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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 profes-
sional 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.
PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn

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

Chassis and vehicle body
Service manual
Overview IN
Vehicle parameters PA
Fuel supply system and exhaust system FE
Clutch CL
Transmission MT
Transfer case TF
Drive shaft PR
Suspension system and axle SA
Braking system BR
Steering system SR
Vehicle body electrical equipment system BE
Air conditioning system AC
Vehicle body BO

OV-1
Overview
Page
How to use this manual................................................... OV-2

Identification number position ....................................... OV-3
Integrated repair instruction .......................................... OV-4
OV
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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 in-
dicate their matching with each other.
For example:
Front reducer assembly
Washer
Bearing
◆ Oil seal
Spacer-drive bevel gear
N ·m :Specified torque
Front reducer main gear flange 140-160 ◆
◆ Parts no longer for use after service and dust shield assembly
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.
Operation title: what to do
For example:
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
Iconography: what to do and where to do it
Specification Detailed instruction: how to do it

Overview — Identification number position OV-3
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.
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
VIN nameplate vehicle certificate.
Certificate plate
Frame number (VIN)
Engine number
Engine number is engraved on the left side of the engine cylinder
Engine number 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.

Overview — Integrated repair instruction OV-5
● 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.
● 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
Locking sealant 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

(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.

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.
Wrong
(b) Do not try to start the engine in the case of the
battery ground cable being loosely connected, or the
Wrong wiring will be seriously damaged.
(c) Check the alternator belt tension.
● Basic operation
Correct 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.
Loosening the coiling
(c) Before connecting the joint, check it is deformed,
Core of conductor damaged and port lost.
(d) When connecting the joint, crack sound indicates
successful connection.
Terminal 2. Inspection of harness joint
deformation
(a) Inspection for joint connected
Gently pulling 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
Terminal like male contact
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

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

4. Dismounting of the harness

Wrong Wrong
(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,
Wrong 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.

● 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
Protect tape
Screwdriver
Protect tape
Screwdriver

OV-10
Continued table:
Shape Disassembling/assembling
Disassembling assembling
Screwdriver
Pressing
Clip detacher
Push out the king pin and remove it, and prize off the king pin bush.
Screwdriver Pressing
Clip detacher
Screw off the king pin and prize off the king pin bush.
Pressing
Screwdriver
Clip detacher
Small clip detacher

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

PA-1
Complete Vehicle parameters

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

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
Type code CC1031PS40 CC1031PS60 CC1031PS41
Drive type 4×2 4×4 4×2
Length mm 5040 5040 5040
Overall
Width mm 1800 1800 1720
dimension
Height (no load) mm 1730 1730 1675
Wheel base (mm) 3050 3050 3050
Front mm 1515 1515 1460
Wheel track
Rear mm 1525 1525 1460
Front suspension mm 745 745 745
Rear suspension mm 1245 1245 1245
Length mm 1380 1380 1380
Trunk
inside Width mm 1460 1460 1460
dimension
Height mm 480 480 480
Curb weight kg 1775 1920 1705
Front axle load kg 975 1090 945
Rear axle load kg 800 830 760
Mass
Weight with full load kg 2580 2725 2510
parameter
Front axle load kg 1050 1165 1020
Rear axle load kg 1530 1560 1490
Load weight kg 480 480 480
Toe in (mm) 0～2 0～2 0±2
Wheel Front wheel camber 0°±30′ 0°±30′ 0°±30′

alignment 30 ′ 30 ′
Kingpin rear inclination 3°30′0 ′ 3°30′0 ′ 3°35′±45′
parameter
(no load) Kingpin inclination angle 12°30′±30′ 12°30′±30′ 12°30′±30′
Inner/outer wheel max.
≥32°/28° ≥32°/28° 37°6′/33°30′
steering angle

Complete vehicle parameters page — Complete vehicle basic parameters PA-3
Complete vehicle basic performance parameters

Engine model GW2.8TC-2
Delivery capacity（L） 2.771
Rated power / rotating speed（kw/rpm） 70/3600
Max. torque / rotating speed (Nm/rpm) 225/1800～2000
Max. vehicle speed (Km/h) ≥140
Accelerating time （0～100km/h） (sec) full load 28
Max. climbing speed（％） ≥30
Service braking distance with initial speed of braking of
≤22（ full load），≤21（ no load）
50km/h（m）
Emergency braking distance with initial speed of braking
≤20
of 30km/h（m）
Parking brake (with grade slope 20％) Not less than 5min
Noise dB (A) emitted by accelerating motor vehicles ≤78
Emission level EuroⅡ
Approach angle (no load) ≥30° ≥24°
Angle of departure (no load) ≥24° ≥21°
Steering ability data Min. ground clearance (full load)
194
（mm）
Min. turning diameter（m） ≤13
Perfect start performance in the environment above －
Engine startup performance
35℃
Structure and performance parameters of main assembly
Engine characteristic parameters
Items Structure parameters
Engine model GW2.8TC-2
4-cylinder, in-line, water-cooling, four-stoke, turbo-charging electric
Engine type
control direct injection diesel
Delivery capacity（L） 2.771
Bore × stroke(mm) 93×102
Rated power / rotating speed（kw/rpm） 70/3600
Max. torque / rotating speed (Nm/rpm) 225/1800～2000
Min. stable idle speed (r/min) 800±50
Compression ratio 17.5:1
Overall dimension（mm） 775×620×761
intake system Air filter, exhaust gas turbo-charging system
Fuel supply Fuel tank Plastic fuel tank: 70L

system Fuel supply control Electric control
Exhaust system First class silencer
Cooling system Closed and forced water-cooling system, electronic fan
Engine layout form Parallel, three-point mounting

PA-4 Complete vehicle parameters page — Complete vehicle basic parameters
Main assembly structure and parameters of chassis

Type Single dry diaphragm spring
Outside diameter of
Clutch 250
friction disc（mm）
Manipulate Hydraulic control
Type Mechanical, 5-forward gear
Center distance (mm) 72
Max. input torque (N.m) ≥230
Net weight（Kg） 35
Odometer speed ratio 17/6
Lubricant type Gear oil 80W/90 (GL-4)
Lubricant amount( L) 2.4
Transmissi st
1 gear 3.992
on
nd
2 gear 2.15
rd
3 gear 1.334
th
4 gear 1
Speed ratio th
5 gear 0.806
R gear 4.22
H gear 1
L gear 2.48
Main reducer speed ratio 4.1 3.9
Front: double spiders
Type Three spider types Three spider types
Rear: three spiders
Drive shaft
Pipe diameter×wall Front: Ф63×2.5，
Ф76×1.8 Ф76×1.8
thickness（mm） Rear: Ф76×1.8
Front axle Non-whole axle
Rear axle Whole axle
Tire type Tubeless radial tire
Wheel and Tire specification P235/70R16 P215/75R15
tire Felloe specification 16×7J 15×6J
Tire pressure (F/R)(KPa) 220/250
Double wishbone torsional bar spring independent Coiled spring
Front
Suspension suspension independent suspension
Rear Leaf spring non-independent suspension
Steering Steering gear type Hydraulic power rack-and-pinion

system Steering column Adjustable or unadjustable Adjustable
Hydraulic double pipeline, with vacuum booster; loading sensing pressure
Structure type
Braking proportoining valve, optional anti-lock brake system (ABS)
system Service brake Front disc brake, rear drum brake
Parking brake Drum brake

Complete vehicle parameters page — Complete vehicle basic parameters PA-5
Vehicle body structure type

Assembly Structure parameters
Vehicle body type Body-chassis frame construction, double seats
White vehicle body All-metal closed structure
Push, four doors open, panel door lock, hinge, central control door lock,
Vehicle Door assembly
electric window regulator
body
Backward opening, hinge with dead axle rotating, sealing with front and
Engine hood
rear weatherstrips, adding heat insulating mattress
Front, rear bumper PP injection molding, connected with body frame using clips and bolts
Body-chassis frame trunk, suspension connected with body equipped with
Trunk Trunk type
cushion, equipped with rear door opening and locking structure
Original inner door panel design, softening ceiling design and softening
nterior trim
carpet
Instrument panel Injection molding, main material with PP, frame with sheetmetal structure
A, B, C column and inner Injection molding, inner door penal with sundries box and partially
door panel softened, main material with PP
Roof door handle Nylon injection molding
Front windshield with double curved laminated glass, rear windshield with
Interior, Windshield
tempered glass
exterior Outer rear-view mirror: two types of electric and manual, optional
trim Rear view mirror
Interior rear-view mirror: manual glare-proof flat-view interior mirror
Seat position adjusted manually front and rear (travel 200), backrest angle
Driver's seat
adjusted manually.
Seat Seat position adjusted manually front and rear (travel 200), backrest angle
Co-driver's seat
adjusted manually.
Rear seat The rear with integrated seat, backrest overturned to folding
Door handle Outer pull door handle
Vehicle Seat belt Three-point emergency locking seat belt
body
Wiper system Electric crank-rocker mechanism
accessorie
s Sun visor PVC leather surface, rotation gear self-locking device
Structure type Refrigerating and heating manually
Refrigerating and heating
Not less than 4000W when the rotating speed of engine is 1800rpm
capacity
Control mechanism Mechanical
Refrigerant R134A
Compressor type JSS-D14
Refrigerati Air purification system With rough filtration
ng and HVAC With (separate)
heating air
Condenser Advection
conditionin
g system Dry reservoir With
Air duct With
Ventilation port With
Refrigerating pipe Low and high pressure tube, hose
Heating pipe Rubber tube
Sensor Evaporator temperature sensor
Pressure switch With (three-state switch)

PA-6 Complete vehicle parameters page — Complete vehicle basic parameters
Electrical system structure and parameters

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

Complete vehicle parameters page — Vehicle body dimension schematic diagram PA-7
Vehicle body dimension schematic diagram

(Two-dimensional distance size)
Unit:mm
(Full load)
Note: after mounting rear bumper, vehicle overall length is 5040mm, angle of departure is 21°.
(Interior height of trunk)

PA-8 Complete vehicle parameters page — Vehicle body dimension schematic diagram
(Two-dimensional distance size)
Unit:mm
W heel base: 3050mm

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

FE-2 Fuel supply system and exhaust system—Trouble shooting
Trouble shooting
Trouble Causes Countermeasures
Engine does not start after Air in the system Loosen the air bleed bolt of the fuel filter and
disassembling and assembling continuously press the hand fuel pump manually to
of fuel supply system discharge air
Engine does not start Too many impurities Clean the fuel line system
in the fuel line, poor
fuel quality
Fuel gauge pointer is not The pointer of the Instrument:
accurate instrumentisblocked
Fuel float vibration Fuel sensor bracket assembly
affects the contact

Fuel supply system and exhaust system — Fuel supply system FE-3
Fuel supply system

Part drawing
Accelerator pedal bracket

M6 bolt
9-12
M6 nut
★ Fuel pump gland

Accelerator pedal
100
Fuel sensor bracket as-

Oil filler assembly
Fuel tank cap sembly
steel wire elastic hoop
Fuel filling ventilation ★ Fuel tank oil return pipe assembly

rubber hose
Fuel tank front bandage
★ Fuel tank oil outlet pipe
C ross recessed screw assembly
M10 bolt
◆ Fuel pump seal ring
M10 bolt 65-75
65-75
★ Engine oil return rubber hose

Fuel tank assembly
Fuel hose clip

★ Engine oil inlet rubber hose
Fuel tank support plate
C type worm gear driving
Fuel tank rear bandage hose hoop
M10 bolt Fuel filter

5-line fuel pipe clip holder
Fuel filter bracket
★ Fuel filter oil inlet rubber hose

Fuel tank oil return tube
Fuel tank oil outlet tube Steel wire elastic hoop
◆ Parts no longer for use after service

★ Precoat parts

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. R em ove the fueltank frontbandage.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 b etween
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

Fuel supply system and exhaust system —Removal of oil filler assembly FE-5
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
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

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.

Fuel supply system and exhaust system — Exhaust system FE-7
Exhaust system
Part drawing
Exhaust elbow gasket joint
Muffler gasket
Nut Exhaust elbow bolt

Three-hole rubber block
Front exhaust pipe
Muffler assembly
Hexagon flange nut
Muffler gasket

Hexagon flange bolt
Middle exhaust pipe

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.

Fuel supply system and exhaust system — Installation of exhaust pipe assembly FE-9
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 three-
hole rubber block should be strained evenly.
3. The tightening torque of each flange coupling bolt and
nut is:(70 ± 5)N·m

CL-1
Clutch
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

CL-2 Clutch — Trouble shooting
Trouble shooting
Hard to shift or Clutch pedal free travel too large Adjust free pedal travel
will not shift Air in the clutch pipeline Discharge the air in clutch system
Trouble of clutch wheel cylinder Replacement
Trouble of clutch master cylinder Replacement
Improper installation position of clutch, too large Inspect clutch plate
deflection, oil adhered or broken of friction lining
Spline of input shaft or clutch plate contaminated or Repair according to needs
with stickers
Trouble of clutch pressure plate Replacement
Transmission Abrasion of clutch guide bearing Replace guide bearing
disconnected with
mesh
Clutch skidding Clutch pedal free travel insufficient Adjust free pedal travel
Oil adhered or broken of clutch friction lining Inspect clutch plate
Trouble of clutch pressure plate Replacement
Block of release yoke Inspect release yoke
Clutch Oil adhered or broken of clutch friction lining Inspect clutch plate
blocked/vibrating Trouble of clutch pressure plate Replace clutch pressure plate
Engine bracket loosened Repair according to needs
Clutch pedal loose Air in the clutch pipeline Discharge the air in clutch system
Trouble of clutch wheel cylinder Replacement
100Trouble of clutch master cylinder Replacement
Too loud noise of Parts in clutch pressure plate loosened Replace clutch pressure plate
clutch Abrasion or contamination of release bearing Replacement
Abrasion of guide bearing Replacement
Block of release yoke Repair according to needs

Clutch — Inspection and adjustment of clutch pedal,Air bleed of clutch CL-3
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.
Pedal height
2. Adjust the pedal height if necessary
adjust point
Loosen the tightening nut and turn the adjusting bolt until the
height is correct. Screw down the tightening nut.
Pedal height
Dash board
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
free pedal travel 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 peda l move upwa rds a nd
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.

CL-4 Clutch — Clutch control mechanism
Clutch control mechanism

Part drawing
Clutch master cylinder fuel pipe

Clutch master cylinder
25-30
Plastic clip 23 ± 3
Spring clip
20
Clutch hose bracket set
Clutch wheel cylinder
Open retainer
Clutch hose
Seal washer 30-40
30 ± 3
N ·m : Specified torque

Clutch — Clutch control mechanism CL-5
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.
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.

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
Clutch pressure plate assembly

Clutch driven plate assembly
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.

Clutch — Clutch set CL-7
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.
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

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.
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.
SST Installation of the clutch set

1. Install the clutch driven plate assembly on the flywheel.
Flywheel Install the clutch driven plate assembly on the flywheel with
side
special service tool.
2. Mounting clutch pressure plate assembly

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

Clutch — Clutch set CL-9
3. Check the height at the disengaging pawl of the

SST diaphragm spring is consistent.
Check the difference in height at the disengaging pawl of the
diaphragm spring with special serrice tools.
SST
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
5. Encase the cup, release rocker, release bearing seat

and bearing into the clutch housing.
6. Install the transmission

MT-1
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 MT
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

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
3rd and 4th shift 3rd shift 2nd shift 1st shift 5th shift Control
Clutch housing gear sleeves gear gear gear gear cover Shift lever
Housing Reverse
gear idler
Input Front Intermediate Rear 5th shift Odometer Output shaft
Reverse Middle
shaft cover shaft housing gear
gear coupling plate
sleeve
shaft Middle 5th shift gear
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.

transmission － Trouble shooting MT-3
Trouble shooting
Trouble type Possible causes Eliminating methods
Noise too loud or Bearing damaged Replacing the bearing
abnormal
Gear tooth face knocked or eroded Repairing or replacing the gear
Gear axial position or clearance improper or inside Check, repair and adjustment
parts scratched
Lubricant level too low or lubricating insufficient Refilling to the marked position
Using inferior lubricant not complying with quality Replacing with specified lubricant
requirements
Damage with the inside parts of clutch Check, repair and adjustment
Putting into gear Clutch improperly adjusted, releasing incompletely Adjustment
difficult
Control mechanism improperly adjusted Adjustment
Synchronizer toothed ring worn severely Replacing the toothed ring
Oil leakage 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 Recoating the sealant or replacing
damaged the washer
The junction plane knock not repaired in time Repair
The breather plug blocked Cleaning and interpenetrating
Out of gear Gear sleeve or combination tooth severely worn Replacement
Control mechanism improperly installed or Check, adjustment or replacement
damaged
Fork deformed severely or worn Replacement
Set spring or steel ball deformed severely or Check and replacement
damaged
Gear axial clearance too large Check and adjustment
Gear shifting Interlock pin lost or damaged severely Replacement
abnormal
Bearing abnormally Lubricating insufficient or lubricant rejected Check and replacement
ineffective
Lubricant too dirty Replacement
The cleaning of each part in the box not perfect Cleaning
Bearing quality rejected Replacement

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.

transmission － Disassembling of the transmission MT-5
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.
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.

(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.

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.
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.

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

(a) Take out the 5th reverse gear shift fork and 1st and 2nd
gear shift fork interlock pin and interlock guide column
with bar magnet.
(b) Remove the 1st and 2nd gear shift fork location bolt.
(c) Remove the 1st and 2nd gear shift fork.

(d) Take out the short interlock pin between the 1st and 2nd
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 2nd
gear and 3rd and 4th gear fork.
(a) Knock out the elastic pin with tip drift pin and hammer.
(b) Take out the 3rd and 4th shift fork and the 1st and 2nd gear
and 3rd and 4th gear fork.

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.
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.

(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.
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

SST 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.

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.
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.
Pressing
loosening

MT-12 transmission － Input shaft assembly
Input shaft assembly

Part drawing
Needle bearing
Input shaft
Bearing
Bearing stop ring
Retainer
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

transmission － Input shaft assembly MT-13
2. Prize out the input shaft bearing with forcing machine
3. Install the new bearing with forcing machine and special

serrice tools.
SST
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

MT-14 transmission － Output shaft assembly
output shaft assembly

Part drawing
3rd and 4th gear synchronizer engagement sleeve
Synchronizer sliding block 3rd and 4th shift gear needle bearing
Synchronizer
spring piston ring
3rd shift gear set
Synchronizer ring Steel ball

Steel ball
Shaft retainer
3rd and 4th synchronizer hub
Output shaft
1st shift gear bush
1st and 2nd gear synchronizer engagement sleeve Rear bearing stop ring
of the output shaft
Synchronizer sliding block 1st shift gear set
Spring piston ring
2nd shift gear needle bearing
Output shaft rear bearing
1st shift gear needle bearing
1st and 2nd gear synchronizer ring
1st and 2nd gear synchronizer ring
2nd shift gear set

Odometer drive gear retainer
Odometer drive gear

5th shift gear shaft retainer
5th shift gear

transmission － Output shaft assembly MT-15
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, 1st
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.
5. Remove the 1st and 2nd gear synchronizer assembly, 2nd

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.

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

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.
Inspection of the output shaft assembly

3 Shift
1. Measure the axial clearance of each gear
Measure the axial clearance of each gear:
1st , 2nd , 3rd gear: (0.1-0.25)mm
1 Shift 2 Shift
2. Measure the axial play of each gear

Measure the radial clearance of each gear with dial gauge.
Allowable clearance (mm)
st
1 shift gear 0.009-0.032
2nd and 3rd shift gear 0.009-0.033
If the clearance exceeds the above limit, replace the gear, needle
bearing or shaft.
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

(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.
nd
At 2 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.

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 3 rd shift gear set and 3 rd and 4 th 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 3 rd shift gear set and 3 rd and 4 th gear

synchronizer with forcing machine.

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

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.
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.
SST
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.

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

Measure the axial clearance of the 1st shift gear with clearance
gauge.
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-22 transmission － Intermediate shaft assembly and reverse gear idler assembly
Intermediate shaft assembly and reverse gear idler assembly

Part drawing
Front bearing stop ring Intermediate shaft rear bearing

of the intermediate shaft Intermediate gear shaft Rear bearing stop ring of the intermediate shaft
Steel ball
Intermediate shaft front bearing
Reverse gear idler shaft
Reverse gear idler set
Reverse gear idler shaft clamping plate

Front shaft retainer of Synchronizer sliding block
the intermediate shaft 5th gear synchronizer engagement sleeve
5th gear needle bearing
5th shift coupling gear
Spring piston ring

5th shift gear thrust washer
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

transmission － Intermediate shaft assembly and reverse gear idler assembly MT-23
3. Check the journal diameter at the intermediate shaft 5th

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.
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

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.
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
Front 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

transmission － Rear housing assembly MT-25
Rear housing assembly

Part drawing
Rear housing set
Rear housing dust cap

Limit mechanism set
Rear housing oil seal subassembly
Guide oil groove

Set spring screw plug and elastic straight pin
Reservoir
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
SST
Replacing the bush

Replace the bush if necessary
SST
(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 mecha-

nism 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.

transmission － Rear housing assembly MT-27
(c) Coat sealant on the screw plug thread.

