Great Wall Deer (2006 year). Service Instruction - page 2
MT-3
Troubleshooting
Gear Box
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
Change
Difficulty in gear engagement
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
Change
Change
Change
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
Methods for troubleshooting
Over-loud or abnormal noise
Common Failures
Causes
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MT-4
Gearbox
Dismantle of Gear Box
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.
Tear down the gear change lever.
7.
Raise the vehicle to discharge the oil in gearbox.
Warning: the reliability of vehicle shall be verified.
8.
Tear down the drive shaft.
(See page PR-5)
9.
Tear down the odometer sensor and the plugging
elements of backup switch
10.
Tear down the vent pipe.
Tear down the heading exhaust pipe from branch exhaust pipe
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
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MT-5
Gearbox
Dismantle of Gear Box
4WD
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:
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.
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MT-6
Gearbox
Dismantle of Gear Box
4WD
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.
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MT-7
Gear Box
Mount of Gear Box
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
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MT-8
Gear Box
Mount of Gear Box
4WD:
(a)
Mount the bracket and supporter of leg washers of rear
engine in 4WD vehicle;(SF)
(b)
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: (30
50)Nm
4WD
4WD
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MT-9
Gear Box
Mount of Gear Box
10.
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.
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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.
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MT-11
Gearbox
Disassembly of Gear Box
(c) Dismantle the nuts of the four-gear driven extension fram.
(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
4WD
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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.
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MT-13
Gearbox
Disassembly of Gear Box
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 gear-
shift 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
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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 first-
second-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-second-
speed gearshift fork axle and the third-fourth-speed gear-
shift fork axle
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MT-15
Gearbox
Disassembly of Gear Box
19. Tear down the third-fourth-speed gearshift fork axle and
the toggle forks of first-second speed gear and third-
fourth 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 first-
second-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.
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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 intermediate-
gear shaft with the split-ring-type pliers.
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MT-17
Gearbox
Disassembly of Gear Box
SST
push down
to close
(b) Taker apart the rear bearing of intermediate shaft with
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 split-
ring-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.
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MT-18
Gearbox
Input Shaft Assembly (Element Drawing, Inspection On Synchronizing Ring, and BearingChange)
Input Shaft Assembly
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 clearance
0.8mm
Bearing Change
1.
Tear down the input shaft bearing with the pressure
machine.
retainer ring
bearing stop ring
bearing
input shaft
needle bearing
synchronizing ring
element drawing
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