great-wall Wingle 5 (2014) Workshop manual

Preface

Great Wall Pickup has a good reputation at home and abroad for the following advantages: good
comfortability, high practicability, complete function and reasonable performance/price ratio . In order to
meet the demand of market, Great Wall company offers second-generation product of Great Wall Pickup:
K2 series Pickup automobile. With novel design and elegant appearance, this automobile applies
turbocharging control direct injection diesel and has the following features: large torque, low fuel
consumption, long service life and perfect reliability etc. In order to meet the demand of most Great Wall
after-sale service technical personnel, we compile this service manual.

Service maintenance and repair information contained in this manual is provided for qualified profes­sional technical personnel. Maintaining and repairing in the case of personnel without regular training or
not using correct tools and devices will injure the personnel himself/herself and others. Meanwhile, it is
possible to cause vehicle damage and unsafe state. Therefore, correct service and maintenance is
very important to customer safety and vehicle reliability.In order to help you make a wise decision,
corresponding safe information or other safe instructions are given in this manual, which is throughout
the manual. Despite all this, we still could not give corresponding warnings to all dangers in service and
repair. You must make use of your correct judgement. Some most important after-sale service safety
preventive measures are given in the following:

1. Ensure that you have a clear understanding on the common sense of safety in all basic service
shops, wear corresponding protective clothing and use safe device. In taking any service, it is
especially necessary to note the following items:

(a)Before starting, read all the safe instructions, ensure that you have well prepared correct tools,

replacing or repairing parts and have required skills to finish the task safely and thoroughly.

(b) In pounding, drilling, grinding operation or working around pressure air, fluid, spring and other

energy accumulating parts, wear safety glasses, safety goggles or face shield to protect eyes.
In any other cases, as long as you are not sure, you must use eye protective device.

(c)Use other safety appliances such as gloves or safety boots if necessary.Moving hot or sharp

parts will cause severe burn or cut, so wear gloves before holding any object that seems to
cause injury.

(d)When lifting vehicles, you must protect yourself and others. Use crane or jack to lift vehicles

and use supporting rack to ensure the vehicles get reliable support.

2. Unless otherwise specified, before starting any maintenance, ensure the engine has flamed out

which can prevent the following dangers:
(a)Engine exhaust gas will cause carbon monoxide intoxication. Ensure perfect ventilation when

starting the engine.

(b)Hot parts or refrigerant burn. Before working near engine and exhaust system area, let the

engine and exhaust system cool down .

(c)Injury caused by rotating parts. When rotating the engine as required, ensure your hands,

fingers and clothes are far away from the rotating parts.

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We get great support and help from professionals in compiling this manual, so we would like to express
our sincere thanks to them here.

We apply the same iconography for similar models in this manual, so the information provided in this
manual may slightly vary from real model.Although we try our best to compile this manual carefully, we
still could not assure all contents are correct .Users are not allowed to bring forward any requirement to
Great Wall company depending on this manual, and we shall not bear any liability for the loss caused by
using this manual.Defects and mistakes are inevitable in this manual for limited level of compiler, we
sincerely expect you to criticize and correct.

Great Wall Motor Co., Ltd has the final explanation right to this manual.

Compiler
June 2006

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Chassis and vehicle body

N

PA

FE

CL

MT

TF

PR

SA

BR

SR

BE

AC

BO

Service manual

Overview I

Vehicle parameters

Fuel supply system and exhaust system

Clutch
Transmission
Transfer case

Drive shaft

Suspension system and axle

Braking system

Steering system

Vehicle body electrical equipment system

Air conditioning system

Vehicle body

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OV-1

OV

Overview

Page

How to use this manual...................................................OV-2

Identification number position.......................................OV-3

Integrated repair instruction..........................................OV-4

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OV-2

Overview— How to use this manual

How to use this manual

In order to help you find the contents of this manual more easily,
chapter name and main title are given on the top of each page.
In order to introduce maintenance items for you, index is given on
the first page of each chap ter.
Cautions for all repair operation related to this chapter are also
given at the beginning of each chapter.

Please read these cautions first before starting repair operation.

The trouble diagnosis table of each system can help you diagnose
system trouble and find out source of trouble.
The repair methods aimed at possible reasons are given in repair
methods column, which can help you get solutions as soon as
possible.

Repair procedures

Most of repair operation can be started through referring to
iconography. These iconographies help you identify parts and in­dicate their matching with each other.
For example:

Spacer-drive bevel gear

N ·m

◆ Parts no longer for use after service

:Specified torque

Iconography: what to do and where to do it

Front reducer assembly

Washer

Bearing

◆ Oil seal

Front reducer main gear flange

and dust shield assembly

140-160

Explain the repair procedures step by step:

● Iconography indicates what to do and where to do it.

● The title of repair operation tells you what to do.

● Detailed instructions tell you how to finish repair work and

introduce other relevant items such as specification and warning
etc.

For example:

Operation title: what to do

2. Measuring radial clearance of intermediate shaft 5th gear

(a) Mount spacer, needle bearing and reverse idler gear on

the intermediate shaft.

(b) Measure the radial clearance of reverse idler gear with

dial gauge.

Radial clearance: (0.009-0.32)mm

Specification

Detailed instruction: how to do it

◆

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Overview — Identification number position

This format can help experienced technical personnel quickly find
out the source of trouble. Repair personnel can browse operation
title and refer to the detailed instructions under it if necessary.
Important specification and warning are written with boldface.

Specification

In the whole manual, the corresponding specification is given with
boldface for each repair step, so you do not need to stop repair
work and see the specification.

Warning, note, remark

● Warning is written with boldface indicating the possibility of

injuring yourself or other persons.

● Note is written with boldface indicating the possibility of

damaging parts under repair.

● Remark is written in the instruction separately but not with

boldface. It is mainly some additional instructions to help you
finish work more effectively.

OV-3

Certificate plate

Frame number (VIN)

VIN nameplate

Identification number position

Vehicle identification number

Vehicle identification number (VIN) is unique number with 17 digits
representing vehicle identification, and this number is also engraved
on the outer right side of the frame right side member and VIN
nameplate of upper left instrument panel besides being present in
vehicle certificate.

Engine number

Engine number is engraved on the left side of the engine cylinder

Engine number

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body.

OV-4

Overview— Integrated repair instruction

Integrated repair instruction

● Protect all the paint coating and seats with clean cloth and

polythene to prevent dust and scratches.

● Concentrate yourself and be careful in working. After lifting

front and rear wheels, wedge the wheels not lifted reliably. If
two or more persons work together, communicate with each
other as much as possible. Do not let the engine rotate unless
workshop or operational area is in perfect ventilation.

● Before removing or disassembling parts, inspect them carefully

to isolate the parts needing repair. Please observe all the safety
instructions and preventive measures given in this manual and
operate as correct steps.

● Mark all the parts taken down or put them on the parts rack in

order so as to reassemble them completely as original order.

● When needing tools, use the special tools as required.

● Assemble parts as the regulations in maintenance standard with

correct tightening torque.

● When tightening a group of bolts or nuts, start from center

bolt or diameter bolt, and finish them in two or more steps in
cross way.

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Overview— Integrated repair instruction

● Parts no longer for use after service

(a) When reassembling parts, use new packing, gasket, O

seal ring and cotter pin.

(b) Parts no longer for use after service are marked with “

◆ ” symbol in part drawing.

● Do not continue using old parts needing replacement and it is

required to change them.

● Use parts and lubricants produced by original factory. When

continue using parts, inspect them carefully and ensure there
is no damage or deterioration and the parts are in perfect service
status.

OV-5

Locking sealant

● Specified grease should be applied on or filled into the parts as

required. When removing the parts, clean all of them with
solvent.

● Precoat parts

Precoat parts are bolts and nuts, and they are coated with
locking sealant in the factory.
(a) If precoat parts are tightened, loosened or moved for a

certain reason, coat them again with specified sealant.

(b) Coating steps for precoat parts

1) Clean off the old sealant from the thread of this part.

2) Blow them dry with compressed air.

3) Coat specified locking sealant on the part thread.

(c) Precoat parts are marked with “ ★ ” symbol in part

drawing.

● Disassembling and assembling of vacuum hose

(a) To disconnect vacuum hose, hold the hose end and pull

it out by twisting. Do not hold the middle hose and pull
forcibly, because this will damage the hose.

Wrong

Correct

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OV-6

Overview— Integrated repair instruction

(b) In order to facilitate reassembling the hose, add labels in

disconnecting to help recognize.

(c) Inspect carefully after finishing the work to ensure the

vacuum hose is connected correctly.

(d) When using vacuum gauge, do not connect the hose to

oversized joint compulsively. Adjust the joint size
gradually, and note that there will be leakage once the
hose is tensed.

● Disassemble the hose clip

(a) Before removing the hose, check the clip position to reset

correctly.
(b) Replace the deformed or dented clip.
(c) When using the clip repeatedly, lock the clip at dented

position.
(d) As to spring clip, gently pull the spring leaf to tighten the

spring clip as the arrow direction after assembling.

● Brake fluid and hydraulic element

(a) When applying fluid to the system, be extremely careful

to prevent dust or contaminant entering into system.
(b) It is forbidden to mix fluid of different brands, because

they may not be solved with each other.
(c) Do not reusing emitted brake oil.
(d) For brake oil may damage paint coat or resin surface, be

extremely careful not to let the brake oil spatter on these

surfaces, and immediately wash with water or warm

water if the brake oil spatters. After disconnecting brake

hose and brake pipe, block the opening to ensure there is

no loss with the brake oil.
(e) Clean all the parts taken down with clean brake oil and

blow all the holes and passes with compressed air.
(f) Avoid the parts taken down contacting with dust and

friction matters brought by the air.
(g) Before assembling parts, inspect and confirm they are

clean.
(h) Avoid smearing oil or grease on rubber parts or pipelines,

unless otherwise specified.
(i) When assembling, check each part is correctly installed

and in normal operation.

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Core of conductor

Gently pulling

Terminal like male contact

Overview— Integrated repair instruction

Wrong

Wrong

Correct

Loosening the coiling

Terminal
deformation

OV-7

Trouble shooting instruction on electrical
equipment malfunction

● Before trouble shooting

(a) Check corresponding fuse/fuse in the relay box.
(b) Check charging status of the battery, whether the battery

is damaged, and clean, and tighten the connector.

Note:

(a) Do not perform quick charge to the battery if the

battery ground cable is not cut, or the diode of
alternator will be damaged.

(b) Do not try to start the engine in the case of the

battery ground cable being loosely connected, or the
wiring will be seriously damaged.

(c) Check the alternator belt tension.

● Basic operation

1. Dismounting of harness joint
(a) When disconnecting the joint, squeeze both ends of the

joint with hands at first to loosen the lock and then press
the lock claw to release the joint.

(b) When disconnecting the joint, do not pull the harness,

directly hold the joint and disconnect it.

(c) Before connecting the joint, check it is deformed,

damaged and port lost.

(d) When connecting the joint, crack sound indicates

successful connection.

2. Inspection of harness joint
(a) Inspection for joint connected

Squeeze both ends of the joint to ensure the joint is safely
inserted and tightly locked.

(b) Inspection for joint disconnected

Inspect by gently pulling the harness from the joint back.
Find the terminal not meshed or fallen off, loosened clip
or broken lead.
Visually check there is corrosion, metal chips, impurities
and water, bending, rust, overheating, contamination or
terminal deformed etc.

(c) Inspecting the terminal contact pressure:

Prepare a male contact matching the joint port, and insert
it into the socket, and then check they are in good tension
status in inserting and after complete mesh.

3. Repair method of harness joint terminal

Correct

Wrong

(a) If there is dust on the terminal, clean the contact with air

gun or duster cloth.Do not wipe with tissue paper, because
this will damage galvanized coating.

(b) If the contact pressure is not normal, replace the same

class socket.

(c) Broken, deformed or eroded terminal should be replaced.

If the terminal is not locked in the housing, the housing
also needs replacing.

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OV-8

Overview— Integrated repair instruction

Wrong

Wrong

Wrong

4. Dismounting of the harness
(a) When dismounting the harness, check the wiring and

tightening of the harness before operating to reassemble
the parts correctly.

(b) It is absolutely forbidden to distort, extend or loosen the

harness.

(c) Do not let the harness contact with high-temperature,

rotating, vibrating or sharp-angled parts. Avoid contacting
the panel edge, screw tip or other similar articles.

(d) When installing parts, do not mix the harness with the

parts.

(e) Do not use the lead or harness whose insulating layer is

cracked.If it is cracked, replace it or wind the cracked
part with electric adhesive tape.

(f) After installing the parts, ensure no lead is locked under

the parts.

(g) If possible, insert the tester probe from lead side (except

waterproof connector).Use the probe with gimlet-point.

Note: piercing the lead insulating layer will result in poor
electrical connection or intermittent electrical connection
fault.

Five-step troubleshooting method

1. Fault check

Connect the power supply of all elements in faulted circuit to
check the fault description of customers, and pay attention to
symptoms.Before confirming the fault position, do not
dismount or test.

2. Principle analysis

Check the circuit diagram to confirm the faulted circuit. Check
all components along the current path from power supply to
ground connection and confirm the operating principle of this
circuit in this way. If there is trouble with several circuits at
the same time, the trouble is likely to be caused by fuse or
grounding.Recognize one or more reasons of the trouble based
on the symptoms and understanding of the circuit operating
principle.