(d) Fasten the screw plug with torque socket wrench.

MT-28 transmission － Bearing front cover
Bearing front cover

Part drawing
★ Front cover assembly
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
Oil seal pressing in depth
13 ± 0.4mm

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

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.
6. Install the reverse gear rocker bracket set

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

7. Install the steel ball and 5th shift gear thrust washer.
Lock ball
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.
(d) Align the synchronizing ring groove with the sliding block,
Socket wrench
and install the 5th shift coupling gear with forcing machine.
(e) Place the middle coupling plate on the leg vice.

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.
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 2nd , 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)

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 1st
and 2nd gear shift fork and middle coupling plate.
(d) Install the 1st and 2nd gear fork set bolt, and screw down
the bolt.
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.

(d) Encase the long interlock pin into the middle coupling
(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 th
reverse gear shift forked axle.
(a) Encase the 5th reverse gear shift guide block into the 5th
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.
(e) Encase the interlock steel ball into the middle coupling
(f) Encase the 5th gear shift forked axle into the middle
coupling plate.

(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 5th
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.
16. Install the gear shift forked axle grip ring

Encase the grip ring with steel bar and hammer.

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
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
sealing material 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.

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.
21. Install the rear housing, gear shift shaft and gear shift
sealing material 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.
Remark: the installing way of the four wheel drive is the same
with the above.

(f) Install and fasten the gear shift block set bolt.
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
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)
25. Install the shift cover of the transmission
(a) Install the shift cover coated with sealant.
(b) Install 6 bolts, and fasten the bolts.
26. Install the clutch housing
(a) Install the clutch housing.
(b) Coat sealant on the bolt thread.
(c) Install and fasten 9 bolts.
27. Install the reverse gear switch
28. Install the odometer driven gear
(a) Install the odometer driven gear
(b) Install and fasten the bolt.

TF-1
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
TF
Attached list on parts inspection, repair and replacement stan-
dard ........................................................................ TF-19
The assemblage of the transfer case .......................... TF-22

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.

Transfer case — Trouble shooting TF-3
Trouble shooting
Common trouble Causes Eliminating methods
Electric shift trouble Electrical control element, electrical Refer to vehicle operation manual, and
control module, speed sensor, diagnose the ineffective element and
electrical motor, electrical clutch or replace it as required.
inner connection harness damaged or
ineffective
Shift cam, connecting sleeve, lock Disassemble and check worn or damaged
sleeve, fork or shift guide shaft part. Replace it as required.
damaged or worn.
Shift fork, lock sleeve or gear glued. Disassemble and check the sliding part
could move freely. Replace it as required.
Mechanical shift not Shift rocker or shift connecting bar Replace the damaged parts.
realized (when the shift broken or damaged.
handle is moving) Shift cam guide plate damaged; shift Open the transfer case rear cover, check
fork broken. the damaged parts and replace them.
Mechanical shift difficult or Incorrect operation. Refer to vehicle operation manual, and
putting into gear not to the operate correctly.
specified position Lubricant improper or the amount Fill specified oil product or amount.
insufficient
Shift fork glued. Open the transfer case rear cover, check
and replace the damaged parts.
Sliding connecting sleeve, lock sleeve Open the transfer case rear cover, check
or gear glued. the sliding parts could move freely on the
shaft, disassemble and replace the
damaged parts.
Mechanical shift transfer Shift connecting bar mechanism Adjust or repair shift connecting bar
case out of gear damaged or improperly adjusted. mechanism.
Replace the parts severely damaged.
Inner shift parts damaged or severely Replace loosened or worn parts.
worn, shift fork assembly loosened
on the guide shaft or damaged.
Mechanical shift blocked at Shift connecting bar mechanism Adjust or repair shift connecting bar parts.
a certain position improperly adjusted.
Shift fork loosened too greatly on the Open the transfer case and check the fork
shift guide shaft. and guide shaft, and replace the parts as
required.
Shift fork assembly worn, including: Open the transfer case to check the parts
pin and contact roller. are worn, replace the parts if they are
worn.
Shift cam hub and bush worn. Open the transfer case to check the parts
are worn, replace the parts if they are
worn.
Combination tooth damaged. Open the transfer case to check the parts
are worn, replace the parts if they are
worn.

TF-4 Transfer case — Trouble shooting
Troubleshooting (continued)
Common trouble Causes Eliminating methods
No front wheel drive when Driving chain broken. Disassemble and check the damage condition
putting into four wheel drive of the inner parts, and replace the chain.
Noise with all gears, the Incorrect lubricant or lubricating Replace lubricant or refill the amount as
noise is from the transfer amount insufficient. required.
case not from the clutch, Connecting bolts loosened or Ensure that the torque of all connecting parts
engine, drive shaft or other other connecting parts loosened. reaches specified value.
parts. Noise with transfer case bearing 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.
Noise with all gears, the Gear noise. Open and check there are worn or damaged
noise is from the transfer parts (including odometer gear), replace them
case not from the clutch, if worn or damaged parts are found.
engine, drive shaft or other
parts.
Noise at high gear and low Sprocket wheel or chain Open and check there is abrasion or damage,
gear of four wheel drive damaged or worn. and replace the parts if abrasion or damage is
found.
Tire pressure improper. Regulate the tire pressure to proper.
Leakage with the transfer Transfer case housing broken. Replace the housing.
case Leakage with other parts. Prove that it is actually the leakage of transfer
case.
Dry it and check the leaking condition.
The breather pipe blocked. Open and clean, and replace it if necessary.
Lubricant amount more than the Use specified lubricant and regulate to proper
required or the lubricant brand amount.
improperly chosen.
Sealing surface bolt loosened. Screw down the bolt as required.
Different brands of sealer or Use specified sealer and screw down the bolt
unusable sealer. as required.
The oil seal worn or damaged Replace the oil seal.

Transfer case － Product instruction and simple maintenance TF-5
Product instruction and simple mainte-

nance
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
Borg Warner product assembly type
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
The transfer case assembly
are driven, and the drive ratio of the transfer case
number of the manufacturer is 1:1.
l 4H-at four high gear positions, foul wheels are all
Borg Warner product assembly serial number driven, and the drive ratio of the transfer case is
Manufacturing date 1:1.
l N – neutral position (only manual shift transfer case
Display: group number has this gear position), output shaft and input shaft
Display: the last number of year
are disconnected, and no power is passed to the
Display: specific manufacturing date of each month
Display: month wheel.
January (A) to December (L) l 4L-at four low gear positions, foul wheels are all
Example indication:
driven, and the drive ratio of the transfer case is
July 1, 1989, second group
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.

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 filler plug

Oil drain 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.
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.
(g) Refill lubricant from the oil hole until the oil flows out.
Install and screw down the oil filler plug as required
torque.

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

3 4
2
1
9 8
1.Input shaft 2. Transfer case front housing
5
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
1. Disassembling of the transfer case is n ot allow ed to h ang dir ectly on the

(a) Drive the vehicle to appropriate lifting jack. transmission through spline shaft, which will
(b) Put the transmission gear position at neutral cause the damage of the transfer case parts.
position, and shift the transfer case to 2H gear (l) Remove the connecting nut between the
and extinguish the engine. transfer case and transmission, and take down
(c) Disconnect the battery cathode. the transfer case.
(d) Lift the vehicle. (m) Directly remove the transfer case backwards
(e) Place the drip pan under the transfer case, and until the spline connection of the transfer case
dismount the transfer case oil drain plug and oil input shaft and the transmission is completely
filler plug to discharge all the lubricant, and then uncoupled.
install two oil plugs over again. (n) Lower the transfer case lifting jack carefully.
(f) Disconnect all the wires and wire harnesses (o) Remove the shim between the transfer case and
related to the transfer case. transmission. Clean up the shim material or glue
(g) Disconnect the odometer connecting wire. on the junction plane of transfer case front
(h) Disassemble the hose on the breather valve of housing and transmission rear housing. Pay
the transfer case. attention not to damage the junction plane.
(i) Uncouple the connection of the front drive shaft 2. Installation of the transfer case
with the transfer case front flange plate. (a) Use a thin sleeve (filled with grease) to coat
(j) Uncouple the connection of the rear drive shaft grease on the transmission output shaft spline.
with the transfer case rear flange plate. (b) Install a new shim on the transfer case
(k) Support the transfer case with lifting jack. installation surface.
Note: before removing the bolts and nuts (c) Lift the transfer case lifting bracket and align
connecting the transfer case and transmission, on the same axial line with the transmission.
ensure that the transfer case is completely Note: before connecting the spline, ensure that
supported by the lifting jack. The transfer case t h e t r an s f e r c a se i s a l i g n e d w i t h t h e

TF-8 Transfer case － Disassembling and assembling of the transfer case
transmission. Do not force the transfer case (k) Fill correct brand lubricant.
spline to press into the transmission. Otherwise, Note: in engine starting, not filling correct lubricant
damage may be caused. Rotate the transfer rear and appropriate lubricant amount as required will
output shaft if necessary to make it align with cause the damage of the transfer case.
the spline. Note: when filling oil to the transfer case having
(d) Move the transfer case forward slowly to make been installed on the vehicle, you must use petrol
the transmission input shaft spline and the pin feed pump.
to the transfer case front housing, shim and Note: if the transfer case is removed to repair or
transmission rear housing be jointed completely. check, there will be no oil in the oil duct lubricated
(e) After ensuring that the installation holes of the through the oil pump on the upper part of the
transfer case front housing, shim and the transfer case.Controlling the oil amount depending
transmission rear housing are in alignment, on the opening of the oil filler plug will not be
install the bolt or nut. accurate until the oil pump rotating oil duct is filled
Tightening torque: (35-48)N·m up.If the wheel could be rotated, this could be done
(f) Connect the rear drive shaft and transfer case on the vehicle lifting jack.Recheck the oil level after
rear output flange plate. the oil pump rotating.
(g) Connect the front drive shaft and transfer case
front output flange plate.
(h) Connect the breather valve and breather hose. (l) After inspecting the lubricant, lower the vehicle
(i) Connect the odometer cable at the transfer case and connect the battery cathode.
rear cover.
(j) Connect all the wire harnesses related to the
transfer case.

Transfer case － Disassembling of the transfer case TF-9
4
2 Disassembling of the transfer case
1 1. Simple instruction
5 As to the transfer case, if only the damaged part is repaired,
disassemble the transfer case to the extent that this damaged
3
part could be taken out. The part disassembled from the transfer
case could be either subassembly or full group, and it is not
6 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
1.Transfer case rear housing
(a) Fix the flange plate, screw off the nut and take down the
2.Flange plate 3.Oil seal
shim, and then remove the flange plate and oil seal.
4.Shim 5.Nut
6.Oil plug (b) Take down two oil plugs from the housing.
1 For electric shift transfer case, remove the electric shift

2
parts. Disassembling steps As follows:
(a) Remove the bolt, shim, three bolts and sensor and harness
7
clips.
3 (b) Remove sensor assembly, and take off O ring from speed
5
4 sensor.
(c) Remove motor assembly.
6
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

TF-10 Transfer case － Disassembling of the transfer case
8 9
11
1.Transfer case front housing
2.Rear output shaft
7 6
3.Clutch coil assembly
5 10
4 4.Snap ring
3
5.Bearing
6.Nut
2
7.Transfer case cover assembly
12
1 13 8.Sign panel
9.Bolt
16 14
7 10.Odometer drive gear
17
15 11.Oil seal
12.Oil seal
13. Bearing
18 14.Transfer case rear cover
15.Needle bearing
16.Shift guide shaft
9 17. Return spring
18.Magnet
19 19.Harness clip
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.
1
(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.
2 6
5 (e) Pluck out the needle bearing from the transfer case rear
4 cover.
3 (f) Pluck out the oil seal from the transfer case rear cover.
(g) Dismount the magnet from the transfer case front
housing.
9
(h) Remove the return spring from the shift guide shaft.
10
(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.
1.Output shaft 6.Snap ring 4. Dismount the connected front axle shift parts
2.Shift engagement 7.Clutch assembly
Remove the following parts from residual transfer case housing
sleeve assembly 8.Tightening snap ring
assembly (electric shift).
3.Lock sleeve 9.Shift guide shaft
4.Return spring 10.Fork (a) Electric shift assembly, remove the snap ring and sliding
5.Engagement sleeve clutch bush from shift lock hub.

2 (b) Remove the shift lock hub from rear output shaft.
(c) Remove the shift engagement sleeve assembly and shift
1 fork from rear output shaft and shift guide shaft.
5 Disconnect all assemblies and remove the shift guide
3 4
shaft.
(d) Disassemble shift engagement sleeve assembly, and take
7 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.
1.Output shaft 2.Drive sprocket 5. Dismount the chain driving system
3.Driven sprocket 4.Washer Remove the following parts from residual transfer case housing
5.Snap ring 6.Driving chain assembly.
7.Front output shaft (a) Remove the snap ring and washer from front output
shaft.
(b) Remove the drive sprocket, driven sprocket and driving
7 4 chain together from two output shafts.
5
(c) Separate the sprocket from the chain.
6
6. Dismount the oil pump assembly
3 Remove the shaft and pump assembly from residual transfer
2
case housing assembly. Remove the pipe clip, oil piper and
filter.
1.Filter 5.Output shaft

2.Oil pump hose 6.Pump pin
3.Clip 7.Output shaft and
4.Oil pump assembly pump assembly
7. Disassembling of the decelerating shift parts

1 Remove the following parts from residual transfer case housing
2
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
6 3 decelerating shift fork assembly, disassemble the
4
1.Decelerating hub 5 decelerating shift fork assembly. Cut the plastic sleeve,
7
2.Shift fork veneer and take down the pin and contact roller.
3.Contact roller
4.Pin
5.Pin and contact roller assembly
6.Decelerating shift fork
7.Decelerating shift fork assembly

TF-12 Transfer case － Disassembling of the transfer case
8. Front output assembly

4
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.
3 2 (b) If the replacement needs, press down the dust cap from
1 the front flange plate
(c) Remove the front output shaft
6 5
7
8
1.Flange plate 2. Dust cap
3.Flange plate assembly
5.Front output shaft 6.Oil seal
7.Washer 8.Nut
9. Dismount the front housing, input shaft assembly and

planetary mechanism assembly.
7
10 Remove the following parts from residual transfer case housing
9
8 assembly.
1 6
5 (a) Remove the breather valve.
4 (b) Remove 6 bolts. Separate the front housing from the
3
transfer case housing, and take down the front housing
16
(take care not to damage the front end cover and transfer
2 case housing).
11 15 (c) Remove the front housing assembly, input shaft assembly
14
and planetary mechanism assembly as groups (loosen
13
12 the snap ring, and remove the input shaft from the front
17
18 end cover).
(d) On the work bench, hold one end of the input shaft, and
19 extend the long end of the snap ring and gently press the
20
front housing, and the front housing assembly could be
disassembled from the residual assembly in this way.
1.Planetary mechanism 12.Oil seal (e) Remove the snap ring and oil seal from the front housing.
assembly 13.Anchor pin Remove the pin only when it needs replacing.
2.Shim 14.Transfer case front (f) After removing the bearing closing ring, remove the
3.Snap ring housing
bearing and shim from the input shaft assembly end.
4.Thrust button 15.Snap ring
Remove the input shaft assembly from the planetary
5.Sun gear 16.Transfer case front
6.Planet carrier housing mechanism assembly.
7.Input shaft assembly 17.Bearing (g) Remove the needle bearing and bearing shell from the
8.Input shaft 18.Bearing closing ring input shaft assembly.
9.Needle bearing 19.Bolt (h) Remove the snap ring, thrust button and sun gear from
10.Bearing shell 20.Breather hole
the planet carrier assembly.
11.Transfer case front
(i) Do not try to disassemble the planet carrier.
housing assembly

1 10. Disassemble the shift flange parts (for electric shift

4 transfer case)
3
(a) Remove the electric shift cam set as a whole from the
2
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.

2.Shift guide shaft 3.Torsion spring
4.Electric shift 5.Shim
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
5
4 housing only when the pin is loosened or damaged.
3 (d) Press out the ring gear from the transfer case housing if
2 1
the ring gear needs replacing.
1.Transfer case front housing assembly
2.Ring gear 3.Oil seal
5.Anchor pin 6.Ball bearing
7.Snap ring

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.

Transfer case － Cleaning, inspection, repair and replacement TF-15
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.
Normal gear shaving mark
Normal gear grinding mark

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.

(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.
(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.

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.

(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 Inspect cracks, contorts and corrosion Reject all parts with cracks
springs) Reject the parts with bends, contorts
and poor circle jumps
Reject all parts with pitting corrosion or
corrosion
All thread parts Inspect the dropout or other damages Reject the parts that could not be screwed
with the thread or without threading
Flange plate Refer to “Inspection” section to inspect Refer to spline inspection in“Inspection”
the spline section
Speed sensor, motor assembly Refer to electrical equipment part Replace parts as required
Parts of electric clutch
Sliding bearing Check the inner surface condition of Reject if there is pitting corrosion or
the sliding bearing damage
Transfer case housing Check the hole matching with the Abandon if there is pitting corrosion or
bearing damage

Attached list on parts inspection, repair and replacement standard

Ball bearing Visually check there is flaking, pasting, Reject damaged bearing
pitting corrosion or other damages with Reject damaged or loosened bearing
the ball and ball race of the bearing. Or check the axial clearance exceeds
Be certain that the bearing has been 0.23mm
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, Reject damaged bearing
pitting corrosion or other damages with
the needle and ball race of the bearing.
Transfer case rear cover, front Check there is burrs or other damages Refer to “Inspection” section to remove
housing and transfer case front obstructing sealing the burrs or replace the dam aged parts
housing
Transfer case rear cover Check the bearing hole Reject if there is pitting corrosion with
the hole
Odometer gear Refer to “Inspection” section to inspect Refer to inspection of gear or sprocket
the gear tooth tooth in “Inspection” section
Transfer case outer Refer to “Inspection” section to inspect Refer to spline inspection
housing,connecting outer sleeve the spline in“Inspection” section
and connecting sleeve
Lock sleeve Check the abrasion or damage condition Reject if step slipping or damage is
of the fork groove Refer to “Inspection” found
section to inspect the spline
Shift guide shaft Check the deformation condition Reject if it bends, and refer
Check the outer circle burrs or other to“Inspection” section to remove burrs,
damages or reject the damaged guide shaft
Check the abrasion condition of the outer Reject if step slipping or damage is
circle found
Shift fork Check the part that the fork matching Reject if step slipping or damage is
with the shift cam and gear sleeve is worn found
of damaged
shift fork assembly Check the abrasion or damage condition Reject this veneer if abrasion or
of the fork veneer matching with the gear damage of thestep is found If the
sleeve contact roller is hard to rotate or it is
Check the contact roller could rotate damaged, use new pin, contact roller
freely or it is damaged and holder assembly
Drive and driven sprocket Refer to “Inspection” section to inspect Refer to inspection of the sprocket
the sprocket tooth tooth in “Inspection” section
Refer to “Inspection” section to inspect Refer to spline inspection
the sprocket spline in“Inspection” section


