronizer Tooth ring of synchronizer choked on conical face Toggle fork deformation or toggle fork axle deformation Severely worn toggle fork Change Change Change Change Change Change Change Change Change MT-4 Gearbox  Dismantle of Gear Box Dismantle of gearbox 1. Disconnect the cathode wire from the cathode of storage cell. 2. Tear down the setting bolts of fan cover. Tear down 4 3. Tear down the shifting ball of gear change lever Loose the locking nuts by dextroroting the ball. 4. Tear down the glove box Dismantle the four bolts of the glove box and put the glove box into the suitable place. 5. Tear down the dust cover. 6. 7. Tear down the gear change lever. Raise the vehicle to discharge the oil in gearbox. 8. Warning: the reliability of vehicle shall be verified. Tear down the drive shaft. (See page PR-5) 9. 10. Tear down the odometer sensor and the plugging elements of backup switch Tear down the vent pipe. Tear down the heading exhaust pipe from branch exhaust pipe Gearbox  Dismantle of Gear Box MT-5 11. Tear down the wheel-brake cylinder of clutch. (a) Dismantle the setting bolts of the wheel-brake cylinder of clutch with spanner. (b) Hang the wheel-brake cylinder with a thread on the side of engine without oscillation. Remark: Do not disconnect the pipeline of the wheel-brake cylinder. 12. Tear down the pawl washer and bracket of the rear part of gearbox: Two-wheel driving: (a) Dismantle the four bracket bolts (skip over this process for the wielding structure). (b) Lift the engine with jack to raise the gearbox a little. (c) Dismantle the pawl washer from the rear part of gearbox. Four-wheel driving: 4WD Dismantle the bolts from the pawl washer and bracket of the rear part of gearbox to tear down the pawl washer and bracket. 13. Insert the wooden plate between the bottom frame and the beam. MT-6 4WD Gearbox  Dismantle of Gear Box 14. Dismantle the eight bolts that fasten the beam of gearbox. 15. Tear down the starter Put the starter on the side of engine. 16. Dismantle the bolts of clutch frame and bracket (wrapping angle). 17. Tear down the remaining bolts of gear box 18. Tear down the gear box (a) Pull out the gear box in backward direction; (b) Put down the engine at the front and tear down the gearbox from the vehicle. Notice: be careful not to damage the dust cover of expansion shell. Gear Box  Mount of Gear Box MT-7 Mount of gear box 1. Put down the gearbox at the mounting place. 2. Mount the bolts of gearbox, clutch bracket and starter. Tightening moment: (a) Setting bolt of gear box (82  10)Nm (b) Enforcement plate bolt (37  5)Nm (c) starter bolt (39  5)Nm Notice: the bolts of gear box and clutch shall be mounted with the clutch pipe clip together. 3. Mount the pawl washer and bracket of gearbox Two-gear driving: (a) Mount the gearbox pawl washer and fasten the relative bolts. Tightening moment: 23  3)Nm (b) Lift the rear part of engine with jack and wooden block so that the gearbox is raised a little. (c) Mount the bracket of gear box on beam and fasten the relevant bolts (this process may skip over in wielding structure) Tightening moment(23  3)Nm (d) Connect the gearbox bracket and supporter with bolts, then tighten the bolts. Tightening moment: (23  3)Nm MT-8 Gear Box  Mount of Gear Box 4WD: 4WD (a) Mount the bracket and supporter of leg washers of rear engine in 4WD vehicle;(SF) (b) 4WD Mount and tighten the third beam of 4WD vehicle. (SF) 4. Remove the wooden spill. 5. Mount exhaust pipe. Mount the exhaust pipe on the branch exhaust pipe. Tightening moment(62  3)Nm 6. Mount the wheel-brake cylinder of clutch. Tightening moment(18  2)Nm 7. Mount odometer sensor and plugging elements of backup switch. 8. Connect the drive shaft. (See page PR-12) 9. Add oil into the gearbox. Lubricating oil grade: GL-5 85W/90 Volume: 2.4L(dry) Remark: the Tightening moment of oil filling/draining plug: (3050)Nm Gear Box  Mount of Gear Box 10. MT-9 Drop the vehicle. 11. Mount the dust cover and gear change lever. 12. Mount storage box. 13. Mount the manual ball, and 14. Mount the fan cover and fasten the bolts. Mount on them and screw up the four bolts. 15. Connect the cell cable to the cathode of storage cell; and 16. Conduct the load test Check whether there is abnormal noise and whether the operation is stable. MT-10 Gearbox  Disassembly of Gear Box Disassembly of Gear Box 1. Tear down the separation toggle fork and separation bearing. 2. Tear down the backup switch, the driven gear of speedometer. 3. Tear down the clutch from the gearbox frame. Take apart the nine boits. 4. Tear down bolts of locating spring of the five-speed toggle fork, locating spring and locking ball. (a) Dismantle the bolts from the rear cover with the torque socket spanner. (b) Take out the spring and locking ball with magnetic rod. 5. Tear down the operating seat of gear change lever. (a) Dismantle the setting bolts of the operating seat of gear change lever. (b) Take away the operating seat lightly and put it at the suitable place. 6. Tear down axial locating pin assembly of shifting gear. 7. Tear down the fastening nuts of extension frame. (a) Tear down the fixing bolts of gearshift shaft. (b) Tear down the fastening nuts of expansion shell. Gearbox  Disassembly of Gear Box MT-11 (c) Dismantle the nuts of the four-gear driven extension fram. 4WD (d) Tap the extension frame lightly with rubber hammer to tear down the selective gearshift shaft and selective rocker arm. 8. Tear down front cover. Dismantle the eight bolts and front cover and axial oil seal. 9. Tear down the input shaft, axial/bearing open ring and countershaft bearing open ring. 10. Dismantle the gearbox frame from the central link plate, (a) Put the gearbox straightly as shown in the drawing. (b) Tap out the gearbox frame out carefully with the rubber hammer. And (c) Pull out the gearbox frame out from the central link plate as the drawing shows MT-12 Gearbox  Disassembly of Gear Box 11. Grip the central link plate in the table vice, (a) Use two clutch bolts, washers and suitable nuts as shown in the drawing. Remark: mount the washer in the reverse direction, increase and decrease the washer quantity to flush the bolts terminal with the external face of the washer. (b) Grip the central link plate in the table vice. 12. Tear down the locating spring bolts, locating spring and locking ball, (a) Dismantle each locating spring bolts with the torque socket spanner. (b) Take out the toggle fork axles of the first, second, third, fourth and reverse as well as the axial locating spring and locking ball of the fifth-gear toggle fork. 13. Tear down the axial retainer ring of the gearshift fork Tap the axial retainer ring of gearshift fork lightly with two screwdrivers and one hammer. Gearbox  Disassembly of Gear Box MT-13 14. Tear down the five-speed gearshift toggle fork, (a) Punch out the spring pin with impact head and hammer. (b) Tap the five-speed gearshift fork until take it out. Notice: It must be the neutral location this time. 15. Tear down the guiding module of the five-speed gearshift and five-speed reverse shift fork axle. (a) Take out the inter-locking steel ball from the guiding module of the fifth reverse shift-shaft. (b) Tear down the fifth reverse shift guiding module and fifth reverse shift fork axle. 16. Take out the five-speed gearshift fork axle MT-14 Gearbox  Disassembly of Gear Box 17. Tear down the reverse shift fork axle, reverse rocker arm, reverse toggle lever and toggle block (a) Tap out the spring pin with the nail punch and hammer. (b) Take out the interlocking ball and interlocking guidepost between the reverse shift fork axle and the five-speed gearshift fork axle. (c) Tear down the reverse shift fork axle, and (d) Tear down the reverse rocker arm and yoke block. 18. Tear down the first-second-speed gearshift fork axle. (a) Take out the interlock pin and interlock guide post between the reverse shift fork axle and the five-speed gearshift fork axle. (b) Dismantle the locating bolts of the toggle fork of the firstsecond-speed gearshift toggle fork. (c) Dismantle the fork axis of the first-second-speed gearshift. (d) Take out the short interlock pin between the first-secondspeed gearshift fork axle and the third-fourth-speed gearshift fork axle Gearbox  Disassembly of Gear Box MT-15 19. Tear down the third-fourth-speed gearshift fork axle and the toggle forks of first-second speed gear and thirdfourth speed gear. (a) Tap out the spring pin with the nail punch and hammer. (b) Tear down the toggle forks of the third-fourth and firstsecond-speed gearshift. 20. Tear down the coupling gear, synchronizer, gear cluster, thrust washer and needle bearing of the five-speed gearshift (a) Tap down the retainer ring of the rear countershaft with two screwdrivers and one hammer. (b) Tear down the synchronizer assembly, coupling gear and gear cluster of the five-speed gearshift. And (c) Dismantle the five-speed needle bearing. 21. Tear down the thrust washer and five-speed lock ball. (a) Tear down the thrust washer of five-speed gear. (b) Take out the lock ball with magnetic rod. MT-16 Gearbox  Disassembly of Gear Box 22. Tear down the reverse rocker arm bracket Dismantle the two bolts and the reverse rocker arm bracket. 23. Tear down the reverse idle gear and reverse idle gear axle (a) Dismantle the setting bolts of idle gear and the pressing plate of reverse idle gear axle. (b) Dismantle the reverse idle gear and the reverse idle gear shaft. 24. Take down the bearing baffle of the output shaft. (a) Dismantle the four bolts with torque socket spanner. (b) Take down the bearing baffle of the output shaft. 25. Dismantle the intermediate-gear shaft. (a) Pry out the split ring of the rear bearing of the intermediategear shaft with the split-ring-type pliers. Gearbox  Disassembly of Gear Box MT-17 (b) Taker apart the rear bearing of intermediate shaft with SST SST tool and wrench. (c) Take down the intermediate shaft. 26. Tear down the input shaft Tear down the bearing with 13 needles and synchronizing ring from the input shaft. 27. Tear down the output shaft (a) Dismantle the stop ring from the output bearing with splitring-type pliers. (b) Tap lightly the central link plate with rubber hammer while pulling the output shaft manually to tear down the output shaft. 28. Check the back-up lamp switch Check the terminal connection, when the switch is pressed down, as shown in the drawing, it is connected, otherwise is disconnected, in case the switch is not in conformity with this, it shall be changed. push down to close MT-18 Gearbox  Input Shaft Assembly (Element Drawing, Inspection On Synchronizing Ring, and BearingChange) Input Shaft Assembly element drawing input shaft needle bearing bearing bearing stop ring retainer ring synchronizing ring Inspection on Synchronizing Ring 1. Run the synchronizing ring and put it into the assembly to check its stopping performance 2. Check the clearance between the rear face of synchronizing ring and the gear. Standard clearance: Tung tooth(11.6)mm Upper tooth(1.51.8)mm Limit clearance0.8mm Bearing Change 1. Tear down the input shaft bearing with the pressure machine. Gearbox  Input Shaft Assembly (Bearing Change) MT-19 2. Mount the new bearing with pressure machine and SST. 3. Select the retainer ring to obtain the minimum axial clearance ppq 4. Mount the retainer ring with the split-ring-type pliers. 5. Mount the retainer ring with the split-ring-type pliers. Transmission  Output Shaft Assembly (Components Figure) MT-20 Output shaft assembly Components figure synchronizer slide block 3th,4th gear synchronizer meshing sleeve 3th gear needle bearing synchronizer spring expansion ring gear components of 3rd gear toothed ring of synchronizer steel ball steel ball snap ring synchronizer hub of 3rd and 4th gear output shaft synchronizer meshing sleeve of 1st and 2nd gear gear components of 1st gear synchronizer sliding block 1st gear shaft sleeve locking ring of output shaft rear bearing spring expansion ring needle bearing of 2nd gear rear bearing of output shaft needle bearing of 1st gear toothed ring of synchronizer for 1st and 2nd gear gear components of 2th gear toothed ring of synchronizer for 1st and 2nd gear drive gear snap ring of odometer odometer drive gear gear of 5th gear snap ring of 5th gear Transmission  Output Shaft Assembly(Disassembly of Output Shaft Assembly) MT-21 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 assembly 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. Transmission  Output Shaft Assembly(Inspection of Output Shaft Assembly) 3rd gear position MT-23 Inspection of output shaft assembly 1. Check the axial clearance of every gear: For the transmission made by Shang Chi:(0.150.33) mm(1st,2nd,and 3rd gear position) For the transmission made by Tang Chi:(0.10.25)mm (1st gear position)(0.090.26)mm,(2nd and 3rd gear position) 1st gear position 2nd 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: (0.0090.033)mm(2nd and 3rd gear position) (0.0090.032)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 MT-24 Transmission  Output Shaft Assembly(Inspection of Output Shaft Assembly) (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:(1.51.8)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(Assembly of Output Shaft Assembly) 3/4 gear posititon 1/2gear posititon MT-25 Assembly of output shaft assembly 1. Assembly of synchronizer (a) Insert the synchronizer hub and sliding block into the gear front sleeve. (b) Install the spring expansion ring under the sliding block. Note:The openings of spring expansion ring should be staggered during installation . front side 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 synchronizer 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. MT-26 Transmission  Output Shaft Assembly(Assembly of Output Shaft Assembly) Standard clearance: For the transmission made by Shang Chi(0.150.33)mm For the transmission made by Tang Chi:(0.090.33)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:(0.150.33)mm For the transmission made by Tang Chi:(0.090.33)mm 7. Assembly the locking ball and gear components of 1st gear (a) Install the locking ball into the shaft. Transmissio  Output Shaft Assembly(Assembly of Output Shaft Assembly) MT-27 (b) Smear the gear oil on the needle bearing of gear of 1st gear. (c) Assembly the gear components of 1st gear,synchronized ring,needle bearing and sleeve of gear of 1st gear. (d) Install the assembly on the output shaft,and align the notch of synchronized ring and sliding block . (e) Turn the sleeve of 1st gear shaft to align the it with the locking ball. 8. Installation for rear bearing of output shaft Fix the bearing of output shaft to the output shaft with SST and pressing machine, make the notch of locking ring of output shaft rear bearing expose to the tail. Remark: Hold the sleeve of gear of 1st gear and don t let it fall off. SST 9. Install the gear of 5th gear Fix the gear of 5th gear with SST and pressing machine. SST 10. Assembly the snap ring of shaft (a) To choose one snap ring which make the axial clearance be Min, and install it on the shaft. Max clearance  0.1mm (b) Knock the snap ring of shaft of 5th gear tightly with screwdriver and hammer. 11. Measure the axial clearance of gear of 1st gear Measure the axial clearance of gear of 1st gear with feeler gauge Standard clearance: For the transmission made by Shang Chi:(0.150.33)mm For the transmission made by Tang Chi:(0.090.33)mm MT-28 Transmission  Output Shaft Assembly(Installation of Output Shaft Assembly) 12. Fix the drive gear of speedometer (a) Install the locking ball and drive gear. (b) Install the drive gear of tachometer with plier for shaft shield ring Gear Box  Countershaft Assembly and Reverse Idle Gear Assembly (Element Drawing, Countershaft Assembly Disassembly, Testing and Assembly) MT-29 Countershaft Assembly and Reverse Idle Gear Assembly Element drawing stop ring for front bearing of countershaft front bearing of countershaft rear bearing of countershaft intermediate-gear shaft stop ring of the rear bearing of countershaft steel ball reverse idle gear shaft reverse idle gear cluster sliding block of synchronize retainer ring for front countershaft axial pressing plate for reverse idle gear engagement sleeve of the five-speed synchronizer five-speed needle bearing synchronizer tooth spring collar of spring collar five-speed thrust washer five-speed cluster coupling gear around the five-speed gear Disassembly, Testing and Assembly of Countershaft 1. Tear down the coupling gear, sliding block and the fivespeed spring collar. Tear down the coupling collar, three sliding blocks and the two five-speed spring collars with screwdriver. 2. Measure the radial clearance of the reverse idle gear with dial gauge Standard clearance: Shang chi:0.05mm Tang chi:(0.10~0.30)mm (Tang chi is the close Spline match, which belongs to radial clearance) Max clearanle: Shang chi:0.05mm Tang chi:(0.10~0.30)mm (Tang chi is the close spline match, which belongs to radial clearance) MT-30 Gear Box  Countershaft Assembly and Reverse Idle Gear Assembly ( Countershaft Assembly Disassembly, Testing and Assembly) 3. Reverse gear inspection Measure the diameter of needle bearing with micrometer. Standard diameter Shang Chi26.000mm Tang Chi(25.9826.00) Limit Diameter Shang Chi25.984mm Tang Chi25.86mm 4. Check the synchronizing ring (a) Run the retainer ring for shaft and put it onto the shaft to check itsstopping performance (b) Measure the clearance between the rear section of the synchronizing ring and the spline. Standard clearance: Shang Chi(1.51.8)mm Tang Chi(12)mm Limit clearance: 0.8mm 5. Measure the clearance of the shift fork and gear sleeve. Test the clearance of the shift fork and gear sleeve with the feeler gauge. Max clearance: Shang Chi: 0.54mm Tang Chi:1.0mm 6. Change the bearing The front bearing of the reverse gear shall be changed when necessary (a) Pry down the retainer ring for shaft with a split-ring-type pliers. Gear Box  Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly) MT-31 (b) Press out the bearing with SST. (c) Press in the bearing, side race and inner race with the SST socket spanner. sleeve wrench (d) 7. Select the split ring that leave the radial clearance to minimum level, and mount it on the shaft. Mount the engagement sleeve of synchronizer, sliding block and the five-speed spring collar. Remark: the opens of the spring collar shall be in nonalignment front Encase the sliding pad into the gear hub and then cover the gear sleeve. Mount the spring retainer under the sliding pad. Notice, the opening direction of the spring retainer shall not face-to-face. Mount of Reverse Gear Assembly 1. Check the reverse idle gear Measure the radial clearance of the reverse idle gear with dial gauge. Standard clearance: Shang Chi0.05mm; Tang Chi(0.040.08)mm Max clearance Shang Chi0.05mm; Tang Chi0.13mm MT-32 Gear Box  Counter Shaft Assembly and Reverse Idle Gear Assembly (Assembly of Reverse Gear Assembly) 2. Measure the clearance between the reverse idle gear and gearshift yoke block Measure the clearance between the reverse idle gear and the gearshift yoke block with feeler. Standard clearance: Shang Chi0.2mm Tang Chi(0.050.27)mm Max clearance Shang Chi0.35mm Tang Chi0.5mm Gearbox  Rear Housing Assembly (Element Drawing, Change of Oil Seal, Change of Shaft Bush) MT-33 Rear Housing Assembly Element drawing rear housing cluster component element of position-limit mechanism rear housing dust cover rear housing oil seal assembly oil groove locating spring bolts and spring cylindrical pin oil reservoir Change of Oil Seal SST 1. The rear housing oil seal shall be changed where necessary. (a) Dismantle the oil seal with SST. (b) Press in the new oil seal with SST SST 2. The driven oil seal of speedometer shall be changed where necessary (a) Pry out the oil seal with SST. (b) Tap the new oil seal into the shaft bracket with SST. SST SST Change of Shaft Bush SST The shaft bush shall be changed where necessary (a) Tear down the oil seal and dust bush. (b) Heat the ending parts of extension frame to 80-100 in the oil groove. (c) Tear down the shaft bush with SST and mount on the new shaft bush. MT-34 Gearbox  Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism) Inspection on and change of the component elements of position-limit mechanism 1. Tear down the component elements of position-limit mechanism (a) Dismantle the bolts with the torque socket spanner. (b) Punch out the spring cylindrical pin with the drift punch and hammer. (c) Tear the component elements of position-limit mechanism down. 2. Check the component element of position-limit mechanism. Run and propel the limit stop and the limit stop can return to the original location automatically, otherwise, change the limit stop. 3. Mount the component element of position-limit mechanism (a) Mount the component elements of position-limit mechanism in the rear housing. (b) Tap the spring cylindrical pins in with drift punch and hammer as shown in the drawing. Gearbox  Rear Housing Assembly (Inspection On and Change of The Component Elements of Position-Limit Mechanism) MT-35 (c) Coat the sealing agent on the bolt thread. (d) Propel the plug with the torque socket spanner. MT-36 Gearbox  Bearing Front Cover Assembly (Element Drawing, Change of Oil Seal) Bearing Front Cover Assembly element drawing bearing front cover assembly front cover oil seal assembly washer Change of oil seal The oil seal of the bearing front cover shall be changed where necessary (a) Pry out the oil seal with screwdriver (b) Press in the new oil seal with SST. Depth of oil seal: SST Upper tooth9.5mm Tang tooth(12.4  0.4)mm Gearbox  Assembly of Gearbox MT-37 Assembly of Gearbox 1. Mount the output shaft in the central link plate (a) Tap the output shaft in the central link plate while pulling it, until mounting it in the central link plate. (b) Mount the stop ring of the rear bearing of output shaft in with the split-ring-type pliers. Remarks: The stop ring shall flush with the surface of central link plate. 2. Mount the input shaft in output shaft (a) Coat the MP lubricant on the bearing with 13 needle rollers, and mount the needle rollers in input shaft. (b) alignment 3. Propel the input shaft in the output shaft and flush the groove of synchronizing ring with the sliding block. Mount the countershaft in the central link plate (a) Mount the stop ring on the rear bearing of countershaft with split-ring-type pliers. Gearbox  Assembly of Gearbox MT-38 (b) Mount the intermediate-gear shaft in the central link plate, and mount the backup rear bearing with SST while holding the intermediate-gear shaft. SST 4. Mount the baffle of rear bearing of output shaft Mount and propel the bolts with torque socket spanner. Tightening moment Tang tooth(1722)Nm Upper tooth(1217)Nm 5. Mount the reverse idle gear and shaft (a) Mount the reverse idle gear and shaft. (b) Mount the axial pressing plate of the reverse idle gear, and then propel the bolts tightly. Tightening moment(1520)Nm 6. Mount the bracket cluster of reverse rocker arm Mount the reverse rocker arm bracket and propel the two bolts tightly. Gearbox  Assembly of Gearbox MT-39 7. Mount the steel ball and the five-speed thrust washer. 8. Mount the five-speed gear cluster locking ball (a) Coat the gear oil on the needle bearing. (b) Mount the five-speed gear cluster. 9. Mount the synchronizing ring and the fifth coupling gear (a) Mount in the synchronizing ring and the fifth coupling gear. (b) Dismantle the old central link plate from the table vice. (c) Put the gearbox straightly as shown in the drawing. socket spanner (d) Flush the groove of synchronizing ring with the sliding block and mount the fifth coupling gear with pressure machine. (e) Mount the new central link plate in the table vice. MT-40 Gearbox  Assembly of Gearbox 10. Mount the split ring (a) Select the retainer for shaft that leaves the minimum radial clearance, which is not larger than 0.1mm. (b) Mount in the retainer for shaft with copper bar and hammer. 11. Measure the radial clearance of the five-speed gear cluster. Measure the radial clearance of the five-speed gear cluster with the measuring gauge. Standard clearance Shang chi(0.1350.325)mm Tang chi(0.10.3)mm 12. Mount the third-fourth-speed gearshift fork axle and the first-second-speed gearshift toggle fork as well as the third-fourth-speed gearshift toggle fork (a) Mount the first-second speed and third-fourth speed gearshift toggle forks. (b) Mount the third-fourth-speed gearshift fork axle in the central link plate and the gearshift toggle fork. (c) Mount the spring cylindrical pin of third-fourth-speed gearshift fork. Notice: The pin port should align with the direction of the shaft.(Same sa below) Gearbox  Assembly of Gearbox MT-41 13. Mount the first gearshift fork axle and first gearshift fork (a) Coat the MP lubricating on the interlocking guidepost and mount the interlocking guidepost on the first-secondspeed gearshift fork axle. (b) Mount the interlocking pin in the central link plate with the magnetic bar. (c) Mount first-second gearshift fork axle in the first gearshift toggle fork and central link plate. d) Mount the setting bolts of the first toggle fork and tighten them. Tightening moment Upper tooth(1520)Nm Tang tooth(1317)Nm 14. Mount the reverse yoke rod, reverse rocker arm and reverse yoke block (a) Mount the reverse yoke rod, reverse rocker arm and reverse yoke block together. (b) Mount the reverse rocker arm on the reverse rocker arm bracket. (c) Coat the MP lubricant on the interlocking guidepost and mount the guidepost on the reverse gearshift fork axle. MT-42 Gearbox  Assembly of Gearbox (d) Mount the interlocking pin in the central link plate with the magnetic bar. (e) Mount the reverse gearshift fork axle in the reverse yoke rod and central link plate. (f) Mount the spring cylindrical pin with the drift punch and hammer. 15. Mount the five-speed reverse gearshift guide block and five-speed reverse gearshift fork axis. (a) Mount the five-speed reverse gearshift guide block in the five-speed reverse gearshift guide shaft. (b) Mount the reverse gearshift fork axle in the next step. (c) Mount the steel ball in the five-speed gearshift guide block with the magnetic bar. (d) Mount the five-speed gearshift fork axle as shown in the drawing. (e) Mount the steel ball in the central link plate with magnetic bar. (f) Mount the five-speed gearshift fork axle in the central link plate. Gearbox  Assembly of Gearbox MT-43 (g) Tap the pin in the five-speed gearshift toggle fork with the drift punch and hammer. (h) Mount the five reverse gearshift guide shaft in the fivespeed reverse guide block and central link plate, and (i) Tap the spring cylindrical pin in the five-speed reverse guide block with drift punch and hammer. 16. Mount the retainer ring gripped by the gearshift fork axle. Mount the clamp retainer ring with the steel bar and hammer MT-44 Gearbox  Assembly of Gearbox 17. Mount the steel ball, locating spring and locating spring plug (a) Mount the steel ball and locating spring. Remarks: Mount the short spring at the bottom of the central link plate. (b) Coat the sealing agent on the plug thread. (c) Mount the plug and tighten them with the torque socket spanner. Tightening moment(1722)Nm 18. Tear down the central link plate from the table vice (a) Tear down central link plate from the table vice. (b) Dismantle the bolts, nuts and washers 19. Mount the gearbox frame (a) Coat the sealing material on the coupling face of the gearbox frame as shown in the drawing. sealed material (b) Put down the central link plate straightly as shown in the drawing. (c) Mount the gearbox frame on the central link plate as shown in the drawing. Gearbox  Assembly of Gearbox MT-45 20. Mount the stop ring of the front bearing (a) Mount the two stop rings in the input shaft bearing and countershaft front bearing with the split-ring-type pliers. (b) Mount the coated component elements of front cover. (c) Coat the sealing agent on the bolt thread, and (d) Mount and propel tightly the bolts. Tightening moment(1520)Nm 21. Mount the rear body, gear-change bar and selection bar and their housings sealed material (a) Coat the sealing materials on the rear body as shown in the drawing. (b) Mount the gearshift shaft and gearshift yoke block in the rear body. (c) Mount the gearshift catching head in the groove of guide block, and (d) Mount the catching head with the rear body together. (e) Mount and propel tightly the bolts. Tightening moment Shang chi(3040)Nm Tang chi(3045)Nm MT-46 4WD Gearbox  Assembly of Gearbox (f) Fasten the rear cover bolts of the four-gear driving gearbox Tightening moment:(3045)Nm(Tang tooth) (g) Mount and propel tightly the setting bolts of the gearshift yoke block. Tightening moment(1722)Nm 22. Mount the steel ball spring and plug (a) Coat the sealing agent on the plug thread. (b) Mount the steel ball, setting spring and setting spring plug. Tightening moment(1722)Nm 23. Check the following items after mounting the rear body or gearbox (a) Check the stability of the running input shaft and output shaft. (b) Check the gearshift stability of each speed 24. Mount the component elements of the locating mechanism (a) Mount the black component elements of the locating mechanism on the side of the five-speed reverse gear. (b) Mount another component element of locating mechanism and propel it tightly. Tightening moment(3040)Nm 25. Mount the gearshift cover of the gearbox. (a) Mount the gearshift cover coated with sealing agent. (b) Mount six bolts and then tighten them. Tightening moment(1520)Nm Gearbox  Assembly of Gearbox 26. Mount the clutch frame (a) Mount the clutch frame. (b) Coat the sealing agent on the bolt thread. (c) Mount the nine bolts and then tighten them. Tightening moment Upper tooth(6070)Nm Tang tooth(3045)Nm 27. Mount the back-up lamp switch. Tightening moment(2040)Nm 28. Mount the driven gear of odometer (a) Mount the driven gear of odometer. (b) Mount the bolts and tighten them. Tightening moment(1015)Nm MT-47 TF-1 Transfer Box page Notice ........................................................................... TF-2 Troubleshooting ........................................................... TF-3 Product Description and Simple Maintenance ............. TF-5 Dismantle and Mount of Transfer Box .......................... TF-7 Disassembly of Transfer Box ....................................... TF-9 Assembly of Transfer Box ............................................ TF-14 Washing, Inspection, Maintenance and Change .......... TF-24 Washing ................................................................... TF-24 Inspection ................................................................ TF-25 Maintenance and Change of Gear and Chain gear .. TF-28 Attachment for Inspection, Maintenance and Change of Parts....................................................... TF-30 TF TF-2 Transfer Box  Notice Notice Notice on transfer box disassembly and assembly Notice shall be taken on the soft handling of the parts (coupling face in particular) during the process of transfer box disassembly to avoid the collision; each parts shall put down in order so as to avoid of missing or mistaking. Notice shall, during assembly process, not only on the aforesaid items, but also on the following items: 1. Wash all parts and fittings before assembly (rubber element and washer excluded). 2. Oil seal, clip for shaft and spring pin of various kinds shall not be reused. 3. Lubricating oil is required to coat on the various friction surface and lubricant on lips of various oil seal. 4. Rolling body is not allowed to use for pressure transmission when mounting various bearings. 5. Lip-type oil seal is not allowed to mount slantwise. 