3. Isolate the trouble by circuit test

Test the circuit to check the diagnosis in step 2.Remember
that clear and simple step is the key to eliminate trouble
effectively. Test the circuit that is most likely to cause the
trouble and start testing from the points easy to approach.

4. Troubleshooting

Once the fault is recognized, repair it immediately.In repairing,
use correct tools and follow safe operational procedure.

5. Confirm normal operation of the circuit

Under all operating modes, connect all components in the loop
that has been repaired, and confirm the whole trouble has
been eliminated.If the fault is the break of fuse, test all the
circuits connected to this fuse. Ensure that no new fault
appears and the former trouble no longer occurs.

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Overview— Integrated repair instruction

● Assembling and disassembling of the clip

The method to assemble and disassemble vehicle body parts is shown as the table below.
Remark: if this clip is damaged during operating, replace new clip.

Shape Disassembling/assembling

Jaw vice

Clip detacher

OV-9

Screwdriver

Screwdriver

Protect tape

Protect tape

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OV-10

Continued table:

Shape Disassembling/assembling

Disassembling

Screwdriver

Clip detacher

Push out the king pin and remove it, and prize off the king pin bush.

Disassembling assembling

Screwdriver

assembling

Pressing

Pressing

Clip detacher

Screw off the king pin and prize off the king pin bush.

Disassembling assembling

Pressing

Screwdriver

Clip detacher

Small clip detacher

Prize out the king pin and remove the rivet, and then prize off the king pin
bush.

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Complete Vehicle parameters

PA

page

Complete vehicle type................................................................ PA-2

Complete vehicle basic parameters........................................... PA-3

Dimension and weight parameters......................................... PA-3

Complete vehicle basic performance parameters.................. PA-4

Structure and performance parameters of main assembly PA-6

Vehicle body dimension schematic diagram.............................. PA-7

PA-1

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PA-2

Complete vehicle parameters page— Complete vehicle type/Complete vehicle basic parameters

Complete vehicle type

Two wheels drive Four wheels drive Two wheels drive

Left rudder Right rudder Left rudder Right rudder Left rudder Right rudder

CC1031PS40 CC1031PS50 CC1031PS60 CC1031PS70 CC1031PS41 CC1031PS51

Complete vehicle basic parameters

Dimension and weight parameters

Drive type

Length

Overall
dimension

Wheel base (mm)

Wheel track

Front suspension
Rear suspension

Trunk
inside
dimension

Width
Height (no load)

Front
Rear

Length
Width
Height
Curb weight
Front axle load

Type code

CC1031PS40 CC1031PS60 CC1031PS41

4×2 4×4 4×2
mm 5040 5040 5040
mm 1800 1800 1720
mm 1730 1730 1675

3050 3050 3050
mm 1515 1515 1460
mm 1525 1525 1460
mm 745 745 745
mm 1245 1245 1245
mm 1380 1380 1380
mm 1460 1460 1460
mm 480 480 480
kg 1775 1920 1705
kg 975 1090 945

Mass
parameter

Wheel
alignment
parameter
(no load)

Rear axle load
Weight with full load
Front axle load
Rear axle load
Load weight

Toe in (mm)

Front wheel camber
Kingpin rear inclination
Kingpin inclination angle

Inner/outer wheel max.
steering angle

kg 800 830 760
kg 2580 2725 2510
kg 1050 1165 1020
kg 1530 1560 1490
kg 480 480 480

0～2 0～2 0±2

0°±30

′

30′

3°30

′

0′

12°30′±30

32°/28°

≥

′

0°±30

′

30′

3°30

′

0′

12°30′±30

32°/28° 37°6′/33°30

≥

′

0°±30
3°35′±45
12°30′±30

′

′

′

′

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35

50km/h

Complete vehicle parameters page— Complete vehicle basic parameters

Complete vehicle basic performance parameters

PA-3

Type code
Engine model GW2.8TC-2

Delivery capacity（L
Rated power / rotating speed（kw/rpm
Max. torque / rotating speed (Nm/rpm) 225/1800～2000
Max. vehicle speed (Km/h)
Accelerating time （0～100km/h） (sec) full load 28
Max. climbing speed
Service braking distance with initial speed of braking of

（m）

Emergency braking distance with initial speed of braking
of 30km/h（m

Parking brake (with grade slope 20％) Not less than 5min
Noise dB (A) emitted by accelerating motor vehicles
Emission level Euro

Steering ability data

Engine startup performance

）

）

（％） ≥

）

Approach angle (no load) ≥
Angle of departure (no load) ≥

Min. ground clearance (fullload)

（mm）

Min. turning diameter（m

）

CC1031PS40 CC1031PS60 CC1031PS41

2.771

70/3600

140

≥

30

≤22（

Perfect start performance in the environment above

℃

full load

30°

≥

24°

≥

），≤21（

20

≤

78

≤

Ⅱ

194

13

≤

no load

）

24°
21°

－

Structure and performance parameters of main assembly

Engine characteristic parameters

Items

Engine model

Engine type
Delivery capacity（L

Bore × stroke(mm)
Rated power / rotating speed（kw/rpm
Max. torque / rotating speed (Nm/rpm)
Min. stable idle speed (r/min)
Compression ratio
Overall dimension（mm
intake system

Fuel supply
system

）

）

Fuel tank Plastic fuel tank: 70L
Fuel supply control Electric control

GW2.8TC-2
4-cylinder,in-line,water-cooling,four-stoke,turbo-chargingelectric

control direct injection diesel

2.771
93×102

）

70/3600
225/1800～2000
800±50

17.5:1
775×620×761
Air filter, exhaust gas turbo-charging system

Structure parameters

Exhaust system
Cooling system
Engine layout form

First class silencer
Closed and forced water-cooling system, electronic fan
Parallel, three-point mounting

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PA-4

independent suspension

Hydraulic double pipeline, with vacuum booster; loading sensing pressure

proportoining valve, optional anti-lock brake system (ABS)

Double wishbone torsional bar spring independent

suspension

Outside diameter of

friction disc

（mm）

Complete vehicle parameters page— Complete vehicle basic parameters

Main assembly structure and parameters of chassis

Clutch

Transmissi
on

Type code

Type Single dry diaphragm spring

Manipulate Hydraulic control
Type Mechanical, 5-forward gear
Center distance (mm)
Max. input torque (N.m)
Net weight（Kg
Odometer speed ratio
Lubricant type Gear oil 80W/90 (GL-4)
Lubricant amount( L) 2.4

Speed ratio

）

1st gear

nd

2

gear
3rd gear
4th gear
5th gear

CC1031PS40 CC1031PS60 CC1031PS41

250

72

230

≥

35

17/6

3.992

2.15

1.334
1

0.806

R gear
H gear 1
L gear 2.48

Main reducer speed ratio

Type Three spider types

Drive shaft

Pipe diameter×wall
thickness（mm

Front axle
Rear axle Whole axle

Tire type Tubeless radial tire

Wheel and
tire

Suspension

Tire specification P235/70R16
Felloe specification 16×7J
Tire pressure (F/R)(KPa) 220/250

Front
Rear Leaf spring non-independent suspension

）

Ф76×1.8 Ф76×1.8

4.1
Front: double spiders
Rear: three spiders
Front: Ф63×2.5
Rear: Ф76×1.8
Non-whole axle

4.22

，

3.9

Three spider types

P215/75R15

15×6J

Coiled spring

Steering
system

Braking
system

Steering gear type Hydraulic power rack-and-pinion
Steering column Adjustable or unadjustable

Structure type
Service brake Front disc brake, rear drum brake

Parking brake Drum brake

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Adjustable

carpet

Vehicle

s

Complete vehicle parameters page— Complete vehicle basic parameters

Vehicle body structure type

PA-5

Vehicle
body

Trunk

Interior,
exterior
trim

Assembly

Vehicle body type
White vehicle body

Door assembly

Engine hood
Front, rear bumper
Trunk type

nterior trim
Instrument panel

A, B, C column and inner
door panel

Roof door handle
Windshield

Rear view mirror

Driver's seat

Seat

Co-driver's seat
Rear seat The rear with integrated seat, backrest overturned to folding

Structure parameters

Body-chassis frame construction, double seats
All-metal closed structure

Push, four doors open, panel door lock, hinge, central control door lock,
electric window regulator
Backward opening, hinge with dead axle rotating, sealing with front and
rear weatherstrips, adding heat insulating mattress

PP injection molding, connected with body frame using clips and bolts
Body-chassis frame trunk, suspension connected with body equipped with

cushion, equipped with rear door opening and locking structure
Original inner door panel design, softening ceiling design and softening

Injection molding, main material with PP, frame with sheetmetal structure
Injection molding, inner door penal with sundries box and partially

softened, main material with PP
Nylon injection molding
Front windshield with double curved laminated glass, rear windshield with

tempered glass
Outer rear-view mirror: two types of electric and manual, optional

Interior rear-view mirror: manual glare-proof flat-view interior mirror
Seat position adjusted manually front and rear (travel 200), backrest angle

adjusted manually.
Seat position adjusted manually front and rear (travel 200), backrest angle
adjusted manually.

body
accessorie

Refrigerati
ng and
heating air
conditionin
g system

Door handle
Seat belt
Wiper system
Sun visor
Structure type

Refrigerating and heating
capacity

Control mechanism
Refrigerant
Compressor type
Air purification system
HVAC
Condenser
Dry reservoir
Air duct
Ventilation port
Refrigerating pipe
Heating pipe

Outer pull door handle
Three-point emergency locking seat belt
Electric crank-rocker mechanism
PVC leather surface, rotation gear self-locking device
Refrigerating and heating manually

Not less than 4000W when the rotating speed of engine is 1800rpm
Mechanical

R134A
JSS-D14
With rough filtration
With (separate)
Advection
With
With
With
Low and high pressure tube, hose
Rubber tube

Sensor

Evaporator temperature sensor
With (three-state switch)Pressure switch

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PA-6 Complete vehicle parameters page— Complete vehicle basic parameters

Electrical system structure and parameters

Power supply,
startup and
charging system

Instrument
system

Auxiliary
electrical system

System

Circuit Single wire, cathode earth, DC voltage 12V
Generator 90A, with vacuum pump, built-in regulator
Starter 12V，2.8KW
Air conditioning system 2-speed
Battery 90Ah
Combination meter Electronic
Indicator light LED
Sensor and light regulating switch Attached relevant system
Audio device CD player, tape player
Cigarette lighter With
Rear window defrost With
Central control lock With
Window regulator With electric, manual
ABS electrical control system With (optional)

Structure parameters

Safe airbag With (optional)

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Complete vehicle parameters page— Vehicle body dimension schematic diagram

Vehicle body dimension schematic diagram

(Two-dimensional distance size)

PA-7

Unit:mm

(Full lo ad)

(In teri or hei ght of trunk)

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Note: after mounting rear bumper, vehicle overall length is 5040mm, angle of departure is 21°.

PA-8 Complete vehicle parameters page— Vehicle body dimension schematic diagram

(Two-dimensional distance size)

Unit:mm

Wheel base: 305 0 mm

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FE-1

Fuel supply system and exhaust
system

Page

Fuel supply system:

Trouble shooting.........................................................FE-2

Fuel supply system.....................................................FE-3

Removal of fuel tank and supporting plate...................FE-4

Removal of oil filler assembly......................................FE-5

Removal of fuel sensor assembly bracket..................FE-5

Exhaust of fuel supply system.....................................FE-6

Replacement of fuel filter element...............................FE-6

Exhaust system:

Exhaust system..........................................................FE-7

Removal of exhaust pipe assembly.............................FE-8

Installation of exhaust pipe assembly..........................FE-9

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FE-2

Fuel supply system and exhaust system—Trouble shooting

Trouble shooting

Trouble Causes Countermeasures

Engine does not start after
disassembling and assembling
of fuel supply system
Engine does not start

Fuel gauge pointer is not
accurate

Air in the system

Too many impurities
in the fuel line, poor
fuel quality
The pointer of the
instrumentisblocked
Fuel float vibration
affects the contact

Loosen the air bleed bolt of the fuel filter and
continuously press the hand fuel pump manually to
discharge air
Clean the fuel line system

Instrument:

Fuel sensor bracket assembly

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Fuel supply system and exhaust system— Fuel supply system

Fuel supply system

Part drawing

FE-3

Oil filler assembly

Fuel tank cap

Cross recessed screw

◆ Fuel pump seal ring

M10 bolt

100

steel wire elastic hoop

Fuel filling ventilation
rubber hose

Accelerator pedal bracket

M6 nut

★ Fuel pump gland

Fuel sensor bracket as­sembly

Fuel tank front bandage

M6 bolt

9-12

Accelerator pedal

★ Fuel tank oil return pipe assembly

★ Fuel tank oil outlet pipe

assembly

M10 bolt

65-75

65-75

Fuel tank assembly

Fuel tank support plate

Fuel tank rear bandage

5-line fuel pipe clip holder

Fuel tank oil return tube

Fuel tank oil outlet tube

M10 bolt

Fuel filter bracket

★ Engine oil return rubber hose

Fuel hose clip

★ Engine oil inlet rubber hose

C type worm gear driving
hose hoop

Fuel filter

★ Fuel filter oil inlet rubber hose

Steel wire elastic hoop

N ·m

◆ Parts no longer for use after service
★ Precoat parts

:Specified torque

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FE-4

Fuel supply system and exhaust system— Removal of fuel tank and supporting plate

Removal of fuel tank and supporting plate

Note: When repairing the fuel supply system, remove
the oil line and release the pressure of the fuel system
to prevent the injection of high-pressure fuel.