Driving chain Check the step slipping, loosening or the Reject the drive sprocket with abrasion or
damage of the pin or connecting parts damage
Filter screen Check the filter screen is clean and there is Clean it if necessary; abandon if it is damaged
hole or damage with it
Pump case Check there is pitting corrosion or step Abandon if the pump case is damaged or
slipping with the inner diameter of the pump excessively worn
case
Oil pump pin Check the pitting corrosion condition Abandon if there is abrasion, pitting corrosion
or damage with the pump case
Output shaft Refer to “Inspection” section to inspect the Refer to spline inspection in “Inspection”
spline section
Check the surface condition Reject if there is pitting corrosion or damage
Reject if it bends or poor circle jump with it
Decelerating hub Refer to “Inspection” section to inspect the Refer to spline inspection in “Inspection”
sprocket spline section
Check the abrasion or damage condition of the Reject if step slipping or damage is found
position matching with the fork
Front output shaft Check the surface condition matching with the Reject if there is pitting corrosion or damage
bearing
Refer to “Inspection” section to inspect the
spline
Input shaft Refer to “Inspection” section to Refer to spline inspection in“Inspection”
inspect the spline section
Check the contort condition Reject if it bends or poor circle jump with it
Thrust plate and Check the pitting corrosion condition Reject if there is pitting corrosion or damage
thrust button
Sun gear Refer to “Inspection” section to inspect the Refer to inspection of the gear tooth in
gear tooth “Inspection” section
Refer to “Inspection” section to inspect the Refer to spline inspection in“Inspection”
spline section
Planetary Refer to “Inspection” section to inspect the Refer to inspection of the gear tooth in
mechanism gear tooth “Inspection” section
assembly Check the abrasion of the planetary shaft pin Reject if step slipping or pitting corrosion is
or it is loosened and the abrasion condition of found
the thrust plate
Electric shift cam Check there is pitting corrosion or step Reject if pitting corrosion or step slipping is
slipping found
Shift guide shaft Check there is pitting corrosion or step Reject if step slipping or pitting corrosion is
slipping found
Check the contort condition Reject if it bends
Planetary ring gear Check the matching condition with the Check the transfer case housing assembly to
transfer case housing see whether the ring gear is loosenedin the
Refer to “Inspection” section to inspect the housing
gear tooth Refer to inspection of the gear tooth in
“Inspection” section

TF-22 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
Install the parts removed from the transfer case housing, the
7
6 process is as follows:
5
4 (a) If the ring gear is replaced, when pressing into new ring
3 1 gear, align the tooth shape protuberance of the new ring
2
gear with corresponding gullet in the transfer case front
housing, and press into the ring gear as shown in the
2.Ring gear 3.Oil seal lower left drawing, and the chamfer end enters first.
4.Transfer case front housing Ensure the ring gear does not upwarp and it is tightly
5.Anchor pin 6.Ball bearing fixed in the housing.
7.Snap ring (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
2 3 and well install the snap ring.
105 1 (d) Place the new oil seal as shown in the lower left drawing
and press it into the housing.
1.Oil seal 2.Transfer case front housing

3.Ring gear 4.Anchor pin

Transfer case － The assemblage of the transfer case TF-23
4. The assembling of mechanical shift flange parts ( electric

shift transfer case)
2
4
For electric shift parts assembly, the installing process is as
follows:
1 3
(a) Insert the shim into the inner diameter of the torsion
spring and make it run through the free end of the shift
shaft.
1.Shift guide shaft 2.Torsion spring

3.Electric shift flange 4.Shim
(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
1
from the free end of the shift shaft).
1.Torsion spring
2.Shim
3.Shift shaft
(c) Twirl the second finger tip of the torsion spring on the
shift shaft to the right end of the drive tongue.
1
3
2
1.Torsion spring 2.Shim 3.Shift shaft

(d) Try your best to push the torsion spring and shim
1 backwards together.
(e) Install the electric shift cam on the shift shaft, and make
the end with drive tongue on the cam enter first. Fix the
2 drive tongue of the cam under the drive tongue of the
shift shaft and make it between two torsion springs at
the same time, and make it enter as interior as possible.
3 (f) then encase the electric shift cam assembly into the
transfer case housing assembly.
1.Torsion spring 2.Shim 3.Shift shaft
5. The assembling of the front housing, input shaft

7 assembly and planet set
10 Install the following parts on the work bench:
9
8
1 6 (a) Put the planet carrier assembly on the work bench with
5 the snap ring groove end toward upward.
4
3 (b) Encase the sun gear with the protuberant end toward
16 upward. Rotate the planet carrier assembly gear until
the sun gear is completely meshed.
2 (c) Align the protuberant teeth, and encase the thrust button
11 15
14 into the planet carrier assembly.
13 (d) Encase the snap ring and finish the whole planet carrier
12
17 assembly.
18
19
20
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
12.Oil seal 13.Anchor pin
15.Snap ring 16.Transfer case front housing
17.Bearing 18.Bearing closing ring
19.Bolt 20.Breather plug

(e) If the parts are removed, place the needle bearing as

1.25-1.75mm shown in the drawing and press into the input shaft. At
the same time, press into the new sliding bearing as shown
in the drawing to finish the whole input shaft assembly.
(f) Lift the planetary mechanism assembly and encase it
into the input shaft assembly, and encase the thrust plate
and press into the bearing through the end of the input
shaft. Encase one snap ring into the snap ring groove of
1 2 3 the input shaft and fix the bearing.
1. Needle bearing
2.Rolling bearing
3.Input shaft
(g) If the parts are removed, press new anchor pin into the
3 front housing, the pressing size is as shown in the
12.70mm
drawing.
(h) Place the oil seal as shown in the drawing and press the
oil seal into the front housing.
2
(i) Place the front housing assembly on two wooden blocks
with the housing junction plane toward upward to make
1 clearance between the output shaft assembly and work
bench. Place the assembled input shaft assembly and
planetary mechanism assembly in the front housing to
4
make the input shaft toward downward. Extend the long
1. Anchor pin end of the snap ring, and encase input shaft and planetary
2.Oil seal
mechanism assembly until the snap ring enters into the
4.Snap ring
snap ring groove of the bearing outer ring.
(j) Coat sealer of 1.6mm thickness on the junction between
the front end cover and transfer case assembly, and
pass by the thread hole when coating and continue
4
without intermittence at the same time.
(k) Screw down 6 bolts.
(l) Install the breather valve.
3 2 6. The assembling of the front output shaft
1 Assemble the following parts:
9 (a) If the dust cap is removed, encase it by pressing.
(b) Put the output shaft in the transfer case front housing,
5 and then install the flange plate assembly, seal ring, washer
6
7 and nut.
8
1. Flange plate 2. Dust cap
(c) Insert into the flange plate hole with torque lever T-13-
3. Flange plate assembly 54-002 and screw it down.
4.Transfer case front housing Tightening torque: (203-244)N·m
5.Front output shaft 6. Seal ring
7.Washer 8.Nut 9.Oil seal

7. The assembling of the decelerating shift parts.

2
The installing process of parts is as follows:
(a) If the disassembled parts are replaced, assemble the shift
1
fork assembly with new pin contact roller assembly.
Press the pin contact roller assembly into the decelerating
fork hole until the pin is completely through and clipped
3 at position. Ensure the contact roller could rotate freely.
(b) Install two fork veneers on the decelerating fork
assembly.
6 7
1.Reduction gear 8
(c) Combine the decelerating fork assembly with the
5
2.Output shaft 4 decelerating gear sleeve and put them in the housing,
3.Fork veneer and put the decelerating gear sleeve in the above
4.Decelerating shift fork assembly assembled planetary mechanism assembly. Install rear
5.Pin, contact roller and bush assembly
output shaft, and combine the end bearings of the input
6.Decelerating shift fork
shaft and output shaft with the spline of the decelerating
7.Contact roller
8.Pin gear sleeve.
Remark: the assembling of output shaft can be delayed after
the oil pump being installed on the output shaft. Immerse oil
7 4 pump filter screen into the lubricant, and rotate the output
5
shaft clockwise (seen from the rear end of the output shaft),
6 and see whether there is oil from the oil pump to check the oil
3 pump operates normally. Encase the assembled parts as an
assembly into the transfer case housing.
2
8. The assembling of the oil pump
Ensure the oil pump parts are lubricated completely in
1
assembling, and ensure the oil could flow out from the tapered
hole of the oil pump front cover. The installing process of oil
1.Filter 2.Oil pump hose pump is as follows:
3.Clip 4.Oil pump assembly
(a) Install the pin on the rear output shaft.
5.Output shaft 6.Pump pin
7.Output shaft and pump assembly
(b) The oil pump assembly is fixed on the rear output shaft
through the pin.
(c) Put the clip at the end of the oil pipe, and install the oil
pipe on the pump case nozzle tip, and screw down the
2
clip.
9. The assembling of driving chain
1 The assembling process of parts is as follows:Łş
5 (a) On the work bench, after assembling the transfer case
3 4
housing assembly, put the drive sprocket on the rear
end of rear output shaft, and put the driven sprocket on
7 the rear end of front output shaft.
(b) Install the chain on the sprocket.
6 (c) Hold two sprockets and make the chain be close to the
sprockets, put them parallel to the transfer case, and
1. Output shaft 2. Drive sprocket encase the chain and sprocket assembly through the
3.Driven sprocket 4. Washer output shaft, and rotate the driven sprocket gently to
5.Snap ring 6. Driving chain ensure it is meshed with the spline of front output shaft.
7.Front output shaft
(d) Install the shim and snap ring on the front output shaft.

10. The assembling of the shift lock parts

1
The assembling process of parts is as follows (for electric
shift transfer case):
8
7 (a) Install the return spring, engagement sleeve on the lock
6 sleeve and fix with snap ring to finish 2W-4W lock sleeve
2
5 assembly.
4 (b) Encase the shift guide shaft into the blind hole of the
3 housing through the assembled decelerating fork
assembly.
(c) Install the shift fork on 2W-4W lock sleeve assembly to
9
make the whole assembly slip over the shift guide shaft
10
and rear output shaft.
(d) Joint the rear output shaft spline with 2W-4W shift
engagement sleeve.
1.Output shaft
2.Shift engagement sleeve assembly
3.Lock sleeve 4.Return spring
5.Engagement sleeve 6.Snap ring
7.Clutch assembly 8.Tightening snap ring.
9.Shift guide shaft 10.Fork
2
(e) For electric shift transfer case assembly, encase the
3 4
above assembled electric shift cam set and clutch
Flange groove
housing, and the process is as follows:
(1) Put the electric shift cam set as shown in the drawing.
1 (2) Hold the shift guide shaft toward downward, and gen-
tly lift the fork assembly. Rotate the electric shift cam
set to position to make the contact roller on the decel-
erating fork assembly enter into the groove of the shift
cam, and lock the heave part of the fork at the tail end
of the shift cam. Then lower the set to make it enter
into the transfer case housing, and then joint the shift
shaft on the pin of the transfer case housing.
6 5 (3) Put the clutch housing through shift outer gear sleeve,
1.Electric shift flange 2.Torsion spring and install the snap ring.
3.Shift shaft
4.Decelerating shift fork assembly
5.Shift fork 6.Shift guide shaft

5 11. The assembling of rear cover

4
Install the parts into the rear cover, and the process is as follows:
(a) Put the rear cover on appropriate press machine with the
3 junction plane toward upward and parallel to the working
2 surface of the press machine.
1
6 (b) Put the needle bearing end with mark upwards, and press it
7
into the rear cover until the upper end of the needle bearing
is lower (40.47-40.97)mm than the rear cover junction plane
matching with the front housing.
(c) Press the ball bearing into the rear cover, and install the
8 snap ring.
1.Clutch coil assembly 2.Snap ring (d) Only for electric shift transfer case, encase the parts as the
3.Ball bearing 4.Rear cover assembly following processes:
5.Nut 6.Oil seal (1) Ensure 4 O rings are all put on the position of the clutch coil
7.Bearing 8.Needle bearing
assembly (one on the coil, three on the pillar bolt). Encase
the clutch coil assembly with the wire and pillar bolt
1 extending out the rear cover, and take care not to damage
1.Bolt 7
9 the wire, and install three nuts and screw down.
2. Harness clip 6
3.Magnet Tightening torque: (8-11)N·m
4. Return spring 8 (2) Encase the motor bearing and oil seal into the rear cover.
5. Shift guide shaft 12. The assembling of rear cover
5 Install the above finished cover assembly into the transfer case
4 housing, and the process is as follows:
(a) Install the return spring on the transfer shift guide shaft.
3 (b) Install the magnet on the groove of the housing.
(c) Coat Loctite 598 with thickness of 1.6mm on the junction
10
plane of the housing, and pass by the thread hole when
coating and continue without intermittence at the same time.
2
1
Note: in the following steps, do not try to buckle the rear
6. Rear cover assembly
7. Sign panel
cover on the transfer case front housing with too much
8.Odometer drive gear force. When the alignment conditions required are met,
9. Oil seal the rear cover can be installed on the front housing
10. Transfer case front housing without too much force. If it could not be installed, take
down the rear cover assembly and check the alignment
6 conditions.
4
5
3 (d) When the rear cover assembly is installed on the transfer
2 case front housing, all the following alignment conditions
1
must be met:
a Align the pin of the housing with the pin hole of the rear
cover.
b Align the rear output shaft with the inner bearing of the
rear cover hole.
c Align the inner blind hole of the rear cover with the shift
guide shaft, and ensure the return spring does not upwarp.
1.Anchor pin 2.Front output shaft Check the hole of the speed sensor on the rear cover with a
3.Shift shaft 4.Return spring pen.
5.Shift guide shaft 6.Output shaft
d Align the shift shaft with the rear cover inner bearing.

(e) After putting the sign panel, screw down 9 bolts.

2 Tightening torque: (27-46)N·m
1
(f) Encase the odometer drive gear into the rear cover
assembly through rear output shaft spline.
(g) Press new oil seal into the rear cover assembly.
3
4
1.Harness clip 2.Motor assembly

3.Bolt 4.Sign panel
13. Installing the outer electric shift parts (electric shift

1 transfer case)
For electric shift transfer case, the installing process is as
follows:
(a) Place the motor assembly, the triangular groove on the
motor will be in alignment with the shift shaft.
1.Motor assembly
2.Shift shaft
(b) Move the motor to combine with the shift shaft and make
1 2 it joint tightly with the rear cover. Then rotate the motor
clockwise until it is in correct position and aligned with
7 the installation hole.
3 (c) Install O ring on the speed sensor and encase the speed
5 sensor assembly into the rear cover. Install the clip on
4
the upper part of the speed sensor and install three bolts.
6 Tightening torque: (8-11)N·m
(d) Install the bolt and shim at the clip end of the motor.
8
1.Sensor fixing bracket 2.Bolt

3.Speed sensor 4.O ring
5.Sensor assembly 6.Bolt
7.Motor assembly 8.Rear cover assembly

4 13. The assembling of the flange plate parts

2
The installing process of parts is as follows:
1
(a) Install two oil plugs on the rear cover.
5
(b) Encase the flange plate, seal ring, shim and tightening
3 nut.
1.Rear cover assembly 2.Flange plate

3.Oil seal 4.Shim
5.Nut 6.Oil plug .

PR-1
Drive shaft
page
Precautions ................................................................ PR-2

Trouble shooting ......................................................... PR-2
Drive shaft .................................................................. PR-3

PR-2 Drive shaft — Precautions,Trouble shooting
Precautions
Note: do not clip the drive shaft pipe casing too tightly
with leg vice to prevent causing deformation.
Trouble shooting
Trouble Possible causes Eliminating methods
Noise The spline of universal joint fork worn Replacement
Intermediate bearing worn Replacement
Spider bearing worn or bitten Replacement
Vibration Drive shaft run out tolerance Replacement
Drive shaft imbalance Replacement
The rear bearing bushing of the Replacement
transmission extension housing worn
The spline of universal joint fork bitten Replacement

Drive shaft — Drive shaft PR-3
Drive shaft
Part drawing
Drive shaft assembly (2WD)
Sliding yoke assembly
Front part of the rear axle drive shaft
Center support assembly
Spline yoke
Circlip
Rear part of the rear axle drive shaft
Flange yoke
80 ± 5 Nut
78 ± 5
Front axle drive shaft assembly (4WD)

Circlip
Spider assembly
Front axle drive shaft assembly
Flange yoke
78 ± 5
Rear axle drive shaft assembly (4WD)
Circlip
Front part of the rear axle drive shaft
Concave margin yoke

Rear part of the rear axle drive shaft
Spider assembly
80 ± 5
78 ± 5

PR-4 Drive shaft — Drive shaft
Removal of the drive shaft

Firstly remove the center support bolt of the drive shaft, then
remove the connection bolt of the drive shaft and rear axle,
and then
Two wheel drive: Take out the drive shaft assembly from the
transmission output spline shaft, and remove them as a whole.
Four wheel drive: remove the connection bolt of the drive
shaft and transmission, and remove the drive shaft assembly
as a whole.
Installation of the drive shaft

1. drive shaft is damaged, the spline is rusted, and there
is knock or sand hole with the coupling surface etc.
2. Two wheel drive: install the coupling spline bush of the
drive shaft on the transmission output spline shaft
carefully, and then install the center support of the drive
shaft on the center carriage of the frame.
Four wheel drive: link the drive shaft to the transfer case
flange plate with special drive shaft coupling bolt and
nut and spring washer.
3. Link the drive shaft to the axle flange plate with special
drive shaft bolt and nut and spring washer.
4. Tighten the coupling bolt of each drive shaft
Tightening torque: (78 ± 5)N·m
5. Tighten the center support bolt of the drive shaft
Tightening torque: (80 ± 5)N·m

SA-1
Suspension system and vehicle

axle
Page
Trouble shooting ......................................................... SA-2

Front wheel alignment ................................................. SA-3
(2WD)
Front wheel hub and steering knuckle ......................... SA-6
Front wheel hub and steering knuckle(coil spring type) SA-13
Front suspension ........................................................ SA-19
Front suspension(coil spring type) .............................. SA-33
(4WD)
Front wheel hub and steering knuckle ......................... SA-41
Front suspension ........................................................ SA-50
Front drive shaft .......................................................... SA-64
Front reducer .............................................................. SA-74 SA
Rear
Rear axle shaft ............................................................ SA-105
Rear reducer .............................................................. SA-109
Rear differential ........................................................... SA-120
Rear suspension ........................................................ SA-122

SA-2 Suspension system and vehicle axle—Trouble shooting
Trouble shooting
Phenomena of Happened reason Contents of repair
troubles
Swim/drag Tyres have been worn or charged improperly Charge tyres to proper pressure or
change them
Wheel alignment is wrong Check the situation of wheel alignment
Wheel bearing is tightened too much Adjust wheel bearing
Parts on front/rear suspension have been loosened Tighten or change suspension
or damaged
Steering rod has been loosened or worn Tighten or change steering rod
Connector of steering equipments is ineffective or Adjust or repair steering equipments
damaged.
Vehicle body Vehicle has over load. Check load weight
sinks Absorber has been worn Change
Spring is too weak Change
Swing left and Tyres have been charged improperly Charge tyres to proper pressure
right/Flop up and Stabilizer bar is bent or damaged Change
down Absorber has been worn CHange
Front wheels Tyres have been worn or charged improperly Charge tyres to proper pressure or
Shimmies change them
Each wheel is imbalance Make each wheel balance
Absorber has been worn Change
Wheel bearing has been worn or adjustment is Adjust or adjust wheel bearing
ineffective
Ball joint or bushing has been worn Check ball joint or bushing
Steering rod has been loosened or worn Tighten or change steering rod
Steering organization has been damaged or Adjust or repair steering equipments
adjusted ineffectively
Abnormal Tyres have been charged improperly Charge tyres to proper pressure
abrasion of tyres Absorber has been worn Change
Suspension has been worn Change suspension
Oil leaks from Oil level is too high or oil grade is wrong Discharge oil to regulated oil level or
differential change oil
assembly Oil seal has been worn or damaged Change
Companion flange has been loosened or damaged Tighten or change companion flange
Noise in axle Oil level is too low or oil grade is wrong Add lubricating grease or change oil
according to related regulations
Clearance between planetary gear and driven tooth Check the clearance
bevel gear and differential side gear is too big.
Driven tooth bevel gear, planetary gear or Check each gear
differential side gear have been worn or damaged
Pinion bearing has been worn Change
Bearing of rear axle shaft has been worn. Change
Bearing of differential has been loosened or worn Tighten or change the bearing

Suspension system and vehicle axle — Front wheel alignment SA-3
Front wheel alignment

1. Make following inspections to remove all malfunctions
(a) Check whether abrasion and charge of tyres are proper
Charged pressure of tyres: (refer to page PA-4)
(b) Check whether front wheel bearing has been loosened
(c) Check whether front suspension has been loosened.
(d) Check whether steering gearing has been loosened.
(e) Make standard spring test to check whether front
absorber works normally.
2. Adjust the height of vehicle
Adjust the height of vehicle to standard value to check
wheel alignment.
B ＝(270 ± 2)mm(Height with no-load)
B：The height of front fixed bolts on bottom swing
arm apart from horizontal ground
B
3. Install four-wheel locator

Do according to concrete instructions of facility manufactur-
ing factory.
A B B A 4. Adjust angle of wheels

Remove the cover of stop bolt on steering knuckle to check
Front
the steering angle A of inner wheels.
Steering angle of inner wheels£ŗ=32°
Note: when steering wheels are turned to bottom, wheels
should not touch braking soft pipe on vehicle body.
If maximal steering angle does not accord with standard value,

adjust wheel angle by stop bolt on steering knuckle.
If wheel angle could not be adjusted in standard range all the
time, check and change damaged or worn parts on steering
organization.