6. The openness on the two sides of spring collar shall not be coupled face-to-face when assembling the component elements of synchronizer. And 7. No parts is allowed the lubricant leakage and penetration when the transfer box locates at the working location. Transfer Box  Troubleshooting TF-3 Troubleshooting Common troubles Causes Resolving approaches Electric gearshift trouble Damage or failure of electrically controlled element, electric module, speed sensor, electric motor, electric clutch, or built-in wire harness. Damage or worn of shifting cam, joint cover, locking sleeve, toggle fork or shift guide axle.Adhesive bonding shift Refer to the vehicle usage manual to diagnose the failure element and change it as requirement. Dismantle the weary or damaged parts and change it as requirement. Dismantle and check the free movement of sliding element, and change it as requirement Mechanic gearshift failure under the movement of shifting handle Break or damage of the shift rocker arm or shift lever. Damage of the guide plate of shifting cam; Change the damaged element. Incorrect operation. Refer to the vehicle manual for correct operation. Add the specified oil of given volume. Difficulty in mechanic gearshift or outplace gear engagement Lubricant of inferior quality or insufficient volume. Adhesive bonding of shift toggle fork. Adhesive bonding of the sliding joint cover, locking sleeve or gear. Open the rear cover of the transfer box to check the damaged element and change it. Open the rear cover of transfer box to check and changer the damaged parts. Open the rear cover of the transfer box to check whether the sliding parts can slide freely along the axle, if not, dismantle it and change the damaged parts. Damage or unsuitable adjustment of the shifting mechanism. Damage or serious wear of the inner shifting parts, or looseness or attainment of the shift toggle fork assembly on the guide shaft. Unsuitable adjustment of shift lever. Adjust or repair the shift lever mechanism. Mechanic gearshift seizing at a certain location Overlarge loose fit clearance of the shift toggle fork on the shift guide shaft. Wear of the shift toggle fork assembly including pin and contact roller. Wear of the shift cam hub and the liner. Attainment of coupling gear Adjust or repair shift lever.Open the transfer box to check the toggle fork and guide shaft, and change the parts as requirement.Open the transfer box to check whether the parts is wearied or not, and, if any, change the weary parts.Open the transfer box to check whether the parts is wearied or not, and, if any, change the weary parts.Open the transfer box to check whether the parts is wearied or not, and, if any, change the weary parts. No driving of front wheel in the fourgear engagement Drive chain break Disassemble and check the damage of inner parts, and change the chain. Noise, which is spreader by the transfer box instead of clutch, engine, drive shaft and other parts, occurs in each speed. Incorrect lubricant or insufficient lubricant volume. Looseness of connecting bolt or other connecting element. Noise from the transfer box bearing Change the lubricant or supplement the lubricant volume. Guarantee the torque of all connecting elements stand at the specified value. Open the transfer case to check the bearing and othe parts whether is weared or daamaged,if this happened,change the parts. Engagement failure of the mechanically shift transfer box Change the seriously wearied parts. Change the loose or weary parts. Transfer Box  Troubleshooting TF-4 Common troubles Causes Resolving approaches Noise, which is spread by the transfer box instead of the clutch, engine or other parts, occurs at each speed. Gear noise. Damage or wear of chain gear or chain. Open to check whether there is weary element or damaged element (including the odometer gear) and, if any, change them Noise occurs in the high-speed or lowspeed four-gear driving. Unsuitable tire pressure. Open to check whether there is wear or damage, and if any, adjust the tire pressure to suitable value. Oil leakage in transfer box. Frame Break of transfer box. Oil leakage of other element. Ventilation pipe block Change the frame. Check the leakage by wiping dry. Open and clean it and, if necessary, change it. Use the specified lubricant and adjust the lubricant to suitable volume. Propel the bolts tightly as requirement. Over-added lubricant or lubricant of unsuitable brand Looseness of the bolts on sealing face. Sealing glue of different brand or unused sealing glue. Oil seal wear or damage. Use the specified sealing glue and propel the bolts tightly as required. Transfer Box  Product Description and Simple Maintenance TF-5 Product instruction and simple maintenance 1. Product Introduction The transfer box adapted by our company is the transfer box of 45-55 manufactured by Bogeguana, which is two-speed and time driving, a set of planetary mechanism used is to borgwarner Transfer Assembly NO. of Manufacturer obtain the speed-reducing performance, while the driving force is transmitted to the front driving gear by a highly precise chain. The planetary gear train and rear output shaft element of transfer box is lubricated initiatively through oil bath and oil pump. This transfer box has four gears:  2H-stands for the two high gears in which, only the two rear wheel are driven, and the gear ratio of the transfer box is 1:1 product assembly NO.  Manufactuer data displaytermnumber displaythe last digit of the year displaythe specific monthly manufactuer data displaythe month numnber Example display:From January (A) to December (L) Product instruction and simple maintenance  4H-stands for the four high gears, in which , all of the four wheel are driven, and the gear ratio of the transfer box is 1:1 N- neutral location (this location only exists in the transfer box of manual gearshift ) No driving force is transmitted to the wheel when the input shaft and output shaft are disconnected.  4L-stands for low gears, the four wheels are all driven, and the gear ratio of transfer box is 2.48:1. The gearshift of the mechanical gearshift transfer box is obtained through the shifting-cam-type guide plate that is operated by the shift rocker arm. Sign board: which is fastened at the obvious external location of transfer box, and on which the detailed data are marked. Transfer Box  Product Description and Simple Maintenance TF-6 2. Regular lubricant change (a) The oil level of lubricant in transfer box shall be checked when exchanging the engine lubricant or after the vehicle covers 8000 kilometers, and the lubricant shall be added as requirement. (b) The lubricant shall be changed with the specified one every year or after the vehicle covers 48000 kilometers. lubricant grade: ATF--3 3. 5D Lubricant inspection approach (a) Clean the oil filling plug and the around area. (b) Open the oil-filling plug to check whether the lubricant 5L can flows out or not. (c) 5D-Oil filling plug 5L-Oil drain plug if the lubricant can flow out, which means the real lubricant volume is under the prescribed value, and the specified lubricant shall be added into the transfer box until the lubricant can flow from the oil filler hole. (d) Propel the oil-filling plug tightly according to the given Tightening moment. Tightening moment(1930)Nm Notice: The vehicle shall run for a certain time before checking or exchanging the lubricant so that the temperature of lubricant in transfer box may be a little higher. Do not use hammer or other punching tools to open or propel the oil drain plug or oil filling plug, otherwise, 4. the thread hole on the frame will be damaged Lubricant change (a) Clean the oil filling plug and oil drain plug and the around area. (b) Put down a oil container under the transfer box. (c) Open the oil drain plug. (d) Open the oil-filling plug. (e) Drain the lubricant up. (f) Mount the oil drain plug and screw it up according to the given Tightening moment. Tightening moment(1930)Nm (g) Add the lubricant through the oil filler hole until the lubricant overflows. Mount the oil-filling plug and tighten it according to the Tightening moment. Tightening moment : (1930)Nm Transfer Box  Disassembly and Mount of Transfer Box TF-7 Disassembly and Mount of Transfer Box 4 3 2 1 7 8 9 1. input shaft 2. front frame of transfer box 3. rear cover of transfer box 4. flange 5. front output fork flange 6. venting valve 7. gasket 8. rear body of gearbox 9. bolt 1. 6 5 Transfer Box Disassembly Notice: The transfer box shall be guaranteed to (a) Drive the vehicle on the lifting jack. (b) Locate the gear of transfer box at the neutral support by the lifting jack before tearing down the sets of bolt and nut that connected with the position, shift the transfer box to the 2H and extinguish the engine. transfer box and gearbox. The transfer box is not allowed to hang directly on the gearbox (c) Disconnect the cell cathode. through spline because such operation will (d) Lift the vehicle. (e) Put down an oil disc under the transfer box, tear damage the transfer box parts. (l) Tear down the connecting nuts between the down the oil drain plug and oil filling plug of the transfer to drain all the lubricant up, then re- transfer box and gearbox and take down the transfer box. mount the two plugs. (m) Move the transfer box backward directly until (f) Disconnect all wires and wire harnesses that connected with the transfer box. the linkage between the input shaft of transfer box and the gearbox spline. (g) Take apart the hose on the venting valve of transfer shaft. (n) Put down the lifting jack of the transfer box, and (o) Tear down the gasket between the transfer box (h) Disconnect the linkage of the front drive shaft and gearbox. Clean the gasket or glue on the (i) with the front flange of the transfer box. Disconnect the linkage of the rear drive shaft coupling face of front body of transfer box with rear body of the gearbox. Take notice not to damage the coupling face. (j) with the rear flange of the transfer box. Raise the transfer box up with the jack. Transfer Box  Disassembly and Mount of Transfer Box TF-8 2. Transfer box mount a) (h) Connect the venting valve and the soft ventilation pipe. Coat the lubricant grease on the output axial spline of the gearbox with a thin sleeve containing lubricant grease. (i) Connect the cables of odometer that locates nearby the transfer box. b) Mount a new gasket on the mounting face of the transfer box. (j) Connect all wire harnesses that connected with the transfer box, and c) (k) Add the lubricant of right brand. Lift the lifting bracket of transfer box and align it to the same axle with the gearbox. Notice: The transfer shall be guaranteed to flush Notice: when starting the engine, if the lubricant is added incorrectly or in unsuitable volume, with the gearbox before connecting the spline. Do not handle it forcefully to press the transfer which may lead the transfer box to damage. box spline into the gearbox. Otherwise, damage Notice: as for the transfer box mounted on will be caused, run the rear output shaft where necessary to aim at the spline. vehicle, oil pump shall be used when adding oil for it. (d) Move the transfer box forward slowly so that Notice: In case the transfer box is taken apart for the spline and pin of the input shaft of gearbox maintenance or inspection, there will be no reach the front body of the transfer box, and the gasket attaches on the gearbox completely. lubricant supplied by oil pump in the oil passage on the top of transfer box. Therefore, it is not Ensure that the mounting holes of the front body of transfer box, gasket, and gearbox are in accurate to control the oil volume by opening the oil filling plug, in such condition, the oil passage alignment and then mount the sets of bolt and will be filled with oil once the oil pump runs. If the (e) nut. Fastening torque(35-48)Nm wheel can run, such operation can be conducted on the lifting jack. The oil level shall be rechecked (f) Connect the rear drive shaft and the rear output flange of the transfer box. once the oil pump runs. (g) Connect the front drive shaft and the front (l) Put down the vehicle after finishing the lubri- output fork flange of the transfer box. cant inspection, and connect the cell cathode. Transfer Box  Disassembly of Transfer Box 1 3 2 4 5 TF-9 Disassembly of Transfer Box 1. Brief instruction In case the transfer box is required to be repaired for the damaged specific element, it shall be taken apart to the degree on which the damaged element is taken out. And the parts taken apart from the transfer box, if it doesnít include the damage element, can exist in the form of sub-assembly or 6 group instead the individual form, otherwise, the parts will be taken apart individually. 2. Transfer Box Disassembly Put the transfer box on the worktable and ensure the rear part or the rear cover faces upward. Put the wooden block under the 1. rear body of transfer box 2. flange 3. oil seal 4. gasket 5. nut 6. oil plug front part of transfer box to keep the transfer box stands horizontally. The disassembly process is as follows: (a) Fasten the flange with the torque arm typed T-13-54002, screw off the nut to take down the gasket, then take apart the flange and oil seal. 1 (b) Take down the two oil plugs from the transfer box body. 2 As for the electric gearshift transfer box, tear down the electric shifting element according to the following disassembly approach: (a) Tear down the three bolts, gaskets, sensor and clip for 3 (b) 4 6 7 8 1. sensor bracket 2. bolt 3. speed sensor 4. o-ring 5. sensor assembly 6. bolt 7. gasket 8. rear body of transfer box wire harness. 5 4 Tear down the sensor assembly and take apart the Oring. (c) Tear down the motor assembly. Transfer Box  Disassembly of Transfer Box TF-10 8 7 9 10 11 6 5 3 4 2 1 16 13 17 14 15 18 9 19 1 8 7 2 3 Q 9 6 5 10 11 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 7 12 1. front case of transfer box 2. rear output shaft 3. cluch coil assembly 4. clip 5. bearing 6. nut 7. transfer cover assembly 8. mark plat 9. bolt 10. odometer drave gear 11. oil seal 12. oil seal 13. bearing 14. rear cover of transfer box 15. rolling needle bearing 16. shift guide shaft 17. back spring 18. magnet 19. bundle clip 3. The disassembly approach for rear cover is as follows (above figure) (a) Dismantle the nine screws and take down the clip of wire harness and signboard in the same time. Notice shall be taken to good keeping for the signboard, which includes the information for the substitutes to be changed. (b) Pry the frame lightly so that the sealing glue on the surface disengages, and then take up the transfer box rear cover assembly directly. (c) As for the electric gearshift transfer box, tear down the oil seal, bearing and three nuts and clutch coil assembly. (d) Tear down the snapping ring, pull out the bearing from the rear cover and take apart the odometer meanwhile. (f) Pull out the oil seal from the rear cover of the transfer box. (g) Tear down the magnet from the front body of transfer box. (h) Take apart the return spring from the shift guide shaft (i) Clear away the sealing glue on the coupling face of the front housing and rear cover of transfer box, take notice not to damage the coupling face of the two housings or cause the materials removed dropping into the transfer box. 4. Tear down the shifting element connected with the front axle. Tear down the following parts from the remaining transfer box housing assembly (electric gearshift). (a) Electric gearshift assembly, tear down the snapping ring and sliding clutch sleeve from the shift locking hub. (b) Tear down the shift-locking hub from the rear output shaft. (c) Tear down the shift engagement sleeve assembly and shift toggle fork from the rear output shaft and shift guide shaft. Separate the assemblies one another and tear down the shift guide shaft. (d) Disassemble the shift engagement sleeve assembly by taking apart the snapping ring, engagement sleeve, return spring, and locking sleeve. (e) A plastic toggle fork that substitutes the metal toggle fork assembly and a independent contact roller in earlier time. Transfer Box  Disassembly of Transfer Box 5. TF-11 Tear down the Chain drive system Take apart the following parts from the transfer box housing 2 5 4 3 assembly. (a) Take apart the snapping ring and washer from the front 1 output shaft. (b) Take apart the driving chain sprocket, driven chain sprocket and drive chain together from the two output 7 shafts. (c) Separate the chain sprocket from the chain. 6 1. output shaft 2. driving chain sprocket 3. driven chain sprocket 4. washer 5. snapping ring 6. transmission chain 7. front output shaft 6. 4 Oil pump assembly Take apart the shaft and pump assembly, pipe clip, oil pipe and filter from the remaining transfer box housing assembly. 7 5 6 3 2 1 1. output shaft 2. driving chain sprocket 3. driven chain sprocket 4. washer 5. snapping ring 6. transmission chain 7. front output shaft 7. 1 2 Deceleration shifting element disassembly Tear down the following parts from the remaining transfer box housing assembly. (a) Take apart the deceleration hub, and deceleration shift fork assembly from the housing. (b) Take apart two plastic inserted faces from the deceleration shift fork assembly 1. deceleration gear hub 3 7 4 2. inserted face of Shift 6 toggle fork 8 3. plastic sleeve 4. contact roller 5. pin 6. pin, contact roller and sleeve assembly 7. deceleration shift toggle fork 8. deceleration shift toggle fork assembly 5 (c) Disassembly the deceleration shift fork assembly only if it were broken.Cut the plastic cover,and take out the pin and truckle. Transfer Box  Disassembly of Transfer Box TF-12 8. 4 Take apart the following parts from the remaining transfer 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. 3 2 (b) The dust cover may also be pressed down from the front 1 fork-type flange where necessary, and (c) Take apart the front output shaft. 6 5 7 8 1. fork-type flange 2. dust cover 3. fork-type flange assembly 4. transfer box front housing 5. front output shaft 6. oil seal 7. washer 8. nut 9. 7 8 6 1 9 planetary mechanism assembly Tear down the following parts from the remaining transfer box 10 housing assembly (a) Take apart the venting valve. (b) Take apart the six bolts to separate the front body from 5 4 3 Tear down the front body, input shaft assembly and 2 the transfer box housing and take down the front body (take notice not to damage the front-end cover and the 16 11 14 transfer housing). 15 (c) 13 12 18 17 (loose the snapping ring to take apart the input shaft from the front end cover). (d) 19 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 20 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 Take apart the front body assembly, input shaft assembly and planetary mechanism assembly in grouping manner 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 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 (f) necessary. 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. Transfer Box  Disassembly of Transfer Box 10. Take apart the shift convex plate parts (for the electric 4 1 TF-13 shift transfer box) 3 2 5 (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. 2. 3. 4. 5. front body of transfer box housing shift guide shaft torsion spring electric gearshift gasket 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 6 5 4 3 1 2 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 7 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. Transfer Box  Transfer Box Assembly TF-14 Transfer box assembly 1. 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. 2. Lubricating during assembling All inner parts without lubricant shall be lubricated with the suitable lubricant before mounting, so that they can be assembled 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 7 leaded into damage even though they are run for a very short time. 6 5 4 3 (c) 1 2 3. Transfer box housing assembly 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 2 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. 3 NMR 1 (b) In case there are two locating pins taken apart, mount two (c) 1. oil seal 2. transfer box front housing 3. gear ring 4. locating pin The lips of oil seal and the metal elements that match with lips shall be lubricated before mounting. 4 new locating pins into the housing. 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. Transfer Box  Transfer Box Assembly 4. TF-15 Mechanic shift convex plate assembly (for electric shift transfer box) 4 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. 3 2 1 1. 2. 3. 4. shift guide shaft torsion spring electric shift convex plate gasket 1. torsion spring 2. gasket 3. shift shaft 1 (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). 2 3 1. torsion spring 2. gasket 3. shift shaft 1 2 3 (c) Twist the second spring ring of the torsion spring on shift shaft to the right side of the driving tongue. Transfer Box  Transfer Box Assembly TF-16 (d) Push the torsion spring and gasket backward together as 1. torsion spring 2. gasket 3. shift shaft 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 1 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 2 (f) can as possible. After mounting the toggle fork, then mount the electric shifting cam assembly in the transfer box housing assembly 3 5. 7 1 9 8 6 10 Assemble for front body, input shaft assembly and planetary 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. 5 4 3 (b) 2 16 Mount in the sun wheel and let the part with projecting end upward, run the gear of the planetary bracket assembly until it completely engages with the sun wheel. 11 14 (c) 15 13 12 18 17 19 20 11. transfer box frontbody assembly 12. oil seal 13. locating pin 14. transfer box front body 15. snapping ring 16. transfer box housing 6. planetary bracket 7. input shaft assembly 17. bearing 18. bearing gripping loop 8. input shaft 19. bolt 9. needle bearing 20. vent 10. bearing shell 1. planetary mechanism assembly 2. gasket 3. snapping ring 4. thrust disc 5. sun wheel 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 planetary bracket assembly. Transfer Box  Transfer Box Assembly TF-17 (e) In the case that the input shaft is taken apart, what need 1.25-1.75mm 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 1. needle bearing 2. bearing roller 3. input shaft 1 2 3 the fixed bearing in the snapping ring groove of the input shaft with a snapping ring. 3 (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. 12.70mm (h) Put down the oil seal as the drawing shows, and press it in the front body according to the dimensions shown in 2 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 1 housing faces upward, so that there is clearance left between the input shaft assembly and the worktable. Put 4 down the input shaft and planetary mechanism assembly in the front body, in which the input shaft shall be 1. locating pin 2. oil seal 3. front body of transfer box 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 4. snapping ring 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 4 glue shall be coated continuously without break and steer clear of the screwed hole. (k) Screw up the six bolts. Fastening torque(2746)Nm 3 2 1 6. Assembly of front output shaft Mount the following parts: 6 8 1. 2. 3. 4. 5 7 fork-type flange dust cover fork-type flange assembly transfer box housing 5. 6. 7. 8. output shaft oil seal washer nut (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(203244)Nm Transfer Box  Transfer Box Assembly TF-18 7. 2 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 1 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 3 run freely. (b) Mount two inserted faces of toggle fork on the decelera6 7 8 tion toggle fork assembly. (c) Engage the deceleration fork assembly and deceleration 9 gear sleeve and put them in the housing, and the decelera- 5 1. deceleration gear 4 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 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 8. Q Ensure the parts of oil pump are completely lubricated when assembling, and the oil can be pumped out from the conical T hole of the oil pump front cover. The mount of oil pump is as follows: R P Oil pump assembly S O N 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 (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. Transfer Box  Transfer Box Assembly 9. 2 5 4 3 TF-19 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 1 of the front output shaft on the worktable after the transfer box housing assembly mount. 1. output shaft 2. driving chain sprocket 3. driven chain sprocket 4. washer 5. snapping ring 6. transmission chain 7. front output shaft (b) Mount the chain on the sprocket. 7 6 (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 1 The parts mounting process is as follows (for the electric shift transfer box): 8 (a) Mount the return spring and locking hub on the locking sleeve and fasten them with snapping ring to finish the 7 2 4 9 5 2W-4W locking sleeve assembly. 6 (b) 3 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 10 11 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 rear output shaft spline as well as the 2W-4W locking sleeve. Transfer Box  Transfer Box Assembly TF-20 (e) 2 sembled electric shifting cam group and clutch shell in 3 4 convex plate groove As for the electric shift transfer box, encase the asthe 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 1 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 6 5 transfer box housing, meanwhile, joint the shift shaft on the pin in transfer box housing. 1. electric shift convex plate 2. torsion spring 3. shift shaft 4. gear down shift fork assembly 5. shift fork 6. gear shifting shaft (3) Locate the clutch shell well through the shift external gear sleeve and mount on the snapping ring. 11. Rear cover Assembly 4 1 2 Mount the parts into the rear cover according to the following 5 process: (a) Locate the rear cover on the suitable press machine, the 3 coupling face of the rear cover shall face upward and 6 7 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 40.4740.97 lower than 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 the coupling face of the rear cover that matches with the 8 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(811)Nm (2) Encase the motor bearing and oil seal in the rear cover. Transfer Box  Transfer Box Assembly 1. 2. 3. 4. 5. 6. bolt wire harness magnet return spring shift guide shaft transfer box rear body assembly V N T TF-21 12. Assembly of Rear Cover Mount the aforesaid accomplished cover assembly on the U transfer box housing according to the following process: (a) Mount the return spring on the shift guide shaft of the S 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 R housing, steer clear of the screwed hole when coating continuously. Q 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 P O NM N 7. sign board 8. driving gear of Odometer 9. oil seal 10. transfer box front housing 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 (d) All of the following aligning conditions shall be satisfied S Q when the rear cover assembly is mounted on the transfer R box front housing: a) Align the pin hole in the rear cover to the pin on the P O N housing. b) Align the rear output shaft to the inner bearing in cover rear hole. c) 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 1. locating pin 2. output shaft 3. shift shaft d) 4. return spring 5. shift guide shaft 6. output shaft. 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 O N through the spline of the rear output shaft. (g) Press the new oil seal in the cover assembly P Q 1. wire harness clip 2. motor assembly 3. bolt 4. sign board Transfer Box  Transfer Box Assembly TF-22 1 12. Mount the external electric shifting element (for the electric 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 2 1. motor assembly 2. shift shaft 2 1 close to the rear cover. Then run the motor clockwise until the motor locates the correct place and the mooting 4 5 holes are aligned. (c) Mount the O-ring on the velocity sensor and encase the 3 6 7 8 9 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 velocity sensor assembly in rear cover. A clip and three bolts shall be mounted on the velocity sensor. Fastening torque(811)Nm (d) Mount the bolts and gaskets on the end of motor clip. Fastening torque(811)Nm Transfer Box  Transfer Box Assembly 1 2 3 4 5 TF-23 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 6 1. transfer box rear body 2. flange 3. oil seal 4. gasket 5. nut 6. oil plug screw up the nuts. Fastening torque(203244)Nm TF-24 Transfer Box  Washing, Checking, Up-Keeping and Exchanging (Washing) Washing, Inspection, Maintenance or Change 1. 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. Transfer Box  Washing, Checking, Up-Keeping and Exchanging (Checking) TF-25 Checking 1. 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 abrasionRefer to the serious or obvious abrasion beyond of application limit.  Reduction changeMaterial slip caused by the heavy pressure on part of it.  adhesive bondingGranules of the soft metal are dispersed and bonded on the hard metal surface.  Ditch trance: partial crack or trough that means the material transfer instead of material loss.  Pitting corrosionDamages to the metal surface caused by pressure, which are displayed due to color change caused by heat generated by metal friction.  Step weara 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. 2. 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 (b) Normal gear grinding trace. normal gear grinding trace TF-26 Transfer Box  Washing, Checking, Up-Keeping and Exchanging (Checking) (c) Ideal engagement contact area (d) Acceptable side-deflective contact area (e) Unacceptable side deflective contact area that must be changed. (f) Acceptable side-deflective contact area (g) Unacceptable side deflective contact area that must be changed. Transfer Box  Washing, Checking, Up-Keeping and Exchanging (Checking) TF-27 (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. 4. 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. TF-28 Transfer Box  Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear) Maintenance or Change of Gear or Chain Sprocket Gear 1. Maintenance principle (a) Conduct the maintenance for the partial, small peel off with the suitable manual high-speed grinding tool. (b) Do not clear away the metal as can as possible when grinding the matrix metal. (c) All pointed angles and sides must be repaired as the slippery contour line. Because the pointed angle or edges may be peeled off again or developed into crack. (d) Clear away the burr with the suitable grinding stone. Take notice not to damage the matrix when clearing away the projecting materials, and (e) When substituting the non-repaired parts (such as bearing), if the part is doubted in its re-application capability, it must be changed. 