1.Remove the screw (Q2214216A) at oil filler.

2.Remove the elastic hoop of tube and hose, and
disconnect the tube and hose.

3. Remove the fuel tank front bandage. Firstly remove the
fixing bolts on the crossrail with another end of the
bandage hung on the T opening of the frame, and move
the bandage downwards and the bandage could be
taken out from the T opening.

4.Remove the fuel tank rear bandage, then remove the
fixing bolt M10 with another end of the bandage fixed on
the frame, and move the bandage upwards and the
bandage could be taken out from the groove.

5.Move the fuel tank downwards, then remove the oil filler
rubber hose and the connecting hoop between
ventilation rubber hose and fuel tank, and remove the
fuel sensor harness joint on the fuel tank, and the fuel
tank could be taken down

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Fuel supply system and exhaust system—Removal of oil filler assembly

Removal of oil filler assembly

1.Remove bolt Q2214216A fixed in the body with cross
screwdriver.

2.Take down the fuel tank opening cable

3.Remove the left rear wheel fender shield

FE-5

4.Remove the hoops at two points connected with fuel
tank with M6 wrench, and remove the oil filler rubber
hose and fuel filling ventilation rubber hose

5.Remove the oil filler assembly along with the ventilation
rubber hose

Removal of fuel sensor assembly
bracket

1.Remove the fuel tank and clean the deposit contaminant
around the fuel pump gland

2.Loosen the fuel pump gland with SST
Mount the tightening torque: (70 ± 5)N·m
Remark : SST----Special Service Tools.

3.Take out the fuel sensor bracket assembly and take
care not to damage the fuel sensor

4.Remove the fuel pump seal ring and cast it aside

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FE-6

Fuel supply system and exhaust system— Replacement of fuel filter element

Exhaust of fuel supply system

Loosen the air bleed bolt of the fuel filter with No.10 wrench
and press the hand fuel pump upwards and downwards until
the fuel coming from the bolt has no air bubble.

Replacement of fuel filter element

Firstly remove the rubber hose connected with both ends of
the fuel filter, and pull out the water level harness connector
at the bottom of the fuel filter, and then take out two M10
bolts, and take down the fuel filter, screw out the filter element
with special tool and replace them completely.
Replacing period of fuel filter element: replacing once for every
10,000 km.

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Fuel supply system and exhaust system— Exhaust system

Exhaust system

Part drawing

Exhaust elbow gasket joint

Muffler gasket

FE-7

Muffler assembly

Three-hole rubber block

Three-hole rubber block

Hexagon flange bolt

Nut

Front exhaust pipe

Hexagon flange nut

Muffler gasket

Three-hole rubber block

Exhaust elbow bolt

Middle exhaust pipe

Three-hole rubber block

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FE-8

Fuel supply system and exhaust system— Removal of exhaust pipe assembly

Removal of exhaust pipe assembly

Warning: the removal of all parts of exhaust system is required
to be performed after parking for 30 minutes to prevent
personnel injury caused by high-temperature parts.

1.Firstly remove the exhaust elbow flange and front
exhaust pipe flange coupling bolt and nut with M16
sleeve, ratchet wrench, extension bar and M15 double
offset ring spanner, and pay attention to the liner between
flanges.

Remark: the liner between flanges is stainless steel stamping
and mainly plays the part of sealing, please replace with new
liner after three times assembling and disassembling.

2.Hoist the vehicle with elevator, or under the trench,
remove the middle exhaust pipe flange and front exhaust
pipe flange coupling bolt and nut with M15 sleeve, ratchet
wrench, extension bar and M13 double offset ring
spanner, and pay attention to the liner between flanges,
and in performing this operation, a person must prop
the front exhaust pipe specially to prevent its falling and
injuring the operator.

Remark: the liner between flanges mainly plays the part of
sealing, please replace with new liner after three times
assembling and disassembling.

3.Remove the middle exhaust pipe flange and muffler
flange coupling bolt and nut in the same way, and pay
attention to the liner between flanges and prop the
middle exhaust pipe.

Remark: the liner between flanges mainly plays the part of
sealing, please replace with new liner after three times
assembling and disassembling.

4.Then take down the three-hole rubber block of the middle
exhaust pipe to take down the middle exhaust pipe.

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Fuel supply system and exhaust system— Installation of exhaust pipe assembly

5.Take down the three-hole rubber block in front, middle
and back of the muffler in order so as to take out the
muffler, and in performing this operation, a person must
prop the muffler specially to prevent its falling and injuring
the operator.

Installation of exhaust pipe assembly

1.The clearance between exhaust pipe assembly and each
part at both ends is not less than 15mm

2.1.Apply proper amount of silicon oil to three-hole rubber
block installation hole before mounting, and the three­hole rubber block should be strained evenly.

3.The tightening torque of each flange coupling bolt and
nut is:(70± 5)N·m

FE-9

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Clutch

CL

Page

Trouble shooting.........................................................CL-2

Inspection and adjustment of clutch pedal...................CL-3

Air bleed of clutch........................................................CL-3

Clutch control mechanism..........................................CL-4

Clutch set...................................................................CL-6

CL-1

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CL-2 Clutch— Trouble shooting

Trouble shooting

Trouble Causes Countermeasures

Hard to shift or
will not shift

Transmission
disconnected with
mesh
Clutch skidding Clutch pedal free travel insufficient

Clutch
blocked/vibrating

Clutch pedal loose Air in the clutch pipeline

Too loud noise of
clutch

Clutch pedal free travel too large
Air in the clutch pipeline
Trouble of clutch wheel cylinder
Trouble of clutch master cylinder
Improper installation position of clutch, too large
deflection, oil adhered or broken of friction lining
Spline of input shaft or clutch plate contaminated or
with stickers
Trouble of clutch pressure plate
Abrasion of clutch guide bearing Replace guide bearing

Oil adhered or broken of clutch friction lining
Trouble of clutch pressure plate
Block of release yoke
Oil adhered or broken of clutch friction lining
Trouble of clutch pressure plate
Engine bracket loosened

Trouble of clutch wheel cylinder
100Trouble of clutch master cylinder
Parts in clutch pressure plate loosened
Abrasion or contamination of release bearing
Abrasion of guide bearing
Block of release yoke

Adjust free pedal travel
Discharge the air in clutch system
Replacement
Replacement
Inspect clutch plate

Repair according to needs

Replacement

Adjust free pedal travel
Inspect clutch plate
Replacement
Inspect release yoke
Inspect clutch plate
Replace clutch pressure plate
Repair according to needs
Discharge the air in clutch system
Replacement
Replacement
Replace clutch pressure plate
Replacement
Replacement
Repair according to needs

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CL-3Clutch— Inspection and adjustment of clutch pedal,Air bleed of clutch

Inspection and adjustment of clutch pedal

1.Check the pedal height is correct
The pedal height calculated from dash board:

Adjust the pedal height if it is not correct.

Dash board

Pedal height
adjust point

Pedal height

free pedal travel

2.Adjust the pedal height if necessary

Loosen the tightening nut and turn the adjusting bolt until the
height is correct. Screw down the tightening nut.

3. Check the free pedal travel is correct

Gently press the pedal until feeling resistance coming from
the clutch.

Free pedal travel: (5-10)mm

4.Adjust the free pedal travel if necessary

(a) Loosen the tightening nut and turn the push rod until

the travel is correct.
(b) Screw down the tightening nut.
(c) Check pedal height after adjustment of free pedal travel.

Air bleed of clutch

Remark: when operating the clutch system or the air is blocked
in the clutch, discharge the air.

Note: do not leave the brake oil on the paint surface,
and immediately clean it off if there is.

1.Fill the brake oil into the clutch master pump oil cup

Often check the master pump oil cup. Refill the brake oil if
necessary.

2.Connect the vinyl resin pipe with the air release valve

Insert another end of the pipe into the container filling with
half of brake oil.

3.Air bleed of clutch system

(a) Slowly let the clutch pedal move upwards and

downwards several times.
(b) When pressurizing the pedal, loosen the air release valve

until the brake oil flows put, and then screw down the

air release valve.
(c) Repeat this action until the air bubble in the brake oil

disappears.

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CL-4

Plastic clip

Clutch— Clutch control mechanism

Clutch control mechanism

Part drawing

Clutch master cylinder fuel pipe

Clutch master cylinder

25-30

23± 3

20

Open retainer

Spring clip

Clutch hose

Clutch hose bracket set

Clutch wheel cylinder

Seal washer

30-40

30± 3

N · m

: Specified torque

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Clutch— Clutch control mechanism

Removal of clutch master pump and wheel
pump

1.Drain off the clutch fluid

Remove the hose connection hole bolt with specification of
16 open wrench, and cover the wheel pump oil outlet with
cloth to prevent the brake oil spattering, and continuously
depress the clutch pedal several times to drain off the clutch
fluid.

2.Removal of the clutch master cylinder

Remove the master pump hitch yoke and the pedal connection
cotter pin and straight pin, and remove two installation master
pump nuts Q32008 with specification of 16 sleeve wrench,
and the master pump could be taken down. Check the clutch
master pump, if there is abnormal noise inside the master pump
and oil leakage etc, replace the master pump as a whole.

CL-5

Precautions for installation of clutch control
mechanism

1.Installation of clutch tube

Check the tube is deformed, curling at the connection pipe
orifice is complete, and install the clutch tube after confirming
there is no problem, and fix the tube in the front wall clip and
tube clip.

2.Coat lithium base grease at each rotating part.

3.Check the clutch hose surface -- cracks, oil leakage and
dog leg not permitted, and fix the clutch hose in the body
bracket with open retainer and spring clip.

4.Respectively connect the joint of master pump oil pipe
and master pump, wheel pump as the specified
tightening torque.

5.Discharge the air after oil filling of the clutch fuel line
(except refilling after evacuation).

Depress the clutch pedal after toping up the reservoir. If you
feel hard to do this, loosen the air release screw plug with
specification of 11 open wrench to discharge the air, and then
screw down the screw plug. Repeat this several times and
screw down the air release screw plug when there is no air
bubble with the flowing fluid. Refill the oil amount in the
reservoir up to between Max and Min.

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CL-6

Clutch— Clutch set

Clutch set

Part drawing

Release rocker ball support

Release bearing assembly

Cup

Abnormal type spring

Release rocker set

30-40

N · m

Clutch pressure plate assembly

Clutch driven plate assembly

: Specified torque

Removal of clutch set

1.Remove the transmission

Remark: do not dry the gear oil.

2.Remove the clutch pressure plate and clutch plate

(a) Make alignment mark on the clutch pressure plate and

fly wheel.

(b) Gradually loosen the fixing screw until the spring tension

is released.

(c) Remove the fixing bolt, and pull out the clutch pressure

plate and clutch plate.

3.Remove the release bearing and release rocker from
the clutch housing.

(a) Remove the spring and pull out the bearing.
(b) Remove the release rocker and cup.

Warning: when repairing the clutch set, cleaning with
sand grind or dry brush and compressed air is not
permitted to prevent producing powdered scrap (with
water - dipped cloth). The clutch friction disc contains
“asbestos fiber “. If powdered scrap is produced in
repairing, the asbestos fiber in the powdered scrap will
float in the air, and persons who inhale the air containing
asbestos fiber will be injured severely.

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Clutch— Clutch set

Inspection of clutch parts

1.Check the clutch plate is worn or damaged.

Measure the rivet head depth with calipers.

Min. rivet head depth: 0.3mm

If the rivet head depth exceeds the limit, replace the clutch
plate.

2. Check the axial run out of the clutch

Check the axial run out of the clutch with dial gauge.

Max. axial run out: 0.8mm

If the axial run out tolerance exceeds the max. value, replace
the clutch plate.

CL-7

3.Measure the axial run out of the flywheel

Check the axial run out of the flywheel with dial gauge.

Max. axial run out: 0.2mm

If the axial run out tolerance exceeds the max. value, replace
the flywheel.

4.Check the guide bearing

Apply force along the axial line direction, and turn the bearing
with hands.
If you could not turn or the resistance is too strong, replace
the guide bearing.
Remark: cleaning and lubricating are not necessary for
permanent lubrication of this bearing.

5.Replace the guide bearing if necessary.

(a) Remove the guide bearing with special serrice tools.

SST

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CL-8

Clutch— Clutch set

(b) Install the guide bearing with special serrice tools.

Remark: after encasing the guide bearing into the flywheel

SST

hub, ensure the bearing is in perfect operating status.

6.Check the diaphragm spring is worn.

Check the depth and width of the diaphragm spring abrasion

5

0

.

6

with calipers.

Limit value: Max. depth: 0.6mm
Max. width: 5mm

If the depth and width of the diaphragm spring abrasion
exceeds the limit value, replace the diaphragm spring.

Flywheel

side

SST

7.Check the release bearing

Apply force along the axial line direction, and turn the bearing
with hands.
If you could not turn or the resistance is too strong, replace
the release bearing.
Remark: cleaning and lubricating are not necessary for
permanent lubrication of this bearing.

Installation of the clutch set

1.Install the clutch driven plate assembly on the flywheel.

Install the clutch driven plate assembly on the flywheel with
special service tool.

2. Mounting clutch pressure plate assembly

Alignment

mark

(a) Line the alignment mark of clutch pressure plate and

flywheel.