SA-4 Suspension system and vehicle axle — Front wheel alignment
Kingpin caster angle

5. Adjust camber angle of front wheels and kingpin
Camber angle of front wheels
caster angle
camber angle of front wheels:(refer to page PA-2)
kingpin caster angle: (refer to page PA-2)
Front
If obliquity is not at regulated value, adjust it by increasing or

decreasing shim on upper arm.
Thickness of shim:：3.0、1.5、0.5mm
When shim is increased by 1mm, wheel camber angle changes
7'，and kingpin caster angle changes 20'.
Adjust the difference of left and right kingpin caster angle in
30'.
After adjusting wheel camber angle and kingpin caster angle,
if kingpin inclination angle does not reach regulated value all
the time, check whether steering knuckle and front wheels
Adjustment of front cam
are bent or loosened.
If wheel camber angle or kingpin caster angle does not accord
with regulated value, adjust by front or rear adjusting cam.
Decrease Increase
Adjustment of rear cam
Increase Decrease
6. Adjust wheel toe-in

B
Adjust wheel toe-in by following methods:
(a) Shake vehicle up and down to make suspension reach
the stable statement.
(b) When front wheels locate at the beeline forward position,
impel vehicle for 5 m ahead on flat ground.
Front (c) Mark the center of rear parts on front wheels, and measure
the distance “B” between the marks of left and right tyre.

Suspension system and vehicle axle — Front wheel alignment SA-5
(d) Move vehicle ahead to make the mark on rear part of

tyres move to the height on front part which could be
Move vehicle ahead measured by device.
Remark: if tyres roll too far, repeat step (b).
(e) Measure the distance between the marks on front parts

A of tyres.
(f) Measure the wheel toe-in.
Toe-in=B-A
Testing standard: (refer to page PA-2)
If toe-in does not accord with regulated value, adjust by left
and right tie rod.
(g) When adjusting toe-in, turn the tie rod on left and right
side evenly. After the adjustment, tighten locknut.
Screw-on moment:：(55-65)N·m.
(h) Check sideslip

Sideslip: between ±5m/km

SA-6 Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle
Front wheel hub and steering knuckle

Part drawing
Stabilizer bar
◆ 63 ± 5 ◆ Spring washer
140 ± 10
Upper swing arm Plate braking pliers
Flat washer
◆ Cotter pin
connecting rod of
stabilizer bar Steering knuckle
Locknut
145 ± 15 Stop shim
Flat washer
Lower swing arm
Bush com-
◆
pressed 1/3
Gasket washer 1
◆ Cotter pin Bolt
Rubber cover of
Gasket washer 2 absorber
230 ± 20
Gasket washer 1
Front absorber assembly ◆ 63 ± 5
◆ Spring washer
23 ± 3
90 ± 10 Cover shell of arrester
◆ Oil seal
Bearing
Wheel hub and braking plate

Bearing
N ·m :Specified torque ★ 65 ± 5
◆ Parts no longer for use after service Cover of wheel hu
★ Precoat parts

Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle SA-7
Front wheel hub

Disassembly of front wheel hub
1. Dismantle plate braking pliers
Dismantle braking pliers and hang it with tightwire.
Remark: do not dismantle braking soft pipe and braking pipe
2. Dismantle front wheel hub cover

Unscrew fastening bolts to dismantle wheel hub cover with
inner hexagon wrench.
3. Dismantle front wheel hub and front braking plate

(a) Unscrew lock bolt with cross screwdriver and dimantle
stop shim.
SST (b) Dismantle locknut with special serrive tools.
Brief chart of SST
(c) Dismantle wheel hub, braking plate and exterior bearing.

4. Dismantle oil seal of front wheel hub and inner bearing

(a) Prize the oil seal with screwdriver.
(b) Dismantle inner ring on inner bearing from wheel hub.
Inspection and repair of front wheel hub

1. Check each bearing
Clean inner ring and exterior housing ring on each bearing,
and check whether they have be worn or damaged.
2. Change exterior housing ring of bearing
(a) Hit out exterior housing ring with brass stick and hand
hammer.
(b) Press in new exterior housing ring of bearing with special

serrive tools.
SST Brief chart of special

serrive tools
Installation of front wheel hub

1. Spread lubricating grease on inner surface of wheel
hub and exterior housing ring of bearing.
Lubricating grease Lubricating grease: JinZhi HP-R lubricating grease or other
lubricating greases according to following requirements
Representative
Item
parameters
Dropping point,℃ 289
Lost circulation(104℃,6h),g 0.48
Performance of extreme 178
Lubricating grease
pressure(Timken method)okvalue, N
2. Put inner ring of bearing in
Fill in the clearance between inner ring and exterior ring of
bearing with HP-R lubricating grease.
Lubricating greas

Brief chart of special 3. Install inner bearing and oil seal

serrive tools (a) Put inner bearing in wheel hub.
(b) Hit new oil seal in wheel hub with special serrive tool.
(c) Spread HP-R lubricating grease on lip of oil seal.
4. Install wheel hub on steering knuckle

(a) Install wheel hub on steering knuckle.
(b) Install exterior bearing.
Brief chart of special 5. Adjust pre-load

serrive tools (a) Screw locknut by regulated moment with special serrive
tools.
Screwing moment: (80-100)N·m
(b) Turn wheel hub for 1/3 «1/4 ring to left and right
independently.
(c) Loosen nuts until it could be turned by hand.
SST (d) Tighten locknut again with special serrive tools.
Screwing moment: 28N·m
(e) Check pre-load with spring tensometer.

Pre-load (when starting): (28-56)N
6. Install stop shim

Install stop shim, make the side with counterbore outward,
and fix it on locknut with bolt.
Remark: if the hole for installing bolt on stop shim could not
head the screw thread hole on locknut rightly, dismantle stop
shim, then make a little adjustment for locknut (turn to the
direction whose adjustment is minimal), lastly install the stop
shim.

7. Check pre-load again

Check pre-load again with spring tensometer
If pre-load does not accord with regulated value, it is necessary
to dismantle stop shim and adjust with adjusting nut.
8. Install wheel hub cover

(a) Spread silicon rubber plane sealant on the connecting
surface of wheel hub and wheel hub cover.
(b) Spread screw thread lock sealant on the screw thread of
bolt.
(c) Fix wheel hub on wheel hub with inner hexagon bolt,
and screw the bolt by regulated moment.
Screwing moment: (45±5)N·m
9. Install plate braking pliers

Install plate braking pliers on steering knuckle, and screw it
by regulated moment.
Steering knuckle
Disassembly of steering knuckle
1. Dismantle plate arrester and front wheel hub
(refer to page SA-7)
2. Dismantle cover shell of arrester
3. Take off steering transverse tie rod from steering knuckle

arm
(a) Dismantle cotter pin and nut on sphere pin.
(b) Take off steering transverse tie rod from steering
knuckle arm with special serrive tools.
SST

4. Take off connecting rod of stabilizer bar from lower arm

Fix the sphere pin with inner hexagon wrench, then dismantle
self locking nut.
5. Dismantle steering knuckle

(a) Dismantle cotter pin and nuts on upper sphere pin.
SST (b) Take off steering knuckle from upper sphere pin with
special serrive tools.
(c) Dismantle cotter pin and nut on lower sphere pin.

(d) Take off steering knuckle from lower sphere pin with
special serrive tools.
(e) Dismantle steering knuckle.
SST
Inspection and change of steering knuckle

Check whether steering knuckle has crack with coloration
penetrant. If there is any crack, it is necessary to change
steering knuckle.
Installation of steering knuckle

5. Install steering knuckle
(a) Link lower sphere pin to steering knuckle and install slot
nuts.

(b) Press down upper arm to link upper sphere pin to steering
knuckle, and install and screw nuts by regulated moment.
(c) Install new cotter pin.
Remark: when installing cotter pin, head the notch on nut to
pin hole correctly, at this time, nut must be tight.
(d) Unscrew sphere pin nut by regulated moment.

(e) Install new cotter pin.
2. Link stabilizer bar on lower arm

Support lower arm with jack, fix the sphere pin with inner
hexagon wrench and screw self-locking nut by regulated
moment.
3. Link steering transverse tie rod on steering knuckle arm

(a) Screw slot nut by regulated moment.
(b) Install new cotter pin.
4. Install cover shell of arrester

5. Install front wheel hub and plate braking pliers


Front wheel hub and steering knuckle(coil spring type)

Part drawing
Upper swing arm

◆ Spring gasket Front braking pliers
140 ± 10
Lower swing arm 145 ± 15
◆ Cotter pin
Cover shell of front arrester
◆ Spring gasket
23 ± 3
230 ± 20
◆ Cotter pin
Steering knuckle
◆ Cotter pin
Oil seal
Bearing
Bearing Stop washer

Wheel hub and braking plate
140 ± 10 Anti-loose cover
Cover of front wheel hub
Front wheel hub

Support vehicle frame, and dismantle front wheels
1. Dismantle braking pliers
Dismantle braking pliers and hang it with tightwire
Remark: do not dismantle braking soft pipe.

2. Dismantle the cover of front wheel hub

Dismantle the cover of front wheel hub from the gap touched
by cover and front wheel hub with slot type screwdriver.

(a) Dismantle cotter pin, and take off anti-loose cover.
(b) Unscrew locknut on wheel hub bearing with wrench,
and take off stop washer.
(c) Dismantle the assembly of front wheel hub and braking
plate together with inner and exterior bearing of steering
knuckle.
4. Dismantle oil seal and inner bearing

(a) Dismantle assembly of inner ring and roller on exterior
bearing from wheel hub.
(b) Prize the oil seal with screwdriver.
(c) Dismantle assembly of inner ring and roller on inner
bearing from wheel hub.
Inspection of front wheel hub

1. Inspection and change of bearing
(a) Check each bearing
Clean each bearing, and check whether they have been worn
or damaged.
(b) Dismantle exterior ring of bearing
Hit out exterior ring of bearing with copper stick and hand
hammer lightly.
2. Inspection and change of front braking plate

(a) Check the abrasion of front braking plate.
Remark: there must be no any nick on plate surface, and plate
thickness must be more than 24mm.
(b) Dismantle connecting bolt of front wheel hub and braking
plate with wrench.

(c) Connect front wheel hub with bolts on front braking

plate and new spring washer, and screw to regulated
moment with the moment diagonal wrench
3. Change of exterior ring of bearing

Hit new exterior ring of bearing in carefully with special serrive
tools.
Remark: inner and exterior ring should be changed at the same
SST time.

1. Install inner ring of steering knuckle inner bearing, roller
assembly and oil seal of front wheel hub.
Spread (HR-P) lubricating grease on the inner surface of
SST
exterior ring of steering knuckle inner bearing and the surface
of wheel hub inner chamber (the thickness is 5mm), encase
bearing inner ring and roller assembly.
Spread some (HP-R) lubricating grease on the lip of front
wheel hub oil seal, and press front wheel hub oil seal to the
position with special serrive tools.
2. Install exterior ring of exterior bearing of steering knuckle
Spread (HP-R) lubricating grease on inner surface of exterior
ring on steering knuckle exterior bearing, encase inner ring of
steering knuckle exterior bearing and roller assembly, and
spread (HP-R) lubricating grease to fill in the inter space
between inner and exterior ring of bearing.
3. Install front wheel hub on steering knuckle

Install front wheel hub and front braking plate on steering
knuckle, then install stop washer-exterior bearing of steering
knuckle.
4. Adjust pre-load
(a) Install locknut, and screw with wrench by regulated
moment

(b) Turn wheel hub for 2-3 rings to left a nd right

independently.
(c) Loosen nut until it could be turned by hand.
(d) Tighten locknut again, and tighten bearing in advance.

(e) Bring wheel hub to rotate at constant speed（45/4s）
with instruction sheet torque wrench.
Range of moment when rotating: (1.0-2.4)N·m
5. Install anti-loose cover and cotter pin

Install anti-loose cover and cotter pin, and disjoin the two feet
of cotter pin.
6. Hit cover of front wheel hub in with rubber hammer.
7. Install braking pliers on steering knuckle


Steering knuckle
1. Dismantle braking pliers, front wheel hub and front
braking plate.
2. Dismantle cover shell of front arrester.

Dismantle the connecting bolt of steering knuckle and cover
shell.

arm
(b) Take off steering transverse tie rod from steering knuckle
arm

(a) Dismantle two cotter pins and slot nuts.
(b) Take off steering knuckle from upper and lower sphere
pin, and dismantle steering knuckle.

Check steering knuckle
Make steering knuckle clean, check whether steering knuckle
has crack with coloration penetrant. If there is steering knuckle,
change steering knuckle.

(a) Support lower arm with jack.
(b) Install steering knuckle on lower sphere pin, and install
nuts.

(c) Press down upper arm, install steering knuckle on upper

sphere pin and install nuts.
(d) Screw sphere pin nuts by regulated moment.

Regulated moment: (145±15)N·m
(e) Screw lower sphere pin nuts by regulated moment.
(f) Install new cotter pin on upper and lower sphere pin.
2. Link steering transverse tie rod to steering knuckle arm

(a) Screw slot nuts by regulated moment.
3. Install cover shell of front arrester

Screw three M8X12 bolts.
4. Install front wheel hub and front braking plate
5. Install front braking pliers

6. Check the location of front wheels

Suspension system and vehicle axle(2WD)—Front suspension SA-19
Front suspension
Part drawing
Shim
★ Upper arm shaft 210 ± 10

Upper arm bushing
Front stabilizer bar
210 ± 10 Upper arm bushing
Upper swing arm

Shim
Rubber cover
63 ± 5
Clamp Upper sphere pin
23 ± 3 Flat shim
78 ± 5 140 ± 10
◆ Cotter pin
Long axle cover of lower arm Torsion rod spring
Torsion rod seat
Connecting rod of stabilizer bar 145 ± 15
290 ± 30
Rear axle of lower arm
Flat shim
Front axle of lower arm Lower swing arm Upper adjusting block
Front axle cover of lower arm
240 ± 20
Adjusting arm
Eccentricity shim Lower adjusting block

◆ Bush compresses 1/3 Gasket washer 1
63 ± 5
Gasket washer 2
Gasket washer 1 Lower sphere pin Adjusting bolt
Rubber cover of absorber
140 ± 10
◆ Cotter pin
230 ± 20
Absorber
90 ± 10
Assembly of front wheel hub and steering knuckle

★ Precoat parts

SA-20 Suspension system and vehicle axle(2WD)—Front suspension
Sphere pin
Inspection of sphere pin
1. Check whether sphere pin has been loosened
(a) Support front part of vehicle with jack, then hold it with
shelf.
(b) Insure front wheels locate beeline advancing position,
then step down braking pedal.
(c) Move swing arm up and down, and check whether
clearance of lower sphere pin is too big.
Maximal vertical clearance: 0mm
2. Check whether upper sphere pin has been loosened

Move wheels up and down, and check clearance of upper
sphere pin is too big.
3. Check movement of sphere pin

(a) Dismantle sphere pin.
(b) Liking shown in figure, shake sphere pin bolt front and
back for several times before installing nuts.
(c) Turn nuts continually with torsiometer, and turn it for a
circle every 2 to 4 seconds, then read the scale on
torsiometer at fifth circle.
Screwing moment(when turning):
Lower sphere pin: (1-4)N·m
Upper sphere pin: (1-4)N·m
Disassembly of sphere pin

1. Dismantle assembly of steering knuckle and front wheel
hub
2. Dismantle lower sphere pin from lower arm
3. Dismantle upper sphere pin from upper arm

Installation of sphere pin

1. Install upper sphere pin on upper arm
2. Install lower sphere pin on lower arm

3. Install assembly of steering knuckle and front wheel hub


Torsion rod spring

Disassembly of torsion rod spring
1. Support vehicle frame with jack and hold it with bracket.
2. Make installing marks on torsion rod spring, torsion seat

and adjusting arm.
3. Liking that shown in figure, measure the length of

extended segment on bolts.
A
Remark: when adjusting the distance from ground of chassis,
this measured value could be referred.
4. Loosen adjusting nut until torsion rod spring do not have

tension.
5. Dismantle adjusting arm and torsion rod spring.
Installation of torsion rod spring

Note: there are left and right mark at the back of torsion
rod spring. Please do not change them wrong. Mark L
represents left and mark R represents right.
1. For re-used torsion rod spring

(a) Spread a folium of lithium base lubricating grease on
spline of torsion rod spring.
(b) Install torsion rod spring on torsion rod seat after heading
installing marks rightly.
(c) Install adjusting arm on torsion rod spring after heading

(d) Screw adjusting bolt to make its extended length equal

to the value before disassembly.
2. For new torsion rod spring

(a) Dismantle wheels.
(b) Spread a folium of lithium lubricating grease on spline of
torsion rod spring.
(c) Install torsion rod spring on torsion rod seat.
(d) Put lower arm to limited position to make adjusting arm

install in torsion rod spring by the angle which could
make adjusting bolt screw in upper adjusting block.
Remark: when adjusting angle, repeat it for several times until
it is appropriate.
(e) Screw adjusting bolt by regulated moment.
Screwing limit of nut: A=80mm
(f) Install wheels, dismantle bracket, and make vehicle
bounce for several times to make suspension enter in
stable statement.
(g) Turn adjusting bolt, and adjust the clearance from ground
of chassis (refer to wheel position of front wheels)

Lower swing arm

Disassembly of lower swing arm
1. Take off connecting rod of stabilizer bar from lower arm
(a) Support one side of lower swing arm with jack.
(b) Dismantle connecting nut, take off connecting rod of
stabilizer bar from lower arm
2. Take off absorber from lower arm
3. Disassembly of torsion rod spring

4. Take off lower sphere pin from steering knuckle

(a) Dismantle cotter pin.
(b) Dismantle slot nuts.
(c) Take off lower sphere pin from steering knuckle with
special serrice tools.
SST
5. Dismantle front axle of lower arm

(a) Make installing marks on adjusting cam.

(b) Dismantle nuts and front axle of lower arm.
6. Dismantle rear axle of lower arm

Unscrew nuts, dismantle rear axle of lower arm axle and dis-
mantle lower swing arm.
Change of lower swing arm bush

1. Dismantle lower arm short bush
Press out short bush from lower swing arm with special
serrice tools.
SST
2. Install lower arm short bush

Press short bush in lower swing arm with special serrice tools.
Remark: do not spread lubricating grease on bush.
SST
3. Dismantle lower arm long bush

Dismantle lower arm long bush with special serrice tools.
SST

4. Install lower arm long bush

Install lower arm long bush with special serrice tools.
SST
Installation of lower swing arm

1. Installation of lower swing arm
(a) Install rear axle of lower arm, screw nuts by regulated
moment.
(b) Install front axle of lower arm, then install nuts
temporarily.
2. Install assembly of front wheel hub and steering knuckle

3. Install absorber on lower swing arm

Install absorber on bracket of lower swing arm
screwing moment: (90±10)N·m
4. Install stabilizer bar on lower swing arm


5. Install torsion rod spring

6. Screw nuts on lower arm front axle by regulated moment

(a) Install wheels, dismantle bracket and make vehicle
stable statement.
(b) Screw nuts by regulated moment after heading installing

marks rightly.
7. Check locating parameters of wheels


Upper swing arm

SST
Disassembly of upper swing arm
1. Take off upper sphere pin from steering knuckle
Dismantle cotter pin and nut, and take off upper sphere pin
from steering knuckle with special serrice tools.
2. Dismantle braking soft pipe on upper arm axle

(a) Unscrew fixed nut on oil pipe with open-end wrench.
(b) Pull out braking oil pipe and plug up it with glue block.
Remark: there are two two-way valves on rear braking oil
pipe near right upper arm axle, when dismantling right upper
swing arm, it is necessary to dismantle these four oil pipe
fixed nuts here and plug up them with glue block to prevent
braking liquid from flowing out.
3. Dismantle braking soft pipe from braking pliers

Dismantle bolts of braking soft pipe, take off braking soft
pipe from braking pliers.
Remark: do not lose copper seal shim.
4. Take off braking soft pipe from bracket of upper arm oil
pipe.
Pull out steel sheet spring slip with pliers, and take off braking
soft pipe from bracket of upper arm oil pipe.
5. Dismantle upper swing arm

Dismantle two bolts, then dismantle upper swing arm from
vehicle frame.
Remark: keep adjusting shim carefully, note down the thick-
ness of adjusting shim to install them on original position again.

Suspension system and vehicle axle(2WD)— Front suspension SA-29
Change of upper arm bush

1. Dismantle bush
(a) Dismantle bolts and washer.
(b) Pull out bush with special special tools.

(c) Dismantle upper arm axle, then dismantle the other bush
with same method.
SST
2. Install bush
(a) Press in bush with special tools.
SST
(b) Install upper arm axle, then press in the other bush with
special serrice tools.
SST
3. Screw upper arm axle by regulated torque

(a) Spread whorl locking sealant on two end whorls on upper
90° arm axle, and install washer and nuts.
Remark: adjust the position of upper arm to make installing
plane of sphere pin plumb with installing plane of upper arm
axle.