2. Cases for gear or chain sprocket maintenance or substituting (a) The gear, being peeled off at the two sides of tooth top in contact face, may be repaired for reuse. (b) The gear, being peeled off at the central tooth top of contact face, may be repaired for reuse. (c) The gear, being peeled off at one side of the non-contact face, may be repaired for reuse. Transfer Box  Washing, Checking, Up-Keeping and Exchanging (Maintenance or Change of Gear or Chain Sprocket Gear) TF-29 (d) The gear, being peeled off at the center of one side of contact face, may be repaired for reuse (e) The gear, being peeled off in the center of contact area, shall be changed. (f) The gear, being peeled off at two sides of tooth top, shall be changed. TF-30 Transfer Box  Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts) Attachment for Inspection Maintenance or Change of Parts Parts (items) Checking items Acceptance/Refusal All parts (including all springs) Crack inspection, distortion inspection and erosion inspection All parts with crack, all parts that are bended, distorted or poor in round bouncing are refused. All threaded parts Thread inspection for buckle missing or other damage Those parts cannot be threaded or bottomed in overlap manner shall be refused. Flange and fork flange Please refer to the paragraph ofinspectionto check the spline. Please refer to theinspection paragraphfor spline inspection. Velocity sensor, motor assembly Parts of electric clutch system Please refer to the part of electric appliance Change the parts and fittings as requirement Sliding bearing Inside surface inspection for the sliding bearing In the case that the bearing has pitting corrosion or other damage, refuse it. Ball bearing Check visually the ball and track of the ball bearing to see whether there is damage such as adhesive bonding, pitting corrosion, etc. Ensure that the bearing are all lubricated, run the outer race of the bearing while holding the inner one to feel whether there is poor running or corrosion, the bearing shall be run smoothly without excessive clearance. Refuse to use the damaged bearing; Refuse to use the damaged or loose bearing; or Check the axial clearance to see whether it exceeds 0.23mm. Needle bearing Check the bearing needle roller and track to see whether there is damage such as adhesive bonding, pitting corrosion, etc. Refuse to use the damaged bearing. The rear cover, front body and front housing of transfer box Check to see whether there is burr on the coupling face or other damage that impedes assembling or sealing. Clear away the burr according to the paragraph of inspection, otherwise, change the damaged element Rear cover of transfer box Check the bearing hole Refuse to use the assembly that has pitting corrosion Odometer gear Check the gear teeth referring to the Inspection Refer to the gear or chain sprocket inspection in Paragraph inspection paragraph. Clutch shell, joint outer gear sleeve and joint cover Check the spline according to the Inspection paragraph Refer to the spline inspection of inspection paragraph Locking sleeve Check the wear or damage of the toggle fork groove Refuse the parts with step slipping or damage. Shift guide shaft Check the deformation situation Check the burr or other damage on outer race Check the wear of outer race Refuse to use the bend shaft; clear away the burr according to theinspectionparagraph, otherwise refuse to use. Refuse to use the shaft with step slipping or other damage. Shift toggle fork Check whether there is wear or damage at the location where the toggle fork combines with the shifting cam and gear sleeve. If any step slipping or damage is found, refuse to use it. Transfer Box  Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts) TF-31 Attachment for Inspection Maintenance or Change of Parts Parts (items) Checking items Acceptance/Refusal Shift toggle fork assembly Check the wear and damage of the inserted face that is combined with gear sleeve; Check to see whether the contact roller can rotate freely or is damaged or not If any step wear or damage is found, the inserted face shall be refused to use. If the contact runs difficultly or is damaged, a new pin-contact roller and new cage assembly shall be used. Driving and driven chain sprocket Check the sprocket teeth according to Refer to the sprocket teeth inspection of the inspection paragraph inspectionparagraph Shift toggle fork assembly Check the inner diameter that matches with the output shaft If any pitting corrosion or damage is found, refuse to use it. Driving chain Check the step sliding, looseness or damage of pin or connecting element Refuse to use the weary or damaged driving chain Filtering screen Check to see the filtering screen is clean or with Clean it where necessary, and abandon the damsmall hole or damage aged one. TF-32 Transfer Box  Washing, Checking, Up-Keeping and Exchanging (Attachment for Inspection Maintenance or Change of Parts Pump shell Check to see whether there is pitting corrosion or step slipping Abandon it in case it is seriously damaged or worn Output shaft Check the spline, check the surface that matches with bearing and check the distortion according toinspectionparagraph Refer to the spline inspection of inspection paragraph; Refuse to use the one with pitting corrosion or damage; Refuse to use the one that is bending or poor in round bouncing. Check the spline of chain sprocket and check the wear or damage of the location where matches with the toggle fork according to the inspectionparagraph Refer to the spline inspection of inspection paragraph; refuse to use the one with step sliding or damage. Deceleration hub Front output shaft Check the surface where matches with the Refuse to use the one with pitting corrosion or bearing; damage Check the spline according to theinspection: paragraph Input shaft Check the spline according to theinspection Refer to the spline inspection of inspection paragraph paragraph; Refuse the one that is bending or poor in round Check the distortion bouncing. Thrust washer and thrust disc Sun wheel Check the pitting corrosion Check the gear teeth and spline according to the inspectionparagraph Refuse to use the one with pitting corrosion or damage Refer to the gear teeth inspection and spline inspection ofinspectionparagraph. Planetary mechanism Check the gear teeth according to the Refer to the gear teeth inspection of inspectionparagraph; assembly inspectionparagraph; Check the wear and looseness of the planetary If any step sliding or pitting corrosion is found, refuse to use it gear pin; check the wear of thrust gasket Electric shifting cam Check to see whether there is step slipping or pitting corrosion If any step sliding or pitting corrosion is found, refuse to use it Shift guide shaft Check to see whether there is step slipping or pitting corrosion Check the distortion situation If any step sliding or pitting corrosion is found, refuse to use it Refuse to use the bending one Planetary gear ring Transfer box housing Check the transfer box housing assembly to see whether the gear ring is loose or not in the housing Check the gear teeth according to the Refer to the gear teeth inspection of inspectionparagraph inspectionparagraph Check the match performance of it with the transfer box housing Check the holes matches with the bearing Abandon the one with pitting corrosion or damage. PR-1 Drive shaft page Notice .......................................................................... PR-2 Troubleshooting .......................................................... PR-2 Drive shaft ................................................................... PR-3 PR PR-2 Drive Shaft  Notice and Troubleshooting Notice Notice: do not grip the drive shaft sleeve too tight with vice so as to avoid the deformation. troubleshooting Trouble Causes Resolving approaches Noise Wear of universal joint yoke spline; Wear of central bearing; Wear or seize-up of cross shaft bearing Change the drive shaft; Change the central bearing; Change the bearing of cross shaft Vibration Oscillation difference of the drive shaft; Drive shaft imbalance; Wear of the liner of rear bearing in the lengthening shell of gear box; Spline seize-up of the universal joint yoke Change drive shaft Change drive shaft Change the liner Change drive shaft Drive Shaft  Drive Shaft PR-3 Drive Shaft Element Drawing 2WD two-joint type universal joint flange fork    bearing of cross shaft  snapping ring  rear axle drive shaft universal joint foke 74  5  cross shaft three-joint type center support bearing  bearing of cross shaft flange front joint of rear axle drive shaft  snapping ring washer washer universal  cross shaft joint foke 40  5       universal joint flange fork universal joint flange fork 74  5 N*m : specified torque  Parts that cannot be reused after being used rear section of rear axle drive shaft 74  5 Drive Shaft  Drive Shaft PR-4 Element Drawing(continued) 4WD front axle drive shaft 74  5 74  5 front axle drive shaft rear axle drive shaft two-joint type  universal joint flange fork   bearing of cross shaft   snapping ring rear axle drive shaft 74  5 universal joint yoke  cross shaft 74  5 center support bearing flange  bearing of cross shaft three-joint type  snapping ring universal joint flange fork washer front joint of rear axle drive shaft 40  5 universal joint flange fork  74  5      rear section of rear axle drive shaft 74  5 N*m : specified torque  Parts that cannot be reused after being used 74  5 Drive Shaft  Drive Shaft PR-5 Disassembly of Drive Shaft assembly mark (2WD) 1. Take apart the universal joint flange fork of the drive shaft from the differential flange. (a) Label the two flanges with assembly remarks. (b) Take apart the four sets of bolt and nut. 2. Take apart the center support bearing from the frame beam (for the three-joint type) 3. Take apart the drive shaft from the gearbox (a) Pull out the universal joint yoke from the gearbox. (b) Insert the SST in gearbox for oil leakage prevention. SST assembly mark (4WD) Rear axle drive shaft 1. Take apart the universal joint flange fork of rear axle drive shaft from the differential flange. (a) Label the two flanges with assembly marks. (b) Take apart the four sets of bolt and nut. 2. Take apart the center support bearing from the frame beam (three-joint type Drive Shaft  Drive Shaft PR-6 3. Take apart the drive shaft from the gearbox. (a) Pull out the universal joint yoke from the gearbox. (b) Insert the SST in gearbox to prevent the oil leakage Front axle drive shaft SST 4. Tear down the front universal joint flange fork of the front drive shaft. (a) Hang he front end of the front axle drive shaft. (b) Label the assembly mark on the flange (c) Take apart the four sets of bolt and nut. 5. Disconnect the rear universal joint flange fork from the assembly mark front axel drive shaft along the transmission path. (a) Label the assembly marks on each flange. (b) Take apart the four sets of bolt and nut. assembly mark Drive shaft disassembly 1. Separation of the rear joint of the rear axle drive shaft from the front joint of rear axle drive shaft (a) Label the assembly marks on each flange. (b) Take apart the four sets of bolt and nut. 2. Take apart the center support bearing from the front joint of the rear axle drive shaft. (a) Loosen the riveted nut by chiseling with a chisel and hammer. Drive Shaft  Drive Shaft PR-7 (b) Lock the flange with SST tools to tear down the nuts. (c) Label the assembly marks on flange and shaft. assembly mark SST (d) SST assembly mark Tear down the flange from the front joint of rear axle drive shaft with SST tools. 3. Take apart the universal joint yoke from the rear joint of rear axle drive shaft. (a) Label the universal joint yoke and the shaft with assembly marks. (b) Pull out the universal joint yoke from the shaft. Inspection on Drive Shaft Parts 1. Cross shaft bearing inspection Check the wear or damage situation of the cross shaft bearing and change the weary or damaged bearing where necessary. 2. Check the wear and damage situation of the central bearing. Check the bearing to see whether it can run freely. In case that the bearing is damaged or wearied or cannot run freely, change it in time. Drive Shaft  Drive Shaft PR-8 3. Inspection for the front axle drive shaft (a) Check the wear or damage situation of the shaft. (b) Check the wear or damage situation of the two universal joints grease nozzle 4. Inspection for the drive shaft lubrication If the drive shaft is not lubricated completely, add the Lithium base lubricant grease with SST. rear axle drive shaft front axle drive shaft Cross bearing change assembly mark assembly mark 1. Label the shaft and universal joint yoke with assembly marks. 2. Take apart the snapping ring. (a) Tap in the outer bearing race lightly. (b) 3. Take apart the four snapping rings in the grooves with two screwdrivers. Take apart the cross shaft bearing (a) Pull out the bearing from the drive shaft with SST tools. SST A Remarks: Pull up the part A in the drawing to a enough height so that it cannot contact the bearing. Drive Shaft  Drive Shaft PR-9 (b) Grip the outer bearing race with a vice to tap out the drive shaft lightly with a hammer. Remarks: Take apart another bearing with the same approach. (c) Mount the two outer bearing races that are taken apart on the cross shaft. (d) Pull out the bearing on the universal joint yoke with SST SST tool, and (e) Grip the outer bearing race in the vice and tap lightly out the universal joint yoke with a hammer. Remarks: the bearing at the other end may be taken apart with the same approach. 4. Cross shaft bearing mount (a) Coat the lithium base grease on the cross shaft and the bearing. Remarks: do not over coat the lubricant. (b) Align the assembly marks on the universal yoke and on the shaft. Drive Shaft  Drive Shaft PR-10 (c) Encase the new cross shaft in the universal joint yoke. SST (d) Mount the new bearing on the cross shaft with SST tool, and (e) Adjust the two bearings with SST tool so that the widths of two snapping ring grooves are equal and maximum. 5. Snapping ring mount (a) Mount two snapping rings with the same thickness. Remarks: Do not use the used snapping ring. (b) Tap the universal joint yoke lightly with a hammer until there is no clearance between the outer bearing race and the snapping ring. 6. Cross shaft bearing inspection Check the cross shaft bearing to see whether it can run freely Remarks: the approach for mounting the cross shaft bearing at the bearing end is the same. Drive Shaft  Drive Shaft 2WD 4WD PR-11 Drive shaft assembly 1. Mount the center support bearing on the front joint of rear forward axle drive shaft. Remarks: The notch of the center support bearing shall face backward when mounting it. assembly mark 2. Mount the flange joint on the front joint of rear axle drive shaft. (a) Coat the spline of front joint of rear axle drive shaft with lithium base grease. (b) Mount flange joint on the shaft and align the assembly marks. Remarks: if the central flange joint or the front joint of the rear axle drive shaft is required to change, the front and back universal joint yokes of the rear axle drive shaft shall face in the same direction when re-assembling. (c) Lock the flange joint with SST and screw up the newly- SST changed nut to press the bearing in place. (d) Loosen the nuts. (e) Tighten the nuts again, and (f) 3. Drive shaft mount (a) assembly mark Rivet the nuts with hammer and punch. Align the assembly marks on flanges, and connect the two flanges with four sets of bolt and nut. Remarks: if the central flange or the front joint of the rear axle drive shaft is required to be changed, the front and back universal joint yokes of the front joint of rear axle drive shaft shall face in the same direction when reassembling them. (b) Screw up the sets of bolt and nut according to the specified torque. Fastening torque: (74  5)Nm 4. Insert the universal joint yoke in the universal joint yoke assembly mark (4WD). (a) Coat the lithium base grease on the sliding surfaces of the drive shaft spline and the universal joint yoke. (b) Align the assembly marks on universal joint yoke and drive shaft. (c) Insert the universal joint yoke in drive shaft. PR-12 Drive Shaft  Drive Shaft Mount of Drive Shaft (2WD) 1. Insert the universal joint yoke in the gearbox. (a) Tear down the SST tools. (b) Push the universal joint yoke into the gearbox. SST assembly mark 2. 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)Nm 3. 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 forward drive shaft, and change it where necessary. (c) Check the central line of the central bearing and ensure that the central lines of the central bearing and the bearing seat shall be the same when the vehicle is in the nonloaded 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)Nm assembly mark (4WD) 1. 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)Nm Drive Shaft  Drive Shaft 2. PR-13 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)Nm assembly mark 3. 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)Nm 4. 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 forward 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)Nm 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 Suspension System and Automobile Axle  Troubleshooting SA-2 Troubleshooting Trouble Body wandering/body dragging Causes Tire wear or improper air inflation Incorrect alignment of front wheel Over-tightened wheel bearing Part looseness or damage of front/rear suspension Wear or looseness of steering rod system Poor connection or damage of steering device Inspection items 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/updown 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 mechanism 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 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 Discharge the oil and change with new one Check the wandering clearance Check the gears Change the bearing Change the bearing Tighten or change the bearing Suspension System and Automobile Axle  Alignment of Front Wheel (Dr SL SK SY SJ) SA-3 Alignment of Front Wheel (Dr SL SK SY SJ) 1. 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. 2. Measure the ground clearance of the chassis. Chassis ground clearance: Dr2950+5mm SL SK(255  2)mm SY(310  2)mm SJ(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. 3. Mount on the four-wheel locating device. The mount should be conducted according to the manufacturerís instructions. Suspension System and Automobile Axle  Alignment of Front Wheel (Dr SL SK SY SJ) SA-4 A B B A 4. 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 ( 3640) SJ ( 3234) Remark: The wheel should not contact the body or brake hose front 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)Nm(SJ) If the wheel angle fails to be adjusted within the standard value, adjusting bolt change the weary or damaged parts of steering system. 5. inner tilt angle of kingpin outer tilt angle of front wheel 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 back tilt angle of kingpin Back tilt angle of kingpin Applicable vehicle type Location parameter Dr SL SK SY 930 45 SJ 1452 Mechanic steering Power steering Dr SL SK SY 030 20 Dr SL SK SY 010 10 020 10 SJ 030 15 Mechanic steering Dr SL SK SY 150HPM -20 Power steering Dr SL SK SY SJ 245 15 3 15 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. Suspension System and Automobile Axle  Alignment of Front Wheel (Dr SL SK SY SJ) 6. Wheel toe-in adjustment (a) push forward the vehicle; SA-5 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 (c) marks on left and right treads. 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 forward 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 A the two rods are same in length. Length error of the left and right drag rod should not B A=B be larger than 2.0mm. (g) Tighten the clamping bolts. Fastening torque(20 ) Nm (h) Locate the split pin well. 7. Check the sliding measuring situation. Check the sliding situation with the sliding measuring tester. Sliding measuring value: .5m/km SA-6 Suspension System and Automobile Axle  Alignment of Front Wheel  Alignment of Front Wheel (SF) Alignment of Front Wheel (SF) 1. 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. 2. 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. A B: The center height of the adjusting cam bolt at front end The standard value for the unloaded height is: the B difference of the center height of drive shaft climax and the front adjusting cam bolt is 58.5mm. 3. Mount on the four wheel locating device This approach should be conducted according to the detailed instruction of the equipment manufacturer. the outer tilt angle of front wheel the back tilt angle of kingpin 4. Adjust the outer tilt angle of front wheel and the back tilt angle of kingpin The outer tilt angle of front wheel: 05'  0' front The back tilt angle of kingpin: 20'  0' Outer inclination of front wheel: Suspension System and Automobile Axle  Alignment of Front Wheel  Alignment of Front Wheel (SF) SA-7 In case the outer tilt angle of front wheel or the back tilt angle front cam adjustment of kingpin fails to conform to the specified value, adjust the cam forward or backward may amend them. reduce increase rear cam adjustment increase A reduce B B A 5. 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. front 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. 6. 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. Suspension System and Automobile Axle  Alignment of Front Wheel (SF) SA-8 (c) Mark the center of the back of front wheel, and measure B the distance ìBî between the remarks on the left and right tires. forward (d) Push the vehicle forward so that the mark on the back of move the vehicle forward 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 A 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. front A (i) Ensure the left and the right drag rods are same in length. B A=B Suspension System and Automobile Axle  Alignment of Front Wheel (SF) SA-9 (j) Tighten the clamping bolts and lock them with split pin. Remark: the clamping bolt should face the front of the vehicle. front (k) Side-slip inspection Sideslip: =5m/km SA-10 Suspension System and Automobile Axle (Dr/2WD)  Front Wheel Hub and Steering Knuckle Front wheel hub and steering knuckle Element Drawing Dr 85-105 front brake shell 25-28 front wheel hub snap ring  front wheel hub oil seal brake caliper bearing 30205 plain washer 98-118 locking nut  bearing 32007 front wheel hub cap front wheel hub and front brake disc stop washer dust cover  steering knuckle arm steering knuckle 100-120   132-152 Nm : specific torque  Used component which can not be used any more Suspension System and Automobile Axle (Dr/2WD)  Front Wheel Hub and Steering Knuckle (Front Wheel Hub) SA-11 Front Wheel Hub Disassembly of Front Wheel Hub 1. Take apart the brake caliper. Disassembly the wheel hub and suspend it with tightwire. Remark: Donít dismantle the brake hose and brake metal pipe 2. Take apart the front wheel hub cap. Takeapart the front wheel hub cap from the gap between the front wheel hub cap and the front wheel hub. 3. 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. 4. 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. 5. 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. SA-12 Suspension System and Automobile Axle (Dr/2WD)  Front Wheel Hub and Steering Knuckle (Front Wheel Hub) 6. 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)Nm (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 7. 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 1. Mount on the Bearing 32007 inner race and roller assembly 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. 2. 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) 3. 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 4. washer. Preload adjustment (a) Mount on the lock nut and screw up according to the specified torque. Fastening torque(130-150)Nm (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)Nm (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 reasonable range, screw up the nuts again until the tension force falls within the reasonable range. (e) 5. 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 SA-14 Suspension System and Automobile Axle (Dr/2WD)  Front Wheel Hub and Steering Knuckle (Front Wheel Hub) 6. Tap in the front wheel hub with a rubber hammer 7. Mount the brake caliper on the steering knuckle. Fastening torque(85-105)Nm Steering Knuckle Disassembly of Steering Knuckle 1. Take apart the brake caliper, the front wheel hub and the front brake disc. 2. 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. 3. 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) SA-15 Mount the steering knuckle 1. Mount the steering knuckle (a) Support the lower arm of the steering knuckle with a jack. (b) Mount the steering knuckle on the lower ball stud and screw on the nuts. (c) Press the upper arm to mount on the steering knuckle and screw on the nuts. (d) Screw up the nuts of the upper ball stud according to the specified torque. Fastening torque(100-120)Nm (e) Screw up the nuts of the lower ball stud according to the specified torque. Fastening torque(98-118)Nm (f) Mount on the split pin between the upper and lower ball studs. 2. Mount the steering knuckle arm and the front brake shell; (a) Screw up the two bolts of M8X16. Fastening torque(25-28)Nm (b) Screw up the two bolts and groove nuts (M12X67) to the specified torque. Fastening torque(98-118)Nm (c) Mount on the two split pins. In case the pin hole in the ball stud are not in alignment with the groove nut, adjust the fastening torque and the rotating angle under the condition that satisfying the minimum torque, so as to ensure the torque falls within the specified range, if cannot, mount the split pin with the minimum torque beyond 3. 4. the range Mount the front wheel hub and the front brake disc. Check the Alignment of Front Wheel. (See SA-3) Suspension System and Automobile Axle (Dr/2WD)  Front Suspension SA-16 Front suspension Element figure Dr  rubber liner assembly for  the upper arm 90  110    pinch gasket of the upper arm shaft bush 25  28  110  10  23  3 transverse stabilizer rod  ! torsion bar 23  3 shock  absorber rocker arm 80  10 226  25  80  10   142  10 lower arm lower ball stud 150  10  guide lever Nm : specified torque  Parts that cannot be reused after being used torsion fork 65  70 96  10 Suspension System and Automobile Axle (Dr/2WD)  Front Suspension (Ball Stud) SA-17 Ball stud Inspection on Ball Stud 1. Check the lower ball stud to see whether it is excessively loose or not. (a) Prop up the front of the vehicle with jack and then support it with the bracket. (b) Tread down the brake pedal after verifying that the front wheel are in straight line. (c) Move the arm vertically to check the lower ball stud to see whether the clearance is overlarge. Max vertical clearance : 0.5mm 2. Check the upper ball stud to see whether it is over-loose. Move the wheel vertically to check whether the clearance of the ball stud is over large. 3. Check the rotating performance of ball stud (a) Take apart the ball stud. (b) Shake the ball stud several times forward and backward before mounting on the nut, as shown in the drawing. (c) Rotate the nut continuously with a torsion meter, which rotates the nut round per 2 to 4 seconds, and read the reading of the torsion meter after the fifth round. Fastening torque (running) Lower ball stud: (0.1-4)Nm Upper ball stud: (0.1-4)Nm Disassembly of Ball Stud 1. Tear down the steering knuckle. 2. (see the SA-14). Take apart the lower ball stud from the lower arm; and 3. Take apart the upper ball stud from the upper arm. SA-18 Suspension System and Automobile Axle (Dr/2WD) Front Suspension (Ball Stud) Mount of Ball Stud 1. Mount the upper ball stud on the upper arm; Fastening torque26Nm 2. Mount the lower ball stud on the lower arm; Fastening torque65Nm 3. Mount on the steering knuckle (see page SA-15) Suspension System and Automobile Axle (Dr/2WD)  Front Suspension (Torsion Rod Spring) SA-19 Torsion Rod Spring Dismantle of Torsion Rod Spring 1. Use the jack to raise up the frame and support it with the bracket. 2. Take apart the locking nuts to measure the length of the projecting end of the bolts, as shown in the drawing. Remark: This measuring value can be referred when adjusting the chassis ground clearance. 3. Take apart the dust cover. 4. Loosen the regulating nut until there is no tension on the torsion rod spring. Dr SL SK SY 5. Take apart the torsion arm, torsion rod spring and the torsion regulating arm. (a) Tear down the mounting nuts of the torsion rod arm. (b) Take apart the torsion regulating arm from the adjusting bolt, the torsion regulating arm should be taken apart with the torsion rod spring and the torsion rod arm together. SF SJ SA-20 Suspension System and Automobile Axle (Dr/2WD) Front Suspension (Torsion Rod Spring) Mount of Torsion rod Spring Notice: the torsion rod spring marked with L (left) or R (right), do not mount the springs at the incorrect location. 1. Mount the torsion rod spring, pedestal arm and torsion arm; (a) Coat the lithium base grease on the spline of torsion rod spring. (b) Align the wide-teeth parts and then mount the pedestal arm on the torsion rod spring. (c) Align the wide-teeth parts and then mount the torsion arm on the torsion rod spring. (d) Mount the torsion rod spring on the side of torsion arm and mount on the pedestal arm on the adjusting bolts. (e) Screw up the torsion arm nuts according to the specified torque. Fastening torque(83 )Nm (f) Screw up the adjustable nuts so that the protruding length of the bolt is equal to that before tearing down. (g) Mount on the wheel and dismantle the bracket, bounce the vehicle several times so as to make the suspension in place. (h) Screw up the adjustable nut to regulate the ground clearance. front  2. Tighten the locking nuts according to the specified torque. Tighten torque (83  5)Nm 3. Mount on the dust cover. Suspension System and Automobile Axle (Dr/2WD)  Front Suspension (Lower Arm and Vibration Damper) SA-21 Lower Arm and Vibration Damper Disassembly of Lower Arm And Vibration Damper 1. Take apart the torsion rod spring. (see page SA-19) 2. Take apart the ending part of the torsion rod (a) Take apart the split pin and nuts. (b) Take apart the ending part of drag rod. 3. Take apart the vibration damper 4. Take apart the transverse stabilizer rod from the lower arm. 5. Take apart the guide lever from the lower arm; 6. Take apart the lower ball stud. SA-22 Suspension System and Automobile Axle (Dr/2WD)  Front Suspension (Lower Arm and Vibration Damper) 7. Take apart the lower arm Tear down the nuts and lower arm. Change of Lower Arm Shaft Bush 1. 2. Take down the shaft bush. (a) Shear off the rubber on shaft bush, as shown in drawing. (b) Take apart the shaft bush. Mount the shaft bush. Mount on the new shaft bush. Mount of Lower Arm And Vibration Damper 1. Mount on the lower arm. Adjust the lower arm in the unloaded stage when screw up the axial bolts of the lower arm. Fastening torque(226  5)Nm 2. Lower ball stud and lower arm connection Assemble the lower ball stud and lower arm with three bolts. Fastening torque65Nm Suspension System and Automobile Axle (Dr/2WD)  Front Suspension (Lower Arm and Vibration Damper) 3. SA-23 Mount the guide lever on the lower arm Fastening torque(96  0)Nm 4. Link the transverse stabilizer rod with the lower arm. Fastening torque(23  3)Nm 5. Mount the vibration damper. 6. Mount the ending part of the drag rod: (a) Link the drag rod end to the steering knuckle arm, mount and screw up the nuts according to the specified torque. Fastening torque(91  0)Nm (b) Lock the nut with the new split pin. 7. 8. Mount the torsion rod spring. Check the Alignment of Front Wheel. (See the page SA-3) SA-24 Suspension System and Automobile Axle (Dr/2WD)  Front Suspension (Upper Arm) Upper Arm Dismantle of Upper Arm 1. Take apart the ball stud from the upper arm: (a) Support the upper arm with a jack. (b) 2. Take apart the four sets of bolt and nut. Take apart the upper arm (a) Tear down the bolts and adjusting gasket. (b) Take apart the upper arm. Remark: Do not lose the adjusting gasket. Write down the gasket thickness so that it can be mounted on the original place. Change of the rubber liner of Upper arm shaft 1. Tear down the rubber liner of the upper arm. (a) Tear down the bolts and the pinch-off gasket of the upper arm shaft bush. (b) Push out the rubber liner of upper arm with tools. 2. Mount the upper arm rubber liner. (a) Push in the rubber liner of the upper arm with tools. (b) Mount on the pinch-off gasket of the upper arm shaft bush and tighten the bolts manually. Remark: it is not required to screw up the bolts according to the specified torque. Mount of Upper Arm 1. Screw up the axle bolts of the upper arm according to the specified torque, Fastening torque(100  0)Nm Suspension System and Automobile Axle (Dr/2WD)  Front Suspension (Upper Arm) 2. SA-25 Mount the upper arm (a) Mount on the upper arm and the regulating gasket. (b) Screw up the bolts according to the specified torque. Fastening torque(96  0)Nm Remark: Mount back the gaskets of the same thickness in the same number on the original locations. 3. Connect the upper ball stud and upper arm together. Fastening torque26Nm 4. Check the Alignment of Front Wheel (See page SA-3) SA-26 Suspension System and Automobile Axle (Dr/ 2WD) Front Suspension (Guide Lever) assembly mark Guide Lever Disassembly of Guide Lever 1. Mark the assembly mark on the guide lever. 2. Tear down the front fixing nuts from the guide lever. 3. Tear down the guide lever from the lower arm. Tear down the nuts that fix the guide lever on the lower swimming arm, and then tear down the guide lever. assembly mark Mount of Guide Lever 1. Mount on the front fixing nuts Mount on the front fixing nuts and meanwhile align the assembly marks on the guide lever. 2. Mount the guide lever on the bracket (a) Mount the washer and liner on the guide lever, and then mount the guide lever on bracket. (b) Mount the sleeve ring, the liner and the washer on the guide lever. 3. (c) Screw up the fixing nuts with finger. Mount the guide lever on the lower swing arm. Screw up the fixing nuts according to the specified torque. Fastening torque(96 )Nm 4. Screw up the fixing nuts according to the specified torque, (a) Dismantle the bracket so that make the vehicle bounce sever times to put the suspension in balance. 5. (b) Screw up the front fixing nut. Check the Alignment of Front Wheel (See Page SA-3) Suspension System and Automobile Axle (Dr/2WD) Front Suspension (Transverse Stabilizer Rod) SA-27 Transverse stabilizer rod Dismantle of Transverse Stabilizer Rod 1. Tear down the torsion rod spring 2. Tear down the transverse stabilizer rod from the lower swing arm, (a) Tear down the nuts and cushion blocks that support the two sides of the stabilizer rod from the lower swing arm so as to disconnect the stabilizer rod. (b) Tear down the liner and bracket of the stabilizer rod and then tear down the stabilizer rod. Mount of Transverse Stabilizer Rod 1. Put the transverse stabilizer rod on the frame, Lay the stabilizer rod in place, and mount the stabilizer rod liner on the bracket, then mount the bracket on frame, finally screw up the bolts with fingers. 2. Connect the transverse stabilizer rod to the lower swing arm. Connect the two ends of stabilizer to two lower swing arm with bolts, cushion blocks and new nuts. As shown in the drawing, tighten the nuts according to the specified torque. Fastening torque(29 )Nm 3. Screw up the locating bolts according to the specified torque, Fastening torque(29 )Nm 4. Mount on the torsion rod spring. SA-28 Suspension System and Automobile Axle(SF/2WD) Front Suspension Front wheel hub and steering knuckle Element figures SF2WD nut upper arm transverse stabilizer rod locking ring bolt cushion block cushion block stabilizer rod gasket  rubber snubber washer locking ring rubber snubber washer Brake caliper stabilizer rod gasket  restrictor tube stabilizer rod gasket  shock absorber 132  152 123  stabilizer rod gasket  steering knuckle  70-90 127-147 lower ball stud transverse stabilizer rod gasket  132-152 20-26  brake oil pipe bracket 180 steering knuckle arm  brake shell 25  29 stop washer lock plate  oil seal -front hub front wheel bearing(inner) liner dust cover 135-155 front wheel hub and front brake disc front hub bearing (outer) steering knuckle nut 23  29  steering knuckle outer flange cap Nm :specified torque  Parts that cannot be reused after being used Suspension System and Automobile Axle (SF/2WD) Front Wheel Hub and Steering Knuckle (Front Wheel Hub) SA-29 Front Wheel Hub Disassembly of Front Wheel Hub 1. Tear down the brake caliper. (a) Tear down the brake Bundy tube from the brake caliper, and block the Bundy tube line with a cork. (b) Tear down the brake caliper from the steering knuckle. 2. Tear down the steering knuckle outer flange cap. 3. Tear down the front wheel hub and brake disc. (a) Open the lock plate with a screwdriver. (b) Tear down the steering knuckle nut with the SST tools to take out the. lock plate (c) Tear down the other steering knuckle nut with SST tools to take out the stop washer and the steering knuckle outer bearing. (d) 4. Tear down the front wheel hub and the brake disc assembly. Tear down the front hub, oil seal, front hub bearing (inner) inner race and roller assembly. (a) Pry out the oil seal. Notice: the deformed oil seal should not be reused. (b) Take out the front hub bearing (inner) inner race and roller assembly. SA-30 Suspension System and Automobile Axle (SF/2WD) Front Wheel Hub and Steering Knuckle (Front Wheel Hub) 5. Front hub bearing outer race inspection and change (a) Check each bearing Wash the inner and outer races of each bearing, and check them whether they are wearied or damaged. (b) Tear down the outer race of each bearing. Tap out the bearing outer race with copper bar and hammer. Notice: bind the dismantled inner and outer races of bearing together to prevent from mixing. 6. Front brake disc inspection and change (a) Check the wear situation of front brake disc. (b) Tear down the bolts that connect the front wheel hub and front brake disc. (c) Connect the front wheel hub and front brake disc and screw up the bolts with moment spanner to the specified torque diagonally Fastening torque(70-80)Nm (d) Conduct the dynamic balance test on the dynamic balancer, the amplitude value displayed should not be above 13.5g under the condition that the measuring rotating velocity is 796 r/m and the locking rotating velocity 786 r/m, otherwise, tap in the counter balanced clip, which is 4g each, at the corresponding location, the number of the clip should not be more than 4. (e) Tap in the new bearing outer race with the special service tool. Notice: the inner and outer races of bearing should be changed in set. Assembly of Front Wheel Hub 1. Mount on the inner race and roller assembly of front hub bearing (inner) as well as the front hub oil seal. Coat the lithium base grease of 4 to 5 mm on the inside surface of the bearing outer race and front wheel hub, and plaster the lubricant in the front hub bearing (inner) and the roller assembly. Coat a little lubricant on the lips of oil seal of front wheel hub, and then tap the oil seal of front hub in place with special service tool. Notice: do not coat the lubricant on the front brake disc face. Suspension System and Automobile Axle (SF/2WD) Front Wheel Hub and Steering Knuckle (Front Wheel Hub) SA-31 2. 