(b) Screw down the bolt evenly, and repeat applying force

around the clutch pressure plate till they are tightly jointed
with each other, and screw down the bolt.

Tightening torque: 30N·m

Remark: firstly screw down the uppermost bolt of the three
bolts near the locating pin.

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SST

SST

Clutch— Clutch set

3.Check the height at the disengaging pawl of the
diaphragm spring is consistent.

Check the difference in height at the disengaging pawl of the
diaphragm spring with special serrice tools.

Allowable height change limit: 0.5mm

If the difference in height exceeds the specified value, adjust
with special serrice tools.

4.Coat lithium base grease

Coat lithium base grease on the following parts:

·the contact of the release rocker and the bearing sleeve

·the contact of the release rocker and the push rod

·the release rocker fixed pivot

·Clutch driven plate spline

CL-9

5.Encase the cup, release rocker, release bearing seat
and bearing into the clutch housing.

6.Install the transmission

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MT-1

MT

Transmission

Page

Structure drawing........................................................ MT-2

Precautions................................................................ MT-2

Trouble shooting......................................................... MT-3

Disassembling of the transmission............................. MT-4

Input shaft assembly................................................... MT-12

Part drawing............................................................ MT-12

Inspecting the synchronizing ring .................. MT-12

Replacing the bearing.............................................. MT-12

Output shaft assembly................................................ MT-14

Part drawing............................................................ MT-14

Disassembling of the output shaft assembly........... MT-15

Inspection of the output shaft assembly................... MT-16

Assembling of the output shaft assembly................ MT-18

Disassembling, inspection and assembling of the

intermediate shaft assembly.................................. MT-22

Part drawing............................................................ MT-22

Disassembling, inspection and assembling of the

intermediate shaft assembly.................................... MT-22

The assemblage of reverse gear assembly............. MT-24

Rear housing assembly.............................................. MT-25

Part drawing............................................................ MT-25

Replacing the oil seal.............................................. MT-25

Replacing the bush.................................................. MT-25

Inspection and replacement of limit mechanism set MT-26

Bearing front cover...................................................... MT-28

Part drawing............................................................ MT-28

Replacing the oil seal.............................................. MT-28

The assembling of the transmission......................... MT-29

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MT-2

transmission－ Structure drawing,Precautions

Structure drawing

This product is manual mechanical triaxial transmission, and the control form is floor type direct control, and
there are 5 forward gears with lock loop type full synchronization and 1 reverse gear with sliding type; this product
applies separation structure with complete aluminium alloy housing, and the gear applies small module and slimness
tooth; this makes this product have the following advantages: compact structure, strong deformability, high intensity,
perfect performance, low noise and light mass etc. The drawing below is the structure drawing of the clutch.

1st shift and 2nd shift gear sleeves

Clutch housing

Input

shaft

3rd and 4th shift

gear sleeves

Intermediate

Front
cover

shaft

3rd shift

gear

Housing

Reverse

gear

shaft

2nd shift

gear

Reverse

gear idler

1st shift

gear

Middle

coupling plate

Middle 5th shift gear

5th shift

gear

Rear

housing

Control

cover Shift lever

Odometer5th shift

gear

sleeve

Output shaft

Precautions

Precautions for disassembling and assembling of the transmission

During disassembling of the transmission, pay attention to handle each part with care to avoid knock,
especially the junction plane; put each part in order so as to prevent loss and wrong taking.
When assembling, except the above precautions, the following should be noticed:

1. Do not repeat using various oil seals, shaft retainers and elastic pins after they have been disassembled.

2. Keep all the parts clean, dust, cut chips, rust, oil stain and other impurities must be avoided.

3. For the relative motion friction surface on the parts, lubricant must be coated.

4. Coat lubricant at the mouth of each oil seal, and press into vertically.

5. When assembling each oil seal, do not pass the pressure with rolling objects.

6. When assembling the synchronizer set, spring piston ring opening at both sides must be staggered.

7. During transporting and installing of the assembly, put into a certain gear, and it is strictly forbidden to

erect it under neutral position or make it be impacted forcibly.

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transmission－ Trouble shooting

Trouble shooting

Trouble type Possible causes Eliminating methods

Noise too loud or
abnormal

Bearing damaged Replacing the bearing
Gear tooth face knocked or eroded Repairing or replacing the gear

Gear axial position or clearance improper or inside
parts scratched

Lubricant level too low or lubricating insufficient Refilling to the marked position

Check, repair and adjustment

MT-3

Putting into gear
difficult

Oil leakage

Out of gear

Using inferior lubricant not complying with quality
requirements

Damage with the inside parts of clutch Check, repair and adjustment
Clutch improperly adjusted, releasing incompletely Adjustment
Control mechanism improperly adjusted Adjustment
Synchronizer toothed ring worn severely Replacing the toothed ring
The oil seal worn or damaged Replacing the oil seal
Refilling oil too much, the oil level too high Check and adjustment

The sealant unevenly coated or the seal washer
damaged

The junction plane knock not repaired in time Repair
The breather plug blocked Cleaning and interpenetrating
Gear sleeve or combination tooth severely worn Replacement

Control mechanism improperly installed or
damaged

Fork deformed severely or worn Replacement
Set spring or steel ball deformed severely or

damaged

Replacing with specified lubricant

Recoating the sealant or replacing
the washer

Check, adjustment or replacement

Check and replacement

Gear shifting
abnormal
Bearing abnormally
ineffective

Gear axial clearance too large Check and adjustment
Interlock pin lost or damaged severely Replacement

Lubricating insufficient or lubricant rejected Check and replacement
Lubricant too dirty Replacement
The cleaning of each part in the box not perfect Cleaning
Bearing quality rejected Replacement

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MT-4

transmission－ Disassembling of the transmission

Disassembling of the transmission

1.Remove the release fork and release bearing

2.Remove the backup lamp switch and odometer driven
gear

3.Remove the clutch housing from the transmission case
Remove the 9 bolts.

4.Remove the 5th gear fork shaft set spring screw plug, set
spring and the lock ball

(a) Remove the screw plug from rear cover with socket

wrench.

(b) Take out the spring and the lock ball with bar magnet.

5.Remove the gear shift lever and control cover

(a) Remove the gear shift lever from the control cover
(b) Remove the binding bolt of the control cover.

6.Remove the set mechanism set of the gear-shifting shaft

7.Remove the rear housing

(a) Remove binding bolt of the gear-shifting shaft
(b) Remove the nut fastening the rear housing.

(c) Gently knock out the rear housing with rubber mallet,

and remove the gear-shifting shaft and gear-shifting
rocker.

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transmission－ Disassembling of the transmission

8.Remove the front cover

Remove the 8 bolts, and remove the front cover and the front
cover oil seal.

9.Remove the bearing stop rings of input shaft and
intermediate shaft.

MT-5

10.Take apart the transmission case from the middle
coupling plate

(a) Put the transmission straight as shown in the drawing.
(b) Gently knock out the transmission case with rubber mallet.
(c) Pull out the transmission case from the middle coupling

plate as shown in the drawing.

11.Nip the middle coupling plate on the leg vice

(a) Use 2 clutch housing bolts, washers and appropriate nuts

as shown in the drawing.
Remark: install the washer with contrary direction from the
normal; plus or minus the washer numbers to make the bolt
end align with the washer outer end face.

(b) Nip the middle coupling plate on the leg vice.

12.Remove the set spring screw plug, set spring and lock
ball

(a) Remove each set spring screw plug with torque socket

wrench.

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MT-6

transmission－ Disassembling of the transmission

(b) Remove 1st and 2nd , 3rd and 4th and reverse gear fork

shaft and 5th gear fork shaft set spring and lock ball.

13.Remove the gear-shifting forked axle retainer

Gently turn and extract the gear-shifting forked axle retainer
with 2 screwdrivers and 1 hammer.

14.Remove the 5th gear shift fork

(a) Drift out the spring pin with drift pin and hammer.

(b) Gently knock the 5th gear shift fork until it is taken out.

Note: pay attention to the neutral position at the moment.

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transmission－ Disassembling of the transmission

15.Remove 5th reverse gear shift guide block and 5th reverse

gear shift forked axle.

(a) Take out the interlock steel ball from the 5th reverse gear

shift guide block.

(b) Remove 5th reverse gear shift guide block and 5th reverse

gear shift fork.

MT-7

16.Take out the 5th gear shift forked axle

17.Remove the reverse gear shift fork, reverse gear rocker,

reverse gear deflector rod and block

(a) Knock out the elastic pin with tip drift pin and hammer.

(b) Take out the reverse gear shift forked axle and 5th gear

shift forked axle interlock steel ball and interlock guide

column.
(c) Take down the reverse gear shift forked axle.
(d) Take down the reverse gear rocker and deflector block.

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MT-8

transmission－ Disassembling of the transmission

18.Remove the 1st and 2nd gear shift fork.

(a) Take out the 5th reverse gear shift fork and 1st and 2

gear shift fork interlock pin and interlock guide column
with bar magnet.

(b) Remove the 1st and 2nd gear shift fork location bolt.

nd

(c) Remove the 1st and 2nd gear shift fork.
(d) Take out the short interlock pin between the 1st and 2

gear shift fork and 3rd and 4th gear shift fork with bar
magnet.

19.Remove the 3rd and 4th gear shift fork and the 1st and 2
gear and 3rd and 4th gear fork.

(a) Knock out the elastic pin with tip drift pin and hammer.

nd

nd

(b) Take out the 3rd and 4th shift fork and the 1st and 2nd gear

and 3rd and 4th gear fork.

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transmission－ Disassembling of the transmission

20.Remove the 5th shift coupling gear, 5th gear synchronizer
assembly, 5th shift gear set, 5th shift gear thrust washer
and 5th gear needle bearing.

(a) Gently tap out the intermediate shaft rear shaft retainer

with 2 screwdrivers and 1 hammer.

(b) Take down the 5th gear synchronizer assembly, 5th shift

SST

coupling gear and 5th shift gear set.

(c) Remove the 5th gear needle bearing.

MT-9

21.Remove the 5th shift gear thrust washer and lock ball

(a) Remove the 5th shift gear thrust washer.
(b) Take out the lock ball with bar magnet.

22.Remove the reverse shift rocker bracket

Remove the 2 bolts and reverse shift rocker bracket.

23.Remove the reverse gear idler and reverse gear idler
shaft

(a) Remove the idler shaft set bolt and reverse gear idler

shaft clamping plate.

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MT-10

transmission－ Disassembling of the transmission

(b) Remove the reverse gear idler and reverse gear idler shaft.

24.Remove the rear bearing baffle of the output shaft

(a) Remove 4 bolts with torque socket wrench.
(b) Remove the rear bearing baffle of the output shaft.

SST

25.Remove the intermediate gear shaft.

(a) Prize out the rear bearing split ring of the intermediate

gear shaft with split ring pliers.

(b) Remove the intermediate shaft rear bearing with special

tool and wrench.

(c) Remove the intermediate gear shaft.

26.Remove the input shaft

Remove the input shaft equipped with synchronizing ring and
13 needle bearings.

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transmission－ Disassembling of the transmission

27.Remove the output shaft

(a) Remove the rear bearing stop ring of the output shaft

with split ring pliers.

(b) Pull out the output shaft with hands and gently knock

the middle coupling plate with rubber mallet at the same
time, and remove the output shaft from the middle
coupling plate.

MT-11

Pressing

loosening

28.Inspecting backup lamp switch

As shown in the drawing, check the terminal is connected—
pressing the switch indicating connecting and loosening it
indicating disconnecting, replace the switch if it does not
comply with the specification.

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MT-12

transmission－ Input shaft assembly

Input shaft assembly

Part drawing

Retainer

Bearing stop ring

Bearing

Input shaft

Needle bearing

Synchronizing ring

Inspecting the synchronizing ring

1.Turn the synchronizing ring and push it into to check
its braking effect.

2.Check the clearance between the synchronizing ring
back and the gear
Standard clearance: (1.0-1.6) mm
Limit clearance: 0.8mm

Replacing the bearing

1.Prize out the input shaft retainer with split ring pliers

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transmission－ Input shaft assembly

2.Prize out the input shaft bearing with forcing machine

3.Install the new bearing with forcing machine and special
serrice tools.

SST

MT-13

4.Select the retainer to achieve the min. axial clearance

Remark: the clearance value should not be more than 0.1mm.

5.Install the retainer with split ring pliers

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MT-14

transmission－ Output shaft assembly

output shaft assembly

Part drawing

3rd and 4th gear synchronizer engagement sleeve

Synchronizer sliding block

Synchronizer

spring piston ring

Shaft retainer

3rd and 4

th

synchronizer hub

Synchronizer ring

3rd and 4th shift gear needle bearing

3rd shift gear set

Steel ball

Steel ball

Output shaft

1st shift gear bush

Synchronizer sliding block

Spring piston ring

nd

2

shift gear needle bearing

2nd shift gear set

1st and 2nd gear synchronizer engagement sleeve

1st and 2nd gear synchronizer ring

5th shift gear

Rear bearing stop ring

of the output shaft

1st shift gear set

Output shaft rear bearing

1st shift gear needle bearing

1st and 2nd gear synchronizer ring

Odometer drive gear retainer

Odometer drive gear

5th shift gear shaft retainer

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MT-15 transmission－ Output shaft assembly

Disassembling of the output shaft assembly

1.Remove the odometer drive gear

(a) Prize out the retainers at both ends with split ring pliers.
(b) Remove the odometer drive gear
(c) Take out the lock ball with bar magnet.