SA-30 Suspension system and vehicle axle(2WD)— Front suspension
(b) Screw nuts on upper arm axle by regulated moment.

Installation of upper swing arm

1. Install upper swing arm on vehicle frame
(a) Install upper hanging arm and extroversion adjusting
shim.
(b) Screw each bolt by regulated moment.
Remark: install shim with same numbers and thickness on
original position.
2. Link braking oil pipe on upper arm axle

Press nuts and screw oil pipe tightly by regulated moment.
Remark: screw four tie-ins on two two-way valve by the
moment above tightly when dismantling right upper arm.
3. Link braking soft pipe on bracket of upper arm oil pipe

(a) Drill braking soft pipe through the hole on bracket of
upper arm oil pipe.
(b) Hit steel sheet spring clip in with hand hammer to fix
braking soft pipe.
4. Link upper sphere pin to steering knuckle

(b) Install new cotter pin
Remark: when screwing slot nuts, firstly, take lower limited
value 130 N·m; when installing cotter pin, head notch of nuts
to pin boss rightly; when heading, nuts should be tight.

5. Link braking soft pipe to braking pliers

Install copper seal shim, and screw the bolts of braking soft
pipe by regulated moment.
6. Exhaust front braking system
(refer to page BA-6)
Remark: when dismantling right upper arm, it is necessary to
exhaust rear braking system at the same time.
7. Check whether braking liquid has leaked.

8. Screw nuts of upper arm front axle by regulated moment.
Install wheels, dismantle bracket and make vehicle bounce
for several times to make suspension enter in stable statement.


Stabilizer bar
Disassembly of stabilizer bar
1. Take off connecting rod which supports two sides of
stabilizer bar from stabilizer bar .
Fix sphere with inner hexagon wrench, then dismantle self
tapping nuts.
2. Dismantle bush and clip of stabilizer bar , and dismantle

stabilizer bar .
Installation of stabilizer bar

1. Install stabilizer bar on vehicle frame
Place stabilizer bar on position, and install bush and clip of
stabilizer bar on vehicle frame. Then install bolts temporarily.
2. Link stabilizer bar to connecting rod

Change with new nuts, and screw them by regulated moment.
3. Screw clip locating bolts by regulated moment.


Suspension system and vehicle axle(2WD)—Front suspension(coil spring type) SA-33
Front suspension(coil spring type)

Part drawing
Upper swing arm

210 ± 15
Upper swing axle cover assembly
Upper swing arm axle cover assembly

◆ Spring washer
23 ± 3 Upper sphere pin assembly
145 ± 15 ◆ Cotter pin

Front transverse stabilizer bar
Front suspension
traveler assembly
Assembly of steering knuckle

and wheel hub arrester
200 ± 15
Rubber block
250 ± 20
63 ± 5
Clip
Lower swing arm axle bolt assembly
Eccentricity washer 2
23 ± 3
Lower swing arm axle cover assembly

Eccentricity washer 2
250 ± 20
Lower swing arm
Lower sphere pin assembly
Lower swing arm axle cover assembly
145 ± 10

SA-34 Suspension system and vehicle axle(2WD)—Front suspension(coil spring type)
Sphere pin
1. Check whether lower sphere pin has been loosened
bracket.
(b) Insure front wheels have been in beeline advancing
position, and step down braking pedal.
(c) Move lower swing arm up and down, and check whether
Move wheels up and down, and check clearance of upper
sphere pin is too big.
3. Check turning situation of sphere pin

(b) Liking that shown in figure, shake cotter pin stud forward
and back several times before installing nuts.
(c) Install nuts and turn nuts continually with torsiometer
for one circle every 2 to 4 seconds. Read the scale at
fifth circle.
hub




Lower swing arm

1. Dismantle absorber, stabilizer bar and steering tie rod
2. Dismantle linking nut of lower sphere pin and steering

knuckle
(a) Dismantle cotter pin
(b) Dismantle slot nut


(a) Make installing mark on front and rear eccentricity washer
(b) Dismantle nuts and lower arm axle bolts.

(c) Separate lower sphere pin from steering knuckle, and
dismantle lower swing arm.
Change of lower swing arm axle cover

1. Dismantle lower swing arm axle cover
SST
Press out lower arm axle cover from lower swing arm with
special tools. Pay attention to pressed direction of axle cover.
2. Install lower swing axle cover

Press new axle cover in bushing (lower swing arm) by cor-
SST rect direction with special tools.
Remark: do not spread lubricating grease on axle cover.

1. Install lower swing arm
(a) Install lower swing arm on vehicle frame and install two
lower arm axle bolts.
(b) Install two nuts on lower arm axle bolts temporarily.
Remark: it is not necessary to screw nuts by regulated moment.


Install absorber on bracket of lower swing arm.
3. Link lower swing arm and steering knuckle

Install lower sphere pin on steering knuckle, screw slot nuts
and install new cotter pin.
4. Link stabilizer bar on lower swing arm

5. Link steering tie rod on steering knuckle arm

(a) Link steering tie rod on steering knuckle arm.
Remark: when installing cotter pin, it is necessary to head
notch on nut to pin hole rightly, at this time, nut should be
tight.
6. Screw lower swing front axle nut by regulated moment.

(a) Install wheels, dismantle the support and make vehicle
stable statement.
(b) Arrange installing marks rightly, and screw nuts by

regulated moment.
7. Check locating parameters of wheel


Upper swing arm

1. Dismantle front braking oil pipe on upper arm
Unscrew nuts used for fixing oil pipe bracket with open-end
wrench, and dismantle front braking oil pipe from upper swing
arm.
2. Dismantle upper sphere pin from upper swing pin

Dismantle four bolts to separate sphere pin from swing arm

(a) Dismantle two linking bolts of upper swing arm
(b) Dismantle upper swing arm from vehicle frame.
Change of upper arm axle cover

1. Press out upper arm axle cover with tools, and pay
attention to pressed direction.
SST

2. Press in new upper arm axle cover by correct direction

with tools.
SST

1. Install upper swing arm
Install upper swing arm on vehicle frame, and install linking
bolts and nuts of upper swing arm, at this time, it is not nec-
essary to screw nuts by regulated moment.
2. Link upper arm and upper sphere pin

Install upper arm with upper sphere pin together with four
M8×25 bolts, heavy spring washer and nuts.
3. Screw linking nuts of upper swing arm by regulated

moment.
4. Link bracket of front braking oil pipe to arm

Screw linking nuts by regulated moment.

Stabilizer bar
1. Take off stabilizer bar from coupling position of lower
swing arm
Fix sphere pin with inner hexagon wrench, dismantle nuts,
then take off stabilizer bar .
2. Dismantle stabilizer bar clip, then dismantle stabilizer

bar .

Place stabilizer bar on position, and install stabilizer clip on
vehicle frame. Install bolts temporarily, and pre-tighten them.
2. Link stabilizer bar on lower swing arm

Screwing moment:(63±5)N·m
3. Screw clip locating bolts by regulated moment


Front wheel hub and steering knuckle(4WD)

Part drawing
Stabilizer rod
◆ Spring washer
◆ 63 ± 5 Plate arrester
Upper swing arm 140 ± 10
Flat washer
Connecting rod
◆ Cotter pin Drive shaft
of stabilizer rod ◆ Oil seal

Steering knuckle
145 ± 15
Flat washer Locknut
Lower swing arm
Bush com- Roller pin bearing

pressed 1/3
Thrust shim
Gasket washer 1 230 ± 20 Stop shim
Absorber rubber cover Bolt
◆ Cotter pin
Gasket washer 2
◆ 63 ± 5
Gasket washer 1
Absorber ◆ Spring washer
23 ± 3
90 ± 10
Arrester cover shell
Bearing
Flange plate
◆ Oil seal Snap spring
★ 78 ± 5
Bearing
Front wheel hub and braking plate

Wheel hub cover

★ Precoat parts

Front wheel hub

1. Dismantle plate braking pliers
Dismantle plate braking pliers and hang it with tightwire.
Remark: do not dismantle braking soft pipe and braking pipe.
2. Dismantle front wheel hub cover and flange plate

(a) Unscrew fixed bolts with inner hexagon wrench, then
dismantle wheel hub cover
(b) Dismantle snap spring with pliers, then take off adjusting
washer.
(c) Dismantle flange plate.

(a) Unscrew lock bolts with cross screwdriver, then
dismantle stop shim.
SST
(b) Dismantle locknuts with special service tools.
Brief chart of SST
(c) Dismantle wheel hub and braking plate together with

exterior bearing.

4. Dismantle oil seal of front wheel hub and inner bearing.

(a) Prize out oil seal with screwdriver.
(b) Dismantle inner ring of inner bearing from wheel hub.
Inspection and repair of front wheel hub

1. Check each bearing
Wash inner ring and exterior housing ring of each bearing,
and check whether they have been worn or damaged.
2. Change exterior housing ring of bearing
(a) Hit out exterior housing ring of bearing with copper stick
and hand hammer.
(b) Press in new exterior housing ring of bearing with special

tools.
SST
Brief chart of SST

1. Spread lubricating grease on inner surface of wheel hub
and exterior housing ring of bearing
Lubricating grease Lubricating grease: JinZhi HP-R lubricating grease or
other lubricating greases according to following
requirements
Representative
Item
parameters
Dropping point,℃ 289
Lost circulation(104℃,6h),g 0.48
Performance of extreme
Lubricating grease 178
pressure(Timken method)okvalue, N
2. Put in inner ring of bearing
Fill in the clearance between inner ring and exterior housing
ring of bearing with HP-R lubricating grease.
Lubricating grease

Brief chart of SST 3. Install inner bearing and oil seal

(a) Put inner bearing in wheel hub.
(b) Hit new oil seal in wheel hub with special tools.
(c) Spread HP-R lubricating grease on lip of oil seal.
SST
4. Install wheel hub on steering knuckle.

(a) Install wheel hub on steering knuckle.
(b) Install exterior bearing.
Brief chart of SST

5. Adjust pre-load
(a) Screw locknut by regulated moment with special tools.
(b) Turn wheel hub for 1/3¡«1/4 ring to left and right
independently.
(c) Loosen nuts until it could be turned by hand.
(d) Tighten locknut again with special tools.
SST Screwing moment: 28N·m
(e) Check pre-load with spring tensometer.

6. Install stop shim

Install stop shim, make the side with counterbore outward,
and fix it on locknut with bolt.
Remark: if the hole for installing bolt on stop shim could not
head the screw thread hole on locknut rightly, dismantle stop
shim, then make a little adjustment for locknut (turn to the
direction whose adjustment is minimal), lastly install the stop
shim.

7. Check pre-load again

Check pre-load again with spring tensometer
If pre-load does not accord with regulated value, it is necessary
to dismantle stop shim and adjust with adjusting nut.
8. Install flange plate

(a) Install flange plate on wheel hub.
(b) Install snap spring.
9. Install wheel hub cover

(a) Spread silicon rubber plane sealant on the connecting
surface of wheel hub and wheel hub cover.
(b) Spread screw thread lock sealant on the screw thread of
bolt.
10. Install plate braking pliers

Install plate braking pliers on steering knuckle, and screw it
by regulated moment.
Steering knuckle
1. Dismantle plate arrester and front wheel hub
2. Dismantle cover shell of arrester


arm
(b) Take off steering transverse tie rod from steering knuckle
arm with special tools.
4. Take off connecting rod of stabilizer bar from lower arm.

Fix the sphere pin with inner hexagon wrench, then dismantle
self locking nut.

(a) Dismantle cotter pin and nuts on upper sphere pin.
SST
(b) Take off steering knuckle from upper sphere pin with
service special tools.
(c) Dismantle cotter pin and nut on lower sphere pin.

(d) Take off steering knuckle from lower sphere pin with
service special tools.
SST
(e) Support lower arm with jack, and dismantle steering

knuckle.


1. Check steering knuckle
Check whether there is any crack on steering knuckle with
coloration penetrant
If there is any crack, it is necessary to change steering
knuckle.
2. Dismantle oil seal of steering knuckle

Prize out oil seal from steering knuckle with screwdriver.
3. Take out stop shim.
4. Dismantle roller pin bearing

Hit out roller pin bearing with copper stick and hand hammer.
5. Installation of roller pin bearing

SST Hit in new roller pin bearing with special tools and hand hammer
lightly.
Remark: when hitting in, make one end with thick end surface
of roller pin bearing upwards.

6. Installation of stop shim

Reverse angle
Spread HP-R lubricating grease on stop shim installed position
of steering knuckle, and put in the side with reverse angle of
stop shim towards steering knuckle.
Steering knuckle
Remark: it is necessary to measure the thickness of stop shim
before installation, if thickness is less than 1.5mm, change
with new stop shim. And fair thickness of new stop shim is 2
mm.
7. Installation of oil seal of steering knuckle
SST

(a) Spread lithium base lubricating grease in drive shaft and
dustproof of drive shaft.
(b) Put drive shaft through steering knuckle, at the same

time, link lower sphere pin on steering knuckle and install
slot nuts temporarily.
(c) Press down upper arm and link upper sphere pin on
steering knuckle, then install and screw nuts by regulated
moment.
(d) Install new cotter pin.
Remark: when installing cotter pin, it is necessary to head the
notch on nut to pin hole correctly, at this time, nut must be
tight.

(e) Screw nuts of lower sphere pin by regulated moment.

(f) Install new cotter pin.
Remark: when screwing slot nuts, it is well to take the lower
limited value210N·m ,and when installing cotter pin, it is
necessary to head the notch on nut to pin hole correctly, at
this time, nut must be tight.
2. Link stabilizer bar on lower arm

Support lower arm with jack, then fix sphere pin with inner
hexagon wrench and screw locknuts by regulated moment.

Remark: when installing cotter pin, it is necessary to head the
notch on nut to pin hole correctly, at this time, nut must be
tight.
4. Install arrester cover shell

5. Install front wheel hub and plate braking pliers

Front suspension
Part drawing
Shim
Upper arm bushing ★ Upper arm shaft 210 ± 10
Shim
Front stabilizer bar
Upper arm bushing
210 ± 10
Upper swing arm
Rubber cover
63 ± 5
Upper sphere pin
Clamp
23 ± 3 Flat shim
Long axle cover of 145 ± 15 Torsion rod spring

Connecting rod of stabilizer bar lower arm 140 ± 10
Torsion rod seat

Flat shim
Short axle cover of 290 ± 30 Rear axle of lower arm

lower arm
Front axle of lower arm Upper adjusting block
Lower swing arm
240 ± 20
Adjusting arm
Eccentricity shim
Lower adjusting block
◆ Bush compresses 1/3 Gasket washer 1
63 ± 5
Gasket washer 2 Adjusting bolt
Lower sphere pin
Gasket washer 1
Rubber cover of absorber
140 ± 10
◆ Cotter pin
230 ± 20
90 ± 10
Assembly of front wheel hub and steering knuckle

★ Precoat parts

Sphere pin
1. Check whether lower sphere pin has been loosened
bracket.
(b) Insure front wheels have been in beeline advancing
position, and step down braking pedal.
(c) Move lower swing arm up and down, and check whether

Move wheels up and down, and check clearance of up-
per sphere pin is too big.
3. Check turning situation of sphere pin

(b) Liking that shown in figure, shake cotter pin stud forward
and back several times before installing nuts.
(c) Install nuts and turn nuts continually with torsiometer
for one circle every 2 to 4 seconds. Read the scale at
fifth circle
hub


Screwing moment: (78 ± 5)N·m



Torsion rod spring

Disassembly of torsion rod spring
1. Make installing marks on torsion rod spring, torsion rod
seat and adjusting arm.
2. A Liking that shown in figure, measure the length of

extended segment on bolts.
A Remark: when adjusting the distance from ground of chassis,
this measured value could be referred.
3. Loosen adjusting nut until torsion rod spring do not have

tension.
4. Dismantle adjusting arm and torsion rod spring.
Installation of torsion rod spring

Note: there are left and right mark at the back of torsion rod
spring. Please do not change them wrong. Mark L represents
left and mark R represents right.
1. For re-used torsion rod spring

(a) Spread a folium of lithium base lubricating grease on
spline of torsion rod spring.
(b) Install torsion rod spring on torsion rod seat after heading
(c) Install adjusting arm on torsion rod spring after heading

(d) Screw adjusting bolt to make its extended length equal

to the value before disassembly.
2. For new torsion rod spring

(a) Dismantle wheels.
(b) Spread a folium of lithium lubricating grease on spline of
torsion rod spring.
(c) Install torsion rod spring on torsion rod seat.
(d) Put lower arm to limited position to make adjusting arm

install in torsion rod spring by the angle which could
make adjusting bolt screw in upper adjusting block.
Remark: when adjusting angle, repeat it for several times until
it is appropriate.
(e) Screw adjusting bolt by regulated moment.
Screwing limit of nut: A=80mm
(f) Install wheels, dismantle bracket, and make vehicle
stable statement.
(g) Turn adjusting bolt, and adjust the clearance from ground
of chassis (refer to wheel position of front wheels)

Lower swing arm

1. Disassembly of the assembly of front wheel hub and
steering knuckle
Including disassembly of absorber, stabilizer rod and steering
tie rod.
2. Disassembly of torsion rod spring


(a) Make installing marks on adjusting cam.
(b) Dismantle nuts and front axle of lower arm.
4. Dismantle rear axle of lower arm

Unscrew nuts, dismantle rear axle of lower arm axle and
dismantle lower swing arm.

Change of lower swing arm bush

1. Dismantle lower arm short bush
Press out short bush from lower swing arm with special tools.
SST
2. Install lower arm short bush

Press short bush in lower swing arm with special tools.
SST
3. Dismantle lower arm long bush

Dismantle lower arm long bush with special tools.
SST
4. Install lower arm long bush

Install lower arm long bush with special tools.
SST

1.Installation of lower swing arm
(a) Install rear axle of lower arm, screw nuts by regulated
moment.
(b) Install front axle of lower arm, and pre-tighten nuts.

2. Install assembly of front wheel hub and steering knuckle


Install absorber on bracket of lower swing arm.
4. Install stabilizer bar on lower swing arm


(a) Link steering tie rod on steering knuckle arm.
Remark: when installing cotter pin, it is necessary to head
notch of nuts to pin boss rightly; when heading, nuts should
be tight.
6. Install torsion rod spring


7. Screw nuts on lower arm front axle by regulated moment

stable statement.
(b) Screw nuts by regulated moment after heading installing

marks rightly.


Upper swing arm

SST
1. Take off upper sphere pin from steering knuckle
Dismantle cotter pin and nut, and t ake off upper sphere pin
from steering knuckle with special tools.
2. Dismantle braking soft pipe on upper arm axle

(a) Unscrew fixed nut on oil pipe with open-end wrench.
(b) Pull out braking oil pipe and plug up it with glue block.
Remark: there are two two-way valves on rear braking oil
pipe near right upper arm axle, when dismantling right upper
swing arm, it is necessary to dismantle these four oil pipe
fixed nuts here and plug up them with glue block to prevent
braking liquid from flowing out.
3. Dismantle braking soft pipe from braking pliers

Dismantle bolts of braking soft pipe, take off braking soft
pipe from braking pliers.
Remark: do not lose copper seal shim.
4. Take off braking soft pipe from bracket of upper arm oil
pipe.
Pull out steel sheet spring slip with pliers, and take off braking
soft pipe from bracket of upper arm oil pipe.

Dismantle two bolts, then dismantle upper swing arm from
vehicle frame.
Remark: keep adjusting shim carefully, note down the
thickness of adjusting shim to install them on original position
again.

Change of upper arm bush

1. Dismantle bush
(a) Dismantle bolts and washer.
(b) Pull out bush with special tools.

(c) Dismantle upper arm axle, then dismantle the other bush
with same method.
SST
2. Install bush
(a) Press in bush with special tools.
SST
(b) Install upper arm axle, then press in the other bush with
special tools.
SST
3. Screw upper arm axle by regulated torque

(a) Spread whorl locking sealant on two end whorls on upper
90° arm axle, and install washer and nuts.
Remark: adjust the position of upper arm to make installing
plane of sphere pin plumb with installing plane of upper arm
axle.

(b) Screw nuts on upper arm axle by regulated moment.