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. 3. 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. 4. Adjust the preload (a) Mount on the steering knuckle nut and screw up them according to the specified torque. Tighten torque: (100-120)Nm (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 torque25Nm (d) Mount on the lock plate and another steering knuckle nut. Tighten torque60Nm (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. SA-32 Suspension System and Automobile Axle (SF/2WD)  Front Wheel Hub and Steering Knuckle (Steering Knuckle) (h) Bend one tooth of the lock plate inside and other teeth outside to lock the steering knuckle nut. 5. Mount on the liner and the steering knuckle outer flange cap. Fastening torque(23-29)Nm 6. Mount the brake caliper (a) Mount the brake caliper on the steering knuckle and screw up the bolts according to the specified torque. Fastening torque123Nm (b) 7. Connect the Bundy tube. Fastening torque(20-22)Nm 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 1. Tear down the brake caliper, front wheel and the front brake disc. 2. Tear down the dust cover, and the brake shell. 3. Tear down the steering knuckle arm from the steering knuckle. Suspension System and Automobile Vehicle (SF/2WD) Front Wheel Hub and Steering Knuckle (Steering Knuckle) SA-33 4. Tear down the vibration damper from the lower arm. 5. Tear down the transverse stabilizer rod from the lower arm. 6. 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. SA-34 Suspension System and Automobile Axle (SF/2WD) Front Wheel Hub and Steering Knuckle (Steering Knuckle) 7. Tear down the lower ball stud assembly from the steering knuckle. Inspection on and Change of Steering Knuckle 1. 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 1. 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)Nm 2. 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)Nm 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)Nm 3. Mount the stabilizer rod on the lower arm. Fastening torque(20-26)Nm 4. Mount the vibration damper on the lower arm. Fastening torque(127-147)Nm 5. 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 torque180Nm 6. 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 concentric with the steering knuckle. Fastening torque(25-29)Nm 7. Mount the front wheel hub and the front brake disc as well as the brake caliper. 8. Check the height of brake liquid level and add the brake liquid as requirement, then exhaust the gas in the braking system. SA-36 Suspension System and Automobile Axle(SF/2WD) Front Suspension Front Suspension Elemtents figures SF 178  15 upper arm shaft bush and tube(long) upper swing arm shaft upper arm shaft bush(short) upper arm shaft bush pinch-off gasket(large) 89  7 torsion bar yoke 225  5 upper arm shaft bush pinch-off gasket(small) 27  2 upper ball stud upper arm  transverse stabilizer rod 142  10 vibration damper 137  10 23  3 lower arm shaft bush pinch-off gasket(large) lower arm shaft bush pinch-off gasket(small) lower ball stud eccentric gasket lower arm lower arm shaft bush and tube NM   23  3 : specified torque  Parts that cannot be reused after being used 142  10 142  10 Suspension System and Automobile Axle (SF/2WD) Front Suspension (Ball Stud) SA-37 Ball Stud Inspection on Ball Stud 1. 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 2. 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 3. Check the rotating performance of the ball stud: (a) Tear down the ball stud; (b) Shake the ball stud column several times before mounting 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)Nm Upper ball stud: (0.1-4)Nm Disassembly of Ball Stud 1. Tear down the steering knuckle, steering knuckle arm 2. and the lower ball stud assembly. Tear down the ball stud from the steering knuckle; 3. Tear down the ball stud from the upper ball stud. SA-38 Suspension System and Automobile Axle (SF/2WD) Front Suspension (Ball StudTorsion Rod Spring) Mount of Ball Stud 1. Mount the upper ball stud on the upper arm; Fastening torque(27 )Nm 2. Mount the lower ball stud on the steering knuckle; Fastening torque(80  0)Nm 3. Mount on the steering knuckle and hub brake disc assembly (See Page SA-34) Torsion Rod Spring (see Page SA-19) Suspension System and Automobile Axle (SF/2WD) Front Suspension (Lower Arm and Vibration Damper) SA-39 Lower arm and Vibration Damper Disassembly of Lower Arm 1. Tear down the transverse stabilizer rod; 2. Tear down the vibration damper; 3. Disconnect the lower arm ball stud seat and the lower ball stud; Remove the cotter pin and the groove nut. 4. Tear down the lower arm (a) Make a mark on the mounting position of the eccentric gasket. (b) Tear down the lower arm. SA-40 Suspension System and Automobile Axle (SF/2WD) Front Suspension (Lower Arm and Vibration Damper) Change of Lower Arm Shaft Bush and Tube 1. 2. Tear down the lower arm shaft bush and shaft tube: (a) Tear down the large and small pinch-off gaskets of the (b) lower arm shaft bush first. 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 1. Mount on the lower arm Align the marks on the eccentric gasket and on the frame, and then screw up the lower arm bolt. 2. 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)Nm 3. Vibration damper mount Mount the vibration damper on the lower arm bracket; Fastening torque(137  0)Nm Suspension System and Automobile Axle (SF/2WD) Front Suspension (Lower Arm and Vibration Damper) 4. Mount the transverse stabilizer rod on the lower arm; Fastening torque(23 )Nm 5. SA-41 Check the Alignment of Front Wheel; (See Page SA-6) SA-42 Suspension System and Automobile Axle (SF/2WD)  Front Suspension (Upper Arm) Upper Arm Dismantle of Upper Arm 1. Tear down the torsion rod spring: (See page SA-19) 2. Tear down the upper ball stud: (a) Support the upper arm with a jack. (b) Tear down the four sets of bolt and nut. 3. 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 1. 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. 2. 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 )Nm (c) Mount on the torsion bar yoke. Notice: the notch of torsion bar yoke should face downward; Fastening torque(89 )Nm Suspension System and Automobile Axle (SF/2WD)Front Suspension \(Lower arm, Guide Lever and Transverse Stabilizer Rod) SA-43 Mount of Upper Arm 1. Screw up the axle nut of upper arm according to the specified torque; Fastening torque(225 )Nm 2. 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)Nm 3. 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 )Nm 4. Mount the torsion rod spring; 5. Check the Alignment of Front Wheel: (See Page SA-6) Guide Lever (See page SA-26) Transverse Stabilizer rod (See page SA-27) SA-44 Suspension System and Automobile Axle (SF/4WD) Front Wheel Hub and Steering Knuckle Front Wheel Hub and Steering Knuckle Element Figure SF 4WD nut upper arm transverse stabilizer rod lock ring cushion block lock ring bolt 123 transverse stabilizer rod gasket  rubber snubber washer transverse stabilizer rod gasket  brake stabilizer rod limit tube caliper transverse stabilizer rod gasket  transverse stabilizer rod gasket  constant speed steering knuckle drive shaft needle  inner oil bearing seal- drive shaft steering knuckle small sleeve cushion block shock absorber rubber snubber washer  132-152  127-147 lower ball stud  70-90 transverse stabilizer rod gasket  132-152 retainer ring thrust platesteering knuckle 20-26  brake oil pipe bracket 180 washer-spline of steering knuckle shaft steering knuckle arm  brake shell 25-29 stop washer  oil seal front hub dust cover lock plate liner front hub bearing (inner)  135-155 front wheel hub and front brake disc 25-29 front hub bearing (out) steering knuckle big nut gasket free wheel hub noumenon 6-12 gasket free wheel hub cap Nm specified torque  Parts that cannot be reused after being used Suspension System and Automobile Axle (SF/4WD) Front Wheel Hub and Steering Knuckle (Front Wheel Hub) SA-45 Front Wheel Hub Disassembly of Front Wheel Hub 1. 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. 2. Tear down the free hub. 3. Tear down the retainer ring and the axle spine of washersteering knuckle: Tear down the retainer ring with the pliers for retainer ring, and take down the axle spline of washer-steering knuckle by hand. 4. 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. SA-46 Suspension System and Automobile Axle (SF/4WD) Front Wheel Hub and Steering Knuckle (Front Wheel Hub) 5. 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). 6. 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. 7. 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 spanner according to the specified torque. Fastening torque(70-80)Nm (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 rotating 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) SA-47 Assembly of Front Wheel Hub 1. Mount on the inner race and roller assembly of front hub bearing as well as the oil seal of front hub. Coat the lithium base grease of (4-5)mm on the inside surfaces of the bearing outer race and the front wheel hub, put in the inner race and roller assembly of front hub bearing (inner), then plaster the lubricant. Plaster a little lubricant on the lips of front wheel hub oil seal, and finally tap the front hub in place with special service tool. Notice: Do not plaster the lubricant on the face of front brake disc. 2. Mount the inner race of front hub bearing (outer) and roller assembly Coat 4  5 mm of lithium base grease on the outer race of bearing, and then put the inner race of front hub bearing (outer) and roller assembly in it, finally plaster with lubricant. 3. Mount the front wheel hub on the steering knuckle Coat a little lubricant on the oil seal of steering knuckle, and then mount the front wheel hub and front brake disc on the steering knuckle, finally mount on the stop washer. 4. Adjust preload: (a) Mount on the steering knuckle nut and screw it up according to the specified torque. Fastening torque(100-120)Nm (b) Run the front wheel hub by 1/4-1/3 round so as to seat the bearings. (c) Loosen the steering knuckle nut to ensure the front brake disc can run freely. Screw up the steering knuckle nut again to the specified torque. Fastening torque25Nm (d) Mount on the lock plate and mount on another steering knuckle nut. Fastening torque60Nm SA-48 Suspension System and Automobile Axle (SF/4WD) Front Wheel Hub and Steering Knuckle (Front Wheel Hub) (e) Hold the bolt of front wheel hub with the spring-tension meter and drag slowly in the direction of the spot tangent line. Suitable tension range(29-54)N The nut should be screwed up again within the suitable range if the tension value is overlarge or over small. (f) Check the bearing to ensure it cannot leap excessively (the axial clearance should not be more than 0.05mm). (g) Measure the bouncing value of the front brake disc, which should not be more than 0.11mm, and (h) Bend one tooth of lock plate inside and other teeth outside so as to lock the steering knuckle nut. 5. Mount the liner and the free hub: (a) Tear down the free wheel hub cap firstly. (b) Mount the liner and the free hub on the front wheel hub. Fastening torque(25-29)Nm (c) Mount on the free wheel hub cap. Fastening torque(6-12)Nm 6. Mount the brake caliper: (a) Mount the brake caliper on the steering knuckle and screw up the bolts according to the specified torque. Fastening torque123Nm (b) Connect the Bundy tube. Fastening torque20-22Nm 7. Check the height of brake liquid level and, if required, add the brake liquid, exhaust the gas from the brake system. Suspension System and Automobile Axle (SF/4WD)  Front Wheel Hub and Steering Knuckle (Steering Knuckle) SA-49 Steering Knuckle Dismantle of Steering Knuckle 1. Tear down the brake caliper, he front wheel and the front brake disc. 2. Tear down the dust cover and the brake shell; 3. Tear down the steering knuckle arm from the steering knuckle; 4. Tear down the vibration damper from the lower arm; 5. Tear down the transverse stabilizer rod from the lower arm; 6. Tear down the steering knuckle: (a) Tear down the split pin and groove nut from the position where the ball stud locates. (b) Tear down the steering knuckle from the position where the ball stud locates with the special service tool. SA-50 Suspension System and Automobile Axle(SF/4WD)  Front Wheel Hub and Steering Knuckle (Steering Knuckle) (c) Tear down the split pin and groove nut from the position where the lower ball stud. (d) Tear down the steering knuckle from the position where the lower ball stud with the special service tool, and (e) Press down the lower arm to tear down the steering knuckle. 7. Tear down the Lower ball stud assembly from the position where the steering knuckle locates. Steering knuckle inspection and change Inspection on and Change of Steering knuckle 1. Check the steering knuckle Check the steering knuckle with the dye penetration agent to see weather has crack, if any crack is found, change the steering knuckle. 2. Tear down the inner oil seal  drive shaft and the thrust plate  steering knuckle. Prize out the inner oil seal  drive shaft from the steering knuckle with the screwdriver to take out the thrust plate  steering knuckle. Suspension System and Automobile Axle(SF/4WD)  Front Wheel Hub and Steering Knuckle (Steering Knuckle) 3. SA-51 Tear down the needle bearing; Tap out the steering knuckle small sleeve with hammer and copper. 4. Tear down the needle bearing. Tap out the needle bearing with the hammer and copper bar. 5. Mount the steering knuckle small sleeve; Tap in the steering knuckle small sleeve with the special service tool. 6. Mount on the needle bearing; Tap in the needle bearing with the special service tool. 7. Mount on the thrust plate- steering knuckle; Coat the needle roller of the needle bearing with the lithium base grease, and plaster the lubricant on the both sides of the thrust plate ñsteering knuckle. SA-52 Suspension System and Automobile Axle (SF/4WD) Front Wheel Hub and Steering Knuckle (Steering Knuckle) 8. Mount the inner oil seal óon the steering knuckle. Check the oil seal visually, if any deformation or glue lack is found, change the oil seal Mount of Steering Knuckle 1. Mount the lower ball stud on the steering knuckle; Connect the lower ball stud and the steering knuckle with bolts, and screw up the bolts according to the specified torque. Fastening torque(70-90)Nm 2. Mount on the steering knuckle (a) Coat the lubricant HP-R on the drive shaft. (b) Press down the lower arm to mount on the steering knuckle. (c) Mount on the groove nut of lower ball stud and screw up the nut according to the specified torque, and then mount on the split pin. Fastening torque(132-152)Nm (d) Mount on the groove nut of upper ball stud and screw up the nut according to the specified torque, and then mount on the split pin. Fastening torque(132-152)Nm Suspension System and Automobile Axle (SF/4WD)  Front Wheel Hub and Steering Knuckle (Steering Knuckle) 3. SA-53 Mount the stabilizer rod on the lower arm. Fastening torque(20-26)Nm 4. Mount the vibration damper on the lower arm. Fastening torque(127-147)Nm 5. Mount the steering knuckle arm and the brake oil pipe bracket on the steering knuckle, and coat the sealing agent 1271 on the bolt thread. Fastening torque180Nm 6. Mount on the dust cover and the brake shell. Align the locating hole of dust cover and the groove of the steering knuckle so as to guarantee the dust cover and the steering knuckle are concentric. Fastening torque(25-29)Nm 7. Mount the front wheel hub and the front brake disc as well as the brake caliper. 8. Check the height of the brake liquid level and, if required, add the brake liquid, exhaust the gas of the braking system. Suspension System and Automobile Axle (SF/4WD)  Constant Speed Drive Shaft SA-54 Constant Speed Drive Shaft Element figure SF4WD axially movable three-ball universal joint front drive axle shaft sleeve assembly front speed reducer and differential assembly mobile joint snapping ring triangular joint extensible-end large gripping hoop constant speed drive shaft extensible-end dust cover extensible-end small gripping hoop  shaf fixed-end small gripping hoop fixed-end dust cover fixed-end large gripping hoop steel retainer ring ball-cage type universal joint inner oil seal- drive shaft NM specified torque  Parts that cannot be reused after being used Suspension System and Automobile Axle (SF/4WD)  Constant Speed Driving Shaft SA-55 Disassembly of Constant Speed Driving Shaft 1. Tear down the brake caliper. 2. Tear down the free hub 3. Tear down the retainer ring from the drive shaft with the calipers, and take down the washer-steering knuckle shaft spline. 4. Tear down the front wheel hub and the steering knuckle together. 5. Screw off the nuts that connect the constant speed drive shaft to take down the constant speed drive shaft. 6. Check and repair the constant speed drive shaft Inject the molybdenum disulphide lithium grease of 100-110 g in the end of ball-cage type universal joint and the end of axially movable tripod universal joint. The ball-cage type universal joint and the axially movable tripod universal joint should swing freely, and no clipping stagnant is allowed. The dust cover should be prevented from deformation and every gripping loop shall be clamping tightly. SA-56 Suspension System and Automobile Axle (SF/4WD)  Constant Speed Driving Shaft Mount of Constant Speed Drive Shaft 1. Mount the constant speed drive shaft on the flanges of the long and short axle shafts. 2. Mount on the front wheel hub and the steering knuckle. 3. Mount on the washer-steering knuckle shaft spline, and then use the caliper to mount on the retainer ring. 4. Mount on the free hub. 5. Mount on the brake caliper. Suspension System and Automobile Axle (SF/4WD)  Front Speed Reducer (Change of Driving Bevel Gear Oil Seal of Front Speed Reducer) SA-57 Front Speed Reducer Change of driving bevel gear oil seal of front speed reducer  140-210 main-tooth nut oil-guard tray flange and dust cover  driving bevel gear oil seal front speed reducer and differential assembly NM specified torque  Parts that cannot be reused after being used 1. Support up the front of vehicle to tear down the front 2. wheel and the steering knuckle. Drain off lubricant in the front speed reducer. 3. Disconnect the front speed reducer flange and the drive shaft. Notice: Mark the assembly marks on the speed reducer 4. 5. and the drive shaft before disconnecting them. Tear down the front speed reducer. Tear down the flange and dust cover: (a) Loosen the riveted position on main-tooth nut with the hammer and chisel. SA-58 Suspension System and Automobile Axle (SF/4WD)  Front Speed Reducer (Change of Driving Bevel Gear Oil Seal of Front Speed Reducer) (b) Lock the flange with special service tool to tear down the main-tooth nut. (c) Tap down the flange and dust cover with copper bar. 6. Tear down the driving bevel gear oil seal and oil-guard tray: (a) Tear down the driving bevel gear oil seal with special service tool. (b) Tear down the oil-guard tray. 7. Tear down the inner race of conical roller bearing; If the bearing is damaged, change a new bearing. 8. Mount the new bearing. Suspension System and Automobile Axle (SF/4WD)  Front Speed Reducer (Change of Driving Bevel Gear Oil Seal of Front Speed Reducer) 9. SA-59 Mount the new driving bevel gear oil seal: (a) Encase the oil-guard tray. (b) Press the new oil seal in the speed reducer shell with the special service tool; the mounted oil seal should be 1.5 mm away from the end face of the housing. Notice: Coat the lithium base grease evenly on the lips of oil seal. 10. Mount the flange and dust cover: (a) Encase the flange and dust cover in the front speed reducer shell through the clinch of oil seal. (b) Lock the flange with the special service tool and screw up the nuts according to the specified torque. Fastening torque(140-210)Nm 11. Adjust the preload of driving bevel gear bearing Measure the play preload between the driving bevel gear and the driven bevel gear with the torque tester. Preload:(1.8-2.4)Nm Remark: if the requirement is not satisfied, change the adjusting washer between the adjusting washer jackets and bearing 32307, see the disassembly and assembly for front speed reducer, until the requirement is satisfied. (a) If the preload is larger than the specified value, change with a thicker adjusting washer; (b) If the preload is smaller than the specified value, change with a thinner adjusting washer. 12. Rivet the main-tooth nut. SA-60 Suspension System and Automobile Axle (SF/4WD)  Front Speed Reducer (Change of Driving Bevel Gear Oil Seal of Front Speed Reducer) 13. Mount the front speed reducer assembly on the frame. 14. Connect the drive shaft to the flange: (a) Align the assembly mark and then connect the drive shaft and the front drive axle flange with four sets of bolt and nut. (b) Screw up the nuts according to the specified torque. Specified torque(69-79)Nm Suspension System and Automobile Axle (SF/4WD) Front Speed Reducer (DisassEmbly of Front Speed Reducer) SA-61 Dismantle of Front Speed Reducer constant speed drive shaft front drive axle shaft sleeve assembly front drive axle hanger rubber jacket and shaft tube front speed reducer and differential assembly constant speed drive shaft front speed reducer shell hanger  NM cpecified torque  Parts that cannot be reused after being used SA-62 Suspension System and Automobile Axle (SF/4WD) Front Speed Reducer (DisassEmbly of Front Speed Reducer) 1. Disconnect the front speed reducer flange and the drive shaft. 2. Screw off the nuts that connect the constant speed drive shaft. 3. Screw off the bolts connecting the rubber jacket and shaft tube of the front speed reducer cover and the frame. 4. Screw off the bolts connecting the front drive axle hanger assembly and the front speed reducer shell hanger, and tear down the front speed reducer. Suspension System Automobile Axle (SF/4WD) Front Speed Reducer (Change of Axle Shaft Oil Seal) SA-63 Change of Axle Shaft Oil Seal  snapping ring  oil seal-front half-shaft front minor half-shaft 88  snapping ring front speed reducer and differential NM specified torque front long semi-axis  Parts that cannot be reused after being used) 1. 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. 2. Tear down the front drive axle shaft sleeve and screw off the bolts connecting the half-shaft sleeve. 3. Tear down the oil seal - front half-shaft: Tear down the oil seal-front half-shaft with the special service tool. SA-64 Suspension System Automobile Axle (SF/4WD) Front Speed Reducer (Change of Axle Shaft Oil Seal) 4. 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. 5. Mount on the upper front drive axle shaft sleeve, Coat the bolt thread with thread locking agent. Fastening torque88Nm 6. 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 (Disassembly and Assembly of Front Speed Reducer) SA-65 Disassembly and Assembly of Front Speed Reducer Element figure  oil seal-front half-shaft flange and dust cover front speed reducer shell front minor half-shaft bearing 31306 oil-guard tray  snapping ring bearing 32307  140-210 driving bevel gear oil seal  driving bevel gear oil seal  oil seal-front half-shaft jacket adjusting washer adjusting washer speed reducer cover  snapping ring 47 retainer ring bearing B36Z-10 bearing 50KB801 adjusting washer front long semi-axis cap-differential bearing 70-90 78  lock plate front differential housing half axle gear thrust gasket pin planetary gear axle driven bevel gear planetary gear shaft planetary gear stop gasket half-axle gear adjusting gasket NM specified torque  Parts that cannot be reused after being used SA-66 Suspension System Automobile Axle (SF/4WD) Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer) Disassembly of Front Speed Reducer 1. Tear down the speed reducer cover: Screw off the eight bolts connecting the speed reducer cover. 2. Tear down the front long semi-axis and the front minor half-shaft: Tear down the front long semi-axis and the front minor halfshaft from the speed reducer assembly with the special service tool. 3. Tear down the front drive axle shaft sleeve Screw off the four bolts connecting the front drive axle shaft sleeve. 4. Tear down the oil seal ó front half-shaft; Tear down the oil seal ófront half shaft with the special service tool. 5. 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 6. 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. 7. Check the engagement trace of the axle driven bevel gear. (See page SA-76) 8. 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. (c) Tap down the driving bevel gear flange and dust cover with copper bar. SA-68 Suspension System Automobile Axle (SF/4WD) Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer) 9. Tear down the driving bevel gear oil seal and the oilguard tray: (a) Tear down the oil seal from the driving bevel gear with SST. (b) Take out the oil-guard tray. 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 right clearly the left and right parts to avoid of confusion during reassembling. left 14. Tear down the adjusting gaskets and clearly mark the left right left and right to avoid of confusion during re-assembling. Suspension System Automobile Axle (SF/4WD)  Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer) SA-69 15. Tear down the driving bevel gear. . Inspection on and Change of Front Speed Reducer 1. 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. 2. 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. SA-70 Suspension System Automobile Axle (SF/4WD) Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer) 3. 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. 4. 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. 5. 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. 6. 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 7. 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 abovementioned 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. SA-72 Suspension System and Automobile Axle (SF/4WD) Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer) (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)Nm 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 together with the differential. (k) Mount on the right and left cap-differential bearing, and screw up the bolts with spanner according to the specified torque. Fastening torque78Nm Suspension System and Automobile Axle (SF/4WD) Front Speed Reducer (Disassembly and Assembly of Front Speed Reducer) (l) SA-73 Run the flange to check the swing difference of axle driven bevel gear. Max swing difference0.07mm Remark: if the requirement is not satisfied, tear down the axle driven bevel gear from the differential, and then screw up the bolts again. 8. 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 semiaxis. (c) Mount on the new grooved ball bearing on the long semiaxis (d) Mount on the retainer ring with calipers. SA-74 Suspension System and Automobile Axle (SF/4WD) Front Speed Reducer (Assembly of Front Speed Reducer) Assembly of Front Speed Reducer 1. Clean the front speed reducer shell; press the outer races of bearing 31306 and bearing 32307 to mount 2. 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. 3. Encase the flange and dust cover in the front speed reducer through the lip open of oil seal and press it by hand. 4. Select the adjusting washer ñdriving bevel gear according 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. 5. 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. 6. Screw up the main-tooth nuts to the specified torque with the SST. Fastening torque(175  35)Nm 7. Measure the preload on the driving bevel gear bearing with torque tester : New bearing(1.2-1.7)Nm Old bearing(0.9-1.3)Nm Suspension System and Automobile Axle (SF/4WD)  Front Speed Reducer (Assembly of Front Speed Reducer) 8. 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. 9. 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 clearance between the bearing 50KB801 and the front speed reducer 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. SA-76 Suspension System and Automobile Axle (SF/4WD)  Front Speed Reducer (Assembly of Front Speed Reducer) 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. 13. Mount on the left and the right cap-differential bearing: Screw up the bolts with spanner to the specified torque; Fastening torque78Nm 14. Measure the total preload of the front speed reducer with torque tester; Fastening torque(1.8-2.4)Nm 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 adjusting 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 concave surface of gear Suspension System and Automobile Axle (SF/4WD) Front Speed Reducer (Assembly of Front Speed Reducer) heel end engagement SA-77 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. SA-78 Suspension System and Automobile Axle (SF/4WD) Front Speed Reducer (Assembly of Front Speed Reducer) 18. Mount on the front drive axle shaft sleeve; Notice: Thread locking agent should be coated on the bolt thread. Fastening torque88Nm 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 halfshaft. 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 torque47Nm SA-79 Suspension System and Automobile Axle (rear) Rear Axle Shaft Rear Axle Shaft Element figure rear brake brake drum  O rubber O-ring seal rear axle housing bearing seat oil seal of rear wheel bearing inner oil seal seat of rear wheel bearing grooved ball bearing oil-guard tray  flat steel retainer ring for shaft rear brake  Parts that cannot be reused after being used liner half-shaft SA-80 Suspension System and Automobile Axle (rear) Rear Half Axle Shaft Dismantle of Rear half Axle Shaft 1. Tear down the wheels. 2. Tear down the rear brake drum. 3. Tear down the grab end of the bracing wire of hand brake from the rear brake. 4. Tear down the half-shaft and the rear brake assembly from the rear axle housing. 5. Tear down the flat steel retainer ring for shaft from the half-shaft; Tear down the flat steel retainer ring for shaft with the ring calipers. 6. Tear down the half-shaft: Put down a wooden plate on the flat ground, and thrust the end of spline of half-shaft and rear brake assembly toward the wooden plate to separate the shaft and the rear brake assembly. Inspection on and repairing of half-shaft parts 1. Check the wear, damage and swing difference half-shaft and the flange. Max shaft run-out: 2 mm Max flange run-out: 0.2 mm In case the half-shaft is damaged, or wearied or the measuring value of the swing difference is excessive, change the halfshaft. 2. Check he oil seal of rear wheel bearing: Check to see whether there is wear or damage, and change the oil seal if necessary. 3. The disassembly of the outer oil seal of rear wheel bearing; Tear down the outer oil seal of rear wheel bearing with SST. Suspension System and Automobile Axle (rear) Rear half Axle Shaft 4. SA-81 Check the grooved ball bearing Check the grooved bearing to see whether there is damage or 5. wear. Change the bearing where necessary: (a) Press out the grooved ball bearing with SST. (b) Press in the new grooved ball bearing with SST. 6. Mount the new oil seal of rear wheel bearing. Press in the new oil seal of rear wheel bearing with SST Coat moderate lithium base grease on the lip open of oil seal. 7. Check the bearing seat. Check the wear or damage situation. 8. Change the bearing seat where necessary: (a) Tear down the oil seal of rear wheel bearing and the grooved ball bearing with SST. (b) Tap the bolts with copper bar to tear down the bearing seat. (c) Mount the new grooved ball bearing and the oil seal of rear wheel bearing on the bearing seat (d) Press the rear brake, which is put on with bolts, in the bearing seat. 9. Check the wear or damage of the inner oil seal of the rear wheel bearing. 10. Change the rear wheel bearing where necessary: (a) Tear down the oil seal of rear wheel bearing with SST. SA-82 Suspension System and Automobile Axle (rear)  Rear Half Axle Shaft 11. Mount the new inner oil seal of rear wheel bearing. Coat the hyperbolic gear oil on the axle housing where matches with the oil seal; and plaster the moderate lithium base grease on the lip open of the oil seal, then put them on the pressure head and press them in. Mount of Rear Axle Shaft 1. Press the rear brake and the bearing seat assembly on the haft shaft. 2. Press the heated inner oil seal seat of rear wheel bearing on he half shaft; Notice: the face at the chamfering end of inner oil seal of rear bearing should contact the oil seal closely, do not mount it at the incorrect position. Requirement for heat mount: heat the inner oil seal seat into the 22# oil (GB443-1989) to 100, after the part is heated completely, take it out for mount. 3. Mount on the flat steel retaining ring with the ring calipers. 4. Encase the half-shaft rear brake in the axle housing, screw on the self-locking nut. Tightening moment(63-79)Nm Notice: protect the oil seal lip open, bracing wire assembly 5. and the oil-guard sleeve. Mount on the hand brake wire and the brake pipe. 6. 