2.Remove the 5th shift gear, output shaft rear bearing, 1
shift gear set, 1st shift gear bush and 1st shift gear needle
bearing.

(a) Turn and extract the 5th shift gear shaft retainer with 2

screwdrivers and 1 hammer.

(b) Remove the output shaft rear bearing, 1st shift gear set

and 1st shift gear bush with forcing machine.

(c) Remove the 1st shift gear needle bearing

3.Remove the synchronizer

4.Remove the steel ball

Take out the steel ball with bar magnet.

st

5.Remove the 1st and 2nd gear synchronizer assembly, 2
shift gear set and 2nd shift gear needle bearing

(a) Remove the 2nd gear synchronizer assembly and 2nd shift

gear set.

(b) Remove the 2nd shift gear needle bearing

6.Remove the engagement sleeve, sliding block and
spring from the 1st and 2nd gear synchronizer assembly

Remove 3 sliding blocks and 2 springs from the synchronizer
assembly with 1 screwdriver.

nd

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MT-16

1

shift gear

transmission－ Output shaft assembly

7.Remove the 3rd and 4th gear synchronizer assembly, 3
shift gear and needle bearing

(a) Remove the split ring with split ring pliers.
(b) Remove the 3rd and 4th gear synchronizer assembly and

3rd shift gear with the forcing machine.

(c) Remove the needle bearing.

8.Remove the engagement sleeve, sliding block and
spring from the 3rd and 4th gear synchronizer assembly

Remove 3 sliding blocks and springs from the engagement
sleeve with 1 screwdriver.

rd

3 Shift

1 Shift 2 Shift

Inspection of the output shaft assembly

1.Measure the axial clearance of each gear

Measure the axial clearance of each gear:

1st , 2nd , 3rd gear: (0.1-0.25)mm

2.Measure the axial play of each gear

Measure the radial clearance of each gear with dial gauge.

Allowable clearance (mm)

st

2nd and 3rd shift gear 0.009-0.033

If the clearance exceeds the above limit, replace the gear, needle
bearing or shaft.

0.009-0.032

3.Check the output shaft and 1st shift gear bush

(a) Measure the flange thickness of the output shaft with

calipers.

Min. thickness: 4.80mm

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MT-17 transmission－ Output shaft assembly

(b) Measure the flange thickness of the 1st shift gear bush

with calipers.

Min. thickness: 3.99mm

(c) Measure the outer diameter of the output shaft journal with

micrometer.

At 2nd shift gear: 37.974mm
At 3rd shift gear: 34.974mm

(d) Measure the outer diameter of the 1st shift gear bush

with micrometer.

Min. diameter: 38.975mm

(e) Check the radial run out of the shaft with dial gauge

Max. radial run out: 0.05mm

4.Inspect the synchronizing ring

Turn this ring and push it into to check its braking action.

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MT-18 transmission－ Output shaft assembly

5.Measure the clearance between the shift fork and
engagement sleeve

Measure the clearance between the gear sleeve and the shift
fork with a clearance gauge.

Max. clearance: 1.0mm

Assembling of the output shaft assembly

1.Assemble the synchronizer

(a) The side with 45¡ãstep of the 3rd and 4th gear synchronizer

hub is facing the input shaft position, and the side with
big chamfer of the 3rd and 4th gear synchronizer gear
bush is facing the input shaft position; the opening
directions of two 3rd and 4th gear synchronizer spring
piston rings should be staggered.

(b) The 1st and 2nd gear synchronizer set is relative to the

installation direction of the output shaft, i.e. the side with
fork facing the middle coupling plate position; the opening
directions of two 1st and 2nd gear synchronizer spring
piston rings should be staggered.

2.Install the 3rd shift gear set and 3rd and 4th gear
synchronizer on the output shaft

(a) Coat gear oil on the shaft and 3rd shift gear needle bearing.
(b) Put the synchronizing ring on the 3rd shift gear set, and

align the synchronizing ring notch with the sliding block.

(c) Encase the needle bearing into the 3rd shift gear set.

(d) Install the 3rd shift gear set and 3rd and 4th gear

synchronizer with forcing machine.

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3.Install the shaft retainer

Choose a shaft retainer that could make the min. axial clearance
(clearance value not more than 0.1mm), and install it on the
shaft.

4.Measure the axial clearance of 3rd shift gear set

Measure the axial clearance of 3rd shift gear set with clearance
gauge.

Standard clearance: (0.1-0.25) mm

MT-19 transmission－ Output shaft assembly

5. Install the 2nd shift gear set and 1st and 2nd gear
synchronizer

(a) Coat gear oil on the 2nd shift gear needle bearing.
(b) Put the synchronizing ring on this gear, and align the

ring notch with the synchronizer sliding block.

(c) Encase the needle bearing into the 2nd shift gear set.

(d) Install the 2nd shift gear set and 1st and 2nd gear

synchronizer set with forcing machine.

6.Measure the axial clearance of 2nd shift gear set

Measure the axial clearance of 2nd shift gear set with feeler
gauge.

Standard clearance: (0.1-0.25) mm

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MT-20

transmission－ Output shaft assembly

7.Install the lock ball and 1st shift gear set

(a) Encase the lock ball into the shaft.

(b) Coat gear oil on the 1st shift gear needle bearing.
(c) Install the 1st shift gear set, synchronizing ring, needle

bearing and 1st shift gear bush.

(d) Install the assembly on the output shaft to align the

synchronizing ring notch with the sliding block.

(e) Turn the 1st shift gear bush to align it with the lock ball.

SST

8.Install the output shaft rear bearing

Install the output shaft bearing on the output shaft with special
service tool and forcing machine to make the groove of the
output shaft rear bearing stop ring face the end.
Remark: hold the 1st shift gear bush to prevent it from falling.

SST

9.Install the 5th shift gear

Install the 5th shift gear with special service tool and forcing
machine.

10.Install the shaft retainer

(a) Choose a 5th shift gear shaft retainer that could make the

min. axial clearance, and the clearance value should not
be more than 0.1mm.

(b) Gently knock tight the 5th shift gear shaft retainer with

screwdriver and hammer.

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11.Measure the axial clearance of the 1st shift gear

Measure the axial clearance of the 1st shift gear with clearance
gauge.

Standard clearance: (0.1-0.25) mm

12.Install the odometer drive gear

(a) Install the lock ball and the drive gear.
(b) Install the odometer drive gear retainer with shaft retainer

pliers.

MT-21 transmission－ Output shaft assembly

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MT-22

transmission－ Intermediate shaft assembly and reverse gear idler assembly

Intermediate shaft assembly and reverse gear idler assembly

Part drawing

Front bearing stop ring

of the intermediate shaft

Intermediate shaft front bearing

Front shaft retainer of

the intermediate shaft

Intermediate gear shaft

Synchronizer sliding block

5th gear needle bearing

Intermediate shaft rear bearing

Rear bearing stop ring of the intermediate shaft

Steel ball

Reverse gear idler shaft

Reverse gear idler set

Reverse gear idler shaft clamping plate

5th gear synchronizer engagement sleeve

5th shift coupling gear

th

5

shift gear thrust washer

Spring piston ring

5th shift gear set

Synchronizer ring

Disassembling, inspection and assembling
of the intermediate shaft assembly

1.Remove the 5th shift coupling gear, sliding block and
spring piston ring

Remove the 5th shift coupling gear, 3 sliding blocks and 2
spring piston rings with screwdriver.

2.Measure the radial clearance of the intermediate shaft

5th gear

(a) Mount spacer, needle bearing and reverse gear idler on

the intermediate shaft.

(b) Measure the radial clearance of the reverse gear idler

with dial gauge.

Radial clearance: (0.009-0.32) mm

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transmission－ Intermediate shaft assembly and reverse gear idler assembly

MT-23

3.Check the journal diameter at the intermediate shaft 5
gear needle bearing installation position

Measure the needle bearing diameter with micrometer.

Allowable limit diameter: 25.975 mm

4.Inspect the synchronizing ring

Turn the shaft retainer and push it into to check its braking
action.

th

5.Measure the clearance between the shift fork and gear
sleeve

Measure the clearance between the gear sleeve and the shift
fork with a clearance gauge.

Max. clearance: 1.0 mm

6.Replace the bearing

Replace the reverse gear front bearing if necessary

(a) Prize out the shaft retainer with shaft retainer pliers.

(b) Press out the bearing with special service tool.

SST

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MT-24

transmission－ Intermediate shaft assembly and reverse gear idler assembly

(c) Press in the bearing, side ring and inner race with socket

Socket wrench

wrench.

(d) Choose a split ring that could make the min. axial

clearance, and install it on the shaft.

Front

7.Install the 5th gear synchronizer engagement sleeve,
sliding block and spring piston ring

(a) Encase the sliding block into the hub and then encase the

gear sleeve.

(b) Install the spring piston ring under the sliding block.

Note: the opening directions of the spring piston ring
should be staggered during installing.

The assemblage of reverse gear assembly

1.Check the reverse gear idler

Measure the radial clearance of the reverse gear idler with dial
gauge.

Allowable radial clearance: (0.009-0.033) mm

2.Measure the clearance between the reverse gear idler
and the shift block

Measure the clearance between the reverse gear idler and the
shift block with a clearance gauge.

Max. clearance: 1.0 mm

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Limit mechanism set

Guide oil groove

transmission－ Rear housing assembly

Rear housing assembly

Part drawing

Rear housing set

Set spring screw plug and elastic straight pin

Reservoir

MT-25

Rear housing dust cap

Rear housing oil seal subassembly

SST

SST

Replacing the oil seal

1.Replace the rear housing oil seal if necessary

(a) Remove the oil seal with special service tool.
(b) Press in the new oil seal with special service tool.

SST

2.Replace the odometer driven oil seal if necesssary

(a) Prize out the oil seal with special service tool.
(b) Knock the new oil seal into the shaft bracket with special

service tool.

SST

Replacing the bush

SST

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Replace the bush if necessary
(a) Remove the oil seal and dust cap.
(b) Heat the rear housing end up to celsius 80-100 degree in

the oil groove.

(c) Remove the bush and install the new bush with special

service tool.

MT-26 transmission－ Rear housing assembly

Inspection and replacement of limit mecha­nism set

1.Remove the limit mechanism set

(a) Remove the screw plug with torque socket wrench.

(b) Drift out the elastic straight pin with drift pin and hammer.

(c) Remove the limit mechanism set

2.Check the limit mechanism set

Turn and push into the limit block with hands and it could
return automatically. Otherwise, replace it.

3.Install the limit mechanism set

(a) Encase the limit mechanism set into the rear housing.
(b) As shown in the drawing, drive in the elastic straight pin

with drift pin and hammer.

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MT-27 transmission－ Rear housing assembly

(c) Coat sealant on the screw plug thread.
(d) Fasten the screw plug with torque socket wrench.

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MT-28

★ Front cover assembly

transmission－ Bearing front cover

Bearing front cover

Part drawing

Front cover oil seal assembly

★ Precoat parts

Replacing the oil seal

Replace the bearing front cover oil seal if necessary

(a) Prize out the oil seal with screwdriver.

(b) Press in the new oil seal with special service tool.

Oil seal pressing in depth:(13± 0.4) mm

SST

13 ± 0.4mm

Oil seal pressing in depth

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MT-29 transmission－ The assembling of the transmission

The assembling of the transmission

1.Encase the output shaft into the middle coupling plate

(a) Pull out the output shaft and drive in the middle coupling

plate at the same time, and encase the output shaft into
the middle coupling plate.

(b) Encase the rear bearing stop ring of the output shaft

with snap ring pliers.
Remark: the stop ring should be kept close with the middle
coupling plate surface.

Aligning

2.Encase the input shaft into the output shaft

(a) Coat the grease on 13 needles bearing, and encase the

needles into the input shaft.

(b) Rotate the input shaft into the output shaft to align the

three grooves of the synchronizing ring with the

synchronizer sliding block

3.Encase the intermediate shaft into the middle coupling
plate

(a) Install the rear bearing stop ring of the intermediate shaft

on the rear bearing.

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MT-30 transmission－ The assembling of the transmission

(b) Encase the intermediate gear shaft into the middle coupling

plate and hold the intermediate gear shaft at the same
time, and install the intermediate shaft rear bearing with
special service tool.

SST

4.Install the output shaft rear bearing baffle

Install and fasten the bolt with torque socket wrench.

Tightening torque: (17-22)N¡¤m

5.Install the reverse gear idler and shaft

(a) Install the reverse gear idler and shaft

(b) Install the reverse gear idler clamping plate and fasten

the bolt.

Tightening torque: (15-20)N¡¤m

6.Install the reverse gear rocker bracket set

Install the reverse gear rocker bracket, and fasten 2 bolts.

Tightening torque: (17-22)N¡¤m

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Lock ball

MT-31 transmission－ The assembling of the transmission

7.Install the steel ball and 5th shift gear thrust washer.

8.Install the 5th shift gear set

(a) Coat gear oil on the needle bearing.
(b) Install the 5th shift gear set

9.Install the synchronizing ring and 5th shift coupling gear

(a) Cover the synchronizer ring on the 5th shift coupling gear

conical surface.

(b) Remove the middle coupling plate from the leg vice.
(c) Put the transmission straight as shown in the drawing.

Socket wrench

and install the 5th shift coupling gear with forcing machine.

(e) Place the middle coupling plate on the leg vice.