1. Install upper swing arm on vehicle frame
(a) Install upper hanging arm and extroversion adjusting
shim.
(b) Screw each bolt by regulated moment.
Remark: install shim with same numbers and thickness on
original position.
2. Link braking oil pipe on upper arm axle

Press nuts and screw oil pipe tightly by regulated moment.
Remark: screw four tie-ins on two two-way valve by the
moment above tightly when dismantling right upper arm.
3. Link braking soft pipe on bracket of upper arm oil pipe

(a) Drill braking soft pipe through the hole on bracket of
upper arm oil pipe.
(b) Hit steel sheet spring clip in with hand hammer to fix
braking soft pipe.
4. Link upper sphere pin to steering knuckle

Remark: when screwing slot nuts, firstly, take lower limited
value 130 N·m; when installing cotter pin, head notch of
nuts to pin boss rightly; when heading, nuts should be tight.

5. Link braking soft pipe to braking pliers

Install copper seal shim, and screw the bolts of braking soft
pipe by regulated moment.
6. Exhaust front braking system

(refer to page BA-6)
Remark: when dismantling right upper arm, it is necessary to
exhaust rear braking system at the same time.
7. Check whether braking liquid has leaked.
8. Screw nuts of upper arm front axle by regulated moment.

stable statement.
(b) Arrange installing marks rightly and screw nuts by

regulated moment.


Stabilizer bar
1. Take off connecting rod which supports two sides of
stabilizer bar from stabilizer bar .
Fix sphere with inner hexagon wrench, then dismantle self
tapping nuts.
2. Dismantle bush and clip of stabilizer bar , and dismantle

stabilizer bar .

Place stabilizer bar on position, and install bush and clip of
stabilizer bar on vehicle frame. Then arrange installing marks
rightly to make left and right clearance of stabilizer rod keep
consistent. Lastly install bolts temporarily and pre-tighten them.
2. Link stabilizer bar to connecting rod

3. Screw clip locating bolts by regulated moment.


SA-64 Suspension system and vehicle axle —Front drive shaft
Front drive shaft

Installation resolving chart of front drive shaft assembly on front drive axle
Front drive shaft assembly
Hanger plate-right 90-110 ★
Oil seal-front retarder

Snap spring
Bearing-front retarder
Snap spring
Assembly of front retarder and electric-control separator
Power tie-in of electric clutch
23-26
Front drive axle ventilation pipe connector assembly

Snap spring
Snap spring
Oil seal-front retarder
Hanger plate-left
★ 90-110
★ Precoat parts

Suspension system and vehicle axle —Front drive shaft SA-65
Front drive shaft resolving chart
Inner trumpet tie-in
Snap spring Three-pin joint assembly
Inner sheath big clip Inner sheath
Inner sheath small clip
Exterior sheath small clip
Exterior sheath
Exterior sheath big clip
outer trumpet tie-in
dustproof cover
Disassembly of front drive shaft assembly

1. Support vehicle at the middle of repair platform or ground
channel, hold its front part (on vehicle frame) to dismantle
Snap spring
left and right front wheel. (Make vehicle locate two-drive
★ Bolt statement before dismantling)
2. Dismantle beam under front drive axle assembly
Flange plate 3. Disconnect the joint of front drive axle flange and
Wheel hub cover transmission shaft, and make installing marks.
4. Discharge lubricating grease in retarder.
5. Unscrew linking bolts of front wheel hub cover, and take
off front wheel hub.
6. Dismantle snap spring from drive shaft with snap spring
pliers, and dismantle steering knuckles on left and right
ends.
7. Disconnect power tie-in of electric clutch.
8. Unscrew the bolts on ventilation pipe bracket that are

used for fixing connecter assembly of front drive axle
ventilation pipe with wrench.
Wrench

180
180
180
N ·m :Specified torque 180
9. Hold fro nt drive axle with jack, then unscrew lift bolts of
★ 90-110 hanger plate and vehicle frame.
10. Dismantle whole drive axle.
Held part
11. Unscrew connecting bolts of hanger plate and front drive
axle assembly.
12. Pull out oil seal, hanger plate, bearing and front drive
shaft assemblies on left and right side.
Note: when pulling out drive shaft assembly, support
underside of drive shaft to make it could not take off
from inner sheath, at the same time, do not break inner
and exterior sheath.
13. Dismantle exterior snap spring of lower bearing with snap
Sn ap sprin g spring pliers.
pliers
Note: in progress of disassembly, support underside of
drive shaft to make it could not take off from inner
sheath, at the same time, do not break inner and exterior
sheath.
Hold up under end
14. Pull out bearing with special service tools.

15. Dismantle snap spring on the other side of lower bearing
Hold with snap spring pliers.
SST Note: in progress of disassembly, support underside of
drive shaft to make it could not take off from inner
sheath, at the same time, do not break inner and exterior
Shim sheath.
Hold up under end

Disassembly of front drive shaft assembly
1. Check front drive shaft assembly
(a) Check whether inner trumpet tie-in could slide fluently
on shaft direction.
(b) Check whether universal joint part has obvious clearance
on redial direction.
(c) Check whether inner and exterior sheath has been
damaged.
Note: it is necessary to use shim plate to avoid damaging
front drive shaft before nipping front drive shaft.

2. Dismantle inner sheath big clip

Note: do not break inner and exterior sheath.
Pliers
3. Disassembly of inner trumpet tie-in part

(a) Make installing marks on inner trumpet tie-in and three-
Installing mark
pin joint assembly.
Note: before making marks, remove lubricating grease
in tie-in and do not punch out marks with punch or other
hard things.
(b) Take off inner trumpet tie-in.
4. Disassembly of three-pin joint assembly

Installing mark
(a) Dismantle snap spring with snap spring pliers.
(b) Make installing marks on shaft and three-pin joint
assembly with adz and hand hammer.
(c) Dismantle three-pin joint assembly with copper stick and

hand hammer.
Note: it any copper scrap is on shaft or three-pin joint
assembly, remove it.
5. Dismantle inner sheath

(a) Dismantle inner sheath small clip with pliers.
(b) Move out inner sheath.
Note: remove lubricating grease in sheath, and keep
dismantling spot clean.

6. Dismantle exterior sheath big clip and small clip with gad
screwdriver.
7. Dismantle exterior sheath

Clean sheath and remove lubricating grease on exterior trumpet
tie-in, and do not disconnect exterior trumpet tie-in.
8. Dismantle dustproof cover with screwdriver and hand

hammer.
Installation of front drive shaft assembly

1. Install dustproof cover with screwdriver and hand
hammer.
If dustproof cover has distorted seriously, change with new
one.
2. Harness in exterior sheath big clip, exterior sheath and

exterior sheath small clip.
If exterior sheath has been damaged or its aging is heavy,
change with new one, at the same time, it is necessary to
twine plastic strip and spread some lubricating greases on shaft
end before harnessing.

3. Harness inner sheath small clip, inner sheath and inner

sheath big clip
If inner sheath has been damaged or its aging is heavy, change
with new one.
4. Install three-pin joint assembly on front drive shaft

(a) Head one end with transverse angle of three-pin joint
End with
transverse angle assembly to inner shaft direction.
If roller pin bearing part of three-pin joint assembly has been
damaged, change with new three-pin joint assembly.
(b) Arrange the install marks made before dismantling rightly.
(c) Install three-pin joint assembly in front drive shaft with

hand hammer and copper stick.
(d) Install new snap spring with snap spring pliers.

5. Install exterior sheath on exterior trumpet tie-in

CAPLEX or KY1 Use lubricating grease that is provided
as a set of sheath to fill sheath before installing sheath.
Lubricating greases recommended:
Lubricating grease dosage: about 110 grams
6. Install inner trumpet tie-in on front drive shaft

(a) Fill lubricating grease that is provided as a set of sheath
in inner trumpet tie-in and inner sheath.
Lubricating greases recommended: CAPLEX or KY1
Lubricating grease dosage: about 140 grams
(b) Arrange the install marks made before dismantling rightly,

and harness inner trumpet tie-in.
Installing mark (c) Harness inner sheath on inner trumpet tie-in.
7. Nip inner and exterior sheath with inner and exterior

sheath clip
Exterior sheath clip
Inner sheath clip
(a) Use special clip pliers without ear to lock inner sheath
Clip pliers without ear
big clip.

(b) Use nutcracker to lock inner sheath small clip.

Make big and small connecting part of sheath locate at
corresponding flute of trumpet tie-in and shaft.
nutcracker
(c) Use special pneumatic power pliers to lock big and small
clip of exterior sheath.
SST
(d) Insure sheathes on both sides could not be elongated or

shortened when front drive shaft locates at standard
length.
Standard length: 400.5mm
If it is only necessary to change exterior parts of front drive

shaft assembly on vehicle, you could disconnect inner trumpet
tie-in of front drive shaft assembly before dismantling left and
right steering knuckle of vehicle, and take out three-pin joint
and shaft from inner trumpet tie-in to change.

Installation of front drive shaft assembly on

front drive axle
1. Harness hanger plate in drive shaft, harness oil seal
Snap spring pliers
and install inner snap spring with snap spring pliers.
If oil seal has been damaged, change it with new one.
Hold up underside
2. Tap in bearing with special service tools

SST Note: hold up under part of drive shaft assembly when
tapping to make it could not take off.
3. Install exterior snap spring on front drive shaft assembly
with snap spring pliers.
4. Install hanger plate, oil seal, snap spring, bearing and
Stick underside snap spring on drive shaft of the other side repeating
methods above.
5. Arrange the spline part on connecting end of drive shaft
and retarder in electric-control clutch and differential
half-shaft gear spline hole of retarder slowly.
6. Drip one to two thread locker in the middle of coupling
bolt thread of hanger plate and retarder.
7. Tighten coupling bolt of hanger plate and drive axle with

wrench, and screw it to regulated moment.
Note: when screwing bolts, firstly, screw all bolts,
secondly, screw bolts by transverse angle, lastly, check
whether hanger plate has been planished after bolts
have been screwed to regulated moment, if it is not flat,
dismantle hanger plate and re-install.

8. Install ventilation pipe connecter assembly, and link each

Installing mark interface between it and front drive axle.
9. Firstly, hold up whole drive axle with jack, and use hanger
plate to hang drive axle and screw hanging bolts to
regulated moment, secondly install steering knuckle on
both sides and upper and lower sphere pin, lastly, link
the connecter of front axle ventilation pipe assembly and
vehicle frame and re-link the connecting part of electric-
control separator.
(Pre-drip one to two thread locker in middle front part of
thread for hanging bolts)
10. Link front drive axle flange and transmission shaft with
bolts by the marks made before dismantling, and screw
it to regulated moment.
11. Install beam under front drive axle, and screw its linking
bolts to regulated moment

SA-74 Suspension system and vehicle axle — Front reducer
Front reducer
Change of main gear oil seal of front reducer assembly
Front reducer assembly
Washer
Bearing
◆ Oil seal
Spacer bush- Driving bevel gear
:Specified torque 140-160 ◆

N ·m
◆ Parts no longer for use after service Assembly of front reducer Driving bevel gear and dustproof cover
1. Support front part of vehicle, then dismantle left and

Installing mark right front wheel and beam under reducer.
2. Discharge lubricating grease in front reducer, then
dismantle left and right steering knuckle.
3. Sep arate front retarder assem bly flange f rom
transmission shaft, and dismantle front drive axle with
jack.
Before separating retarder and transmission shaft, make
installing marks on them.
4. Dismantle front retarder assembly
5. Dismantle assembly of main gear flange and dustproof
cover
(a) Chisel riveted parts on nuts with hand hammer and chisel.
(b) Lock main gear flange with special tools, then dismantle
SST main gear nuts.

Suspension system and vehicle axle — Front reducer SA-75
(c) Knock down assembly of main gear flange and dustproof

cover with copper stick.
Rotate wrench clockwisely 6. Dismantle main gear oil seal

Dismantle oil seal with special tools, and note do not damage
inner wall of decreased shell.
SST
7. Install new main gear oil seal

(a) Hit in new oil seal lightly with special tools.
SST
(b) Top surface of oil seal is horizontal with top surface of
decreased shell.
Note: spread lithium base lubricating grease evenly on
oil seal lip, and hit it correctly.
8. Install assembly of main gear flange and dustproof cover

(a) Head assembly of main gear flange and dustproof cover
in front drive main gear.
(b) Spread lithium base lubricating grease on new nuts.
(c) Lock flange with special tools, and screw nuts by

regulated moment.

9. Adjust pre-load of Driving bevel gear bearing

(a) Measure the pre-load in clearance of driving bevel gear
and driven bevel gear with torquemeter.
Pre-load: (1.2-1.7)N·m
(b) If pre-load exceeds regulated value, change it with thicker
washer.
Difference of washer with each-grade thickness: 0.03mm
(c) If pre-load is less than regulated value, change it with
thin washer, repeat this operation until it reaches
requirement.
33 Note: do not reduce pre-load with method of loosening
nuts.
10. Check axial and radial flopping quantity of flange
Measure the axial flopping quantity of flange with percentage
meter.
Maximal axial flopping quantity: 0.1mm
Unit: mm
Maximal radial flopping quantity: 0.1mm

If radial flop is too big, check the bearing.
11. Rivet main gear nuts after meeting those requirements

above.
12. Install retarder assembly on front drive axle assembly,
and install front shaft assembly.
(refer to page SA-68 and SA-103)
13. Install drain plug, then screw oil filler plug and fill hypoid
lubricating grease.
Drain plug screwing moment: (30-35)N·m
Lubricating grease type: GL-5
Filled quantity: equal to the lower edge of oil filler.
14. Underlay oil filler plug washer, and screw oil filler plug to
regulated moment.
Installing mark
Regulated moment: (140-150)N·m
15. Install front drive axle assembly on vehicle frame
16. Link transmission shaft on flange
(a) Head install marks rightly, then link transmission shaft
with front drive axle flange with four bolts and nuts.
(b) Screw nuts by regulated moment.
Remark: keep repair spot clean in the progress of repair.

Disassembly of front reducer assembly
Hanger plate-right 90-110 ★
Oil seal- front retarder

Snap spring
Snap spring
Assembly of front retarder and electric-control separator
Power tie-in of electric-control separator
23-26
Front drive axle ventilation pipe assembly
Snap spring
Snap spring
Oil seal- front retarder
Hanger plate-left
★ 90-110
★ Precoat parts

1. Support front part of vehicle, then dismantle left and

Installing mark right front wheel and beam under retarder.
2. Discharge lubricating grease in front retarder assembly.
3. Separate f ront retarder assem b ly f lang e from
transmission shaft.
Note: before disconnecting retarder and transmission
shaft, make installing marks on them.
4. Disconnect power tie-in of electric-control separator.

Wrench
6. Cut the connection of front drive shaft assembly and

Adjusting washer group steering knuckle-front wheel hub assembly.
(a) Unscrew the coupling bolts used for fixing front wheel
Snap spring hub cover, and take off front wheel hub cover.
★ Bolt
Flange plate
Wheel hub cover
(b) Dismantle snap spring from front drive shaft with snap
spring pliers.
(c) Disconnect steering knuckles on both sides, and separate
them from front drive shaft assembly.

180 180
Tie-in of electric separator
7. Hold front drive axle with jack.

8. Dismantle lift bolts of front drive axle hanger plate and
vehicle frame.
9. Dismantle front drive axle assembly
Note: do not damage drive shaft or break front drive
shaft sheath.
10. Dismantle front drive shaft assembly on both sides from
front drive axle assembly.
Remark: keep repair spot clean in the progress of repair.
11. Dismantle the bolts and nuts used for fixing front retarder
shell with wrench.

Change of front retarder assembly side oil seal and long half-axle oil seal
Change of front retarder assembly side oil seal

1. Dismantle front drive axle assembly
2. Dismantle left and right front drive shaft assembly on
front drive axle.
3. Dismantle side oil seal and change with new side oil by
the dismantling and installing steps for front drive shaft
assembly, then harness new oil seal in front drive shaft
and install them in front retarder assembly
90-110
23-26
Snap spring
Long half-shaft oil seal
Long half-shaft pressed assembly
Mechanical wheel of separator
★ Precoat parts

Change of long half-shaft oil seal

1. After making electric clutch stay in four-drive statement,
stop vehicle and dismantle front drive shaft assembly.
Wrench
3. Disconnect the connecter of electric clutch shell

Dismantle this position
ventilation pipe and front drive axle ventilation pipe
connecter assembly.
4. Disconnect the connecter of ventilation pipe on electric

clutch and connecter assembly of ventilation pipe.
5. Dismantle the bolts used for fixing electric clutch shell
and front axle pipe flange, and knock out electric clutch
shell with copper stick, then take out mechanical wheel
of separator.
Remark: lubricating grease will leak when separating electric
clutch shell and front axle flange, at this time, use vessel to
Dismantle this position
fill.

6. Disconnect snap spring used for locking long half-shaft

bearing exterior ring with snap spring pliers.
Shim plate
Bolt pins (two)
Ejection bolts (three)
SST
7. Dismantle long half-shaft and bearing, snap spring as-

sembly with special service tools
8. Dismantle long half-shaft oil seal with special service

tools
Note: do not nick inner surface of flange
SST
9. Scrape all seal glue on connecter of flange and electric

clutch with knife.
Note: do not nick connecting surface

10. Hit new oil seal in oil seal position in flange with special
service tools.
Note: it is necessary to spread some lithium base
lubricating grease evenly when installing new oil seal in
front lip, and hit oil seal rightly.
SST
11. Head spline of long half-shaft small end in that spline of

front retarder half-shaft gear lightly, then hit it in with
copper stick and hand hammer.
Note: do not damage roller pin bearing in long half-shaft
big end spline when hitting in long half-shaft.
12. Install snap spring in flange and lock bearing exterior

Snap spring ring with snap spring pliers.
Remark: if snap spring has been distorted heavily, change it
with new one.
Snap spring pliers
13. Clean the connecting surface of flange and electric clutch

shell with clean cotton cloth.
14. Arrange the spline in separator mechanical wheel, front

drive shaft and separator fork cover rightly, and install
them in front drive shaft and separator fork cover.

15. Spread a sheet of 1596 silicon rubber flat sealant evenly

on connecting surface of flange, and scrape it flat with
flat plate.
Note: insure sealant is a continue bed, and it is necessary
to keep away from thread to avoid sealant enters in
thread hold when spreading.
16. Arrange fork cover and long half-shaft upper spline, and
make mechanical wheel of separator enter in long half-
shaft, then link electric-control separator shell and front
axle pipe flange with bolts, and screw them to regulated
moment. At the same time, pre-spread thread locker on
bolts (drip one to two drips at the middle of thread).
Remark: avoid abnormal things enter front drive axle when
installing.
17. Screw the bolts used for fixing ventilation pipe bracket
to regulated moment with wrench
18. Unscrew oil filler plug on electric clutch shell, take off
washer and fill in gear lubricating grease to oil surface
that equals to the bottom of oil filler.
Type of lubricating grease: GL-5
19. Harness washer of oil filler plug, and screw plug to
regulated moment.
20. Link the connecter assembly of ventilation pipe on

Link this position electric clutch shell and ventilation pipe of front axle
21. Link the connecter assembly of electric clutch ventilation
pipe and front axle ventilation pipe.
Link this position

Disassembly and installation of front reducer assembly and electric clutch part
Part drawing of front reducer assembly
Bearing gland
Adjusting male tab
90-115
Bearing
Differential shell 80-95 ★
Pin Stop shim of half-shaft gear
Half-shaft gear
Driven bevel gear Planetary gear shaft
Planetary gear
Assembly of front drive main gear

Front drive axle shell 18-25 ★
flange and dustproof cover
Washer Small bearing
Oil filler plug Oil seal
Ventilation pipe
30-35
★ 90-110
Spacer bush-driving
Front axle ventilation pipe ★ bevel gear ◆
connector assembly
140-160
Long half-shaft oil seal

23-26
Adjusting washer
Long half-shaft Snap spring
Roller pin bearing
Front reducer shell
Bearing
Electric clutch Ventilation
pipe Snap spring
Dowel pin
Oil filler plug
Big bearing
Washer Adjusting washer
★ 23-26 Electric clutch shell Driving bevel gear
Fork cover
★ Precoat parts

Disconnect this position

Disassembly of front retarder assembly
Disconnect this
1. Dismantle front drive axle, left and right front drive shaft
position assembly.
(refer to page SA-64 and SA-77)
2. Dismantle those three connecting position of front drive
axle ventilation pipe connecter assembly.
Disconnect this position
3. Unscrew the bolts used for fixing ventilation pipe

connecter assembly with wrench and take off ventilation
pipe connecter assembly.
4. Unscrew the bolts used for fixing electric clutch, and

knock down electric clutch with copper stick.
5. Disconnect oil filler plug with wrench and take off washer,
then pull out ventilation pipe tie-in.
6. Disconnect the bolts used for linking electric clutch shell

and front axle pipe flange with wrench, then take out
fork cover and mechanical wheel of separator.
Remark: when dismantling, it is necessary to use vessel to fill
the leaked gear oil to avoid polluting environment.