7. Mount on the liner and rear brake drum; Make a trial gas exhaust on the braking system, and 8. Mount on the rear wheels. Suspension System and Automobile Axle (Rear)  Rear Speed Reducer SA-83 Rear speed reducer Element figure 80-110 column bolt double-eared stop washer 18-26 bearing7306E  washer stop gasket oil-guard tray  oil seal flange and dust cover assembly speed reducer housing and differential bearing cover adjusting ring bearing 200719E flat washer  differential housing =lock plate adjusting washer adjusting washer axle driven bevel gear jacket driving bevel gear Bearing 7607E NM :specified torque  Parts that cannot be reused after being used 65-95 SA-84 Suspension System and Automobile Axle (Rear)  Rear Speed Reducer On-vehicle Change of main-teeth oil seal 1. Disconnect the drive shaft from the speed reducer: (a) Mark the assembly mark on the two flanges; (b) Tear down the four sets of bolt and nut. 2. Tear down the flange and dust cover assembly. 3. Tear down the oil seal. Tear down the oil seal with SST.  4. Mount on the new oil seal: (a) Coat the lithium base grease on the lips of oil seal; (b) Tap in the new oil seal with SST. Remark: tap the new oil seal until it is in place. 5. 6. Mount the flange and dust cover assembly. Screw up the nut to the specified torque. Specified torque: (140-160)Nm 7. Rivet the nut. 8. Connect the drive shaft flange with the speed reducer flange: Align the assembly mark and connect the flanges with bolts. Tightening moment(69-79)Nm 9. Check the oil level of the speed reducer. Change the gear oil where necessary. Oil brand: heavy-duty oil of grade GL-5 Oil volume: add the oil until it overflows from the oil filler outlet. Viscosity: SAE 85W/90 Suspension System and Automobile Axle (Rear)(Dismantle of Rear Speed Reducer) SA-85 Dismantle of Rear Speed Reducer 1. Take out the oil drain plug to drain the oil in the speed reducer up. 2. Tear down the rear axle shaft. 3. Disconnect the drive shaft from the speed reducer. 4. Tear down the nuts on the bolts that connect the rear axle 5. housing and the speed reducer. Tear down the rear speed reducer. Disassembly of Rear Speed Reducer Remark: in case the noise is over loud, the following item should be checked before taking apart it to find out the causes. If the speed reducer has serious drawback, take it apart for repairing where necessary. 1. Check the play between the axle driven bevel gear; In case the play value fails to be within the specified range, adjust the preload of bearing 200719E or repair it where necessary. (see page SA-91) 2. Standard play: (0.13-0.25)mm Check the teeth engagement of the driving bevel gear with the axle driven bevel gear. (See Page SA-92) Record the teeth engagement positions. 3. Check the clearance between the half-shaft gear thrust gasket and the differential housing. Check the clearance between the half-shaft gear thrust gasket and the differential housing with the feeler. Standard clearance(0.45-0.75)mm Remark: in case the clearance value fails to fall within the above range, change the half-shaft gear stop gasket, and ensure the half-shaft gear stop gaskets on the left and right sides are same in thickness. (See Page SA-95) Suspension System and Automobile Axle (Rear) (Dismantle of Rear Speed Reducer) SA-86 4. Tear down the differential and the axle driven bevel gear: (a) Mark the assembly marks on the differential bearing cover and the speed reducer housing. (b) Tear down the stop gasket and take down the adjusting ring. (c) Loosen the double-stop washer and screw off the nut to take down the differential bearing cover. (d) Tear down the differential and axle driven bevel gear from the rear speed reducer. (e) Tear down the outer race of bearing 200719E. Remark: mark the label on the parts to clarify the position for re-assembling left right 5. Tear down the flange and dust cover assembly: (a) Loosen the riveted part of the nut with hammer and chisel; (b) Lock the flange with SST to tear down the nuts. Notice: those nuts should not be reuse.  (c) Tear down the flange and dust cover assembly with copper bar. Suspension System and Automobile Axle (Rear)(Dismantle of Rear Speed Reducer) 6. SA-87 Tear down the oil seal and oil-guard tray: (a) Support the face at the teeth end of the driving bevel gear to tear down the oil seal with SST. (b) Take out the oil-guard tray. 7. Tear down the inner race and roller assembly of bearing 7306E; Tear down the inner race and roller assembly of bearing 7306E with SST. 8. Tear down the driving bevel gear; Tear down the driving bevel gear, which is mounted with adjusting washer and inner race of bearing 7306E, together with another adjusting washer and jacket 9. Change the bearing 7306E: (a) Press out the bearing from the driving bevel gear with pressure machine and SST. (b) Mount the new inner race and roller assembly of bearing 7306E on he driving bevel gear with pressure machine and SST. SA-88 Suspension System and Automobile Axle (Rear) (Dismantle of Rear Speed Reducer) 10. Change for the bearing 7306E and the outer race of bearing 7607E: (a) Tap out the bearing outer race with hammer and copper bar. (b) Press in the new bearing outer race with pressure machine and SST. 11. Tear down the inner race and roller assembly of bearing 200719E from differential. Pull out the inner race and roller assembly of bearing 200719E from the differential housing with SST. 12. Tear down the axle driven bevel gear. (a) Tear down the lock plate and bolts on the axle driven bevel gear. (b) Mark the assembly marks on the axle driven bevel gear and the differential housing. (c) Tap down the axle driven bevel gear with rubber hammer and copper bar. Suspension System and Automobile Axle (Rear) (Dismantle of Rear Speed Reducer) SA-89 Assembly of Rear Speed Reducer 1. Mount the inner race and roller assembly of bearing 7306E, oil-guard tray and oil seal. (a) Put the inner race and roller assembly of bearing 7306E in the speed reducer housing, and put the oil-guard tray on it. (b) Coat the lithium base grease on the position of speed reducer where oil seal locates and on the lips of oil seal, align the oil seal and press it to mount. 2. Mount the flange and dust cover assembly Encase the flange and dust cover assembly in the speed reducer housing, then flat it by hand. 3. Mount the driving bevel gear: (a) Put the adjusting washer, jacket on the driving bevel gear, which is mounted with adjusting washer and inner race and roller assembly of bearing 7607E, then encase the driving bevel gear in the speed reducer housing. (b) Screw up the nuts to tighten the flange, flat washer and the driving bevel gear with SST, and the thread locking agent is required to be coated when screwing. Tightening moment(140160)Nm 4. Measure the pre-tightening torque of the bearing: New bearing(1.2-1.7)Nm The reused bearing(0.9-1.3)Nm Remark: if the requirement is not satisfied, change the adjusting washer under jacket until the requirement is satisfied. (a) If the measure value is smaller than the standard one, reduce the thickness of adjusting washer; (b) If the measure value is larger than the standard one, increase the thickness of adjusting washer. SA-90 Suspension System and Automobile Axle (Rear) (Dismantle of Rear Speed Reducer) 5. Mount the axle driven bevel gear on the differential housing: (a) Mount on the lock plate and screw up the bolts to the specified torque. Tightening moment(65-95)Nm Notice: screw up the bolts diagonally. (b) Tighten the lock plate with hand hammer and flat head pinch. 6. Mount the inner race and roller assembly of bearing 200719E; Mount the bearing inner race and roller assembly in differential housing with the pressure machine and SST. 7. Mount the differential assembly; Mount the differential in the speed reducer housing. When mounting the differential that hasnít changed the inner race and roller assembly of bearing 200719E, ensure the outer race of the left and the right bearings that has disassembled should match with their inner racers respectively. 8. Mount the adjusting ring; Adjust the clearance between the driving bevel gear and the axle driven bevel gear to the moderate size. And press the bearing outer race to flatten it with adjusting ring, and then screw up moderately. Notice: the two adjusting rings should be adjusted synchronically in the movement of same direction. Suspension System and Automobile Axle (Rear) (Dismantle of Rear Speed Reducer) 9. SA-91 Mount on the differential bearing cover: (a) Align the assembly marks on differential bearing cover and the speed reducer housing, and press down the differential bearing by hand. (b) Mount on the double-eared stop washer and the hex nut. 10. Adjust the clearance between the driving bevel gear and the axle driven bevel gear (a) Screw up the hex nuts connecting the differential bearing cover to the specified torque. Tightening moment(80-110)Nm (b) Attach the measuring meter seat on the face of speed reducer housing with the measuring head touching the teeth face, run the axle driven bevel gear with hand to measure the teeth engagement clearance, and then compare it with the clearance value in step (d) to decide the order of the adjusting ring tightening according to the values. (c) Adjust and screw up the adjusting rings with SST. Tightening moment(115-135)Nm (d) Check the engagement clearance again until the clearance value of the three spots evenly locates on the circumference of axle driven bevel gear. Otherwise, adjusting ring adjustment is suggested. Engagement clearance(0.13-0.25)mm SA-92 Suspension System and Automobile Axle (Rear) Rear Speed Reducer (Disassembly of Speed Reducer) 11. Check the engagement situation of the axle driven bevel gear and the driving bevel gear: (a) Coat four teeth locating on different spots of axle driven bevel gear with red powder. (b) Rotate the axle driven bevel gear in different directions. (c) Check the teeth engagement situation. The teeth trace of axle driven bevel gear should satisfy this requirement. If not, select the suitable adjusting washer to correct according to the poor teeth engagement situation. Washer thickness (unit: mm) see the following table: teeth convex =teeth concave heel end engagement tooth top engagement select the adjusting washer that make the main teeth contact the axle driven bevel gear more closer. toe end engagement teeth root engagement select the adjusting washers that make the main teeth apart from the axle driven bevel gear. Group NO. 1 2 3 4 5 6 Washer thickness 1.60 1.65 1.70 1.75 1.80 1.85 Group NO. 7 8 9 10 11 12 Washer thickness 1.90 1.95 2.00 2.05 2.10 2.15 Suspension System and Automobile Axle (Rear) Rear Speed Reducer (Disassembly of Speed Reducer) SA-93 12. Lock the double-eared stop washer to mount the stop gasket and bolts: (a) If the engagement trace satisfies the requirement, lock tightly the double-eared stop washer with hand hammer and pinch. (b) Mount on the stop gasket, spring gasket and bolts, and then screw up the bolts. Tightening moment(18-26)Nm (c) Tap in he adjusting ring with the pinch and hammer. 13. Measure the total preload: Preload: (1.8-2.4) Nm If the preload is beyond the specified range, change the gaskets between the jacket and bearing 7607E, until they meet the requirement. (a) If the preload is larger than the specified value, change the adjusting washer. (b) If the preload is smaller than the specified value, screw up the nuts again slowly but not exceed 160N.m. Notice: if the screwing torque exceeds the max torque, change the adjusting washer and repeat the preload process. Do not screw back the main-tooth nut to reduce the preload. 14. Check and adjust the flange bouncing (a) Attach the dial indicating lamp seat on the speed reducer housing with the measuring head contact the flange face, run the flange to observe the swing out range of the dial indicating lamp hand. Radial full bouncing tolerance0.10mm 30mm Remark: the two bouncing values should be controlled within 0.10 mm, as for the parts of bounce exceeding the tolerance, loosen the nut-driving bevel gear to assembly them in another angle, measure the bounce value again. Observe carefully the swing direction of the hands, which can be referred when changing the locations of flange and the driving bevel gear. If the requirement cannot be satisfied after several trials, change the new flanges until the requirement is met. 15. Rivet the driving bevel gear nuts.s SA-94 Suspension System and Automobile and Axle (Rear) Rear speed reducer (Mount of Rear Speed Reducer and Differential Assembly) Mount of Rear Speed Reducer and Differential Assembly 1. Mount the speed reducer and differential assembly on the rear axle housing. Tightening moment(18-26)Nm Remark: in case the sealing gasket is mounted, it should be checked to see whether it is damaged before mounting, if damaged, change with the new sealing gasket, and the damaged sealing gasket should be clear away; if no sealing gasket is mounted, no mount is required to mount. Clean the contact face of the mounted axle housing and coat it with siliconrubber plain sealing agent. 2. Connect the drive shaft and flange well and be careful to align the assembly marks marked when disassembling. Tightening moment(69-79)Nm Screw up the oil drain plug with the Tightening moment of (140-150)Nm Mount on the half-shaft and the brake assembly to adjust the brake oil path so that the wheel brake pump is filled with brake liquid. 3. Inject in the heavy-duty oil. Oil brand: heavy-duty oil graded GL-5; Viscosity: SAE 85W/90 Oil volume: add the oil until it overflows from the oil filler outlets. Screw up the oil-filling plug. Tightening moment(140-150)Nm SA-95 Suspension System and Automobile Axle (Rear) Rear differential Rear Differential Element Figure planetary gear differential housing pin half axle gear thrust gasket planetary gear stop gasket planetary gear shaft 1. half-axle gear Tear down the speed reducer and the differential assembly. 2. Tear down the differential from the speed reducer and differential assembly. Change of Differential Parts 1. Disassembly of Differential (a) Tap out the pin with hammer and pinch. (b) Tear down the planetary gear shaft, the planetary gear, planetary gear stop gasket, half-shaft gear and half axle gear thrust gasket. SA-96 Suspension System and Automobile Axle (Rear) Rear differential 2. Assembly of Differential (a) Put the half-axle gear thrust gasket on the half-axle gear and then encase them in the differential housing. (b) Encase the planetary gear stop gasket, planetary gear and encase the planetary gear shaft. (c) Check the clearance between the half-axle gear thrust gasket and the differential housing. Remark: the half-axle gear and the planetary gear should run freely without stagnant, push the planetary gear inside, then measure the clearance between the half-axle gear thrust gasket and the differential housing with dial indicating lamp. Reasonable clearance range: (0.45-0.75)mm. Remark: if the clearance value fails to fall within the above range, change the half axle gear thrust gasket, at the same time, ensure the left and right half axle gear thrust gasket are same in thickness. (d) Tap the pin in the pinhole, and rivet the end of the pinhole so as to prevent from the pin missing. Mount of Differential 1. Encase the differential assembly in the speed reducer housing. 2. Mount the speed reducer and differential. Suspension System and Vehicle Axle  Rear Suspension (Leaf Spring Type) SA-97 Rear suspension(leaf spring) Leaf spring and shock absorber u-shaped bolt spring seat 110  10 90  10 liner 90  10 liner Nm rear ear pin rront ear pin specified torque Dismantle of leaf spring and vibration damper 1. Raise the vehicle body with a jack and support it with a bracket; (a) Raise the vehicle body with a jack and support it with a bracket; (b) Lower the axle housing until the leaf spring is loosened to the degree there is no tension existing. Keep the leaf 2. spring in such status. Tear down the vibration damper. SA-98 Suspension System and Vehicle Axle  Rear Suspension (Leaf Spring Type) 3. Tear down the U-shaped bolt; (a) Tear down the mounting nuts of U-shaped bolts. (b) Tear down the spring seat; (c) Tear down the U-shaped bolts. 4. Tear down the leaf spring; (a) Tear down the mounting nuts of front ear pin; (b) Tear down the front ear pin; (c) Disconnect the leaf spring from the bracket; (d) Tear down the rear ear pin and the leaf, and then take apart the leaf spring. Change of leaf spring 1. Loosen the spring clip; Loosen the spring clip with a chisel. 2. Tear down the central bolt; Clamp the spring with a table vice at the position near to the central bolt to take apart the central bolt. 3. Change the spring clip if necessary; (a) Cut the rivet-head with a drill-head and tap the rivet out. (b) Tap a new rivet in the hole of leaf spring and spring clip and rivet it with pressure machine. Suspension System and Vehicle Axle  Rear Suspension (Leaf Spring Type) 4. SA-99 Mount the central bolt of leaf spring; (a) Align the bolt with the spring hole after clamping the steel spring with a table vice. (b) Mount on and tighten the spring central bolt. Tighten torque:(50  5)Nm 5. Bend the spring clip to a correct angle. Bend the spring clip to the correct position with a hammer. Mount of leaf spring 1. Mount the steel spring; (a) Encase the front end of leaf spring into the front bracket; (b) Mount on the bolt of front ear pin. (c) Screw on the nut of front ear pin with fingers; (d) Encase the rear end of leaf spring into the rear bracket and mount on the rear ear pin. (e) Mount on the leaf and tighten the nuts with fingers. 2. Mount the U-shaped bolt; (a) Mount the U-shaped bolt on the axle housing. (b) Mount the spring seat and nut under the steel spring. (c) Tighten the mounting nut of U-shaped bolt. Tightening moment: (110  0)Nm SA-100 Suspension System and Vehicle Axle  Rear Suspension (Leaf Spring Type) Remark: Tightening U-shaped bolt to the degree that the protruding lengths of all U-shaped bolts under the spring seat are the same. all lengths of bolts protruding are same 3. Mount the rear vibration damper (a) Connect the vibration damper to the vehicle frame with bolts and then tighten the bolts. Tightening moment: (25 )Nm (b) Connect the vibration damper to the sprint seat with bolts and tighten these bolts. Tightening moment: (25 )Nm 4. Keep the suspension frame in stable status; (a) Mount on the wheel; (b) Remove the bracket, and make the vehicle bounce vertically for several times so as conduce it in stable status. 5. Tighten the front ear pin and rear ear pin; Tighten the nuts of front ear pin; Tightening moment: (90  0)Nm Tighten the nuts of rear ear pin; Tightening moment: (90  0)Nm BR-1 Braking System Page Notice .......................................................................... Troubleshooting .......................................................... Inspection and Adjustment .......................................... Master Cylinder ........................................................... Vacuum Booster .......................................................... Front Brake ................................................................. Dr .......................................................................... SF .......................................................................... Rear Brake .................................................................. Dr .......................................................................... SF .......................................................................... Load sensing proportion valve .................................... BR-2 BR-2 BR-5 BR-8 BR-10 BR-13 BR-13 BR-20 BR-26 BR-26 BR-34 BR-42 BR Braking System  Notice and Troubleshooting BR-2 Notice: 1. Carefully change each part where necessary because any mistake will affect the brake system properties, and will lead accidents during driving. And the parts to be changed must be the same in part number or equal in quality. 2. Keep the parts and each position clean when repairing the braking system. Troubleshooting Trouble Causes Inspection items Lower or soft pedal Abrasion of brake shoe Abrasion of brake pad Oil leakage of braking system Master cylinder failure Air in braking system Wheel-brake cylinder failure Failure in the automatic regulator of rear brake. Change the brake shoe; Change the brake pad; Repair the oil leakage; Change the master cylinder; Drain out the air from braking system; Change the wheel-brake cylinder; Repair or change the regulator Brake stagnant Poor adjustment of parking brake; The bracing wire of parking brake is seized; Poor adjustment of vacuum booster pushrod) Failure of the drag spring or the return spring Pipe line blockage Brake shoe breakage or deformation Brake pad breakage or deformation Seizing of the wheel-brake cylinder or the brake caliper piston Automatic regulator breakage Master cylinder failure Adjust the parking brake; Make repairing according to real situation; Adjust the drag rod; Change the drag spring or the return spring Make repairing according to real situation; Change the brake shoe Change the brake pad Make repairing according to real situation; Unsuitable tire inflation There is oil stain or lubricant on the brake shoe or brake pad; Brake shoe deforms, the brake liner is worn or polished; Brake pad deforms or is worn or polished; Brake drum or brake disc deforms Drag spring or return spring has trouble The wheel-brake cylinder has trouble The inner piston of wheel-brake cylinder is seized; The brake pad is seized; Inflate the air to suitable pressure; Change the brake shoe or the brake pad; There is oil stain or lubricant on the brake shoe or brake pad; The brake shoe deforms, brake liner is worn or polished, or the brake wheel is worn; The brake pad deforms, or is worn or polished; The piston of wheel brake pump is seized; The vacuum booster has trouble The vacuum degree is unsuitable The brake pipe line is blocked Change the brake shoe brake pad; Over large braking distance The brake pedal is hard but doesnt work; Change the regulator Change the master cylinder Change the brake shoe; Change brake pad Change the brake drum or the brake disc; Change the spring; Change the wheel-brake cylinder; Change the wheel-brake cylinder Change the brake pad Change the brake shoe Change the brake pad; Change the wheel-brake cylinder; Change the vacuum booster; Make repairing according to real situation; Make repairing according to real situation; Braking System  Notice and Troubleshooting BR-3 Troubleshooting (continued) Trouble There is clatter noise when using the brake Causes (Drum-type brake) The brake shoe is seized on the flange of rear baffle; The flange of rear baffle is worn; The pressure spring of brake shoe is loose or missing; The fixed bolts of brake bottom plate is loose; (disc type brake) The brake pad support plate is loose or missing The mounting bolts are loose; There is hoarse noise or quackquack when using the brake The brake shoe or brake pad is worn; There is such noise as continuous screaming, quackquack, oscillating sound, etc. Notice: the braking materials may generate the natural noise and heat during friction, and thus emit the energy. Therefore, it is normal to have the screaming noise. These phenomena will be more serious under the condition of frigidity, torridity, and over humidity, snowing and mud. the screaming noise occurring occasionally will not lead the fatal brake trouble nor reduce the effective properties of the brake. The brake drum, brake liner, liner or brake pad is worn or scraped The brake liner or brake pad is dirty or with oil stain or polished. The brake liner or brake pad is improperly used. The brake pedal or vacuum booster drag rod is unsuitably adjusted. (disc type brake) The brake pad silent pad is loss or damaged; The brake pad is worn to the degree that the abrasionindicating lamp of brake pad has friction with the rotator. There is burr or rust on the brake caliper. (Drum type brake) The pressure spring of brake shoe is soft in rigidity, or is damaged or unsuitable. The pressure spring pin or spring of brake shoe is loose or damaged; There is crack on the brake bottom plate flange Inspection items Add lubricant Change the lubricating flange Change Tightening it Change Tightening it Change the part, and re-process precisely the brake drum or rotator if the abrasion is serious; The brake caliper, the wheel or the rotator interferes each Make change according to real situation; other. repair or change There is friction between the dust cover and brake disc, Make repairing according to real situation; the brake bottom plate and the brake drum; Change The other braking part has trouble Check or maintain the part There is friction between the tire and body Check, repair or change Clean or change Check or change Check for adjustment Change Change Clean or polish the burr Check, repair or change Check, repair or change Check, repair or change BR-4 Braking System  Notice and Troubleshooting Troubleshooting (continued) Trouble Causes There are quack- Alien materials such as stone is reeled inside the wheel shell q u a c k n o i s e s Nuts on hub is loose; without using the brake. The brake pedal or vacuum booster pushrod is adjusted improperly; The wheel bearing is worn or damaged or lubricated insufficiently; (disc type brake) The outer end edge of brake pad support plate or brake pad is dog-eared; The silent pad is poor in properties; The sliding liner is worn; The mounting bolt is loose The piston returns incompletely (drum type brake) There is loose or redundant part. Inspection items Clear away the alien materials Tighten the nut to the specified torque; and change it in case the bolt hole is enlarged; Check and adjust Check, lubricate or change Check repair or change Check and make change according to real situation Check and make change according to real situation Check and tighten according to the necessity. Check, repair or change Check, take out or repair. There is continuous The brake pedal or vacuum booster pushrod is adjusted Check and adjust screaming noise improperly without using brake The vacuum booster, master cylinder or wheel-brake cylinder Check, repair or change returns incompletely. (Disc type brake) Check and add the lubricant according to The piston is rusted or seized; the necessity; Repair or change The brake pad in brake caliper locates improperly; There is friction between the brake disc and brake caliper Repair or change shell; Repair or change The brake pad support plate is mounted improperly; There is interference between the abrasion indicating lamp Change of brake pad and the brake disc due to the brake pad abrasion; (Drum type brake) The pressure spring of brake shoe is soft rigidity, damaged Change or unsuitable; Repair or change There is crack on the brake bottom plate flange; There is interference of brake bottom plate with the brake Repair or change drum after it is bending or warping. The brake drum interferes with the brake bottom plate or Change the brake drum with brake shoe due to it is processed improperly; Other brake parts Check, maintain and change according to the necessity; There is loose or redundant part in braking system; The brake liner is polished due to it is adjusted over-tightly; Check, maintain and change according to the necessity; The wheel bearing is worn, damaged or lubricated Check, maintain and change according to insufficiently. the necessity; Braking System  Inspection and Adjustment braking lamp switch BR-5 Inspection and adjustment Inspection on and adjustment of brake pedal pedal push rod 1. Check the pedal height as shown in the drawing to whether it is correct, The height from the pedal to the front floor: Dr SF160mm SL SK SY SJ (190-200)mm 2. Adjust the pedal height if necessary: (a) Loosen the locking nuts of braking lamp switch; (b) Loosen the braking lamp switch to the most degree. (c) Loosen the locking nuts of drag rod; (d) Adjust the pedal height through rotating the pedal drag rod; pedal height (e) Rotate the stop light switch reversibly until it contact with the stop baffle of pedal. (f) Screw up the two locking nuts. (g) Check the braking lamp is lightened or not when tread down the brake pedal. (h) Check and adjust the pedal free stroke after adjusting the pedal height 3. Inspection on Pedal Free Stroke: (a) Stop the engine working and tread down the brake pedal pedal push-rod several times until the vacuum booster is not in the stage of vacuum. (b) Tread down the pedal until the resistance occurs, and measure the distance shown in the drawing. Pedal free stroke(3-6)mm QK Adjust the free stroke of pedal if necessary: (a) Loosen the locking nuts of the pedal drag rod and rotate the pedal drag rod to adjust the pedal free stroke. (b) Start the engine to confirm the free stroke. (c) Check the pedal height after adjusting the pedal free stroke. free stroke of pedal: (3-6) mm Braking System  Inspection and Adjustment BR-6 Operation test of vacuum booster Remark: check the operation of vacuum booster with the vacuum booster tester if workable. 1.Operation inspection (a) Before starting the engine, tread down the brake pedal several times, and check the pedal reservation distance to ensure there is no change occurs. (b) Tread down the brake pedal and start the engine. If the treaded pedals continue to move downward, which means the operation is normal. 1. normal abnormal Inspection on Air-tight (a) Start the engine for 1-2 min and then turn it off. Then tread down the brake pedal slowly for several times, if the pedal move downward continuously in the first, but return gradually in the second or third time, which means the vacuum booster has a good air-tight. (b) Tread down the brake pedal when the engine is working, the third time the second time the first time then stop the engine, but tread the pedal down. If the reservation distance doesnít change within the 30 seconds, which shows the air tight of vacuum booster is good. Air-bleeding of braking system Remark: air-bleeding is required if any operation for braking system is conducted or the pipe line is doubted to have air. 1. Fill the oil cup with the brake liquid Check the liquid level of oil cup after the air in each wheel brake pump is exhausted. If necessary, add the brake liquid. 2. Connect the vinyl resin pipe with the vent screws. Insert the other end of pipe into the container with half brake liquid. Remark: the air-bleeding shall begin from the longest pipe line when the wheel-brake cylinder is exhausting the air. 3. Air exhaust of the pipe line in braking system (a) Tread down brake pedal slowly several times. (b) Loosen the vent screws until the brake liquid flows out while letting the assistant tread down the pedal. Then screw up the vent screws. (c) Repeat this approach until there is no air in the liquid. 4. Repeat the approach for the wheel-brake cylinder. Braking System  Inspection and Adjustment BR-7 Check and adjust the parking brake 1. Check the stroke of operating lever of the parking brake to see whether it is correct. Drag the brake operating lever to the max stroke and count the grooves it passes. Stroke of operating lever of parking brake: Dr(9-10) Teeth SL SK SY(7-9) Teeth 2. Adjust the parking brake lever where necessary: Remark: Adjust the rear brake shoe clearance before the adjustment. Brake shoe clearance: 0.6mm (a) Loosen the locking nut and then rotate the adjustable nut until the stroke is correct, then screw up the nuts. (b) The brake shoe shall not be stagnant after the adjustment. Braking System  Master Cylinder BR-8 Master Cylinder Disassembly of Master Cylinder cup cap filtering screen oil cup vacuum booster assembly sealing liner front three-way valve master cylinder body 1. Tear down the alarm joint for liquid level; 2. Exhaust the brake liquid with the injector: Notice: brake liquid must not be left on the paint surface, if any, clear it away. 3. SST Tear down the pipeline of braking system; Tear down the pipeline of braking system from the master cylinder with SST. 4. Take apart the master cylinder: (a) Tear down the four nuts and the three-way joint. (b) Tear down the master cylinder and sealing washer from the vacuum booster SST Braking System  Master Cylinder BR-9 Mount of Master Cylinder 1. Adjust the length of vacuum booster pushrod before mounting the master cylinder; 2. Mount the master cylinder: Mount the master and sealing washer on the vacuum booster with four nuts. SST 3. Connect the two pipelines of braking system; Mount the brake pipeline on the master cylinder with SST and screw up the nuts. Fastening torque Dr SF(18  2)Nm SL SK SY SJ(19  1)Nm SST 4. Connect the alarm switch joint for liquid level; 5. Fill the oil cup with brake liquid and exhaust the air in the brake pipeline; 6. Check to see whether there is brake liquid leakage; 7. Check and adjust the brake pedal. Brake System  Vacuum Booster BR-10 Vacuum booster Disassembly of Vacuum Booster U-shaped clip head bracket shock pad one-way valve adjusting shim shock pad sealing liner vacuum booster master cylinder body front three-way valve Disassembly of Vacuum Booster 1. Take apart the master cylinder 2. Tear down the vacuum hose from the vacuum booster 3. Tear down the return spring 4. Tear down the clamping pin and U-shaped clamping pin 5. Tear down the vacuum booster, sealing washer and Ushaped clamping head Brake System  Vacuum Booster air BR-11 Inspection on Vacuum booster parts Operation for one-way valve inspection (Gasoline engine) engine side (a) Tear down the one-way valve; (b) Check the air to see whether it flows from the vacuum booster side booster side toward the engine side. (c) Check the air, change the one-way valve if the air flows air airless from the side of engine toward the vacuum booster. (d) Mount the one-way valve in the right place. (Diesel engine) air (a) Tear down the one-way valve from the vacuum pipe. hose side (b) Check the air to see whether it flows from the side of vacuum room to the hose. vacuum side (c) Check the air, and change the one-way valve if the air flows to the hose to the vacuum room. airless air Mount of Vacuum Booster SST 1. Adjust the length of vacuum booster pushrod: (a) Mount the sealing washer on the master cylinder; (b) Put SST on the sealing washer and descend the pin rod until it contact lightly the piston with its top; washer (c) Put top of SST downward ,and mount it on the vacuum booster. SST (d) Check the clearance between the vacuum booster pushrod and the head of pin on SST. (e) Adjust the length of vacuum booster pushrod until the pushrod touches the pinhead. 