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(d) Align the synchronizing ring groove with the sliding block,

MT-32 transmission－ The assembling of the transmission

10.Install the split ring

(a) Choose a shaft retainer that could make the min. axial

clearance, and the clearance value should not be more
than 0.1mm.

(b) Encase the shaft retainer with bar copper and hammer.

11.Measure the axial clearance of 5th shift gear set

Measure the axial clearance of 5th shift gear set with a feeler
gauge.

Standard clearance: (0.1-0.3) mm
Max. clearance: 0.3mm

12. Install the 3rd and 4th gear shift forked axle and 1st and
2nd gear shift fork, 3rd and 4th gear shift fork.

(a) Install the 1st and 2

nd

, 3rd and 4th gear shift fork.

(b) Encase the 3rd and 4th gear shift forked axle into the

middle coupling plate and shift fork.

(c) Install the elastic straight pin of 3rd and 4th gear shift

fork.

Note: the pin opening should be in the same direction
with the axle. (The same with the following)

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MT-33 transmission－ The assembling of the transmission

13.Install the 1st and 2nd gear shift forked axle and 1st and
2nd gear shift fork

(a) Coat the grease on the interlock guide column, and install

it on the 1st and 2nd gear shift forked axle.

(b) Encase the short interlock pin into the middle coupling

plate with bar magnet.

(c) Encase the 1st and 2nd gear shift forked axle into the 1

and 2nd gear shift fork and middle coupling plate.

st

(d) Install the 1st and 2nd gear fork set bolt, and screw down

the bolt.

Tightening torque: (13-17)N¡¤m

14.Install the reverse gear deflector rod, reverse gear
rocker and reverse gear block

(a) Assemble the reverse gear deflector rod, reverse gear

rocker and reverse gear block together.

(b) Install the reverse gear rocker on the reverse gear rocker

bracket.

(c) Coat the grease on the interlock guide column, and install

it on the reverse gear shift forked axle.

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MT-34 transmission－ The assembling of the transmission

(d) Encase the long interlock pin into the middle coupling

plate with bar magnet.

(e) Encase the reverse gear shift forked axle into the reverse

gear deflector rod and middle coupling plate.

(f) Encase the elastic straight pin with drift pin and hammer.

15.Install the 5th reverse gear shift guide block and 5
reverse gear shift forked axle.

(a) Encase the 5th reverse gear shift guide block into the 5

reverse gear shift forked axle.

(b) Install the 5th gear shift fork.

(c) Encase the steel ball into the 5th reverse gear shift guide

block with bar magnet.

(d) Install the 5th gear shift forked axle as shown in the

drawing.

th

th

(e) Encase the interlock steel ball into the middle coupling

plate with bar magnet.

(f) Encase the 5th gear shift forked axle into the middle

coupling plate.

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MT-35 transmission－ The assembling of the transmission

(g) Encase the pin into the 5th gear shift fork with drift pin

and hammer.

(h) Encase the 5th reverse gear shift forked axle into the 5

reverse gear shift guide block and middle coupling plate.

(i) Encase the elastic straight pin into the 5th reverse gear

shift guide block with drift pin and hammer.

th

16.Install the gear shift forked axle grip ring

Encase the grip ring with steel bar and hammer.

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MT-36 transmission－ The assembling of the transmission

17.Install the steel ball, set spring and set spring screw plug

(a) Install the steel ball and set spring.

Remark: Encase the short spring into the bottom of the middle
coupling plate.

(b) Coat sealant on the screw plug thread.
(c) Install the screw plug, and fasten it with torque socket

wrench.

Tightening torque: (17-22)N·m

sealing material

18.Remove the middle coupling plate from the leg vice.

(a) Remove the middle coupling plate from the leg vice.
(b) Remove the bolt, nut and washer.

19.Install the transmission case

(a) Coat sealing material on the transmission case junction

plane as shown in the drawing.

(b) Put the middle coupling plate straight as shown in the

drawing.

(c) Install the transmission case on the middle coupling plate

as shown in the drawing.

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20.Install the front bearing stop ring

(a) Install 2 stop rings on the input shaft bearing and

intermediate shaft front bearing with snap ring pliers.

(b) Install the front cover set coated with sealant.
(c) Coat sealant on the bolt thread.
(d) Install and fasten the bolt.

Tightening torque: (15-20)N·m

MT-37 transmission－ The assembling of the transmission

sealing material

21.Install the rear housing, gear shift shaft and gear shift
block.

(a) Coat the sealing material on the rear housing as shown in

the drawing.

(b) Encase the gear shift shaft equipped with gear shift

deflector rod into the rear housing (not reach the
designated position), and put the transmission into the
3rd gear position.

(c) Put into the gear shift deflector rod from the upper

opening of the rear housing, and continue encasing the
gear shift shaft to let it go through the cross bore of the

gear shift block.
Remark: the installing way of the four wheel drive is the same
with the above.

(d) Insert the gear shift deflector rod into the 3rd and 4th gear

forked axle groove to align the 5th reverse gear shift forked

axle with the rear housing installation hole, and push into

the rear housing.

(e) Install and fasten the rear housing bolt.

Tightening torque: (30-45)N·m

Remark: the installing way of the four wheel drive is the same
with the above.

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MT-38 transmission－ The assembling of the transmission

(f) Install and fasten the gear shift block set bolt.

Tightening torque: (15-20)N·m

22.Install the steel ball, spring and screw plug

(a) Coat sealant on the screw plug thread.
(b) Install the steel ball, set spring and set spring screw plug

Tightening torque: (17-22)N·m

23.After installing the rear housing or transmission case,
check the following items

(a) Check the rotation of the input shaft and output shaft is

stable.

(b) Check the shift of each gear is clear and reliable, and

check there is reverse gear lock function.

24.Install the limit mechanism set

When installing, distinguish the left and right-less elastic force
of left limit mechanism set (seen from the output shaft to the
input shaft of the transmission)

Tightening torque: (30-50)N·m

25. Install the shift cover of the transmission

(a) Install the shift cover coated with sealant.
(b) Install 6 bolts, and fasten the bolts.

Tightening torque: (15-20)N·m

26.Install the clutch housing

(a) Install the clutch housing.
(b) Coat sealant on the bolt thread.
(c) Install and fasten 9 bolts.

Tightening torque: (30-45)N·m

27.Install the reverse gear switch
Tightening torque: (20-50)N·m

28.Install the odometer driven gear

(a) Install the odometer driven gear
(b) Install and fasten the bolt.

Tightening torque: (15-20)N·m

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TF-1

TF

Transfer case

Page

Precautions................................................................ TF-2

Trouble shooting......................................................... TF-3

Product instruction and simple maintenance............... TF-5

Disassembling and assembling of the transfer case... TF-7

Disassembling of the transfer case............................. TF-9

Cleaning, inspection, repair and replacement.............. TF-14

Cleaning................................................................. TF-14

Inspection............................................................... TF-15

Repair or replacement of gear and sprocket tooth... TF-18
Attached list on parts inspection, repair and replacement stan-

dard........................................................................ TF-19

The assemblage of the transfer case.......................... TF-22

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TF-2

Transfer case— Precautions

Precautions

Precautions for disassembling and assembling of the transfer case

During disassembling of the transfer case, pay attention to handle each part with care to avoid knock,
especially the junction plane; put each part in order so as to prevent loss and wrong taking.
When assembling, except the above precautions, the following should be noticed:

1. Clean all the parts before assembling (except rubber parts and liner).

2.Do not repeat using various oil seals, shaft retainers and elastic pins.

3.Coat lubricant on all friction surfaces, and coat grease on all oil seal mouths.

4.When assembling each bearing, do not pass the pressure with rolling objects.

5.When assembling mouth shape oil seal, do not tilt it.

6.When the transfer case is in operating position, there should not be lubricant leakage at each part.

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nnecting bar mechanism

Transfer case— Trouble shooting

Trouble shooting

TF-3

Common trouble

Electric shift trouble

Mechanical shift not
realized (when the shift
handle is moving)

Mechanical shift difficult or
putting into gear not to the
specified position

Mechanical shift transfer
case out of gear

Mechanical shift blocked at
a certain position

Causes Eliminating methods

Electrical control element, electrical
control module, speed sensor,
electrical motor, electrical clutch or
inner connection harness damaged or
ineffective
Shift cam, connecting sleeve, lock
sleeve, fork or shift guide shaft
damaged or worn.
Shift fork, lock sleeve or gear glued.

Shift rocker or shift connecting bar
broken or damaged.
Shift cam guide plate damaged; shift
fork broken.
Incorrect operation.

Lubricant improper or the amount
insufficient
Shift fork glued.

Sliding connecting sleeve, lock sleeve
or gear glued.

Shift connecting bar mechanism
damaged or improperly adjusted.

Inner shift parts damaged or severely
worn, shift fork assembly loosened
on the guide shaft or damaged.
Shift co
improperly adjusted.
Shift fork loosened too greatly on the
shift guide shaft.

Shift fork assembly worn, including:
pin and contact roller.

Shift cam hub and bush worn.

Combination tooth damaged.

Refer to vehicle operation manual, and
diagnose the ineffective element and
replace it as required.

Disassemble and check worn or damaged
part. Replace it as required.

Disassemble and check the sliding part
could move freely. Replace it as required.
Replace the damaged parts.

Open the transfer case rear cover, check
the damaged parts and replace them.
Refer to vehicle operation manual, and
operate correctly.
Fill specified oil product or amount.

Open the transfer case rear cover, check
and replace the damaged parts.
Open the transfer case rear cover, check
the sliding parts could move freely on the
shaft, disassemble and replace the
damaged parts.
Adjust or repair shift connecting bar
mechanism.
Replace the parts severely damaged.
Replace loosened or worn parts.

Adjust or repair shift connecting bar parts.

Open the transfer case and check the fork
and guide shaft, and replace the parts as
required.
Open the transfer case to check the parts
are worn, replace the parts if they are
worn.
Open the transfer case to check the parts
are worn, replace the parts if they are
worn.
Open the transfer case to check the parts
are worn, replace the parts if they are
worn.

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TF-4

Prove that it is actually the leakage of transfer

Transfer case— Trouble shooting

Troubleshooting (continued)

Common trouble

No front wheel drive when
putting into four wheel drive
Noise with all gears, the
noise is from the transfer
case not from the clutch,
engine, drive shaft or other
parts.

Noise with all gears, the
noise is from the transfer
case not from the clutch,
engine, drive shaft or other
parts.
Noise at high gear and low
gear of four wheel drive

Leakage with the transfer
case

Causes Eliminating methods

Driving chain broken. Disassemble and check the damage condition

of the inner parts, and replace the chain.

Incorrect lubricant or lubricating
amount insufficient.
Connecting bolts loosened or
other connecting parts loosened.

Noise with transfer case bearing

Gear noise. Open and check there are worn or damaged

Sprocket wheel or chain
damaged or worn.

Tire pressure improper.
Transfer case housing broken.
Leakage with other parts.

The breather pipe blocked.
Lubricant amount more than the
required or the lubricant brand
improperly chosen.
Sealing surface bolt loosened.

Different brands of sealer or
unusable sealer.
The oil seal worn or damaged

Replace lubricant or refill the amount as
required.

Ensure that the torque of all connecting parts
reaches specified value.
Open the transfer case to check the bearing
and other parts are worn or damaged, and
replace them if damaged or worn parts are
found.

parts (including odometer gear), replace them
if worn or damaged parts are found.

Open and check there is abrasion or damage,
and replace the parts if abrasion or damage is
found.
Regulate the tire pressure to proper.
Replace the housing.

case.
Dry it and check the leaking condition.
Open and clean, and replace it if necessary.
Use specified lubricant and regulate to proper
amount.

Screw down the bolt as required.

Use specified sealer and screw down the bolt
as required.
Replace the oil seal.

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Transfer case － Product instruction and simple maintenance

Borg Warner product assembly type

The transfer case assembly
number of the manufacturer

Borg Warner product assembly serial number

Manufacturing date

Display: group number
Display: the last number of year

Display: specific manufacturing date of each month

Display: month

January (A) to December (L)

Example indication:
July 1, 1989, second group

TF-5

Product instruction and simple mainte­nance

1.Product instruction

This company applies Borg Warner 45-55 transfer case. It is
2-speed part-time drive, and a set of planetary mechanism
aims to realize decelerating, and the power is passed to the
front drive wheel through 1 high precision chain. The planetary
gear pair and rear output shaft parts of this transfer case are
actively lubricated through oil bath and oil pump.

This transfer case has four gear positions:

l 2H-at two high gear positions, only two rear wheels

are driven, and the drive ratio of the transfer case
is 1:1.

l 4H-at four high gear positions, foul wheels are all

driven, and the drive ratio of the transfer case is
1:1.

l N – neutral position (only manual shift transfer case

has this gear position), output shaft and input shaft
are disconnected, and no power is passed to the
wheel.

l 4L-at four low gear positions, foul wheels are all

driven, and the drive ratio of the transfer case is

2.48:1.

The shift of mechanical shift transfer case is realized through
one shift rocker controlling one shift cam shape guide plate.
Sign panel: fixed at the outer obvious position of the transfer
case, the detailed information of manufacturing marked on it.

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TF-6

Transfer case－ Product instruction and simple maintenance

2.Replacing the lubricant regularly

(a) When replacing the engine lubricant or after driving 8000

km, check the transfer case oil level and refill the
lubricant according to need.

(b) Every year or every 48000km, replace with specified

lubricant.