7. Dismantle the snap spring used for fixing long half-shaft

bearing exterior ring with snap spring pliers.
8. Pull out long half-shaft, long half-shaft bearing and inner
ring snap spring of long half-shaft with special service
tools.
9. Dismantle long half-shaft oil seal with special service
tools
10. Pull out ventilation pipe head on front axle pipe.
11. Dismantle the snap spring used for fixing long half-shaft
bearing inner ring with snap spring pliers.
12. Press out long half-shaft bearing on press (or hit it out
with hand hammer).
Note: do not damage spline on long half-shaft end.
SST
13. Pull out roller pin bearing in long half-shaft with special
service tools.
Note: it is necessary to use shim plate when using vice
to nip long half-shaft.
14. Dismantle the bolts and nuts used for fixing front retarder
assembly and front axle shell with wrench.

15. Knock front retarder shell to separate it from front drive

axle shell with copper stick or hand hammer.
16. Check swing difference of driven bevel gear

Turn the flange, then measure swing difference of driven bevel
gear with percent meter
Maximal swing difference: 0.07mm
If swing difference exceeds 0.07mm, it is necessary to change
driving and driven bevel gear.
17. Check the clearance between gear sides of driving and

driven bevel gear.
(a) Install percent meter, and insure side head axle line is
vertical with contacting gear surface.
(b) Hold main gear flange, and turn driven bevel gear come-
and-go to measure clearance value.
Regulated range of clearance value: (0.15-0.25)mm
Remark: check over three even points on driven bevel gear
ring.
18. Check mesh moulage of driving and driven bevel gear.

19. Measure pre-load of driving bevel gear bearing

Measure the pre-load of clearance between driving and driven
bevel gear bearing with torquemeter.
Pre-load range: (1.2-1.7)N·m
20. Measure total pre-loads of driving bevel gear

21. Dismantle the assembly of main gear flange and

dustproof cover
(a) Loosen riveted part of main gear nut with hand hammer
and chisel.
(b) Lock main gear flange to dismantle main gear nuts with
SST special service tools.
(c) Knock down assembly of main gear flange and dustproof

cover with copper stick.
22. Dismantle main gear oil seal with special service tools
Hold
SST
Pliers
Screw clockwise
23. Dismantle small bearing inner ring with special service

tools and overturn retarder to slide out spacer bush
Remark: if bearing has been damaged, change it with new
one.
SST

24. Dismantle two bearing pressed covers with wrench

Remark: distinguish left and right to avoid confusion when
dismantling bearing pressed cover.
25. Shake differential assembly upwards with copper stick,
then take out differential assembly.
26. Dismantle side bearing exterior ring and mark left and
right part.
L
27. Take down left and right adjusting washer, measure their
thickness and mark left and right
28. Take out driving bevel gear and adjusting washer under
spacer bush.
Inspection and change of retarder

1. Change big bearing of driving bevel gear
(a) Press out driving bevel gear big bearing with special
service tools.
Remark: if driving bevel gear has been damaged, change the
SST whole set of driving and driven bevel gear before changing
big bearing.

(b) Install washer on driving bevel gear, and install new big
bearing with special service tools.
SST
2. Change big bearing exterior ring of driving bevel gear

(a) Knock down big bearing exterior ring with copper stick
and hand hammer.
(b) Press in new big bearing exterior ring with special service
SST
tools.
3. Change small bearing of driving bevel gear

(a) Knock down small bearing exterior ring of driving bevel
gear with copper stick and hand hammer.
(b) Press in new small bearing exterior ring with special

service tools.
(c) Change new bearing inner ring before installing small
bearing.
SST

4. Dismantle two side bearing inner rings from differential

shell
(a) Dismantle side bearing inner ring on the side with bolts
from differential assembly with special service tools.
(b) When dismantling bearing inner ring on the other side ,
note do not damage driven bevel gear which is nipped by
vice.
Rubber shim plate
5. Dismantle the bolts used for fixing driven bevel gear with
wrench
Note: before dismantling, make installing marks on
driven bevel gear and differential shell.
Installing mark
Rubber shim plate
6. Disassembly of differential assembly

(a) Hit out pin with hand hammer and special service tools
after dismantling driven bevel gear.
(b) Knock out planetary gear shaft, and turn half-shaft gear
to take out planetary gear, then take out half-shaft an
stop shim.
7. Installation of differential assembly

(a) Clean differential shell.
(b) Harness stop sheet of half-shaft gear in half-shaft gear,
then install them in differential shell.

(c) Turn half-shaft gear, rotate to install it in planetary gear

and put through planetary gear shaft.
(d) Check the clearance of stop sheet of half-shaft gear and

differential shell.
If turning half-shaft gear and planetary gear flexibly, pull
planetary gear to inside, then measure the clearance of stop
sheet of half-shaft gear and differential shell with percent meter.
Proper range of clearance: (0.4-0.75)mm
If clearance value is not at the range above, it is necessary to
change half-shaft gear stop sheet and insure their thickness
on left and right sides is same.
(e) Hit in pin to forelock planetary gear shaft with special

service tools, at the same time, rivet the hit hole to prevent
pin from taking out.
SST
(f) Clean the surface of differential shell, and install driven

bevel gear on differential shell with copper stick.
Note: head the installing marks made in disassembly
when installing driven bevel gear, and hit in evenly on
circle direction, if there is any copper scrap on driven
bevel gear, remove it in time.
(g) Spread a sheet of thread locker on the bolts used for

fixing driven bevel gear, then screw them to regulated
moment.
Regulated screwing moment: (80-95)N·m
Note: when screwing bolts, it is necessary to accord with
the cross angle sequence, and screw them a little when
beginning, then screw to regulated moment evenly.

(h) Press two inner rings of side bearing in bearing

SST
position on both sides of differential shell on press
with special service tools.
SST
(i) Put a adjusting male tab in side bearing position of

Bearing Bearing front retarder shell and place it near exterior side.
(j) Install the other adjusting male tab together with
bearing exterior ring on the other side in front re-
Adjusting Adjusting male tab tarder shell with differential assembly.
male tab
(k) Install left and right bearing pressed cover and

screw bolts to regulated moment with wrench.
regulated moment: (90-115)N·m
(l) Turn driven bevel gear, and check swing difference

of driven bevel gear.
Maximal swing difference: 0.07mm
Installation of front retarder assembly

1. Harness adjusting washer in driving bevel gear, and in-
stall big bearing inner ring of driving bevel gear.
2. Clean front retarder shell, and install exterior ring of big
and small bearing in retarder shell.
3. Install driving bevel gear in front retarder shell, then in-
stall washer, spacer bush and small bearing inner ring.

4. Install driving bevel gear oil seal with special service tools.
Note: before instating oil seal, it is necessary to spread
SST
lithium base lubricating grease on lip, and rear plane of
oil seal should equal to top surface of front retarder shell
after hitting in oil seal.
5. Install assembly of main gear flange and dustproof cover.
6. Tighten main gear nuts to regulated moment with special

service tools, and firstly spread lithium base lubricating
grease on nuts.
7. Measure pre-load of big and small bearing of driving

bevel gear with torquemeter.
Range of pre-load: (1.2-1.7)N·m
8. Put differential assembly on corresponding position of

front retarder shell.
9. Choose a adjusting male tab to insert one side with

exterior ring of side bearing, and pull differential
assembly to the side with adjusting male tab.

10. Measure the clearance value of gear side between

driving and driven bevel gear with percent meter, and
choose the adjusting male tab on the side whose
clearance is 0.15mm.
11. Measure the thickness of this adjusting male tab.
12. After choosing this adjusting male tab, choose the

L1 adjusting male tab on the other side by the theoretical
L2
thickness of adjusting male tab on the other side equals
to that value which is calculated by the opposite distance
of front retarder two side bearing positions L1 minuses
the thickness of chosen shim, then minus the distance
of two side bearing exterior rings of differential assembly
L2.
13. Put a adjusting male tab in side bearing positions of

front retarder shell and press it close to exterior side.
14. Install the other adjusting male tab together with bearing
exterior ring on the other side in front retarder shell with
differential assembly.
Remark: insure there is no any clearance between chosen
adjusting male tab and front retarder shell.
15. Turn driven bevel gear to make differential assembly
close to front retarded shell.
16. Measure the clearance of gear sides of driving and
driven bevel gear with percent meter.
Proper range of clearance value: (0.15-0.25)mm
If measured clearance is not in this range, it is necessary to
increase and decrease thickness of male tab to adjust at the
same time.(If one side increase some thickness, the other side
should decrease the thickness with same number)
adjusting male tab and front retarded shell.

17. Adjust pre-load on axial direction of side bearing

(a) Take off two adjusting male tab, and re-measure the
thickness of two adjusting mal tabs.
(b) Re-install new adjusting male tab whose thickness is 0.
06-0.09 mm more than dismantled adjusting male tab,
and re-install them together with differential assembly in
retarded shell.
(c) RE-measure the clearance of gear sides of driving and

driven bevel gear
Proper range of clearance value: (0.15-0.25)mm
If measured clearance is not in this range, it is necessary to
increase and decrease thickness of male tab to adjust at the
same time.(If one side increase some thickness, the other side
should decrease the thickness with same number)
adjusting male tab and front retarded shell.
18. Install bearing press cover on both sides and screw it to

regulated moment
Remark: distinguish left and right when installing.
19. Measure total pre-loads of f ront retarded w ith

torquemeter.
Regulated moment: (1.8-2.4)N·m
20. Check mesh moulage of driving and driven bevel gear.

(a) Spread three to four teeth with red lead independently on
three different positions of driven bevel gear.
(b) Hold main gear flange, and turn driven bevel gear come-
and-go.

(c) Check the contacting situation of gear.

1 4
4 18-2 2
5 If mesh moulage of driving and driven bevel gear could not
5 15-2
5
accord with that shown in figure, choose proper adjusting

1.2
washer to amend by the concrete methods of mesh moulage.
Driven bevel gear convexity Driven bevel gear concave
Unit: mm
Big end contact Gear top contact
Choose the shim that could make drive small gear near driven bevel gear.
Small end contact Gear base contact
Contact is well
Choose the shim that could make drive small gear far from driven bevel gear.
(d) When changing washer, firstly dismantle driving

bevel gear, then dismantle big bearing of driving
bevel gear with special service tools.
SST
(e) Harness new adjusting washer and press it in big

bearing of driving bevel gear with special service
tools.
(f) Harness the adjusting washer of big bearing on
driving bevel gear, and install spacer bush in re-
tarded shell, then install main gear flange and screw
nuts to regulated moment.
(g) Re-measure the pre-load of main gear bearing
clearance and retarded assembly to make them
meet the requirement.

21. Measure the axial and radial flopping quantity of driving

33
bevel gear flange with percentage meter.
Maximal axial flopping quantity: 0.1mm
Unit: mm
Maximal radial flopping quantity: 0.1mm

If flopping quantity exceeds 0.1 mm, it is necessary to check
big and small bearing of driving bevel gear.
22. Rivet nuts of driving bevel gear
23. Screw two dual-head bolts in corresponding thread holes

of front axle shell with gas-drive wrench to the end.
(Before screwing dual-head bolts, spread a sheet of
thread locker evenly on the thread of front axle shell
and the spread quantity should cover the thread on front
axle shell)
Remark: the position of dual-head bolt should accord with
that before disassembly.
24. Spread a sheet of continue 1596 silicon rubber flat

sealant evenly on connecting surface of front axle shell,
and scrape it flat with flat plate.
Remark: keep away from thread to avoid sealant enters in
thread hold when spreading.

25. Install front retarded assembly on front drive axle shell,

and screw hexagon bolts and spring washer combination
part, then draw spring washer on dual-head bolts and
screw nuts to regulated moment. (Threads of all bolts
have been pre-spread thread locker)
Remark: tighten bolts evenly by relative bolts, and check
whether there is any clearance on contacting surface of
retarded shell and axle shell, and whether there is any rupture
of sealant. If having, dismantle retarded to re-install.
26. Harness oil filler plug on washer and screw it on front
drive axle shell.
Remark: do no screw tightly.
27. Screw oil drain plug on front drive axle shell
28. Install long half-shaft oil seal in front axle pipe with special
service tools.
Remark: pre-spread some lithium base lubricating grease evenly
on lip of oil seal, and install oil seal rightly.
29. Install roller pin bearing in long half-shaft with special
service tools.
SST
30. Install long half-shaft bearing with special service tools.

SST 31. Install snap spring to lock inner ring of long half-shaft
bearing with snap spring pliers.
SST
32. Head spline of long half-shaft small end in that spline of

front retarded half-shaft gear lightly, then hit it in front
retarded with copper stick and hand hammer.
Note: do not damage roller pin bearing in long half-shaft
big end spline when hitting in long half-shaft.

33. Install snap spring to lock exterior ring of long half-shaft

bearing with snap spring pliers.
34. Pull mechanical wheel of separator in roller pin bearing

inner ring of long half-shaft until it could not be pulled.
35. Check the electric clutch assembly

(a) Measure the clearance value between fork and fork
cover.
Range of clearance value: (0.2-0.4)mm
If clearance value is not in this range, it is necessary to change
electric clutch assembly and fork cover.
(b) Link electric clutch assembly on electric clutch tester
and connect 220 volt power to electric clutch tester to
check electric clutch (before testing, adjust testing
controller to make electric motor start time is 3 seconds,
the time from finding executer has not on position to
starting again is 2.5 seconds, and the time when controller
re-drives electric clutch is 2 seconds), and electric motor
has started for 3 seconds when the shift switch converts
from two-drive to four-drive, at the same time, light
flashes, clutch reaches four-drive statement, indicating
light shines usually. If it has not reached four-drive
statement, after delaying 2.5 seconds, controller drives
it again for 2 seconds, at the same time, light flashes, if
it has not reached all the time, indicating light flashes
twice continually, indicating light extinguishes for 1
Electric clutch tester
second, electric motor stops, this shows electric clutch
is not eligible, it is necessary to change with new one.
When clutch switches from four-drive to two-drive,
electric motor starts for 3 seconds normally, at the same
time, light flashes, when clutch reaches two-drive
statement, indicating light extinguishes usually. If clutch
has not reached two-drive statement at first time, after
delaying for 2.5 seconds, controller drives electric motor
for 2 seconds, at the same time, light flashes, if it has
not reached two-drive statement , indicating light flashes
twice continually, then extinguishes for 1 second, electric
motor stops, this shows electric clutch is not eligible, it
is necessary to change with new eligible one.

36. Harness fork cover on the spline of long half-shaft.

37. Install electric control separator shell on the flange of
front axle pipe, and screw it to regulated moment with
bolts.
Pre-spread a sheet of thread locker evenly on bolts, and its
dosage is that could cover all threads exactly.
Remark: before installing, clean the sundries on two connecting
surface of separator shell and front axle pipe flange, and pre-
spread 1596 silicon rubber flat sealant on front axle pipe flange.
At the same time, avoid sealant enters in thread hole.
38. Press in the plastic ventilation pipe on electric control
separator shell and front axle pipe.
39. Install two dowels in dowel hole of electric control
separator shell independently.
40. Spread a sheet of 1596 silicon rubber flat sealant evenly
on connecting surface of electric control separator shell
and electric control clutch, and scrape it flat with flat
plate.
Remark: connecting surface should be clean without any oil
dirt or other things, and sealant could not enter the shell chamber
and thread hole of electric-control separator.
41. Install electric-control clutch assembly on electric control
separator shell.
(a) Make fork bestraddle on fork cover.
(b) Head dowel hole of electric-control clutch to two dowels
and screw them with bolts, then screw bolts to regulated
moment.( Pre-spread one to two drips of thread locker
at the middle of thread)
42. Fix connecter assembly of front drive axle ventilation
pipe by bolts with wrench.
43. Link connecter assembly of front drive axle ventilation

pipe with the three interfaces of front axle pipe, electric-
control clutch and electric-control separator shell.

44. Unscrew oil filler plug of front drive axle shell and fill hypoid
gear oil in axle shell, then screw oil filler plug to regulated
moment.
Gear oil trademark: GL-5
Filled quantity: oil surface should equal to lower edge of
oil filler hole.
45. Fill gear oil in electric-control separator, then screw oil
filler plug to regulated moment.
Gear oil trademark: GL-5
Filled quantity: oil surface should equal to lower edge of
oil filler hole.
Installation of front retarder assembly

180
180
180
N ·m :Specified torque 180
1. Install front drive shaft assembly on retarder assembly.

180 180
2. Support front drive axle with jack, and put on hanger

plate with washer, then screw them to regulated moment.
Remark: do not put on front two bolts wrongly.
Regulated moment: 180N·m

3. Link front drive axle flange and transmission shaft with

Installing mark
bolts by the marks made before disassembly, then screw
them to regulated moment.
4. Install the beam under front drive axle, and screw the
licking bolts of this beam to regulated moment.
5. Link power tie-in of electric clutch on power-output wire
of vehicle.

Suspension system and vehicle axle(Rear)— Rear axle shaft SA-105
Rear axle shaft

Part drawing
Rear braking drum Half-shaft assembly ◆ Spring washer

◆ Inner oil seal
100 ± 10
Rear axle shell
Half shaft Bearing seat Double row tapered

roller bearings
◆ Retainer ring
◆ Exterior oil seal Rear axle oil seal seat
Rear arrester
Disassembly of rear axle shaft

1. Drain out gear oil in retarder
Unscrew oil drain plug at the bottom of axle shell, hold the
drained oil with clean vessel.
Remark: keep working environment clean.
2. Dismantle wheels
3. Dismantle rear braking hub
4. Dismantle handbrake bracing wire head from rear
arrester.

SA-106 Suspension system and vehicle axle(Rear)— Rear axle shaft
5. Dismantle half shaft assembly from rear axle shell

(a) Link half shaft flange surface with special tools by bolts.
SST
(b) Hold swimming hammer of special tools to impact it again
and again
Note: do not damage oil seal.
6. Dismantle retainer ring from half-shaft assembly

Dismantle retainer ring with lock pliers.
7. Dismantle half shaft from half shaft assembly

(a) Link the half shaft assembly with special linking plate,
and screw with nuts.
SST
(b) Put the assembly linking half shaft assembly with special
tools on press to press out half shaft.
(c) At the same time, dismantle oil seal seat of rear axle.
Remark: pressure of press=200KN, mileage=800mm.
Inspection and repair of rear axle shaft parts

1. Check the abrasion, damage and swing difference of
rear axle shaft and flange.
Radial maximal swing offset of shaft: 2mm
Maximal swing offset of flange end surface: 0.2mm
If rear axle shaft or flange has been damaged or worn, or
swing difference exceeds standard, change rear axle shaft.

Suspension system and vehicle axle(Rear)— Rear axle shaft SA-107
2. Check exterior oil seal

(a) Dismantle exterior oil seal with special tools, check
SST whether lip has been worn or damaged, and change it if
necessary.
(b) Note oil seal lip especially.
Note: do not damage oil seal when dismantling.
3. Check bearing
SST Check whether bearing has been worn or damaged, change it
if necessary.
4. Dismantle bearing
Press out double row tapered roller bearings with special
service tools.
5. Install new oil seal

SST (a) Clean the bearing seat.
(b) Spread proper HP-R lubricating grease on oil seal lip.
(c) Press in new oil seal with special service tools.
6. Change with new bearing

SST
Press in new bearing with hydraulic pressure machine.
7. Install assembly of new bearing seat (press in bearing

and oil seal)
(a) Put arrester assembly through half shaft, and put through
bolts-bearing seat.
(b) Install assembly of bearing seat, and install assembly of
bearing seat on half shaft.
Note: put bolts through the four bolt holes in assembly
of bearing seat, and head them rightly.

SA-108 Suspension system and vehicle axle(Rear)— Rear axle shaft
8 Install oil seal seat of rear axle

Install heated oil seal seat of rear axle on half shaft.
Requirement of heating installation: heat oil seal pressed seat
in 22# motor oil to 100, after heating all parts completely, take
out them to install immediately.
9. Install retainer ring

Install new retainer ring in the slot of half shaft with retainer
pliers.
10. Check inner oil seal of rear axle.