2. Mount the vacuum booster, sealing washer and Ushaped clip head. (a) Mount the vacuum booster and sealing washer. (b) Mount the U-shaped clip head. 3. (c) Mount and tighten the assembling nuts of vacuum booster. Connect the U-shaped clip head and the brake pedal: Encase the U-shaped clamping pin in the hole of U-shaped clip head and the brake pedal, and then mount the spring pin on the U-shaped clamping pin. BR-12 Brake System  Vacuum Booster 4. Mount the pedal return spring. 5. Mount the brake master cylinder (see Page BR-8) 6. Connect the hose and the vacuum booster. 7. Fill the oil cup with brake liquid and exhaust the air in braking system. (see page BR-6) 8. Check the liquid leakage; 9. Check and adjust the brake pedal (See page BR-5) 10. Check the operation (See Page BR-6) Braking System  Front Brake (Dr) BR-13 Front Brake Element figure Dr No. 1 lock plate of brake pad No. 2 lock plate of brake pad silent pad cluster brake pad assembly silent pad cluster caliper body No. 2 lock plate of brake pad No. 1 lock plate of brake pad long sliding caliper liner sliding sleeve dust cover sliding sleeve dust cover caliper body piston dust cover rectangular sealing ring long sliding caliper sleeve vent screw dust cover vent screw piston dust cover snapping spring piston sliding sleeve dust cover sliding sleeve dust cover short sliding caliper sleeve short sliding caliper liner BR-14 Braking System  Front Brake (Dr) Brake pad change Remark: Check the thickness of the friction material of brake pad through the observation hole on caliper body after the vehicle covers thirty thousand; if the thickness fails to fall within the specified range, change is required. (If the brake is used often, the thickness of friction materials of brake pad is required to check whether it is within the specified range after the vehicle covers more than ten thousand, if not, change it. 1. Tear down the front wheel; 2. Check the thickness of friction material of brake pad: Check the thickness of friction material of brake pad through the observation hole on caliper body, if it fails to be within the specified range, change it. Min thickness: 2.0mm 3. Raise the wheel-brake cylinder: (a) Tear down the short bolts of sliding sleeve; (b) Uplift the wheel brake pump and hang it with rope to protect the brake oil pipe. Remark: Do not loosen the brake oil pipe and the bleeding plug. 4. Tear down the following parts: (a) Two braking pads; (b) Two silent pad clusters; (c) Four braking pad lock plates. Braking System  Front Brake (Dr) 5. BR-15 Brake disc measurement (See page BR-17) 6. Measure the radial run-out of the brake disc; (See BR-18) 7. Mount the lock plate of brake pad. 8. Mount the new brake pad. (a) Mount the silent pad cluster on brake pads of both the inner and outer sides; Remark: Pollution of oil stain or coat is not allowed on the work faces of brake pad or brake disc. (b) Draw out a little brake liquid from the liquid container to prevent the brake liquid overflowing from the liquid container; (c) Press in the piston with the hammer lever or similar tool. 9. Mount the wheel-brake cylinder; Mount and screw up the hex bolts (the hex bolts shall be coated with the thread locking sealing agents. Fastening torque(38-50)Nm Remark: only one brake pad can be changed in one time so as to prevent the piston of other wheel being shot out. BR-16 Braking System  Front Brake (Dr) 10. Mount the front wheel; Screw up the fixing nut of wheel. Fastening torque(135150)Nm Disassembly of Wheel-brake Cylinder 1. Take apart the brake pipeline. (a) Tear down the brake pipeline. And block the outlet with a clean cork. (b) Tear down the brake oil pipe bracket from the wheelbrake cylinder. 2. Tear down the wheel-brake cylinder from the caliper bracket. Tear down the two hex bolts and the wheel-brake cylinder. 3. Tear down the brake pad: (a) Two brake pad; (b) Two silent pad cluster; (c) Four brake pad lock plate. Pump Disassembly of Wheel brake 1. Take apart the following parts: (a) Two sliding sleeve; (b) Four sliding sleeve dust cover; (c) Two sliding liner. Braking System  Front Brake (Dr) 2. BR-17 Tear down the piston dust cover snapping ring and the piston dust cover; Tear down the piston dust cover snapping ring and the piston dust cover with screwdriver. 3. Tear down the piston from the wheel-brake cylinder: (a) Put a wooden plate between the piston and the caliper body. (b) Tear down the piston from wheel-brake cylinder with the compressed air. Warning: Do not put your finger in front of the piston when using the compressed air. 4. Tear down the piston sealing ring from the caliper body. Tear down the piston sealing ring with bent needle. Notice: the tools used shall not be sharp so as not to scrape the piston sealing ring. Check the front brake parts 1. Measure the thickness of brake pad liner; Standard thickness10.0mm Min thickness2.0mm If the thickness is less than the min thickness or is unevenly worn; change the brake pad. 2. Measure thickness of brake disc Standard thickness25.0mm Min thickness23.0mm If the brake disc is scraped, repair it, if the brake is serious worn to the degree that its thickness is less than the min thickness, brake disc requires to be changed BR-18 Braking System  Front Brake (Dr) 3. Measure the bouncing value of the brake disc face; Remark: verify the bearing is aligned correctly before measuring. The bouncing value of max face: 0.11mm 4. Change the brake disc according to the requirements (a) Tear down the calipers body from the steering knuckle. (b) Tear down the hub and the brake disc (See Page SA-11). (c) Mount the new brake disc and screw up the connecting bolts according to the specified torque. Fastening torque(6079)N.m (d) Mount the hub and brake disc assembly (see page SA-12); (e) Mount the caliper bracket on the steering knuckle and screw up the bolts according to the specified torque. Fastening torque(85105)N.m Cylinder Assembly of Wheel-brake 1. Preparation All parts shall be washed, dried and cleared away the alien materials before the assembly. And coat moderate vacuum silicon base grease on the work faces of sliding sleeve dust cover, sliding sleeve and the sliding liner; and plaster the moderate rubber lubricant on the work faces of piston, piston dust cover and the rectangular sealing ring. 2. Encase the piston sealing ring and piston in the caliper body; (a) Screw the vent screw in the vent hole of calipers. Fastening torque(813)N.m (b) Coat moderate rubber lubricant on the work face rectangular sealing ring and encase the caliper body in groove. (c) Encase the piston in the caliper body. 3. Encase the piston dust cover and the dust cover snapping ring in the wheel-brake cylinder. Braking System  Front Brake (Dr) 4. BR-19 Mount the sliding liner, sliding sleeve dust cover and sliding sleeve. (a) Encase the sliding liner and sliding sleeve dust cover in the wheel-brake cylinder. (b) Ensure the sliding sleeve dust cover in the ring groove of wheel-brake cylinder hard. (c) Encase the sliding sleeve in the sliding sleeve dust cover. (d) Ensure the sliding sleeve dust cover in the ring groove of sliding sleeve. Mount of Brake Calipers 1. Mount the brake pad; 2. Mount the wheel-brake cylinder: (a) Mount the wheel-brake cylinder; (b) Mount and tighten the two assembling bolts (the bolts shall be coated with the thread locking sealing agent). Fastening torque(3850)N.m 3. Connect the brake pipeline. Connect the brake pipeline with the calipers. 4. Fastening torque(21  2)N.m Observe the height of brake liquid level and, if necessary, add in the brake liquid and exhaust the air in braking system. Notice: prevent the brake liquid from spraying on the 5. brake disc when exhausting air. Check to see whether there is leakage of brake liquid. Braking System  Front Brake(SF) BR-20 Front Brake Element figure SF spring gasket12 brake caliper brake pad snapping ring 123 separation pads silent pad brake pad guide pin lock spring brake disc guide pin sealing ring piston NM : fastening torque dust cover steel gripping hoop piston dust cover Change of Brake pad Remark: In case there is a continuous screaming from the front wheel when braking the vehicle during driving, check the alarm pad for friction limit for brake pad. If there is friction trace on the alarm pad with the brake disc, change the brake pad 1. Disassemble the front wheel; 2. Check the thickness of friction material of brake pad. Check the thickness of friction material of brake pad, if it fails to be within the specified range, change the brake pad. Min thickness2.0mm Braking System  Front Brake(SF) 3. BR-21 Disassemble the following parts: (a) Guide pin snapping spring; (b) Two guide pins; (c) Brake pad snapping ring (d) Two brake pads; (e) Two silent pads; and (f) 4. Two separation pads Measure the thickness of brake disc. (See BR-24) 5. Measure the radial swinging of the brake disc. (see page BR-24) 6. Mount on the new brake pad; (a) Draw out a little brake liquid from the liquid container. (b) Press in the piston with the hammer lever and similar tool. Remark: Only one brake pad of the same wheel can be changed in one time so as to prevent the piston on the other face ejecting out. (c) Mount two silent pads and two separation pads on the new brake pad. Remark: coat the brake oil for disc on the inner silent pads. (d) Mount the brake pad with the worn limit alarm pad on the inner side, while the other brake pad on the outer side. Note: Pollution of oil stain or coat is not allowed on the work faces of brake pad or brake disc. 7. Mount the brake pad snapping spring; Brake pad snapping spring shall be mounted at the lower position; BR-22 Braking System  Front Brake(SF) 8. Mount the two guide pins; 9. Mount the guide pin snapping spring Disassembly of Wheel brake Pump 1. Disassemble the front wheel;í 2. Disassemble the brake pipeline; Tear down the brake pipeline with a container containing the brake liquid. 3. Disassemble the wheel-brake cylinder. Tear down the two hex bolts and the wheel-brake cylinder. 4. Disassemble the following parts: (a) Guide pin snapping spring; (b) Two guide pins;í (c) Brake pad snapping spring; (d) Two brake pads; (e) Two silent pads and (f) Two separation pads. Braking System  Front Brake(SF) BR-23 Wheel-brake cylinder disassembly: 1. Tear down the dust cover steel gripping hoop and the dust cover. Tear down the dust cover steel gripping hoops and piston dust covers of the four wheel-brake cylinders with the screwdriver. 2. Tear down the piston from the wheel-brake cylinder: (a) Prepare a wooden block with the dimensions as shown in the drawing (which is used to support the piston) mm mm mm (b) Put the wooden block between the pistons and insert one brake pad on one side of the wooden block. (c) Tear down the four pistons from the wheel-brake cylinder by using the compressed air. Warning: do not put your fingers in front of the piston when using the compressed air. 3. Tear down the piston sealing ring. Tear down the four piston sealing ring from the wheel-brake cylinder with the screwdriver. Check the front brake parts 1. Measure the thickness of brake pad liner; Standard thickness9.0mm Min thickness2.0mm In case the liner is less than the min thickness or the liner is worn unevenly, change the brake pad. BR-24 Braking System  Front Brake(SF) 2. Measure the thickness of brake disc; Standard thickness20.0mm Min thickness18.0mm If the brake pad is scraped, repair it; where the abrasion is serious and its thickness is smaller than the min thickness, change the brake disc. 3. Measure the bounding value of the brake disc face; Remark: the bearing is required to be verified in the suitable adjustment before measuring. Max face bouncing value: 0.11mm; 4. Change the brake disc according to the requirement: (a) Tear down the hub and the brake disc. (see the paragraph of front wheel hub) (b) Mount the new brake disc and screw up the connecting bolts as the specified torque. (c) Mount the hub and brake disc assembly. (see the paragraph of front wheel hub). Fastening torque(75  5)Nm (d) Mount the caliper bracket on the steering knuckle and screw up the bolts according to the specified torque. Fastening torque123Nm. Assembly of Brake-wheel pump 1. Preparation All parts shall be washed, dried and cleared away the alien materials, and coat moderate rubber lubricant on the work faces of piston, piston dust cover and rectangular sealing ring. 2. Encase the piston sealing ring in the caliper body Braking System  Front Brake(SF) 3. Encase the piston in the caliper body. 4. Encase the piston dust cover, dust cover steel- BR-25 gripping hoop in the caliper body. Mount of Brake Calipers 1. Mount the brake caliper and screw up the two mounting bolts. Fastening torque123Nm 2. Mount the brake pads; 3. Connecting the brake pipeline; Use the open spanner to connect the pipeline. 4. Fastening torque(21  1)Nm Observe the height of brake liquid level and, if necessary, add in the brake liquid and exhaust the air in braking system. Notice: avoid the brake liquid of spraying on the brake disc 5. when exhausting the air. Check to see whether there is leakage of brake liquid. Braking System  Rear Brake (Dr) BR-26 Rear brake Element figure wheel-brake cylinder cluster Dr pressure spring drag rod brake shoe gear return spring  split pin self clearanceadjusting bracing wire parking brake arm flat washer parking brake push plate back brake shoe front brake shoe push-plate spring self clearanceadjusting toggle tension spring pressure spring brake drum clearance adjuster pressure spring seat  Parts that cannot be reused after being used Disassembly of Rear drum-type Brake Remark: if the braking torque of manual brake cannot satisfies the braking requirement, it is suggested to check the thickness of brake shoe liner, where the thickness is less than the min thickness, change the brake shoe. Min thickness1.0mm 1. Tear down the rear wheel; 2. Tear down the brake drum; Remark: in case the brake drum is not easy to tear down, the following steps shall be adapted: (a) Tear down the clearance-adjusting hole; insert a screwdriver in the brake bottom plate hole to prize up the adjusting bolt inner tilt angle with the self-adjusting fork. (b) Use another screwdriver to adjust the adjusting bolt inner tilt angle to loosen the clearance adjuster of brake shoe. Braking System  Rear Brake (Dr) 3. BR-27 Tear down the return springs of the two brake shoes. 4. Tear down the self-adjusting bracing wire, brake shoe retainer ring, bracing wire guide seat and the selfclearance adjusting toggle plate. (a) Press and push the self clearance-adjusting toggle plate to teardown the bracing wire of self clearance-adjuster, brake shoe retainer ring and bracing wire guide seat. (b) Take out the spring from the self clearance-adjusting toggle plate to tear down the clearance-adjusting toggle plate and the spring. 5. Tear down the tension spring; Tear down the tension spring with the pliers. 6. Tear down the brake shoe, clearance adjuster and parking brake push plate. (a) Tear down the pressure spring seat, pressure spring and pressure spring drag rod. (b) Tear down the brake shoe, clearance adjuster and parking brake push plate. (c) Tear down the bracing wire from the parking brake. BR-28 Braking System  Rear Brake (Dr) 7. Tear down the parking brake arm; Tear down the split pin with pliers to take apart the parking brake arm. 8. Take apart the brake pipeline from the wheel pump; Tear down the brake pipeline and block the oil pipe with a clean cork. 9. Tear down the wheel brake pump; Tear down the two bolts and the wheel-brake cylinder. 10. Tear down the following bolts and wheel-brake cylinder parts: (a) Two piston rod; (b) Two dust cover (c) Two pistons (d) Two piston rubber bows (e) Spring. Braking System  Rear Brake (Dr) BR-29 Check and Repair the Rear Brake Parts 1. Check and test the disassembled parts; Check the disassembled parts to see whether there is abrasion, rust or damage. 2. Measure the inner diameter of brake drum; Standard inner diameter)254.0mm Mix inner diameter: 256.0mm 3. Measure the thickness of brake shoe liner; Standard thickness5.0mm Min thickness1.0mm In case the thickness of brake shoe liner is less than the min thickness or there is uneven abrasion, change the liner. Remark: if one of the brake shoes is needed to change, all of the brake shoes are required to change so that the even braking performance is maintained. 4. Measure the brake liner and the brake drum to see whether they contact closely; If there is poor contact between the brake liner and the brake drum, repair the brake shoe with the grinding devices, or change the brake shoe cluster. BR-30 Braking System  Rear Brake (DR) Assembly of Rear Brake remark: assemble the parts according to the direction in the drawing; forward forward left wheel right wheel Assembly of Rear Brake 1. Assemble the wheel-brake cylinder: (a) Coat moderate lithium soap base glycol grease on the piston cup; (b) Assemble the wheel-brake cylinder: Mount the two piston cups on two piston; Encase the spring and two pistons in the wheel cylinder body and Mount the two dust covers Remark: Assembly shall be conducted correctly according to the direction shown in the drawing.    2. Mount the wheel-brake cylinder: (a) Use two bolts to fix the wheel-brake cylinder on the rear bottom plate. Coat moderate sealing glue (Glue 704) on the position where the wheel-brake cylinder connects with the bottom plate. Fastening torque(1620)Nm (c) Connect the brake pipeline on the wheel-brake cylinder. Fastening torque18Nm 3. Coat the following parts with moderate lubricant that resistant high temperature (do not pollute the friction plates); (a) The upper plain of the hex convex platform where the bottom plate connects the brake shoe; (b) Contact face of the brake shoe and the top lever of wheel cylinder; (c) Contact face of the brake shoe with the support pin. Braking System  Rear Brake (DR) BR-31 (d) Adjusting bolts (e) Contact position where the clearance adjuster and the brake shoe. 4. Mount the parking brake drag arm; Mount the new split pin with pliers to mount the parking brake drag arm. 5. Mount the rear brake shoe: (a) Mount the parking brake bracing wire on the parking brake drag arm. (b) Mount the rear brake shoe in such way that its end is inserted into the cylinder rod. Encase the pressure spring drag rod in the brake bottom plate and the brake shoe assembly in turn and then insert it in the pressure seat , pressure spring, pressure spring seat, finally rotate the pressure spring in place with the pressure spring fork. 6. Mount the parking brake pull plate and the front brake shoe: (a) Mount the pull plate and the spring. (b) Mount the front brake shoe, of which, the end is inserted in the piston rod, and mount the pull plate. Insert the pressure spring drag rod in the brake bottom plate and brake shoe assembly in turn, then encase it in the pressure spring seat, pressure spring and pressure spring, finally rotate the pressure spring in place with the pressure spring. 7. Mount the tension spring; Mount the tension spring with pliers. BR-32 Braking System  Rear Brake (DR) 8. Mount on the adjuster; Poke the brake shoes with the screwdriver and then mount the adjuster. 9. Mount the brake shoe retainer ring, bracing wire of guide seat, self clearance-adjusting bracing wire and the return spring. (a) Mount the brake shoe retainer ring, then the front return (b) spring. Mount the return spring ,and then mount the forward return spring. 10. Mount the self-clearance toggle plate: (a) Mount the toggle plate bracing wire torsion spring on the rear brake shoe. (b) Mount the clearance self-adjusting toggle plate and hook It with the clearance-adjusting bracing wire. (9) forward Hook the self clearance-adjusting toggle plate with the bracing wire torsion spring 11. Check the operation of self-adjusting mechanism. (a) Drag the clearance-adjusting bracing wire backward as shown in the drawing, then release it. Check the clearance-adjusting bolts to see whether it is rotating. If not, check the rear brake to verify which part has problem. (b) Adjust the clearance adjuster to shorten its length as possible as can. (c) Mount the brake drum Braking System  Rear Brake (DR) BR-33 12. Check the clearance between the brake shoe and the brake drum: (a) Tear down the brake drum; (b) Measure the inner diameter of the brake drum and the outer diameter of brake shoe to check whether the difference of the two diameters falls within the standard clearance range. Shoe clearance: 0.6mm If it is not correct, check the parking brake system. 13. Mount the brake drum and the rear wheel; screw up the nuts of rear wheel hub. Fastening torque(145  10)Nm 14. Fill the liquid container with brake liquid and exhaust the air in braking system. 15. Check to see whether there is leakage of brake liquid. Braking System  Rear Brake (SF) BR-34 Rear brake Element figure SF wheel-brake cylinder cluster observation hole cork  claming pin clearance adjuster rear brake shoe brake lever observation hole cork  toggle plate  open retainer ring upper tension spring lower tension spring front brake shoe clearance-adjusting spring pressure spring pressure spring cap brake drum  Parts that cannot be reused after using. Disassembly of Rear Brake 1. Check the thickness of the brake shoe liner: Tear down the observation hole cork I and measure the thickness of brake shoe liner through the observation hole. If the thickness if less than the min thickness, change the brake shoe. 2. Min thickness1.0mm Tear down the rear wheel. 3. Tear down the brake drum; Remark: if the brake cannot be tear down easily, the following steps shall be adapted: (a) Tear down the observation hole cork II by inserting the screwdriver in the hole of brake bottom plate, and poke the toggle plate from the self-adjusting screw arbor. (b) Loosen the brake shoe clearance adjuster with another screwdriver by screwing the self-adjusting screw arbor. Braking System  Rear Brake (SF) 4. BR-35 Tear down the front brake shoe: (a)Tear down the tension spring from the front brake shoe; (b) Tear down the pressure spring cap of brake shoe, the pressure spring and claming pin. (c) Tear down the lower tension spring from the front shoe and the shoe pads. (d) Tear down the lower tension spring from the rear shoe. 5. Tear down the rear brake shoe: (a) Tear down the shoe pressure spring cap, pressure spring and claming pin. (b) Tear down the upper tension spring from the shoe pad. (c) Tear down the rear brake shoe and the clearance adjuster. (d) Tear down the parking brake bracing wire from the brake shoe. 6. Tear down the clearance adjuster from the rear brake shoe: (a) Tear down the clearance-adjusting spring. (b) Tear down the clearance adjuster. BR-36 Braking System  Rear Brake (SF) 7. Tear down the toggle plate and the brake lever: (a) Tear down the open retainer ring; (b) Tear down the toggle plate; (c) Tear down the pin clip; (d) 8. Tear down the brake lever. Tear down the wheel-brake cylinder: (a) Tear down the brake pipeline. And block the pipeline (b) with a clean cork. Tear down the two bolts to take apart the wheel-brake cylinder. 9. Tear down the following parts: (a) Two dust covers; (b) Two pistons; (c) Two piston cups (d) Spring. Braking System  Rear Brake (SF) BR-37 Check and Repair the Brake Parts 1. Check the disassembled parts; Check the disassembled parts to see whether there is abrasion, rust or damage. 2. Measure the inner diameter of the brake drum; Inner diameter295.0mm Max diameter297.0mm 3. Measure the thickness of brake shoe liner; Standard thickness6.5mm Min thickness1.5mm In case the thickness of brake shoe liner is less than the min thickness or there is uneven abrasion, change the brake shoe. Remark: if either brake shoe is required to change, all rear brake shoes shall be changed to maintain the even braking properties. 4. Check the brake shoe liner and the brake drum to see whether there is close contact; If there is poor contact between the brake shoe liner or brake drum, repair or change the brake shoe cluster with the grinding devices. Braking System  Rear Brake (SF) BR-38 Assembly of Rear Brake remark: assemble the component elements in the direction shown in the drawing; forward forward left wheel right wheel 1. Assemble the wheel-brake cylinder: (a) Coat moderate lithium soap base glycol grease on the piston cup. (b) Assembly the wheel-brake cylinder Mount the two piston cups on two pistons   Mount the two dust cover on two pistons. Encase the spring and the two pistons in the wheel cylinder body.  Remark: assembly correctly according to the direction shown in the drawing. 2. Mount the wheel-brake cylinder: (a) Mount the wheel-brake cylinder on the rear bottom plate with two bolts. Fastening torque(6.510)Nm (b) Connect the brake pipeline on the wheel-brake cylinder. Fastening torque(18+2)Nm 3. Coat the lithium base grease on the following parts: (a) Hex convex platform where the bottom plate contacts with the brake shoe. (b) Two ends of support brocks (c) Contact position where the piston and the shoe rib. Remark: Do not pollute the friction pads. Braking System  Rear Brake (SF) BR-39 (c) Self adjusting screw arbor thread; (d) Contact position where the self-adjusting screw sleeve and the brake shoe. 4. Mount the parking brake lever and the toggle plate (a) Mount the parking brake lever and lock it with a new pin. (b) Mount the toggle plate and a new open retainer ring. 5. Mount the adjuster on the rear brake shoe: (a) Mount the adjuster; (b) 6. Mount the clearance-adjusting spring; Mount the rear brake shoe: (a) Mount the brake bracing wire on the parking brake lever; (b) Mount the tension spring on the rear brake shoe; (c) Encase the rear brake shoe in such way that the end shoe is inserted in the wheel-brake cylinder. (d) Mount the brake shoe pressure spring, pressure spring cap and the claming pin. Notice: Do not let the oil or lubricant touch the brake shoe. BR-40 Braking System  Rear Brake (SF) 7.Mount the front brake shoe: (a) Mount the lower tension spring between the front shoe and the back shoe. (b) Mount the front brake shoe in such manner that the end shoe is inserted in the wheel-brake cylinder, and mount correctly the adjuster. (c) Mount the pressure spring, pressure spring cap and claming pin. Notice: Do not let the oil or lubricant touch the brake shoe. (d) 8. Mount the upper tension spring. Check the operation of self-adjusting mechanism. (a) Move the parking brake lever of rear brake shoe forward and backward as shown in the drawing, check the selfadjusting screw arbor to see whether it can rotate or not, if not, check the rear brake to see which part has problem. (b) Adjust the adjuster length and shorten it as can as possible. (c) Mount the brake drum. (d) Drag the parking brake lever to the max distance until no quack-quack is heard. Braking System  Rear Brake (SF) 9. BR-41 Check the clearance between the brake shoe and the brake drum: (a) Tear down the brake drum. (b) Measure the inner diameter of brake drum and the outer diameter of brake shoe, then Check the difference of the two diameters to see whether it falls within the standard clearance range. Shoe clearance: 0.6mm If it is not correct, check the parking braking system. 10. Mount the brake drum and rear wheel; Fastening torque(145  10)mm 11. Fill the liquid container with brake liquid and exhaust air in the braking system. 12. Check to see whether there is leakage of brake liquid Braking System  Load Sensing Proportion Valve BR-42 Load Sensing Proportion Valve Element figure location plate braking hose bracket valve bracket load inductive valve snapping ring flat washer flat washer load inductive spring assembly claming head I inductive spring bracket claming head II  split pin shaft bush  Parts that cannot be reused after being used Inspection on and Adjustment of hydraulic pressure 1. Adjust the load on rear shaft Load on rear shaft (including the vehicle weight): 800kg 2. Mount the load sensing proportion valve instruments (SST) and exhaust the air. Braking System  Load Sensing Proportion Valve 3. BR-43 Check the rear brake pressure on the condition that the front brake pressure increases to 7,845kPa Rear brake pressure: (4,315  490)kPa If the brake pressure is incorrect, adjust the hydraulic pressure. kPa kPa 4. Adjust the hydraulic pressure if necessary: (a) Adjust the length of claming head II. When lengthen the A distance, the rear brake pressure; if A distance is shortened, the rear brake pressure reduces. Initial adjustment: 78mm A Adjust range: (72-84)mm (b) In case no even brake pressure is obtained after adjusting the claming head, raise the valve or move it downward. If the valve moves forward, the rear brake pressure will reduce; if the valve moves downward, rear brake pressure will increase. (c) Screw up the nuts. (d) Adjust the length of claming head II again. If it is unsuitable after re-adjustment, change the valve. Disassembly of load sensing proportion valve SST 1. Tear down the claming head II from the bracket; 2. Tear down the load sensing proportion valve cluster: (a) Tear down the brake pipeline from the valve with SST. BR-44 Braking System  Load Sensing Proportion Valve (b) Tear down the mounting bolts of valve bracket, and load sensing proportion valve cluster. Mount of Load Sensing Proportion Valve 1. Mount the load sensing proportion valve cluster on the frame. 2. Connect the claming head II with the bracket: (a) Mount the claming head on the load inductive spring; (b) Adjust the spacing A. Initial adjustment: 78 mm; (c) Mount the claming head II on the claming head bracket SST 3. Connect the brake pipeline; Connect the brake pipeline with SST. Fastening torque Dr SF(18  2)Nm SL SK SY SJ(19  1)Nm 4. Adjust the rear shaft load 5. Adjust the valve: (a) When drag downward the load inductive spring, the valve piston shall move downward smoothly. (b) When mount the valve body, the valve piston shall touch the load inductive sensing spring lightly. (c) Screw up the mounting nuts of valve body. Braking System  Load Sensing Proportion Valve 6. Exhaust the air in braking system 7. Check and adjust the hydraulic pressure of load sensing proportion valve. BR-45 SR-1 Steering System Page Notice .......................................................................... Troubleshooting .......................................................... Inspection on Vehicle .................................................. Steering Column ......................................................... Manual Steering Gear ................................................. Power Steering ............................................................ General Introduction ................................................ Inspection on vehicle ............................................... Power Steering Oil Pump ........................................ Power Steering Gear ............................................... Steering linkage .......................................................... SR-2 SR-2 SR-3 SR-4 SR-9 SR-11 SR-11 SR-13 SR-16 SR-18 SR-20 SR Steering System  Notice and Troubleshooting SR-2 Notice The parts change should be conducted correctly because any error will affect the properties of steering system, or lead to accidental or damage when driving. Troubleshooting Trouble Difficulty in steering Causes Unsuitable tire inflation Insufficient lubricant Over-large inclination Steering gear joint wear Lower swing arm ball head wear Steering column seize-up Steering gear unsuitable adjustment or damage Power steering conveyer looseness Over-low liquid level in oil cup of steering pump Failure in power steering mechanism Poor returning Unsuitable tire inflation Insufficient lubricant Incorrect wheel alignment Inspection items Inflate the tire to specified pressure Lubricating the hanging devices Check the Alignment of Front Wheel Change the Steering gear joint Change the lower swing arm ball head; Check the steering column Adjust or repair the gear. Adjust the conveyor. Check the steering pump oil cup Check the power steering devices Steering column seize-up Steering gear unsuitable adjustment or damage Inflate the tire to specified pressure Lubricating the hanging devices. Check the Alignment of Front Wheel Check the steering column Change the steering gear. Over-large play Front wheel bearing wear Steering drive shaft yoke wear Lower swing arm ball head wear Steering gear joint wear Steering gear unsuitable adjustment or damage Change the front bearing Change the steering drive shaft Change the swing arm ball head Change the steering gear joint Change the steering joint Abnormal noise Steering drive lever looseness Steering gear joint wear Steering gear unsuitable adjustment or damage Oil lack or poor sealing of steering machine. Tighten the steering drive lever Change the steering gear joint Change the steering gear Add the oil or change the sealing washer Steering system inspection on vehicle. Steering System  On-vehicle Inspection SR-3 On-vehicle Inspection max play Steering wheel play 1.SR-18Check to see whether the steering wheel play is correct; Park the vehicle stably and align the tires in correct direction, press the steering wheel with finger and swing it in left and right direction. The play should not exceed the max play. (Max play) 6(Dr SF) If the play is nor correct, adjust or repair the steering wheel as 2. requirement. Adjust the steering wheel play: (a) Align the wheel forward precisely; (b) Loosen the locking nuts of steering gear; (c) Rotate the adjusting screws of steering gear clockwise to reduce the steering wheel play, while contrarotate the adjusting screws to increase the steering wheel play. Remark: screw the adjusting screws and enlarge the play a little each time to check the adjusted play. 3. Check to see whether there is steering inconvenience Rotate the steering wheel by half round in right and left direction to check whether the play is correct, and whether the wheel runs smoothly or any seize-up in its running. 