Oil drain plug

oil filler plug

Lubricant class: Dexron ¢ó or other the same class
lubricant.

3.Lubricant inspection methods

(a) Clean up the oil filler plug and the area around.
(b) Screw off the oil filler plug, check the oil could flow

out.

(c) The oil not flowing out indicates the actual oil amount

lower than specified value, and refill specified lubricant
to the transfer case until the oil flows out from the oil
hole.

(d) Screw down the oil filler plug as required torque.

Tightening torque: (19-30)N·m
Precautions: before inspecting or replacing the lubricant,
rotate the vehicle for a while to increase the oil
temperature of the transfer case. Do not open or screw
down the oil drain plug and oil filler plug with hammer or
other attack tool, or the thread on the housing will be
damaged.

4.Replacing the lubricant

(a) Clean up the oil drain plug and oil filler plug and the area

around.
(b) Place a container filling oil under the transfer case.
(c) Screw off the oil drain plug.
(d) Screw off the oil filler plug.
(e) Drain off the lubricant.
(f) Install and screw down the oil drain plug as required

torque.

Tightening torque: (19-30)N·m

(g) Refill lubricant from the oil hole until the oil flows out.

Install and screw down the oil filler plug as required

torque.

Tightening torque: (19-30)N·m

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Disassembling and assembling of the transfer case

TF-7Transfer case－ Disassembling and assembling of the transfer case

2

1

6

7

9

8

1.Input shaft 2. Transfer case front housing

3.Transfer case rear cover 4.Flange plate

5.Front output shaft flange plate 6.Breather valve

7.Shim 8.Transmission rear housing

9. Bolt

3

5

4

1.Disassembling of the transfer case

(a) Drive the vehicle to appropriate lifting jack.
(b) Put the transmission gear position at neutral

position, and shift the transfer case to 2H gear

and extinguish the engine.
(c) Disconnect the battery cathode.
(d) Lift the vehicle.
(e) Place the drip pan under the transfer case, and

dismount the transfer case oil drain plug and oil

filler plug to discharge all the lubricant, and then

install two oil plugs over again.
(f) Disconnect all the wires and wire harnesses

related to the transfer case.
(g) Disconnect the odometer connecting wire.
(h) Disassemble the hose on the breather valve of

the transfer case.
(i) Uncouple the connection of the front drive shaft

with the transfer case front flange plate.
(j) Uncouple the connection of the rear drive shaft

with the transfer case rear flange plate.
(k) Support the transfer case with lifting jack.

Note: before removing the bolts and nuts
connecting the transfer case and transmission,
ensure that the transfer case is completely
supported by the lifting jack. The transfer case

is not allowed to hang directly on the
transmission through spline shaft, which will
cause the damage of the transfer case parts.

(l) Remove the connecting nut between the

transfer case and transmission, and take down
the transfer case.

(m) Directly remove the transfer case backwards

until the spline connection of the transfer case
input shaft and the transmission is completely

uncoupled.
(n) Lower the transfer case lifting jack carefully.
(o) Remove the shim between the transfer case and

transmission. Clean up the shim material or glue

on the junction plane of transfer case front

housing and transmission rear housing. Pay

attention not to damage the junction plane.

2.Installation of the transfer case

(a) Use a thin sleeve (filled with grease) to coat

grease on the transmission output shaft spline.
(b) Install a new shim on the transfer case

installation surface.
(c) Lift the transfer case lifting bracket and align

on the same axial line with the transmission.

Note: before connecting the spline, ensure that
the transfer case is aligned with the

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TF-8

Transfer case－ Disassembling and assembling of the transfer case

transmission. Do not force the transfer case
spline to press into the transmission. Otherwise,
damage may be caused. Rotate the transfer rear
output shaft if necessary to make it align with
the spline.

(d) Move the transfer case forward slowly to make

the transmission input shaft spline and the pin
to the transfer case front housing, shim and
transmission rear housing be jointed completely.

(e) After ensuring that the installation holes of the

transfer case front housing, shim and the
transmission rear housing are in alignment,
install the bolt or nut.

Tightening torque: (35-48)N·m

(f) Connect the rear drive shaft and transfer case

rear output flange plate.

(g) Connect the front drive shaft and transfer case

front output flange plate.
(h) Connect the breather valve and breather hose.
(i) Connect the odometer cable at the transfer case

rear cover.
(j) Connect all the wire harnesses related to the

transfer case.

(k) Fill correct brand lubricant.

Note: in engine starting, not filling correct lubricant
and appropriate lubricant amount as required will
cause the damage of the transfer case.
Note: when filling oil to the transfer case having
been installed on the vehicle, you must use petrol
feed pump.
Note: if the transfer case is removed to repair or
check, there will be no oil in the oil duct lubricated
through the oil pump on the upper part of the
transfer case.Controlling the oil amount depending
on the opening of the oil filler plug will not be
accurate until the oil pump rotating oil duct is filled
up.If the wheel could be rotated, this could be done
on the vehicle lifting jack.Recheck the oil level after
the oil pump rotating.

(l) After inspecting the lubricant, lower the vehicle

and connect the battery cathode.

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Transfer case－ Disassembling of the transfer case

TF-9

2

1

1.Transfer case rear housing

2.Flange plate 3.Oil seal

4.Shim 5.Nut

6.Oil plug

7

4

3

Disassembling of the transfer case

1.Simple instruction

5

6

1

2

3

5

4

6

As to the transfer case, if only the damaged part is repaired,
disassemble the transfer case to the extent that this damaged
part could be taken out. The part disassembled from the transfer
case could be either subassembly or full group, and it is not
necessary to take it apart unless it contains damaged parts.

2.Disassembling of the transfer case

Place the transfer case on the work bench with rear part or
rear cover upward. Place a wooden block under the front part
to keep the transfer case level. The disassembling process is
as follows

(a) Fix the flange plate, screw off the nut and take down the

shim, and then remove the flange plate and oil seal.

(b) Take down two oil plugs from the housing.

For electric shift transfer case, remove the electric shift
parts. Disassembling steps As follows:

(a) Remove the bolt, shim, three bolts and sensor and harness

clips.

(b) Remove sensor assembly, and take off O ring from speed

sensor.

(c) Remove motor assembly.

8

1.Sensor fixing bracket 2.Bolt

3.Speed sensor 4.O ring

5.Sensor assembly 6.Bolt

7.Motor assembly 8.Transfer case rear housing

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TF-10

Transfer case－ Disassembling of the transfer case

9

8

6

7

5

4

3

2

1

16

17

18

9

19

15

10

11

14

7

13

12

1.Transfer case front housing

2.Rear output shaft

3.Clutch coil assembly

4.Snap ring

5.Bearing

6.Nut

7.Transfer case cover assembly

8.Sign panel

9.Bolt

10.Odometer drive gear

11.Oil seal

12.Oil seal

13. Bearing

14.Transfer case rear cover

15.Needle bearing

16.Shift guide shaft

17. Return spring

18.Magnet

19.Harness clip

1

2

4

3

10

1.Output shaft

2.Shift engagement
sleeve assembly

3.Lock sleeve

4.Return spring

5.Engagement sleeve

6

5

6.Snap ring

7.Clutch assembly

8.Tightening snap ring

9.Shift guide shaft

10.Fork

3.The process of disassembling the rear cover is as follows
(the above drawing):

(a) Remove 9 screws and take down harness clips and sign

panel at the same time. Keep well the sign panel, because
it contains the information replacing the substituting
parts.

(b) Pry the housing gently and disconnect the surface sealer,

and then directly take up the transfer case rear cover
assembly upward.

(c) For electric shift transfer case, remove the oil seal, bearing

and 3 nuts and clutch coil assembly.

8

7

(d) Remove the snap ring, pluck out the bearing from rear

cover and remove the odometer gear at the same time.

(e) Pluck out the needle bearing from the transfer case rear

cover.
(f) Pluck out the oil seal from the transfer case rear cover.
(g) Dismount the magnet from the transfer case front

9

housing.
(h) Remove the return spring from the shift guide shaft.
(i) Clean out the sealer on the junction plane of the transfer

case front housing and rear cover, and take care not to

damage the junction plane of the two housings or let the

cleanings fall into the transfer case.

4.Dismount the connected front axle shift parts

Remove the following parts from residual transfer case housing
assembly (electric shift).

(a) Electric shift assembly, remove the snap ring and sliding

clutch bush from shift lock hub.

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Transfer case－ Disassembling of the transfer case

TF-11

2

1

3 4

7

1.Output shaft 2.Drive sprocket

3.Driven sprocket 4.Washer

5.Snap ring 6.Driving chain

7.Front output shaft

7

5

6

5

4

3

(b) Remove the shift lock hub from rear output shaft.
(c) Remove the shift engagement sleeve assembly and shift

fork from rear output shaft and shift guide shaft.
Disconnect all assemblies and remove the shift guide
shaft.

(d) Disassemble shift engagement sleeve assembly, and take

down the snap ring, engagement sleeve, return spring
and lock sleeve.

6

(e) One plastic fork substitutes early metal fork assembly

and independent contact roller parts.

5.Dismount the chain driving system

Remove the following parts from residual transfer case housing
assembly.

(a) Remove the snap ring and washer from front output

shaft.

(b) Remove the drive sprocket, driven sprocket and driving

chain together from two output shafts.

(c) Separate the sprocket from the chain.

6.Dismount the oil pump assembly

Remove the shaft and pump assembly from residual transfer

2

case housing assembly. Remove the pipe clip, oil piper and
filter.

1.Filter

2.Oil pump hose

3.Clip

4.Oil pump assembly

1

1.Decelerating hub

2.Shift fork veneer

3.Contact roller

4.Pin

5.Pin and contact roller assembly

6.Decelerating shift fork

7.Decelerating shift fork assembly

5.Output shaft

6.Pump pin

7.Output shaft and
pump assembly

2

6

7

1

7.Disassembling of the decelerating shift parts

Remove the following parts from residual transfer case housing
assembly.

(a) Remove the decelerating hub and decelerating shift fork

assembly from the housing.

(b) Remove two plastic veneers from the decelerating shift

fork assembly.

(c) Only when replacing the damaged parts of the

3

4

5

decelerating shift fork assembly, disassemble the
decelerating shift fork assembly. Cut the plastic sleeve,
and take down the pin and contact roller.

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TF-12

Transfer case－ Disassembling of the transfer case

4

3

2

1

6

7

8

1.Flange plate 2. Dust cap

3.Flange plate assembly

4.Transfer case front housing

5.Front output shaft 6.Oil seal

7.Washer 8.Nut

7

11

6

14

8

15

20

1

5

4

3

13

12

1.Planetary mechanism
assembly

2.Shim

3.Snap ring

4.Thrust button

5.Sun gear

6.Planet carrier

7.Input shaft assembly

8.Input shaft

9.Needle bearing

10.Bearing shell

11.Transfer case front

housing assembly

10

9

2

17

18

19

12.Oil seal

13.Anchor pin

14.Transfer case front
housing

15.Snap ring

16.Transfer case front
housing

17.Bearing

18.Bearing closing ring

19.Bolt

20.Breather hole

16

8.Front output assembly

Remove the following parts from residual transfer case housing
assembly.

(a) Fix the front flange plate, screw off the nut and remove

the shim, and pluck out the front flange plate assembly
and the seal ring.

(b) If the replacement needs, press down the dust cap from

the front flange plate

(c) Remove the front output shaft

5

9.Dismount the front housing, input shaft assembly and
planetary mechanism assembly.

Remove the following parts from residual transfer case housing
assembly.

(a) Remove the breather valve.
(b) Remove 6 bolts. Separate the front housing from the

transfer case housing, and take down the front housing
(take care not to damage the front end cover and transfer
case housing).

(c) Remove the front housing assembly, input shaft assembly

and planetary mechanism assembly as groups (loosen
the snap ring, and remove the input shaft from the front
end cover).

(d) On the work bench, hold one end of the input shaft, and

extend the long end of the snap ring and gently press the
front housing, and the front housing assembly could be
disassembled from the residual assembly in this way.

(e) Remove the snap ring and oil seal from the front housing.

Remove the pin only when it needs replacing.

(f) After removing the bearing closing ring, remove the

bearing and shim from the input shaft assembly end.
Remove the input shaft assembly from the planetary
mechanism assembly.

(g) Remove the needle bearing and bearing shell from the

input shaft assembly.

(h) Remove the snap ring, thrust button and sun gear from

the planet carrier assembly.

(i) Do not try to disassemble the planet carrier.

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Transfer case－ Disassembling of the transfer case

TF-13

1

3

2

1.Transfer case front housing

2.Shift guide shaft 3.Torsion spring

4.Electric shift 5.Shim

5

4

3

2

1

10.Disassemble the shift flange parts (for electric shift

4

transfer case)

(a) Remove the electric shift cam set as a whole from the

transfer case housing.

(b) Remove the electric shift cam from the shift guide shaft.

5

(c) Clamp the end of the shift guide shaft with soft mouth

jaw vice, and knock with a bolt driver to disconnect the
torsion spring and remove it.

11.Disassemble the transfer case housing assembly

Disassemble the transfer case housing assembly in the

following way.
(a) Remove the oil seal.
(b) Remove the snap spring and pluck out the bearing.

7

6

(c) Remove the anchor pin from the transfer case front

housing only when the pin is loosened or damaged.

(d) Press out the ring gear from the transfer case housing if

the ring gear needs replacing.