4. Fix the adjusting screws and fasten the adjustable nut. Oil level height Check the oil level height in the steering gear housing. Oil level height: flush with the filler opening. If there oil is insufficient, add the gear oil and check to see whether there is oil leakage. Steering System  Steering Column SR-4 Steering Column Element figure of non-adjustable steering column Dr 50  5 upper part of steering column universal cardan joint fixed support seat dust cap steering drive shaft 30  2 SL SK SY upper part of steering column steering drive shaft Nm specified torque Steering System  Steering Column SR-5 Steering Column Element figure of adjustable steering column Dr SF upper part of steering column universal cardan joint steering drive shaft SL SK SY upper part of steering column universal cardan joint steering drive shaft SJ steering column universal cardan joint SR-6 Steering System  Steering Column Dismantle of the steering wheel 1. Dismantle of the steering wheel; (a) Take down the bugle cap; (b) Pull down the bugle wire. (c) Tear down the fixing nut of steering wheel. 2. Tear down the combined switch cover; 3. Tear down the cover at left bottom part. 4. Tear down the fixing bracket for the left-bottom cover. 5. Tear down the air passage; 6. Tear down the combined switch; 7. Tear down the fixed support seat bolts on front-wall panel; 8. Tear down the fixing bolts at upper part of steering column, and 9. Tear down the connecting bolts of steering column drive shaft. 10. Pull out the steering column. Steering System  Steering Column SR-7 Mount of Steering Column SST 1. Mount the ignition switch assembly Fix the ignition switch on the steering column with SST. 2. Mount the dust cap and fixed support seat of steering column on the front-wall panel. 3. Mount the upper part of steering column; Mount the upper part of steering column on the fixed bracket with SST. 4. Connect the upper part of steering column and the steering drive shaft with the universal cardan joint; 5. Connect the steering drive shaft and the steering gear; 6. Mount the combined switch. Fix the combined switch with SST. 7. Mount the combined switch cover; SST SST Fix the combined switch cover with SST. SST SR-8 Steering System  Steering Column 8. Mount the steering wheel: (a) Screw up the fixing nuts of steering wheel according to the specified torque. Specified torque Dr SF(50  5)N.m SL SK SY SJ(30  2)Nm (b) Connect the bugle wire; (cMount the bugle cap. Steering System  Manual Steering Gear SR-9 Manual steering gear Disassembly and mount of manual steering gear steering drive shaft manual steering gear box worm shaft 96  10(Dr SL SK SY) swing arm 245  25(Dr) Nm specified torque assembly mark Points on disassembly and mount 1. Disassemble the steering drive shaft: (a) Loosen the fixing bolts at upper part of steering column; (b) (c) Tear down the connecting bolts of steering drive shaft; Mark the assembly marks on the steering drive shaft and worm shaft; (d) Slide the shaft backward to tear it down from the worm shaft. 2. Tear down the swing arm from the steering gear: SST (a) Loosen the fixing nuts of swing arm; (b) Tear down the swing arm from the steering gear with SST. Steering System  Manual Steering Gear SR-10 3. Connect the swing arm to the steering gear: (a) Mount the swing arm on the segmental gear shaft, and mount the spring washer and steering arm. (b) Screw up the swing arm nuts. Fastening torque(245  25)Nm(Dr) 4. SST Tear down the swing arm from the central transverse drag rod; Tear down the swing arm from the central transverse drag rod with SST. Steering System  Power Steering (General Introduction) SR-11 Power steering Introduction Principal of Power Steering steering drive shaft oil cup The power steering is a kind of hydraulic device that use the engine power to steer. The engine drive the power steering oil pump to generate the hydraulic pressure, which actuates the piston in steering gear, so that the worm shaft can provide to the piston with a supplementary force, which has relation with the pressure actuated on the piston. Therefore, pressure increase is required if larger steering force is needed, and the pressure variation is accomplished through the control valve. power steering oil pump power steering gear control valve pump Intermediate position (forward straightly) drain outlet The liquid from the power steering oil pump is sent to the control valve, which, if locates at the intermediate, will power cylinde steering gear power piston allow the liquid to pass and enter into the drain outlet, finally return the pump. At this time, it is difficult to increase the pressure; meanwhile, due to the equal pressures at the both sides of the power piston, it cannot move toward either side. worm shaft segmental gear shaft Pump Steering time When the steering drive shaft move toward either side, the control valve will move together with it, in case one oil passage is shut off, meanwhile open the other larger, the liquid flow variation will increase the pressure, as result, the unequal pressure at both sides of piston will make the piston move toward the side of smaller pressure, therefore, the liquid is pressed in the pump through the control valve. SR-12 Steering System  Power Steering (Introduction) Suggestion on maintenance The failure of power steering system usually relates to the steering difficulty due to lack of supplementary force. In such case, it is the first to verify the problem is produced by the pump or steering gear when repairing. In doing so, the problem can be checked on vehicle with the pressure meter. On-vehicle Inspection As the power steering is a hydraulic pressure device, its trouble usually caused by the lack of specified hydraulic pressure or the abnormal work of control valve. As a result, it cannot acquire the moderate hydraulic pressure. In case the problem is caused by the pump, the steering wheel will deflect toward right or left. On the other side, if the problem is caused by control valve, when the steering wheel rotates to left or right, the steering will become more difficult due to the unequal supplementary force. However, when there is wear on the piston sealing ring of power cylinder, it also cause the hydraulic pressure loss that may lead into steering difficulty toward right or left. Before making inspection on vehicle, verify the power steering system firstly to see whether there is air. If any, the air volume will increase with the variation of hydraulic pressure, which will cause the hydraulic pressure fluctuation that makes the power steering work abnormally. In order to verify whether there is any air in the system, check whether the liquid level varies or not when the steering wheel rotates completely toward the right or left. For instance, if there is air in the system, the air will be compressed, which will reduce the liquid level remarkably, when the steering wheel rotating. If there is no air in system, the liquid level variation is very small even though the hydraulic pressure increases. This is because the liquid volume will not varies when being compressed. And the small liquid level variation is caused by the expansion of hose between the pump and steering gear when the hydraulic pressure increasing. Meanwhile, the air in system sometimes will cause the pump or steering gear produce noise when the steering wheel rotating completely toward a certain direction. After checking or exchanging the pump or steering gear, the on-vehicle inspection should be often conducted to guarantee the normal work of power steering system. Steering System  Power Steering (On-Vehicle Inspection) tensioning wheel power steering oil pump SR-13 On-vehicle inspection Inspection on tension of driver conveyor Measure the tension of drive conveyor. Drive conveyor tension: under the condition of 98 N. New conveyor: (5-7)mm Old conveyor:(7-9)mm Remark: ìnew conveyorî means the conveyor that is used on the crankshaft machine less than five minutes; ìold conveyorî means the conveyor that is used on machine more than five minutes Check for height of liquid level 1. 2. Keep the body in horizontal status Increase the liquid temperature When the engine runs idly by 1000 r/m or less, rotate the steering wheel several times from the locking position to the reverse locking position to increase the liquid temperature. 3. Check to see whether there is foam or emulsification; Remark: the foam or emulsification shows there is air in the system or the liquid level is over-low. 4. Check the liquid level height in oil cup; Check the liquid level height and, if needed, add the oil. SR-14 Steering System  Power Steering (On-Vehicle Inspection) Change of power steering liquid 1. Tear down the oil-returning hose from the oil cup to drain the liquid into the container; 2. Run the engine in the idle status, and rotate the steering wheel toward the max rotating angle for several times in right or left direction while draining the liquid, until the oil in steering liquid is drained up. 3. Turn off the engine. 4. Connect the oil-returning pipe and inject the new power steering liquid in the liquid tank; Hydraulic oil type: No.8 Liquid drive oil (Q/SH003.01.012-88) 5. Start the engine, and make it running in the idle status. Rotate the steering wheel to the max rotating angle repeatedly several times, meanwhile, supplement new power steering liquid in the liquid tank until there is no foam or turbidities in the liquid tank, and the oil indicating lamp reaches the marked range when the engine is turned off. 6. 7. Tighten the liquid tank cover Exhaust the air in the power steering system; Ai-r bleeding in power steering system 1. Check the liquid level height in the liquid tank Check the liquid level and, if needed, supplement the liquid. 2. Start the engine in the idle status and rotate the steering wheel repeatedly to the max rotating angle 3. several times. Turn off the engine and connect the ethane pipe and 4. bleeding plug. Start the engine and rotate the steering wheel repeatedly to the max rotating angle several times. 5. Locate the steering wheel at the intermediate position. Steering System  Power Steering (On-Vehicle Inspection) 6. SR-15 Exhaust the air in steering system: (a) Loosen the bleeding plug; (b) Screw up the bleeding plug when there is no air bubble exhausted from the pipeline. Notice: take care not let the ethane pipe slide from the bleeding plug, because the liquid is high in temperature and pressure. 7. Check to see whether there is air bubble or turbidities in the oil cup, and ensure the liquid level will not exceed the max value when the engine stops, RPM RPM Measure the liquid height under the condition of engine running, then turn off the engine and measure the liquid height again. In case any problem is found, repeat the approaches of (5) and (6) in Power Steering Liquid Change. If the problem still exists, repair the power steering oil pump. Steering System  Power Steering (Oil Pump of Power Steering) SR-16 Oil Pump of Power Steering Dismantle and Mount of Oil Pump of Power Steering Gasoline Engine Series power steering oil pump power steering oil pump bracket belt pulley HP oil pipe LP oil pipe driving belt Diesel Engine Series HP oil pipe oil cup belt pulley LP oil pipe power steering oil pump power steering oil pump bracket Steering System  Power Steering (Oil Pump of Power Steering) SR-17 Points on disassembly and mount 1. Disassemble and connect the pressure pipe; Tear down and mount the pressure pipeline on the power SST 2. steering oil pump with SST. Loosen the belt pulley nuts; Press the driving belt by hand to fix the belt pulley to immobilize and loosen the belt pulley nut. 3. Adjust the driving belt tension after mounting the power steering oil pump; (See page SR-13) Steering System  Power Steering Gear SR-18 Power steering gear Disassembly and mount of power steering gear Dr SF SJ LP oil pipe steering drive shaft(Dr SF) HP oil pipe steering drive shaft(SJ) power steering gear 96  10(Dr) 145  10(SF) 78  10(SJ) 245  25 swing arm steering drag rod 91  10(Dr SF) pi=ph=pv LP oil pipe HP oil pipe steering drive shaft 96  10 power steering gear swing arm 245  25 Nm specified torque Steering System  Power Steering (Power Steering Gear) SR-19 Points on disassembly and mount 1. Tear down the HP oil pipe and LP oil pipe from the steering gear; Tear down the HP oil pipe and LP oil pipe from the steering gear. assembly mark 2. Tear down the steering power shaft (a) Make assembly marks on the steering drive shaft and the worm shaft. (b) (c) 3. Tear down the connecting bolts of drive shaft Dismantle the steering drive shaft from the worm shaft. Tear down and connect the swing arm: (a) Tear down the swing arm fixing bolts; (b) Tear down the swing arm from the steering gear with SST. SST 4. Tear down the fixing bolts of steering gear; Tear down the fixing bolts from the steering gear and then the steering gear can be disassembled. SR-20 Steering system - Steering Linkage Steering Linkage Dismantle and mount of steering linkage   side drag rod assembly joint clip 80  10(Dr) 83  10(SL SK SY) 142  10(SF) 78  10(SJ) 91  10(Dr SF) 90  10(SL SK SY) 78  10(SJ)   91  10(Dr) 59  5(SF) auxiliary steering arm   intermediate lateral drag rod assembly Nm specified torque  Parts that cannot be reused after being used Remark (a) Where the bolts of recirculating ball are connected with the arm or lever, the lubricant on its surface should be cleaned. (b) Screw up the bolts and nuts of re-circulating ball to the specified torque, and then screw the nut forward to the degree that the split pin can be encased in. (c) Check the Alignment of Front Wheel and side slip after any part of steering linkage is mounted. Steering System - Steering Linkage SR-21 Points on Dismantle and Mount 1. Tear down and connect the swing arm on segmental gear shaft: SST (a) Loosen the swing arm nuts; (b) Tear down the swing arm from the segmental gear shaft with SST; (c) Mount the swing arm on the segmental gear shaft and mount the spring washer and nut when connecting. 2. SST Tear down the swing arm from the intermediate lateral drag rod; Tear down the swing arm from the intermediate lateral drag rod with SST. 3. SST Tear down the side drag rod assembly from the intermediate lateral drag rod; Use the SST to tear down the side drag rod assembly from the intermediate lateral drag rod; 4. Connect the side drag rod assembly: (a) Screw the two ends in the side drag rod. A A A=A B Remark: the thread length at the two ends that cannot screw in the side drag rod should be equal. B B=B Steering System  Steering Linkage SR-22 (b) Rotate the two ends of side drag rod to make them intercross at 90angle, and connect the side drag rod. SST 5. Tear down the auxiliary steering arm from the intermediate lateral drag rod. Tear down the auxiliary steering arm from the intermediate lateral drag rod with SST. BE-1 Body Electric System Page Protective box Location and content ............................ BE-6 Power Supply System .................................................. BE-16 Starting System ............................................................ BE-17 Lighting System ........................................................... BE-19 Combination Instrument ............................................... BE-32 Backup Radar System ................................................. BE-39 Wiping and Washing System ....................................... BE-40 Central control lock and Power regulator System ......... BE-50 Acoustical Equipment System ..................................... BE-61 Wire Harness Arrangement.......................................... BE-68 BE Body Electric System  Brief Introduction BE-2 Brief Introduction 1. Power supply system The power supply system includes accumulator, generator and its adjustor. Generator is the main power supply; the accumulator is the auxiliary power supply. The generator, parallel with the accumulator, is equipped with the adjustor, which is used to maintain the voltage of generator stable when the rotating velocity and the load varies. 2. Starting System Which includes the direct current motor, drive mechanism and control device, etc. its performance is to start the engine. 3. Lighting system Which includes various lighting lamps inside and outside of the body and their control device; they are used mainly to guarantee safety driving in night. 4. Alarming System Which includes the electric horn, flasher and various service signal indicating lamps, etc. they are mainly used to guarantee the physical and driving safe when driving. 5. Auxiliary Electric Appliance System It includes the electric wiper, air-conditioner, recorder and cigarette lighter, etc. English letters for wiring colors code: R B =black Bl =blue R =red Br =brown Lg =reseda V =purple G =green O =orange red W =white Gr =gray P =pink Y =yellow First letter stands for the basic color, while the second for the stripe color. R/G green red 1 2 3 4 5 S 3 6 N 2 5 4 1. The codes of sockets of socket plugging element are complied from left to right. 2. The codes of sockets of socket plugging element are compiled from right to left. Remark: all of plugging elements are watched from the inwiring direction. socket plugging element plug plugging element 3. Comparison between plug and socket plugging elements The plug and socket plugging elements are classified according to their in-built socket shape. (a) All of plugging element are marked according to the opening end and are locked at their tops. (b) When pulling the plugging element, pull the plugging element itself instead of wire. Remark: before pulling the plugging element, check the socket plugging element plug plugging element plugging element that you want to disconnect first to verify their classifications. Body Electric System  Brief Introduction pull up BE-3 pull up press down 10A same rated current 10A press down Change of fuse and maxi-fuse Remark: in case of exchanging the fuse or maxi-fuse, the fuse or maxi-fuse with same rated current should be used. Notice: 1. Before exchanging the fuse or maxi-fuse, all electric appliances and ignition switches should be turned off firstly. And the rated current of fuse or maxi-fuse should 2. not be exceeded. When disassembling or assembling the fuse, the disassembly and assembly tools must be used. And they must be pulled out or plugged in vertically. No bend is allowed because the bend will make the connecting terminals depart away, and thus poor connection will occur. In case the fuse or maxi-fuse is burned, it shows there is short circuit. In such situation, the systematic inspection should be conducted by the qualified technician. Remark: the disassembly and assembly tools are put on the protective box cover. Body Electric System  Brief Introduction BE-4 How to make systematic inspection The inspection order is a simple troubleshooting approach, which is used to check and diagnose the failure on vehicle when there is part (wiring and plugging elements excluded) failure in the systematic operation or presupposed system. Following items should be considered firstly when checking the failure.  wiring failure  open circuit or short circuit of electric wiring  failure in plugging element connection or terminal connection  failure of fuse or maxi-fuse Notice: 1. The inspection is conducted on vehicle when the system is in operation, therefore, security should be taken into account when checking. 2. Care should be paid not to make short circuit in the system under the condition that the accumulator is directly connected, and the applicable voltage should be selected correctly. IG terminal connected to ignigtion switch of SW Voltage inspection (a) Verify the voltage situation at the inspection spots. For example: fuse Put the ignition switch atON position  Put the ignition switch and SW1 at ONposition;   Put the ignition switch of SW, SW1 and the relay at ONposition (SW2 atOFFposition) (b) Connect the cathode lead (-) to the normal grounding SW1  0 V relay place or the cathode terminal of accumulator with the voltmeter; while connecting the positive lead (+) to the plugging element or part terminal. Such inspection can be conducted with the test bubble instead of voltmeter.  SW2 12 electromagnetic coil  0 Inspection on Conductance and Resistance (a) Disconnect the terminal or wire of accumulator to guar- ohmn meter  antee there is no voltage between the inspection sports. (b) Connect the two measuring leads of ohmn meter with the inspection spots. SW Body Electric System  Brief Introduction   0 BE-5 If there is diode in the circuit, connect the two leads in reverse 0 polar and make another inspection. When the cathode lead (-) K ohmn meter is connected with the positive (+) side of diode, and the positive (+) lead should be connected with the cathode (-) lead K of diode, the diode should conduct, while the two leads connected to the reverse polar, the diode should not contact. Remark: the specification may be not same due to different testing meter types; therefore, the application instruction for testing meter should be referred before the inspection. diode   0 0 ohmn Check the light emitting diode (LED) according to the same approach for diode inspection. Remark: K K  The testing meter should be used the one with 3V voltage or the one has larger resistance than that in circuit. If no suitable testing meter is applied, the voltage of accumulator may be added to check the LED to see whether it is lighted. LED digital type (c) analogue type Use the voltage or ohmn meter with high-impedance (min voltage of 10 KV) to diagnose the failure in electric circuit.  DC D C V LG terminal of ignition switch Check to see whether there is short circuit (a) Tear down the burned fuse and remove all loads from fuse box testing bubble short circuit  the fuse. (b) Connect the testing bubble at the fuse position; (c) Verify the situation of testing bubble position: For example: Put the ignition switch of SW atONposition; SW1 disconnectiong short circuit  Put the ignition switch of SW and SW1 at ONposition;  Put the ignition switch of SW, SW1 and Relay at disconnection electromagnetic coil short circuit  ONposition (which connects with the relay), and put SW2 at OFF ) position (or disconnect the SW2). (d) Disconnect or re-connect the plugging elements when observing the testing bubble. In case the testing bubble disconnection SW2 electromagnetic coil keeps lighting, which shows there is short circuit between the plugging elements; if the testing bubble extinguishes, there is short circuit between the plugging elements. (e) Shake the trouble wire alongside the body to locate the Body Electric System  Protective Box Position and Content BE-6 Position and content of protective box Parts mounting Position Dr SF protective box III time-delay relay protective box I SL SK SY SJ protective box I flasher relay rear defrost relay SY rear air-conditioning relay SY pre-heating timer SL diesel SY diesel horn relay SL diesel SY diesel Body Electric System  Protective Box Position and Content Parts Mounting Position (Continued) ECU relay fuel pump relay air-conditioner relay preheating relaydiesel protective box II BE-7 Body Electric System  Protective Box Position and Content BE-8 Content of Protective Box Dr 1 protective box I relay fuse  A  B C 1.Small lamp 2.Rain brus 10A 20A A electric window relay B. small lamp relay 3.Ceiling lamp 10A C.(flasher) 4.(Cigarette lighter) 5.Back -u 15A 15A (plugging elements of ceiling lamp wire harness) 6.Brake 7.electric window 10A 30A (plugging elements of wire harness in engine room) 8.Instrument 10A fuel delivery/break electromagnetic valve10A(diesel 9.Central control lock 15A 1 2 3 4 5 6 7 8 9 FUSE 1. Protection SL SK 10A 2. Unload 3. Charging 4. Back-up 10A 10A U N 5. ECU 6. Unload 10A V O 7. Rain wiper 10A NM P 8. Stop lamp 9. Ceiling lamp 10A 10A NN Q 10. Central control lock 15A 11. Dual flasher 10A NO R 12. EC 10A NP S 13. Fuel pump 14. Cigarette lighter 10A 15A NQ T Body Electric System  Protective Box Position and Content BE-9 Protective bos I (continued) SF   A  B C D E 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 fuse 1. Small lamp 10A relay A. electromagnetic fan relay 2. Brake 5A B. lasher 3. Ceiling lamp 4. Central control lock 5A 15A C. electromagnetic fan relay D. small lamp relay 5. Electric rocker gear 6. Dual flasher 30A 10A E. electric window relay 7. Cigarette lighter 15A 8. Rear vision mirror 9. Unload 5A (1) plugging elements of ceiling lamp wire harness (2) plugging elements of wire harness at front left door 10. Acoustic device 11. Rear window 15A 20A (3)plugging elements of wire harness in engine room 12. Electromagnetic fan 10A 13. Instrument 14. Back-up lamp 5A 5A 15. Rain brush 16. Steering 10A 5A 17. Unload 18. Unload Body Electric System  Protective Box Position Content BE-10 1Protective box I (continued) pv=pg Fuse 1 2 3 Vehicle Model 1. Standby 30A Standby 2. Standby 20A SJ 15A SY Standby 4 5 6 7 8 9 10 11 12 16 20 13 17 21 14 18 22 15 19 23 10A 3. Standby 4. Unload Bass bubble Power amplification SJ 10A SY SJ SY 10A 10 A SJ top SY 5. Unload SY SJ 6. Unload 7. Unload SY SJ SY SJ 8. Air-conditioner 9. Charging 10A 10A SY SJ SY Instrument 10A SJ 10.ECU 11.Back-up lamp 10A 10A SY SJ SY SJ 12.Cigarette lighter receiver 30A SY SJ 13.Unload SY Refrigerant 14.Unload 10A SJ top SY SY SJ 15.Steering electric window 10A SY 10A SJ 16.Stop lamp 17.Power aerial of inside lamp 10A 10A SY SJ SY SJ 18.Central control lock 20A SY SJ 19.Dual flasher 20.Front rain brush 10A 10A SY SJ SY SJ 21.Rear air-conditioner Unload 15A SY SJ 22.Rear defroster 15A SY 10A SJ SY Humid display of steering sindicating lamp Unload 23.Rear rain brush Unload SJ Body Electric System  Protective Box Position and Content BE-11 1.Protective box I (continued) SLDiesel SYDiesel Fuse Vehicle model 1 1. Standby 2. Standby 10A 15A (SL diesel)(SY diesel) (SL diesel) (SY diesel) 2 3. Standby 30A (SL diesel) (SY diesel) 3 4 8 12 5 9 6 7 NM 11 13 14 15 16 17 18 19 20 21 22 23 4. Unload 5. Unload (SL diesel) (SY diesel) (SL diesel) (SY diesel) 6. Unload 7. Unload (SL diesel) (SY diesel) (SL diesel) (SY diesel) 8. Start 10A (SL diesel) (SY diesel) 9. Rear defroster Unload 15A (SY diesel) (SL diesel) 10.Cigarette lighter and receiver 30A (SY diesel) Cigarette lighter 15A (SL diesel) 11.Rear rain brush Unload 10A (SY diesel) (SL diesel) 12.Front rain brush Rain brush 15A 5A (SY diesel) (SL diesel) 13.Steering 10A (SY diesel) Dual flasher 14.Preheating 10A 15A (SL diesel) (SL diesel)(SY diesel) 15.Electric window 16.Small lamp 30A 10A (SL diesel)(SY diesel) (SL diesel)(SY diesel) 17.Stop lamp 10A (SL diesel)(SY diesel) 18.Inside lamp and electric aerial 15A (SY diesel) eiling lamp 19.Central control lock 10A 20A (SL diesel) (SY diesel) Central control lock 15A (SL diesel) 20.Rear air-conditioner Unload 15A (SY diesel) (SL diesel) 21.Unload Refrigerant (SL diesel)(SY diesel) 10A (top SY diesel) 22.Unload (SL diesel )(SY diesel) Power amplification 23.Unload 10A (top SY diesel) (SL diesel)(SY diesel) Body Electric System  Protective Box Position and Content BE-12 Protective box II Dr SF 1 2 3 4 5 6 7 8 9  A  B C  Fuse 1. Front fog lamp Relay A. electromagnetic fan relay vehicle Dr 15A SF Dr charging relay electric horn relay Dr diesel SF 10A SF B. large lamp Dr SF 3. Large lamp Horn 10A 15A Dr SF C. frost relay Dr SF 4. Horn Lower beam 15A 10A Dr SF 5. ECU1 10A Dr Unload 2. Electromagnetic fan ECU1 Vehicle 15A Dr Charging 10A Dr diesel Rear frost 5A SF 6. Large lamp 10A Dr (1) plugging elements of wire harness in engine room none (2) plugging elements of wire harness in engine room 10A SF 7. Rear frost Upper beam 10A 10A Dr SF 8. ECU2 10A Dr 10A 10A Dr diesel SF 10A Dr SF Dr diesel Preheating Front fog lamp 9. Fuel pump Unload Dr SF (3) plugging elements of wire harness in engine room ECU2 Dr SF Dr SF Body Electric System  Protective Box Position and Content BE-13 Protective box II (continued) SL SK 1 2 3 4 6 7 14 17 8 9 10 11 12 A B C D E F 13 15 16 I 5 H G Fuse Vehicle Relay Vehicle 1. Standby 2. Standby 10A 10A SL SK SL SK A.electromagnetic fan relay small lamp relay SL SK (SL diesel) 3. Standby 30A SL SK B.electric window relay SL SK 4. Rear fog lamp 20A 10A (SL diesel) SL SK cold start relay C.frost relay (SL diesel) SL SKLeft large lamp 10A (SL diesel) charging relay) (SL diesel) 5. Front fog lamp Right large lamp 10A 10A SL SK (SL diesel) D.blower relay) thermostatic relay SL SK (SL diesel) 6. Small lamp Air-conditioner 10A 10A SL SK (SL diesel) E.small lamp relay heating relay SL SK (SL diesel) 7. Electric horn 10A SL SK F.large lamp relay SL SK Warm air 8. Electric window 20A 30A (SL diesel) SL SK G.air-conditioner relay frost relay SL SK (SL diesel) 10A (SL diesel) SL SK H.rain-brusher intermissive relay I.diod SL SK SL SK 10A (SL diesel) 10.Air blower Electric horn 30A 10A SL SK (SL diesel) 11.Electronic fan Dual flasher 10A 10A SL SK (SL diesel) 12.Right large lamp 10A SL SK 10A (SL diesel) SL SK Unloa 9. A/C Charging Unload 13.Left large lamp Fog lamp 14.60A fuse 10A (SL diesel) SL SK 15.60A fuse SL SK 16.30A fuse 17.30A fuse SL SK SL SK Unload SL diesel Body Electric System  Protective Box Position and Content BE-14 Protective box II (continued) SY SJ 1 2 3 4 5 6 7 8 9 14 17 10 11 12 A B C D E F 13 15 16 H I G Fuse Vehicle Relay Vehicle 1. Standby 2. Standby 10A 10A SY SJ SY SJ A. electromagnetic fan relay small lamp relay SY SJ (SY diesel) 3. Standby 4. Rear fog lamp 30A 10A SY SJ SY SJ B. electric window relay cold start relay SY SJ (SY diesel) 10A (SY diesel) air-conditioner relay SJ 5. Front fog lamp Right large lamp 10A 10A SY SJ (SY diesel) C. frost relay charging relay SY SJ (SY diesel) 6. Small lamp 10A SY SJ D. blower relay SY SJ Air-conditioner 7. Electric horn 10A 10A (SY diesel) SY SJ thermostatic relay E. small lamp relay (SY diesel) SY SJ Warm air 8. ECM 20A 10A (SY diesel) SY SJ heating relay rear defrost relay (SY diesel) SJ (SY diesel) F. large lamp SY SJ H. rain-brusher intermissive relay I. diode SY SJ SY SJ Left large lamp Unload 9. Fuel pump Charging 10A 10A SY SJ (SY DIESEL) 10. Air blower Electric horn 30A 10A SY SJ (SY diesel) 11. Electronic fan 10A SY SJ Dual flasher 12. Right large lamp 10A 10A (SY diesel) SY SJ Rear fog lamp 13. Left large lamp 10A 10A (SY diesel) SY SJ Front fog lamp 10A (SY diesel) 14. 60A fuse 15. 60A fuse SY SJ SY SJ 16. 30A fuse 17. 30A fuse SY SJ SY SJ Unload (SY diesel) Body Electric System  Protective Box Position and Content BE-15 Protective box III Dr SF Fuse 1. Compressor Vehicle model 10A 2. Unload A/C A 1 2 3 3. Warm air Dr SF SF 10A 30A Dr SF Dr Body Electric System  Power Supply System BE-16 Power supply system The power supply system includes the accumulator and the generator, the latter is the main power supply while the accumulator is the auxiliary power supply. The two power supplies are in paralleling connection. fuse  45 ignition switch  fuse ACC ON  ST charging indicating lamp fuse battery generator ignition switch SL SK SY SJ Dr SF 4 3 2 1 5 4 3 2 1 8 7 6 5 10 9 8 7 6 vehicle models in parenthesis belongs to Dr and SF Body Electric System  Starting System BE-17 Starting system The starter, powered by the accumulator, is driven by the direct current motor and is in normal operation through the drive device and control mechanism. fuse 45 ignition switch 53 14 SL SK SY SJ 32 ACC ON ST 4 3 2 1 8 7 6 5 Dr SF starter battery Vehicle models in the parenthesis belong to the Dr SF model. 5 4 3 2 1 10 9 8 7 6 Body Electric System  Starting System BE-18 Parts inspection Ignition switch Check the conductance situation of the switch LOCK OFF SLdiesel SYdiesel ACC terminal 4 1 switch position B Bl terminal 4 1 5 switch position R G W R/W terminal 5/10 4 3 switch position R G 5 3 B/Y W/Bl LOCK 4 3 2 1 8 7 6 5 ACC ON ON START pi=ph=pv=pg START 3 LOCK 4 3 2 1 8 7 6 5 ACC LOCK ACC ON START aê=pc ON R Q P O NM V U T N LOCK ACC ON START START Remark: in case the conductance fails to satisfy the specified requirement, change the switch. 2 W R/W 9 Y Body Electric System  Lighting System BE-19 Lighting system The lighting system includes the front combination lamp, rear combination lamp, fog lamp, inside lamp, instrument lighting lamp, air-conditioner panel lighting lamp and various signal indicating lamps. The small lamps shown in the small lamp system drawing include the instrument lighting lamp, air-conditioner panel lighting lamp, fog lamp, license lamp and ashtray lighting lamp. Upper/lower beam lighting system Dr SF fuse large lamp relay 1017 light surpass vehicle 11 small light headlamp battery fuse low beam large lamp switch high beam 33 7 6 5 4 3 2 1 14 13 12 11 10 9 8 21 20 19 18 17 16 15 The vehicle model in the parenthesis belongs to Dr model. upper beam indicating lamp main-beam headlamp passing-light headlamp combined switch Body Electric System  Lighting System BE-20 Upper/lower beam lighting system (continued) SL SK SY SJ frse large lamp relay frse T 7 small lamp battery upper beam indicating lamp 10 8 head lamp head lamp switch lower beam upper beam N out-drive connecting to combination instrument combined switch 7 6 4 5 3 2 8 1 NS 15 14 13 12 11 10 9 BE-21 Body Electric System - Lighting System Small lamp, steering and alarming system Small lamp system Dr fuse fuse ear small lampv license lamp 8 fog lamp indicating lamp fog lamp relay small lamp relay front small lamp left rear fog lam right rear fog lamp 3 receiver lighting lamp battery ON ON OFF OFF air-conditioner panel lamp small lamp switch 1 10 alarming switch lamp fog lamp switch instrument lighting system combined switch fog-lamp switch lamp 7 6 5 4 3 2 1 14 13 12 11 10 9 8 19 18 17 16 15 1 21 20 3 2 Body Electric System  Lighting System BE-22 Small lamp system SF fuse front small lamp rear small lamp foglamp relay small lamp relay license lamp instrument lighting system front fog lamp indicating lamp front left fog lamp defroster switch lamp 8 front rear fog lamp 6 alarming switch lamp ON rear fog lamp indicating lamp N ON front fog-lamp switch lamp battery OFF OFF small lamp switch left rear fog lamp front fog lamp switch rear fog-lamp switch lamp right rear fog lamp ON OFF tail-door switch lamp 10 rear fog-lamp switch CD switch lamp air-conditioner panel lamp cigarette lighter switch lamp combined switch 7 6 5 14 13 12 21 20 19 4 3 2 1 11 10 9 8 18 17 16 15 front fog lamp switch 6 5 10 9 4 3 rear fog-lamp switch 2 1 4 8 7 6 3 2 1 5 Body Electric System  Lighting System BE-23 Small lamp steering system SL SK SY SJ fuse ignition switch flashing lamp small lamp relay E 10 B i 2 left alarming switch right 5 steering switc ON OFF 1 4 6 8 small lamp small lamp battery large lamp small lamp switch 4 5 combined switch alarming switch lamp 7 6 5 4 3 2 8 1 16 15 14 13 12 11 10 stop lamp switch 4 3 2 1 8 7 6 5 9 1 2 Body Electric System  Lighting System BE-24 Steering and Alarming System alarming lamp switch Dr flasher i B left turn indicating lamp OFF ON 3 2 (turn lamp) on left side) 1 fuse front left turn lamp E ON rear left turn lamp OFF 16 2 horn switch right turn indicating lamp left right 9 (right front turn lamp battery electric horn steering switch turn lamp) on right side (rear right turn lamp) combination switch lamp) alarming switch 7 6 5 4 3 2 1 14 13 12 11 10 9 8 21 20 19 18 17 16 15 1 3 2 Body Electric System  Lighting System BE-25 Steering and Alarming System (continued) SF alarming lamp switch ON OFF fuse ignition switch 2 16 6 2 5 9 3 front left turn lamp 1 flasher E turn lamp) on left side ST ACC ON left turn indicating lamp B fuse 5 tight L 4 3 steering switchleft fuse rear left turn lamp right turn indicating lamp battery right front turn lamp) turn lamp on right side rear tight turn lamp combined switch alarming switch 7 6 5 4 3 2 1 14 13 12 11 10 9 8 6 5 21 20 19 18 17 16 15 10 9 4 3 ignition switch 2 1 5 4 3 2 1 8 7 10 9 8 7 6 BE-26 Body Electric System  Lighting System Inspection on Common Failure FailurePossible Only one lamp doesnt work Causes Burn off bubble Grounding failure of socket or wiring Repairing approaches Change the bubble Make reparation as required. The front combination Burn off fuse Failure of large lamp relay Failure of combinationswitch Wiring or grounding failureMake Change the fuselamp dont work Check the relay Check the switch Make reparation as required Upper beam lamp doesnt work Failure of combination switch Wiring or grounding failure Check the switch Make reparation as required The rear combined tail lampand license lamp dont work Burn off fuse in tail lamp Change the fuse and check whether there is short circuit Change the maxi-fuse; Check the switch; Make reparation as required. Burn off maxi-fuse Failure of combined switch Wiring or grounding failure Alarming lamp doesnt workBurn off horn fuse Change the fuse and check to see Failure of steering signal flasher Failure of steering signal/alarming switch Wiring or grounding failure Change the fuse and check whether there is short circuit Check the flasher Check the switch Make reparation as required. One side of the steering signal doesnít flash Failure of steering signal switch Wiring or grounding failure Check the switch Make reparation as required. Abnormal steering signal Burn off horn fuse Change the fuse and check to see whether there is short circuit Check the flasher Check the switch Make reparation as required. Failure of steering signal flasher Failure of steering signal/alarming switch Wiring or groun ding failure Remark Dr SF Dr SF Body Electric System  Lighting System BE-27 Parts inspection Combined switch conductance Dr Terminal 1 8 10 17 3 7 2 9 function Bl/W Bl/Br B B/Y B/W B G/Y G/R OFF small lamp Large lamp Lower beam upper beam Lamp switch 7 6 5 4 3 2 1 14 13 12 11 10 9 8 21 20 NV 18 17 16 15 Dimmer switch Leftturnn steering switch right turn central overtake SF 1 8 7 10 3 15 2 9 Bl/W Bl/Br B B/Y B/W B G/Y G/R terminal 16 7 15 10 8 9 1 4 3 5 function Bl/Br Bl/W B B/W B/Y Bl/W B G/Y G/R Br Termina function 7 6 5 4 3 O 1 NQ NP NO NN NM V U 21 20 19 18 17 16 NR OFF small Lamp switch lamp large lamp lower dimmer beam switch upper beam left turn steering switch right turn central over drive SL SK SY SJ OFF lampswitch small lamp 7 6 5 4 3 2 8 large lamp 1 16 15 14 13 12 11 10 9 dimmer switch lower beam upper beam right turn wteering switch left turn central over drive Body Electric System  Lighting System BE-28 Combined Switch conductance (continued) SLDiesel SYDiesel Terminal 16 7 15 10 8 9 1 4 3 5 function R R/Bl B R/Y R/B R/Bl B G/B G/W Br OFF 7 6 5 4 3 2 8 1 16 15 14 13 12 11 10 Small Lamp switch lamp Small lamp 9 Dimmer switch steering switch Lower beam Left steering upper beam Right to central overdrive In case the conductance situation fails to satisfy the specified requirement, change the switch. Conductance of Alarming Switch Dr Terminal 1 switch position G/B 2 3 G/Y G/R 1 OFF 3 2 ON SF 6 5 4 3 2 Terminal 8 9 1 2 3 4 switch position B G/W P/G G/B P/B Br/Bl 1 OFF 10 9 8 7 ON 5 6 G/R G/Y Body Electric System  Lighting System BE-29 Conductance of Alarming Switch (continued) SL SK SY SJ Terminal switch position 4 3 2 1 8 7 6 5 1 2 3 4 5 6 7 8 G/B G/R G/Y Br Y W/Br B G/W OFF ON SLDiesel SYDiesel 4 3 2 Terminal 1 2 3 4 5 6 7 8 switch position G G/W G/B Br Y Br/W B G/R 1 OFF 8 7 6 5 ON In case the conductance fails to satisfy the specified requirement, change the switch. Conductance of Fog-lamp Switch Dr Terminal switch position 1 OFF 3 2 ON 1 B 3 Bl/B Body Electric System  Lighting System BE-30 Conductance of Fog-lamp Switch SF Terminal switch position 1 2 5 S 7 8 3 4 OFF 9 10 ON SF 1 3 2 4 5 2 B 5 P/Y 6 B 3 U V NM G/W Nothing Nothing Nothing 7 G/W Terminal 1 2 3 4 5 6 switch position B B W Nothing G/W W P _ S s OFF 6 ON SL SK SY SJ Terminal switch position 3 2 R G/W O B 1 OFF 6 5 4 ON SLDiesel SYDiesel Terminal switch position 3 2 1 6 5 4 OFF ON R G/R O B P S B Bl Body Electric System  Lighting System BE-31 Conductance of Large Lamp Relay Dr SF Terminal 85 30 30 85 85 86 87 30 85 86 87 30 status Fixed 86 87 87 86 Load accumulator voltage on the terminal 85,86. SL SK SY SJ 30 Terminal 85 30 85 status Fixed 87 86 87 86 Load accumulator voltage on the terminal 85,86. In case the conductance of above-mentioned switch fails to satisfy the specified requirement, change the switch. Conductance of Flasher Relay 1. L E B Connect the positive lead from the accumulator to the terminal B, and the cathode lead to terminal E. 2. Connect two turn signal lamps to the terminal L and E and check the flashing situation of the two bubbles. The turn signal lamp should flash 8510 per minute, in case the flashing frequency fails to satisfy the specified requirement, change the flasher relay. turn signal lamp Body Electric System  Combination Instrument BE-32 Combination instrument Electric circuit diagram ^N ^NS    _N      Dr aêaáÉëÉä rear fog lamp indicating lamp A3 rear window/defroster indicating lamp A4 B12 B13 upper beam indicating lamp front fog-lamp indicating lamp A13B3 water connected thermometer with negative tachometer pole speedometer fuel gauge connected with sensor connected with revolution signal connected with sensor anode connected with sensor B5 A10 B4 connected with A15 positive pole A14 connected with sensor braking liquid level indicating lamp parking brake indicating lamp safety airbag indicating lamp A10 connected with positive pole low oil pressure indicating lamp engine failure indicating lamp four wheel drive indicating lamp generator preheating indicating lamp fuel alarming indicating lamp accumulator charging indicating lamp rear fog lamp indicating lamp upper beam indicating lamp front fog-lamp indicating lamp A13B3 connected water thermometer with negative tachometer pole left turn indicating lamp right turn indicating lamp connected with revolution signal connected with sensor anode speedometer connected with sensor fuel gauge connected with sensor oil-water separation indicating lamp B11 B10 B9 B8 B6 A9 safety belt indicating lamp A8 A7 parking brake indicating lamp braking liquid level indicating lamp low oil pressure indicating lamp A10 connected with positive pole engine failure indicating lamp four wheel drive indicating lamp generator preheating indicating lamp fuel alarming indicating lamp A6 accumulator charging indicating lamp A5 B1 A16 ABS failure indicating lamp instrument interior lighting lamp A1 liquid crystal back-light lamp connection with sensor A12 ABS failure indicating lamp A2 connected with negative pole _NP left turn indicating lamp right turn indicating lamp A2 connected with negative pole A3 B12 B13 B5 B4 A15 A14 A12 A4 B11 B10 B9 B8 B6 A9 A8 A7 A6 A5 B1 A16 instrument interior lighting lamp A1 liquid crystal back-light lamp A10 connected with positive pole Body Electric System  Combination Instrument BE-33 Electric circuit diagram (continued) SF A3 connected with negative pole left turn indicating lamp right turn indicating lamp A1 connected with positive pole B15 A2 upper beam indicating lamp B16 rear fog lamp indicating lamp A13 rear window/defroster indicating lamp A16 front fog-lamp indicating lamp connected with sensor B5 water thermometer B8 connected with negative pole tachometer B13 connected with revolution signal instrument plugging element B12 connect to the cathode of sensor A7 connected with sensor anode A5 speedometer connected with sensor 1 2 A11 B14 connected with positive pole digital clock fuel gauge B7 connected with positive pole connected with sensor A12 back door indicating lamp B6 3 4 5 parking brake indicating lamp B4 safety airbag indicating lamp A14 B7 connected with positive pole low oil pressure indicating lamp engine failure indicating lamp B10 6 7 B11 four wheel drive indicating lamp A9 8 generator preheating indicating lamp B1 fuel alarming indicating lamp 9 A15 accumulator charging indicating lamp B9 75  10 11 ABS failure indicating lamp B2 A4 connecting with lighting switch A6 connected with negative pole 12 irect-current power supply 5-9V drive power supply 110V EL luminous plate 13 14 15 In this drawing, A stands for the white plugging elements, B for black plugging elements, they pressure-regulating potential device use the same numerical order. 16 Body Electric System  Combination Instrument BE-34 Electric circuit diagram (continued) A16 A1 SL SK 4P G B1 speed and mileage meter V B16 A9 vehicle speed signal A11 odometer sensor SY SJ B1 accumulator plus four door-closing indicating lamp A3 _NO A11 A10 odometer sensor anode turn on when the door is opened. odometer sensor A10 electronic odometer B11 electronic tachometer engine ignition coil sensor signal B11 electronic tachometer B16 water thermometer fuel gauge coolant temperature sensor B5 A12 fuel gauge sensor water thermometer fuel gauge neutral gear indicating lamp upper beam _NP _NP B14 differential latch-in safety belt vacuum alarming preheating B9 B10 sediment water alarming electricity charging/ discharging A13 fuel level alarming B6 brake failure alarming lamp A14 oil pressure alarming lamp A15 B1 rear fog lamp engine failure four wheel drive indicating lamp A1 Aturn indicating lamp B16 left turn indicating lamp upper beam differential latch-in A2 B3 A1 B5 A12 B2 B15 preheating sediment water alarming electricity charging/ discharging fuel level alarming B10 B3 B9 A13 B6 A14 oil pressure alarming lamp A15 rear fog lamp B1 engine failure B2 four wheel drive indicating lamp B15 A1 left turn indicating lamp A16 A16 B16 right turn indicating lamp B8 B8 A8 B4 + A2 brake failure alarming lamp A8 A16 A9 B14 instrument lighting system B7 - B4 + instrument lighting system B7 - Body Electric System  Combination Instrument BE-35 Common Troubleshooting a. Such failures as inaccuracy indication, out-operation of indicator, on the fly of large and small summation meters (mechanical wheel drive excluded) or incomplete liquid crystal display are caused by the interior failures of the instrument, therefore, these failures, once occur, should be judged according to the instrument interior failures, and change the combination instrument directly. b. In case both the large and small summation meter and the indicator of electronic odometer are on the fly, such failures can be removed by disassembling the speed sensor from the whole vehicle first, then connecting the sensor and combination instruments as shown in the drawing. 12V  sensor combination instrument  signal input Then, open the power supply and run the rotors quickly to observe the indicator variation of odometer. running the rotors, the odometer indicator should be no less than 40Km/ h variation in speed under common condition when otherwise, vÉë No change with the good sensor No good combination instruments Yes No connector for wiring harness failure of instrument panel malfunction of sensor connector for wiring harness installation of sensor Yes Body Electric System  Combination Instrument BE-36 c. The inaccuracy display of tachometer is usually caused by the interior failures of tachometer, in such situation, change the combination directly. As for the good-bad shift or out-operation of tachometer, the failures can be judged according to the following approaches: 1) Start the vehicle, then check the voltage of signal input of tachometer (wire harness with multi-meter, the voltage should be 6 V or so. 2) In case there is no signal voltage, check the power supply system of the whole vehicle to remove the failures in circuit. 3) The plugs of wire harness is only allowed to be inserted in the combination instruments under the condition that the signal voltage is normal, and the instrument is in normal operation. 4) Where the instrument is in abnormal operation, such trouble is caused by the failure of combination instruments, in such case, change the combination instrument directly. d. Troubles of fuel gauge and water thermometer 1) In case the instrument indicator points to the large number after it is powered, disconnect the sensor from the plugging elements of wire harness before judging such kinds of troubles, if the indicator is still at large number, it can be make a judgment that the trouble is caused by the interior failure of instrument, in such case, change the combination instrument directly; if the indicator returns to the small number, according to which it can be judged that the trouble is caused by the sensor failure, therefore, change the sensor directly. 2) where the instrument indicator stands still, such trouble may be caused by three causes probably, interior failure of sensor, plugging elements of wire harness or interior failure of instrument; the inspection may be conducted according to the following approaches: disconnect the plugging elements of wire harness from that of sensor, grounding the wire at the sensor end; in such condition, the indicator should move upwardly to the largest number; if such phenomena occurs, it can show the trouble is caused by the interior failure of sensor, in such case, change the sensor directly; if the instrument indicator is still immobilized after it is powered, it can be judged that the trouble is caused by the interior failure of instrument under the condition that the wire harness and plugging elements are normal, in such case, change the combination instrument directly. Normal indicating range of combination instrument indicator Speedometer Real speed Km/h Displayed speedKm/h 20 40 60 80 100 120 140 160 20  3 4005 6005 8005 10005 12006 14007 16008 Tachometer Dr SL SK SF Real rotating 1000 speedr/min Displayed rotating 1000  100 speedr/min Tachometer SY SL Real rotating 750 speedr/min Displayed rotating 750 +20 -10 speedr/min 2000 2000  200 3000  150 1000 2000 1000-10+50 Fuel gauge Dr SF SY Displayed oil volume Reference resistance  Permitted error  3000 4000 5000 1/2 F 3000 2000  120 3000  150 110 38 7 5 4 +3 Displayed oil volume Reference resistance  Permitted error  7000 4000  200 5000  250 6000  300 7000  350 4000 5000 6000 4000  200 5000  250 6000  300 Fuel gauge SJ E 6000 Fuel gauge SL SK E 1/2 F 110 38 7  12 4 2 Displayed oil volume Reference resistance  Permitted error  E 1/2 F 120 45 17  10  10  10 Body Electric System  Backup Radar System BE-37 Backup Radar System Part Mounting Position Dr SF back up radar control box SL SK rear bumper right rear wheel back up radar control box left rear wheel Body Electric System  Backup Radar System BE-38 Inspection on Common Trouble Trouble description Vehicle model No backup radar display (no system start notification when the reverse gear is engaged) Failure Judgment Methods Repairing and treatment approaches SL SK Check whether the plugging elements of power supply of back up radar control box are in well connection as shown in drawing H in next page.(when the reverse gear is engaged, touch the detector, if there is vibration, which shows the detector is powered. Check whether the wire harness of inner mirror in electric room and that on the top of body are in well connection as shown in the drawing A in next page Check whether the wire harness of back up radar control box is well connected with that of chassis and that on the top of body. Rotate the vehicle key to the ACC position and engage the reverse gear, then measure to see whether the back up power supply reaches to 12 V with the multi-meter of 50 V of voltage, refer to the red and blackpositions shown in the drawing in next page. If the voltage fails to reach 12 v, check the power supply system of original vehicles large wires to restore the voltage to 12 V. If the voltage reaches 12 V, change the backup radar control box in trial firstly, then the inner mirror in electric room, finally change the roof wire harness and the chassis. No backup radar display (but there is start notification when the reverse gear is engaged) remark: such trouble occur under the blocking condition. Check whether the power supply of back up radar is well located, see the red and position in the drawing of next page. Poor properties of ultrasonic wave Check and align the plugging element. Change the ultrasonic detector heads. Continuous back up radar red lamp alarming (remark: there is no obstacle within 0.5 m away from the detector head) Check whether the detectors in the two circuit of back up radar control box is well plugged, see the marked positions F, G in the drawing of next page. Check and well connect those plugging elements Check and well connect those plugging elements Change the ultrasonic detector head Poor connection of the left/right ultrasonic detector head Poor performance of back up radar control box. Change the back up radar control box. Vehicle model pc Alarming by mistake The rear standby tire is removed Conduct the inspection operation for the rear standby tire at the spacious place fail to detect the obstacle The detector head doesnt work Change the detector head fail to detect the obstacle There is dirt on detector head Clean the detector head Rear standby tire inspection 1. engage the reverse gear for five times repeatedly within ten seconds at the spacious place so that the red lamp on the screen flash three times, the system will automatically remember the standby tire status. 2. When the body height varies or the stand by tire is opened, make a new inspection for the rear stand by tire to ensure the backup radar in normal operation. Seven section of lamp display Column I1.49m-1.3m Column II1.29m-1.1m Column III1.09m-0.9m Column IV0.89m-0.75m Column V0.74m-0.6m column VI0.59m-0.45m Column VII 0.45m Remark: the right and left LED display the direction and distance of obstacle respectively for driver reference. Body Electric System  Backup Radar System BE-39 Distribution Drawing of Wire Harness SL SK A inner mirror in electronic room back up radar control box F connected with detector head G connected with detector head red H black BE-40 Body Electric System  Wiping and Washing System Wiping and Washing System Part Mounting position front brusher motor brusher and washer switch washer motor rear washer motor SY rear brusher motor SF rear brusher motor SY Body Electric System  Wiping and Washing System BE-41 Electric circuit diagram of wiping and washing system Dr SF 3 13 fuse 5 OFF brusher switch INT fuse LO ACC ON ST HI ignition switch washing 6 14 5 2 4 20 21 1 washer motor brusher motor battery M M P combined switch 7 6 5 4 3 2 1 14 13 12 11 10 9 8 21 20 19 18 17 16 15 brusher motor ignition switch 5 4 3 2 1 10 9 8 7 6 3 2 1 6 5 4 Body Electric System  Wiping and Washing System BE-42 Electric circuit diagram of wiping and washing system (continued) SL SK fuse 7 P 2 2 1 1 3 power supply grounding wire motor washing returning 4 5 ACC ON ST brusher switch intermission return gear N 2 3 4 5 6 ignition switch OFF INT LO HI washing 6 1 5 4 1 4 brusher motor washer motor battery 2 3 5 combined switch ignition switch 4 3 2 1 8 7 6 5 1 2 3 4 5 6 7 U 9 10 11 12 washer motor rain-brusher intermissive relay 6 MIST brusher motor 1 2 3 1 2 3 4 5 6 4 5 6 1 2 2 1 7 Body Electric System  Wiping and Washing System BE-43 Electric circuit diagram of front and rear brusher and washing system SY SJ heating wire rear defrost relay fuse rear defrost switch 1 3 2 Q 3 1 0 2 rear defrost switch rear brusher motor 1 2 2 1 3 4 4 3 rear brusher motor 4 8 76 5 OFF rear brusher switch ON 4 2 3 2 7 6 5 4 7 3 5 2 4 3 6 2 1 brusher switch return 4 3 2 1 8 7 6 5 rear washer motor 2 front washer motor 1 1 2 2 1 0 front brusher motor rain-brusher intermissive relay 5 4 front brusher motor 1 2 3 1 2 3 4 5 6 4 5 6 4 3 2 1 rear washer switch 1 2 3 4 6 washing 5 power supply intermission 2 return 1 grounding wire 3 rear washer motor washing MI OFF INT LO HI ignition switch 1 2 3 4 5 6 7 8 rear washer switch 0 3 1 4 1 rear brusher switch 4 0 1 2 front washer motor combined switch rain-brusher intermissive relay 8 small lamp switch 7 6 5 16 15 14 13 12 11 10 9 ON OFF 1 6 small lamp relay ONACC ignition switch fuse battery combined switch 1 2 3 4 7 8 9 10 11 12 5 6 1 Body Electric System  Wiping and Washing System BE-44 Electric circuit diagram of rear window, rear brusher and washing system SF 3 ACC ON ST fuse ignition switch rear brusher motor 7 6 M defrost switch M 3 battery 7 5 5 rear washer motor 4 rear window up-down switch 5 4 15 1 3 2 6 4 11 10 1 9 rear window and rear brusher controller 8 6 2 1 1 10 9 8 7 6 2 3 4 9 10 11 12 combined switch 13 14 6 5 4 3 2 1 14 13 12 11 10 9 8 21 20 19 18 17 16 15 rear washer switch 5 6 7 8 1 2 15 16 17 18 5 6 rear brusher motor 7 12 19 defrost switch rear window and rear brusher controller 3 14 back door window location switch 4 12 back door lock switch 5 17 back door regulator defrost indicator light defrost power grill ignition switch 5 3 2 1 6 5 4 7 8 3 4 9 10 Body Electric System  Wiping and Washing System Inspection on Common Trouble Trouble Brusher cannot move or cannot return to the stop position Possible causes Repairing approaches Burn out of brusher fuse; Failure of brusher switch; Change the fuse and check whether there is short circuit; Check the brusher switch. Failure of brusher motor; Brusher or grounding failure; Check the brusher motor; Brusher has no action at the intermissive gear Failure of brusher switch; Wiper or grounding failure; Check the wiping motor. Failure of motor switch; Check the brusher switch; Make reparation as required. Washer has no action The washer hose or nozzle is blocked; Failure of washer motor; Failure of washer switch; Wiring failure. Make reparation as required; Check the washer motor; Check the brusher switch; Make reparation as required. Make reparation as required. BE-45 Body Electric System  Wiping and Washing System BE-46 Parts inspection Brusher switch conductance situation aê Terminal 6 14 13 21 20 switch position Gr Gr/G Gr/Br Gr/Bl Gr/B Terminal 6 14 13 21 20 switch position Gr/R Gr/G Gr/Br Gr/Bl Gr/B OFF 7 S 5 4 3 2 1 14 13 12 11 10 9 8 21 20 18 17 16 15 19 INT LO HI Washing pc OFF 7 6 5 4 P 2 1 14 13 NO 11 10 9 8 21 20 19 18 17 16 15 INT LO HI Washing pi=ph=pv=pg Terminal switch position MIST 1 2 3 7 8 9 4 5 6 OFF 10 11 12 INT LO HI Washing 1 2 W/B Gr/R P 4 Gr/Br Gr/Bl 5 6 7 Gr/G Gr dêL_ê Body Electric System  Wiping and Washing System BE-47 Brusher switch conductance situation (continued) SLDiesel SYDiesel Terminal 1 2 3 4 5 6 7 switch position Bl/B Lg/R Lg/W Bl/Y Bl Bl/O Lg/W MIST 1 2 3 7 8 9 4 5 6 OFF 10 11 12 INT LO HI Washing In case the conductance situation fails to satisfy the requirements in the above-mentioned drawing, change the switch. Conductance Situation of Rear Brusher SY SJ 4 3 2 1 8 7 6 5 Terminal 1 8 7 6 5 switch position R/Y B G/W Bl/Y B/Y OFF ON SYDiesel 4 3 2 1 8 7 6 5 Terminal 1 8 7 6 R switch position R/Y B G/R Bl/Y B/Y OFF ON Where the conductance fails to satisfy the requirements in the above-mentioned drawing, change the switch. Body Electric System  Wiping and Washing System BE-48 3 6 2 5 In low-speed operation Check the front brusher motor Connect the anode lead to the terminal 2 (1) from accumulator, and 1 4 the cathode lead to terminal 3, at this time, the front wiper motor should be in low-speed operation, otherwise change the front brusher motor. 3 6 2 5 In high-speed operation Connect the anode lead to the terminal 1(2) from the accumulator, 1 4 and cathode lead to terminal 3, in such condition, the front wiper motor should be in high-speed operation. In case the operation fails to meet the requirement, change the front wiper motor. in operationstop running at the stop position 3 6 3 6 2 5 2 5 1 4 a. Run the front wiper motor at low speed and stop it at any positions excluding the stop position by disconnect the anode lead from the terminal 2 (1). b. c. 1 4 Connect the terminals 2 and 5.\ Connect the anode lead to the terminal 6 (4) from the accumulator, and the cathode lead to terminal 3, check whether the wiper motor parks at the stop position after it running for another time, if the requirement is not satisfied, change the front brusher motor. Remark: items in parenthesis is for Dr and SF. 2 4 1 3 Rear brusher motor inspection Connect the anode lead to the terminal 3 from the accumulator, and the cathode lead to terminal 4, at this time, the wiper motor will be in normal operation, disconnect the terminal 3, the rear wiper motor should stop running at any position excluding the stop position. Body Electric System  Wiping and Washing System BE-49 Connect the anode lead to terminal 3 from the accumulator, and 2 4 1 3 cathode lead with terminal 4, at this time, the wiper motor should be in normal operation, under such condition, disconnect the terminal 3, which is connected with terminal 1, and the anode lead is connected to the terminal 2, in such case, the rear wiper motor should stop running at the stop position. In case the operation fails to satisfy the specified requirement, change the rear wiper motor. Inspection on Washer Motor 1 2 Connect the anode lead to the terminal 1 from the accumulator, and the cathode lead to the terminal 2, at this time the washer motor should be in normal operation. Notice: this test should be finished rapidly (within 20 seconds). In case the operation fails to meet the specified requirement, change the washer motor. Body Electric System  Central Control Lock and Electric Rocker Gear System BE-50 Central control lock and electric rocker gear system Part Mounting position Dr SF Central control lock box SL SK SY SJ Central control lock box Body Electric System  Central Control Lock and Electric Rocker Gear System BE-51 Electric circuit diagram of central control lock left front door switch aê fuse left front main lock 1 right front main lock central controller box 6 5 3 4 left rear auxiliary lock battery 2 right rear auxiliary lock control case of central control lock 8 7 6 5 4 3 2 1 pc 1 fuse 12 8 to generator power lead 5 to right turn lamp M lock-head lamp battery 13 6 5 4 13 12 a 10 3 2 1 9 8 7 central control lock switch at left front door 11 10 control case of central control lock M 2 M M four doors locker 7 to door lamp switch 3 central controller box 6 to left turn lamp Body Electric System  Central Control Lock and Electric Rocker Gear System BE-52 Definition for connecting wire of central control lock SF 1 2 3 4 5 13P 6 Remark: the inner switch in actuator should be connected when the actuator is in the locking status Remark: In case the actuator is in locking status, connect the switch inside. Power anode 12 V unlocking signal of central control lock K M locking signal of central control lock no signal right turn lamp left turn lamp negative input of door switch 7 ON power check cable ON wire connected to key 8 no connection NOs j h 9 10 11 12 13 lock head lamp unlocking signal locking signal h left front CCL switch power cathode 6 5 4 3 2 1 13 12 11 10 9 8 7 1. Y/V Connect the power anode of 12V Unlocking output of central control lock: 2. B1 3. LG 4. 5. non-connection G/R Right turn lamp 6. G/Y Left turn lamp 7. Br 8. GD Negative input of door switch ON power check cable locking signal of central control lock 9. Non-connection 10. GD/B Lock head lamp output 12. Y/B Locking signal 13. B Power cathode to the cell anode on vehicle, in front of which a fuse of 15 A should be set, and when the motor is started, the voltage should not less than 10V the locking wire of the CCL actuator, and the grounding wire at the normally closed contact inside the relay will contact with the normally opening contact at the common spots inside relay when unlocking with REMOTE CONTROLLER or manually, the wire will output 12 V voltage. The CCL locking signal is connected to the unlocking wire of actuator of CCL, and the normally closed contact in the interior relay is grounding wire, which will output 12 V voltage when unlocking with REMOTE CONTROLLER or manually and the common spots of relay contacting the normally opening contact. There is no wire connected at present Connected to the anode wire of the right turn lamp on the vehicle, and it will output 12 V voltage in operation. Connected to the anode wire of left turn lamp on the vehicle, and it will output 12 V voltage when in operation Which is connected to the door switch and it is grounding when the door is opened (the indoor lamp will light) Connected to the ON wire of the locking door( there will be 12 v voltage when rotating the key atONposition. This wire is not connected temporarily There will be 12 V voltage outputted in this wire when opening the door, and will be powered off (no output) ten seconds later after the door is closed Connected to the locking signal wire of CCL at the left front door, and connect to the grounding wire when in operation. Connect to the body (grounding wire) it should be as short as possible, because the overlong wire will produce the interference source. Body Electric System  Central Control Lock and Electric Rocker Gear System BE-53 Electric circuit diagram of central control lock (continued) SL SK fuse 8 6 battery central controller box 5 4 3 7 left front door main lock right front door main lock left rear door auxiliary lock right rear door auxiliary lock control case of central control lock 1 2 3 4 5 6 7 8 turn lamp pv fuse ignition switch 11 1 8 ACC ON ST 6 central controller box 10 9 1 5 3 7 door lamp switch battery speed sensor 12 4 left front main lock control case of central control lock ignition switch 4 3 2 1 8 7 6 5 1 2 3 6 7 8 9 10 4 5 11 12 right front main lock left rear auxiliary lock right rear auxiliary lock Body Electric System  CCL and Electric Rocker Gear System BE-54 Electric circuit diagram of CCL SJ Top-grade SY left front electric rocker gear switch turn lamp fuse ignition switch 11 10 9 N 8 ACC ON ST 1 6 2 central controller box 5 4 door lamp switch battery speed sensor 7 12 left front main lock central controller box ignition switch 4 3 2 8 7 6 5 1 2 3 6 7 8 4 5 11 12 1 9 10 right front main lock left rear auxiliary lock right rear auxiliary lock Body Electric System  CCL and Electric Rocker Gear System BE-55 Definition of the connecting wire of CCL SY SJ 6 1 left turning light manual switch locking signal 7 2 8 3  closing window output none door switch negative input 9 speed test 10 ACC test power anode 12V K 12V door switch W 11 4 K M M M M remote control opening lock output power cathode 12 5 remote control closing lock output 1. G/R (G/W) Turn lamp 2. Ow/b1) Window-shutting signal output 3. No connection 4. G (Y) Unlocking output of CCL 5. Bl (G) Locking output of CCL 6. Gr (G/B) Turn lamp 7. W (W) Manually controlled unlocking signal 8. Br (R/B) Negative output of door switch 9. R/G (G/B) Rotating speed test 10. W(R ) ACC test 11. R (R ) Power anode (12V) 12. B(B) Power cathode Items in the parenthesis is for SY diesel model Items with  are configuration for SJ and top SY Connected to the anode wire of the turn lamp (right ) on vehicle, it will output 12 V voltage when it is in operation This wire has one second of voltage output of 12V when the car door is locking. (top SY SJ) Connected to the locking wire of actuator of CCL, and