1.Transfer case front housing assembly

2.Ring gear 3.Oil seal

4.Transfer case front housing

5.Anchor pin 6.Ball bearing

7.Snap ring

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TF-14 Transfer case－ Cleaning, inspection, repair and replacement

Cleaning, inspection, repair and replacement

Cleaning

1.Cleaning
Note: before cleaning, firstly check the metal chips condition, and big, small, granular or irregular
granular metal chips indicate the crack or similar damage. Smaller and powdery chips indicate uneven
or excessive abrasion. If metal chips are found, when inspecting the rotating parts and corresponding
matching parts, be extremely careful to check there is damage or abrasion.

(a) General cleaning process

Clean the parts in cleaning agent, and remove the old lubricant and deposits. Wipe off the deposits in the oil
hole with hair brush For the parts that could not be cleaned with hairbrush, take care not to scrape the metal
junction plane etc when cleaning.

(b) Dry the cleaned parts

Dry the parts with compressed air of low pressure (max.137.9kPa). Mopping up with cloth may leave
strand silk. When drying the bearing, hold it with hands to prevent it from rotating.

(c) Lubricate the bearing

After cleaning, immediately lubricate the ball bearing and needle bearing with transfer case oil. When drying,
the bearing without lubricating may cause the damage. Cover the lubricated bearing to prevent dust entering.

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Transfer case－ Cleaning, inspection, repair and replacement

Inspection

1.General inspection process

Visually check all the parts (except the parts that should be
replaced by new ones such as oil pump oil pipe, O ring and oil
seal etc) are damaged or excessively and unevenly worn.
Abandon the damaged or worn parts that will affect
performance. The inspection items are as follows:

l Burrs: partially protruded pointed edge of the

material.

l Chips: broken or smashed small block or grain.
l Cracks: the surface line of rent indicating part or

full separating of the material.

l Excessive abrasion: severe or obvious abrasion

exceeding the operating range.

l Shrink deformation: material sliding caused by

partial oppress.

l Pasting: grains of soft metal material torn up and

pasting on hard metal surface.

l Groove mark: partial crack or furrow, generally

meaning the transfer of material not loss.

l Pitting corrosion: the breaking of metal surface

under contact pressure. Color change caused by
the heat produced by metallic friction can be
displayed.

l Step abrasion: visual or perceivable step pro-

duced by excessive abrasion between adjacent
contact surface and non-contact surface.

l Uneven abrasion: partial, unevenly distributed

abrasion. Including pore space, exploring spot,
uneven polishing and other visual showings.

2.Inspection of gear or sprocket tooth
Note: do not mix the cut mark caused by machining with
the extrusion marks. Typical machining marks are as
shown in the left drawing.

TF-15

Normal gear shaving mark

Normal gear grinding mark

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TF-16 Transfer case－ Cleaning, inspection, repair and replacement

Check the tooth contact zone form of gear or sprocket tooth
as the following way:

(a) Optimal tooth contact zone.

(b) It is allowable for contact zone deviating toward one

side.

(c) It is not allowable for contact zone deviating toward one

side, and replacement is necessary.

(d) It is allowable for contact zone deviating toward another

side.

(e) It is not allowable for contact zone deviating toward

another side, and replacement is necessary.

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TF-17Transfer case－ Cleaning, inspection, repair and replacement

(f) It is allowable for contact zone deviating toward

addendum.

(g) It is not allowable for contact zone deviating toward

addendum, and replacement is necessary.

(h) It is allowable for contact zone deviating toward

dedendum.

l

(i) It is not allowable for contact zone deviating toward

dedendum, and replacement is necessary.

4.Inspection of spline tooth

Inspect broken of flaked spline tooth. For partial small block
flaking, repair it in the same way as that of gear tooth flaking,
and you can reuse it. If any spline tooth is broken, this part
must be abandoned. The contact form of spline tooth is
different from that of gear, but the spline displaying step sliding
must be abandoned.

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TF-18 Transfer case－ Cleaning, inspection, repair and replacement

Repair or replacement of gear and sprocket
tooth

1.Repair principle

(a) Repair the partial small block flaking with appropriate

manual high-speed grinding tool.

(b) When grinding matrix metal, try your best not to remove

more metal.

(c) Revamp the closed angle or edge as sleeky form line.

The closed angle or edge may flake again and form into
cracks.

(d) Remove burrs with appropriate grinding. Take care to

remove heaved material without destroying the matrix.

(e) Replace the unmendable parts (such as bearing), and

replace the part that you doubt about its continuous
usability.

2.Several conditions for repair or replacement of gear and
sprocket tooth

(a) It is maintainable for the inbreak of both sides of the

interface addendum.

(b) It is maintainable for the inbreak of the intermediate

addendum of the interface.

(c) It is maintainable for the inbreak of the non-interface

side.

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TF-19Transfer case－ Cleaning, inspection, repair and replacement

(d) It is maintainable for the inbreak of the middle part of

the interface side.

(e) If the middle part of the contact zone is flaked, replace

this gear.

(f) For inbreak of two sides of the addendum, replace this

gear.

Attached list on parts inspection, repair and replacement standard

Parts (items) Inspection Accept/reject

All parts (including all
springs)

All thread parts Inspect the dropout or other damages

Flange plate Refer to “Inspection” section to inspect

Speed sensor, motor assembly
Parts of electric clutch
Sliding bearing Check the inner surface condition of

Transfer case housing Check the hole matching with the

Inspect cracks, contorts and corrosion Reject all parts with cracks

with the thread

the spline
Refer to electrical equipment part Replace parts as required

the sliding bearing

bearing

Reject the parts with bends, contorts

and poor circle jumps
Reject all parts with pitting corrosion or
corrosion
Reject the parts that could not be screwed
or without threading
Refer to spline inspection in“Inspection”

section

Reject if there is pitting corrosion or
damage
Abandon if there is pitting corrosion or
damage

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TF-20

Transfer case－ Cleaning, inspection, repair and replacement

Attached list on parts inspection, repair and replacement standard

Parts (items) Inspection Accept/reject

Ball bearing Visually check there is flaking, pasting,

pitting corrosion or other damages with
the ball and ball race of the bearing.
Be certain that the bearing has been
lubricated, and hold the bearing inner race
and rotate the bearing outer race slowly at
the same time to feel whether the rotating
is smooth or the parts are rusted, and the
bearing should rotate stably without play
and looseness.

Needle bearing Visually check there is flaking, pasting,

pitting corrosion or other damages with

the needle and ball race of the bearing.
Transfer case rear cover, front
housing and transfer case front
housing
Transfer case rear cover Check the bearing hole Reject if there is pitting corrosion with

Odometer gear Refer to “Inspection” section to inspect

Transfer case outer
housing,connecting outer sleeve
and connecting sleeve

Check there is burrs or other damages

obstructing sealing

the gear tooth

Refer to “Inspection” section to inspect

the spline

Reject damaged bearing
Reject damaged or loosened bearing
Or check the axial clearance exceeds

0.23mm

Reject damaged bearing

Refer to “Inspection” section to remove
the burrs or replace the dam aged parts

the hole
Refer to inspection of gear or sprocket
tooth in “Inspection” section
Refer to spline inspection
in“Inspection” section

Lock sleeve Check the abrasion or damage condition

of the fork groove Refer to “Inspection”

section to inspect the spline
Shift guide shaft Check the deformation condition

Check the outer circle burrs or other

damages

Check the abrasion condition of the outer

circle
Shift fork Check the part that the fork matching

with the shift cam and gear sleeve is worn

of damaged
shift fork assembly Check the abrasion or damage condition

of the fork veneer matching with the gear

sleeve

Check the contact roller could rotate

freely or it is damaged
Drive and driven sprocket Refer to “Inspection” section to inspect

the sprocket tooth

Refer to “Inspection” section to inspect

the sprocket spline

Reject if step slipping or damage is
found

Reject if it bends, and refer
to“Inspection” section to remove burrs,
or reject the damaged guide shaft
Reject if step slipping or damage is
found
Reject if step slipping or damage is
found

Reject this veneer if abrasion or
damage of thestep is found If the
contact roller is hard to rotate or it is
damaged, use new pin, contact roller
and holder assembly
Refer to inspection of the sprocket

tooth in “Inspection” section

Refer to spline inspection

in“Inspection” section

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TF-21Transfer case－ Cleaning, inspection, repair and replacement

Parts (items) Inspection Accept/reject

Driving chain Check the step slipping, loosening or the

damage of the pin or connecting parts

Filter screen Check the filter screen is clean and there is

hole or damage with it

Pump case Check there is pitting corrosion or step

slipping with the inner diameter of the pump
case

Oil pump pin Check the pitting corrosion condition Abandon if there is abrasion, pitting corrosion

Output shaft Refer to “Inspection” section to inspect the

spline
Check the surface condition

Decelerating hub Refer to “Inspection” section to inspect the

sprocket spline
Check the abrasion or damage condition of the
position matching with the fork

Front output shaft Check the surface condition matching with the

bearing
Refer to “Inspection” section to inspect the
spline

Input shaft Refer to “Inspection” section to

inspect the spline

Check the contort condition
Thrust plate and
thrust button
Sun gear Refer to “Inspection” section to inspect the

Planetary
mechanism
assembly

Electric shift cam Check there is pitting corrosion or step

Shift guide shaft Check there is pitting corrosion or step

Planetary ring gear Check the matching condition with the

Check the pitting corrosion condition Reject if there is pitting corrosion or damage

gear tooth

Refer to “Inspection” section to inspect the

spline

Refer to “Inspection” section to inspect the

gear tooth

Check the abrasion of the planetary shaft pin

or it is loosened and the abrasion condition of

the thrust plate

slipping

slipping

Check the contort condition

transfer case housing

Refer to “Inspection” section to inspect the

gear tooth

Reject the drive sprocket with abrasion or
damage
Clean it if necessary; abandon if it is damaged

Abandon if the pump case is damaged or
excessively worn

or damage with the pump case
Refer to spline inspection in “Inspection”
section
Reject if there is pitting corrosion or damage
Reject if it bends or poor circle jump with it
Refer to spline inspection in “Inspection”
section
Reject if step slipping or damage is found

Reject if there is pitting corrosion or damage

Refer to spline inspection in“Inspection”
section
Reject if it bends or poor circle jump with it

Refer to inspection of the gear tooth in
“Inspection” section
Refer to spline inspection in“Inspection”
section
Refer to inspection of the gear tooth in
“Inspection” section
Reject if step slipping or pitting corrosion is
found

Reject if pitting corrosion or step slipping is
found
Reject if step slipping or pitting corrosion is
found
Reject if it bends
Check the transfer case housing assembly to
see whether the ring gear is loosenedin the
housing
Refer to inspection of the gear tooth in
“Inspection” section

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TF-22

2

1.Transfer case front housing assembly

2.Ring gear 3.Oil seal

4.Transfer case front housing

5.Anchor pin 6.Ball bearing

7.Snap ring

3

2

105

1

Transfer case－ The assemblage of the transfer case

The assemblage of the transfer case

1.Overview

During assembling, please refer to specified instruction in this
chapter. In assembling, pay attention to the following problrms:

(a) When there is requirement for the torque of thread parts,

screw down the thread parts with torque wrench.

(b) During installing, coat grease on small parts to make

them be fixed on the installation position.

(c) When assembling the oil seal and bearing, press the oil

seal and bearing with special tool socket T-13-54-001.
Do not directly knock the oil seal or bearing with
hammer.

2.Lubrication in assembling

Lubricate all the inner parts not yet lubricated with correct
lubricant before assembling to make it easy for assembling
and provide initial lubrication.

(a) Before assembling, O ring or the oil seal of shaft without

lubrication may cause damage.

(b) Ensure the bearing or bushing could be lubricated

completely before assembling. Operating the bearing or
bushing without lubrication even for a short time will
cause the damage.

(c) mouth and the metalwork matching with it.

3.The assembling of the transfer case housing

7

6

5

4

3

1

Install the parts removed from the transfer case housing, the
process is as follows:

(a) If the ring gear is replaced, when pressing into new ring

gear, align the tooth shape protuberance of the new ring
gear with corresponding gullet in the transfer case front
housing, and press into the ring gear as shown in the
lower left drawing, and the chamfer end enters first.
Ensure the ring gear does not upwarp and it is tightly
fixed in the housing.

(b) If two anchor pins are removed, encase two new anchor

pins into the housing.

(c) Press the bearing into the transfer case front housing

and well install the snap ring.

(d) Place the new oil seal as shown in the lower left drawing

and press it into the housing.

4

1.Oil seal 2.Transfer case front housing

3.Ring gear 4.Anchor pin

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Transfer case－ The assemblage of the transfer case

2

1

1.Shift guide shaft 2.Torsion spring

3.Electric shift flange 4.Shim

1

TF-23

4.The assembling of mechanical shift flange parts ( electric
shift transfer case)

4

3

For electric shift parts assembly, the installing process is as
follows:

(a) Insert the shim into the inner diameter of the torsion

spring and make it run through the free end of the shift
shaft.

(b) Slide the torsion spring and shim on the shift shaft to

reach the drive tongue, and put the first finger tip of the
torsion spring on the left side of the drive tongue (seen
from the free end of the shift shaft).

2

1.Torsion spring

2.Shim

3.Shift shaft

3

(c) Twirl the second finger tip of the torsion spring on the

shift shaft to the right end of the drive tongue.

1

2

1.Torsion spring 2.Shim 3.Shift shaft

3

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