(a) Dismantle inner oil seal with special service tools, and
SST
check whether lip has been worn or damaged, then change
it if necessary.
(b) Note oil seal lip especially.
Note: do not damage oil seal when dismantling.
11. Install inner oil seal of rear axle

(a) Clean the flange of rear axle shell.
(b) Spread proper HP-R lubricating grease on lip of oil seal.
SST (c) Press in eligible inner oil seal with special service tools.
Installation of rear axle shaft
1. Install half shaft assembly in axle shell
(a) Clean half shaft and oil seal seat of rear axle.
(b) Arrange the half shaft spline with half shaft gear spline
correctly, then hit half shaft in axle shell with copper
stick.
Note: protect the assembly of oil seal lip and bracing
wire when installing, do not damage oil baffle sleeve
assembly, and head bolts of arrester to bolt holes of
rear axle flange.
Screwing moment:(90-110)N·m
2. Install handbrake bracing wire, and braking oil pipe.
3. Install rear braking hub
4. Try to discharge on braking system.
5. Install wheels

Suspension system and vehicle axle(Rear)— Rear retarder SA-109
Rear retarder
Part drawing
Adjusting loop
Adjusting washer
Differential assembly
Driving bevel gear

Rear bearing 78-115
◆ Bearing spacer bush Dual-ear stop washer
Oil baffle disc
Dustproof cover
Flat washer
18-25
Front bearing Bearing cover

◆ Oil seal Stop sheet
◆ Nut
Flange
Change main gear oil seal on vehicle

1. Drain lubricating grease in rear axle.
2. Take off transmission from retarder.
(a) Make installing marks on two flanges.
(b) Dismantle four bolts and nuts.
3. Dismantle the assembly of flange and dustproof cover

(refer to dissolving part of retarder)
4. Dismantle oil seal
Dismantle oil seal with special service tools.

SA-110 Suspension system and vehicle axle(Rear)— Rear retarder
5. Install new oil seal.

(a) Spread HP-R lubricating grease on lip of oil seal.
(b) Hit in new oil seal with special service tools.
depth of oil seal: 1.0mm
6. Install the assembly of flange and dustproof cover
7. Rivet the nuts of drive small gear
8. Link transmission shaft flange with retarder flange.

Installing mark
Arrange installing marks, then link them with bolts.
9. Check oil level in retarder

Change hypoid gear oil if necessary.
Oil trademark: GL-5 grade hypoid gear oil
Viscidity: SAE80W/90
Dosage: fill oil until oil level equals to lower edge of oil
filler plug.
Disassembly of retarder
1. Dismantle oil drain plug, and drain the oil in retarder.
2. Dismantle rear axle shaft
3. Cut off transmission shaft from retarder.
4. Dismantle retarder assembly
Disassembly of retarder
Remark:
● If noise of differential is too big, before dismantling
differential to find its reason, make following inspections.

● If there is any serious problem in differential, dismantle it
to repair if necessary.

1. Check the internal clearance of driven bevel gear

If internal clearance is not in that regulated range, adjust or
repair the pre-load of side bearing.
Standard clearance: (0.15-0.25)mm
2. Check the contact between gears of driving and driven

bevel gear.
Record the contacting position of gears.
3. Check the clearance between stop shim of half shaft
gear and differential shell.
Check the clearance between stop shim of half shaft gear and
differential shell with feeler gauge
If clearance is not in that regulated range, change it with proper
thrust washer.
4. Measure the pre-load of driving bevel gear.
Measure the pre-load of internal clearance between driving
and driven bevel gear with torquemeter.
5. Total pre-loads
Measure the total pre-loads with torquemeter.
6. Dismantle differential and driven bevel gear

(a) Make installing marks on retarder shell and cover of
differential bearing.
(b) Dismantle two stop sheets.
(c) Dismantle two bearing covers and two adjusting loops.
(d) Dismantle exterior ring of bearing.
(e) Dismantle differential from retarder shell.
Remark: make marks on dismantled parts to show their re-

installed positions.
L R

7. Dismantle the assembly of flange and dustproof cover

SST (a) Loosen the riveted part of nuts with hammer and chisel.
(b) Lock flange with special service tools, and dismantle nuts.
Note: do not use the nuts again after this using.
(c) Dismantle the assembly of flange and dustproof cover
8. Dismantle oil seal
Prize out oil seal with tools.
9. Dismantle driving bevel gear and spacer bush

SST Dismantle driving bevel gear, bearing and spacer bush from
retarder shell.
10. Dismantle oil raffle disco and inner ring of front bearing
11. Change rear bearing of driving bevel gear.

(a) Pull out rear bearing from driving bevel gear with press
and special service tools.
SST
(b) Install re-used adjusting washer and new rear bearing

SST on driving bevel gear with press and special service
tools.

12. Change of front and rear bearing exterior ring of driving

bevel gear
(a) Hit out front and rear bearing with hammer and copper
stick.
(b) Press in new bearing exterior ring with press and special
service tools.
13. Dismantle side bearing from differential shell

Pull out side bearing from differential shell with special service
tools.
14. Dismantle driven bevel gear

(a) Make installing marks on driven bevel gear and differential
shell.
(b) Dismantle linking bolts and locking sheet of driven bevel
gear.
(c) Knock down driven bevel gear lightly with rubber hammer
or copper stick.
Installation of rear retarder

1. Install bearing exterior ring of driving bevel gear
2. Install driving bevel gear rear bearing and adjusting

SST
washer
(a) Refer to “mesh situation of driving and driven bevel gear”
to choose proper adjusting washer.
(b) Press in rear bearing and chosen adjusting washer with
press.

3. Install spacer bush

Spacer bush (a) Choose the adjusting washer between rear bearing and
spacer bush by experience.
(b) Install spacer bush.
4. Install front bearing inner ring, oil baffle disco and oil
SST seal of driving bevel gear
(a) Put front bearing inner ring in retarder shell, and put on
oil raffle disco.
(b) Spread lubricating grease on oil seal position of retarder
shell and lip of oil seal, and put oil seal rightly, then install
by press.
5. Install the assembly of driving bevel gear, flange and

Press flat dustproof cover
(a) Install the assembly of flange and dustproof in retarder
shell, and press it flat with hand.
(b) Put the driving bevel gear installed spacer bush, rear
bearing and adjusting washer through flange by spline,
then install nuts.
(c) Screw flange, flat washer and main gear with nuts.
6. Lock flange tightly with special service tools, and screw

SST nuts with torque wrench.

7. Measure turning initial tension of bearing

New bearing: (1.2-1.7)N·m
Re-used bearing: (0.4-0.6)N·m
If it does not meet the requirement, change the adjusting washer
under spacer bush until it meets the requirement.
Specification for torque wrench: (0-3.5)N·m
(a) If measured value is less than standard value, decrease
the thickness of adjusting washer;
(b) If measured value is more than standard value, increase
the thickness of adjusting washer;¡¡
8. Install driven bevel gear on differential shell
(a) Link driven bevel gear with differential shell with bolts
and locking sheets.
(b) Screw them for 3 buttons with hand, then screw them
properly with gas-drive wrench.
(c) Screw them tightly with torque wrench.

Note: screw bolts by transverse angle.
(d) Tighten locking sheets with hand hammer and flat head
punch.
9. Install inner ring of differential side bearing

Press inner ring of differential side bearing on differential shell
SST
with press and special service tools.
SST

10. Install different assembly

(a) Dismantle bearing cover and distinguish left and right.
(b) Install differential assembly in retarder shell.
11. Install adjusting loop

Press bearing exterior ring rightly with adjusting loop, then
screw it properly. Adjust the clearance of main and auxiliary
gear to proper dimension.
12. Install bearing cover

(a) Head the installing marks on bearing cover and differential
shell rightly, and press the cover down with hand.
(b) Install dual-ear stop washer and nuts, and screw hexagon
nuts properly with gas-drive wrench.
Installing mark
13. Adjust mesh clearance of main and auxiliary gear

(a) Screw the four bolts on bearing cover with torque
wrench.
(b) Suck measure meter seat on end surface of retarder shell,

make its side head contact gear surface, then turn auxiliary
gear with hand and measure mesh clearance of main and
auxiliary gear

(c) If mesh clearance do not meet requirement, adjust left

and right adjusting loop with special service tools until
mesh clearance of main and auxiliary gear has met
requirement.
(d) Check mesh clearance of main and auxiliary gear again.

Mesh clearance: (0.13-0.18)mm
14. Check the contacting situation between driving and

driven bevel gear
(a) Spread four gears on the three different positions of driven
bevel gear with red lead powder.
(b) Turn driven bevel gear to two directions with hand, and
check the mesh of gear.
Big end contact Gear top contact
Choose the shim that could make drive small gear more
near driven bevel gear.
Small end contact Gear base contact
Contact is well
Choose the shim that could make drive small gear more
far from driven bevel gear.

f the contacting situation between gears is bad, choose

Rear bearing proper washer to amend by following table. Fair difference
Washer of washer thickness is ±0.01mm. Washer thickness (unit: mm)
Group number Washer thickness Group number Washer thickness
1 1.6 7 1.9
2 1.65 8 1.95
3 1.7 9 2
4 1.75 10 2.05
5 1.8 11 2.1
6 1.85 12 2.15
15. Install stop washer and stop sheet
(a) If mesh moulage of main and auxiliary gear could meet
requirement, lock stop washer with hand hammer and
punch.
(b) Install stop sheet, spring washer and bolts, and screw
bolts.
(c) Knock lower end of stop sheet in adjusting loop hole
with punch and hand hammer.
16. Measure total pre-loads
If pre-load is not in regulated range, change the shim between
spacer bush and rear bearing until it could meet requirement.
(a) If pre-load is more than standard value, change adjusting
washer.
(b) If pre-load is less than standard value, screw nuts again,
and screw them slowly with less than 160N·m.
Note: when screwing nuts, if moment exceeds maximal
value, change adjusting washer and repeat the progress
of pre-adding load. Do not use the method that loosens
main gear nuts back to decrease pre-load.
17. Check and adjust the flop of flange
(a) Suck percent meter seat on retarder shell, and make
percent meter head contact with end surface of flange,
then turn the flange, at this time, mote observing swing
offset range of meter pin.
Total flopping fair difference of end surface: 0.10mm
(b) Suck percent meter seat on retarder shell, and make

percent meter head contact with inner pathway of flange,
then turn the flange, at this time, mote observing swing
offset range of meter pin.
Total flopping fair difference of radial direction: 0.10mm

18. Rivet the nuts of driving bevel gear
Installation of the assembly of rear retarder

and differential
1. Install the assembly of retarder and differential on rear
axle assembly.
(a) Clean the contacting end surface on axle shell for installing
the assembly, then spread silicon rubber flat selant evenly.
(b) Install the assembly of retarder and differential in rear
axle shell, then put on washer and nuts and screw those
nuts by regulated moment.
2. Install the assembly flange of retarder and differential
on flange of transmission shaft
(a) Head the installing marks, and link them with four bolts
and nuts, then screw them by regulated moment.
(b) Install the assembly of half shaft and arrester, and adjust
braking oil way to make sub-pump of arrester fill with
braking liquid, then screw oil drain plug.
3. Fill in retarder with gear oil
Oil trademark: Oil trademark: GL-5 grade hypoid gear
oil
Viscidity: SAE80W/90
Dosage: fill oil until oil level equals to lower edge of oil
filler plug.
Screw oil filler plug

SA-120 Suspension system and vehicle axle(Rear)— Rear differential
Rear differential (common type)

Part drawing
Planetary gear shaft

◆ Locking sheet
65-95
Tapered roller bearing
Straight pin
Half-shaft gear
Planetary gear
Differential shell
Half-shaft gear stop shim
Driven bevel gear
Planetary gear stop shim

Disassembly of differential
1. Dismantle the assembly of retarder and differential
2. Dismantle differential from the assembly of retarder and
differential
Change of differential parts

1. Disassembly of differential
Hit out pin with hammer and punch. Dismantle planetary gear
shaft, two half-shaft gears, two stop shims of half-shaft gear
and two stop shims of planetary gear.

Suspension system and vehicle axle(Rear)— Rear differential SA-121
2. Installation of differential
(a) Harness stop shim of half-shaft gear in half-shaft gear,
then install them in differential shell.
Unit: mm
Group number 1 2
Thickness 1.2 1.5
(b) Install stop shim of planetary gear, then roll planetary

gear in differential and put it through planetary gear shaft.
Unit: mm
Group number 1 2
Thickness 0.8 1
(c) Check the clearance between stop shim of half-shaft gear

and differential shell with filler gauge.
If the clearance is not in regulated range, change it with
stop shim of half-shaft gear with different thickness.
(d) Install straight pin

● Hit in pin by the hole on differential shell and
planetary gear shaft with hammer and punch.
● Rivet the pin hole of differential shell.
Installation of differential
1. LInstall differential assembly in retarder shell
2. Install differential

SA-122 悬架系统和车桥—后悬架
后悬架
元件图
钢板弹簧前销轴
180 ± 15
后吊耳挡板 180 ± 15
后钢板弹簧总成
后吊耳总成
U 形螺栓
后吊耳衬套
后缓冲块
U 形螺栓护板
后减振器固定垫片二
托瓦
180 ± 15
后减振器固定垫片一
后减振器
80 ± 10
牛顿 · 米：规定扭矩
钢板弹簧和减振器的拆卸与安装
1. 用千斤顶顶起车身并用架子托住
(a) 用千斤顶顶起车身并用架子托住。
(b) 将桥壳放低，直到板簧放松至不受负荷没有张力为
止，保持这种状态。
2. 拆下减振器

悬架系统和车桥—后悬架 SA-123
3. 拆下 U 形螺栓
(a) 拆下 U 形螺栓的安装螺母。
(b) 拆下托瓦（弹簧下座）
(c) 拆下 U 形螺栓。
(d) 拆下 U 形螺栓护板。
4. 拆下钢板弹簧
(a) 拆下钢板弹簧前销轴固定螺母。
(b) 拆下钢板弹簧前销轴。
(c) 从支架上将钢板弹簧脱开。
(d) 拆下后吊耳总成和后吊耳挡板，拆下钢板弹簧。
钢板弹簧的更换
1. 将弹簧夹箍扳开
用凿子撬开弹簧夹箍。
2. 拆下中心螺栓
用虎钳夹住弹簧上靠近中心螺栓的地方，拆下中心螺
栓。
3. 必要时，更换弹簧夹箍
(a) 用钻头钻掉铆钉头，将铆钉打出。
(b) 将新的铆钉打入钢板弹簧和弹簧夹箍的孔内。用压
力机进行铆接。

SA-124 悬架系统和车桥—后悬架
4. 安装弹簧中心螺栓
(a) 对准钢板弹簧的中心孔，用虎钳夹住钢板弹簧。
(b) 装上和拧紧弹簧中心螺栓。
拧紧力矩：( 5 0 ± 5 ) N ·m
5. 将弹簧夹箍弯好
用榔头将弹簧夹箍弯到正确位置。
钢板弹簧的安装
1. 安装钢板弹簧
(a) 将钢板弹簧的前卷耳装入前支架内。
(b) 装上前卷耳销轴固定螺栓。
(c) 用手装垫片 Q401 14，并拧紧前卷耳销轴螺母。
(d) 将钢板弹簧的后吊耳装入后支架内，装上后吊耳总
成。
(e) 装上后吊耳挡板，用手指拧上螺母。
2. 安装 U 形螺栓
(a) 将上护板摆正放到桥壳上。
(b) 将 U 形螺栓装到桥壳上。
(c) 在钢板弹簧下面，将 U 形螺栓装入下托瓦孔中之后
再拧上螺母。
(d) 扭紧 U 形螺栓的安装螺母。
拧紧力矩：( 18 0 ± 1 5) N ·m

悬架系统和车桥—后悬架 SA-125
备注：交叉拧紧 U 形螺栓螺母，使所有 U 形螺栓伸出托

瓦下面的长度基本相同。
所有螺栓伸出长度基本相同
3. 安装减振器
(a) 先将减振器上端连接环装入车架的销轴上，并拧紧
螺母。
拧紧力矩：( 8 0 ± 1 0 ) N ·m
(b) 再将减振器下端连接环装入托瓦的销轴上，并拧紧
螺母。
拧紧力矩：（8 0 ± 1 0 ) N ·m
备注：安装减振器固定垫片一、二时，注意其方向，
应将垫片的凸面均朝向减振器。
4. 使后悬架进入稳定状态
(a) 装上车轮。
(b) 拆除架子，使汽车上下跳动几次，从而使悬架进入
稳定状态。
5. 拧紧前卷耳销轴和后吊耳销轴的螺母
上紧前卷耳销轴螺母。
拧紧力矩：( 18 0 ± 1 5) N ·m
上紧后吊耳销轴螺母。
拧紧力矩：( 18 0 ± 1 5) N ·m

BR-1
Braking system
Page
Precautions ................................................................ BR-2

Troubleshooting .......................................................... BR-2
Overhaul of braking system ........................................ BR-6
Brake pedal ................................................................. BR-9
Parking brake control lever assembly .......................... BR-11
Vacuum booster with brake cylinder assembly ............ BR-13
Front brake ................................................................. BR-15
Rear brake .................................................................. BR-22
Loading sensing pressure proportioning valve ............. BR-30

BR-2 Braking system — Precautions,Troubleshooting
Precautions
1. Always be careful when replacing each part, since any
error shall affect the performance of the braking system
and lead to accidents and dangers during running. The
parts to be replaced must be those of the same part No.
or type.
2. It is essential to maintain the cleanliness of each part
and position when repairing the braking system.
Troubleshooting
Pedal too Wear of brake shoe Replace the brake shoe
low or soft Wear of brake stop Replace the brake stop
Oil leakage of braking system Repair the oil leakage position
Failure of master cylinder Repair or replace the master cylinder
Existence of air in braking system Exhaust the air in the braking system
Failure of brake wheel cylinder Replace the brake wheel cylinder
Failure of rear brake automatic regulator Repair or replace the automatic regulator
Brake drag Inappropriate adjustment of parking brake Adjust the parking brake
Parking brake cable stuck Repair as required
Inappropriate adjustment of booster push rod Adjust the push rod
Failure of tension spring or return spring Replace the tension spring or return spring
Pipeline stuck Repair as required
Break up or deformation of brake shoe Replace the brake shoe
Break up or deformation of brake stop Replace the brake stop
Breakage of automatic regulator Replace the automatic regulator
Failure of master cylinder Replace the master cylinder
Braking Inappropriate inflation of tire Inflate the tire to appropriate pressure
distance a Oil stain or lubricant on brake shoe or brake Check and find out the cause，Replace the
little too stop brake shoe or brake stop (according to Job
large Instructions)
Deformation, wear or smoothing of brake shoe Replace the brake shoe
Deformation, wear or smoothing of brake stop Replace the brake stop
Deformation of brake drum or brake disc Replace the brake drum or brake disc
Failure of tension spring or return spring Replace the spring
Failure of wheel cylinder Repair the wheel cylinder
Failure of brake wheel cylinder Replace
Brake stop stuck Replace the brake stop (according to Job
Instructions)
Brake Oil stain or lubricant on brake shoe or brake Determine the causes and replace the brake
pedal rigid stop shoe or brake stop
Deformation, wear or smoothing of brake shoe, Replace the brake shoe
wear of brake drum
Deformation, wear or smoothing of brake stop Replace the brake stop
Failure of brake wheel cylinder Replace
Failure of brake booster Replace the booster
Inappropriate vacuity Repair or replacement as required
Brake pipeline stuck Repair or replacement as required

Braking system — Troubleshooting BR-3
Cracking or clatter (Drum brake)
sound is heard when Brake shoe stuck on flange of brake bottom plate Fill up lubricant
using brakes Wear of flange of brake bottom plate Replace the lubricant flange
Brake shoe compression spring loose or lost Replacement

Fixed bolt of brake bottom plate loose Tightening
(Disc brake)
Brake stop supporting plate loose or lost Replacement
Holddown bolt loose Tightening
Rustle or quack sound Wear of brake shoe lining or brake stop Replace it, if abrasion is serious,
is heard when using perform fine finishing on the brake
brakes drum or rotor
Interference between brake caliper and wheel or Replacement as required
rotor
Interference between dust cap and brake disc and Correction or replacement
between brake bottom plate and brake drum
Failure of other braking system parts Repair or replacement as required
Squeak, continuous Wear or abrasion of brake drum and brake shoe Check, repair or replacement
squealing, creak or lining, rotor and brake stop
vibrating sound is Defilement, oil stain or smoothing of brake lining Clean or replace it
heard when using or brake stop
brakes Improper use of brake lining or brake stop Check and replacement
Attention: friction Adjustment error of brake pedal or booster push Check and adjustment
matters of the brake rod
shall produce intrinsic (Disc brake)
noise and heat during Loss or damage of brake stop silencer sheet Installation for
friction, thus emitting complement/replacement
energies. Therefore, Brake stop abrasion indicator interfering with Replacement
the occasionally heard rotor due to wear of brake stop
squeak sound is Burrs or rusts on brake caliper Clean and remove burrs
regarded as normal. It (Drum brake)
shall become worse in Rigidity of brake shoe compression spring soft, Check, repair or replacement
bad environment, e.g. damaged or inappropriate, compression spring pin
coldness, torridity, and spring of brake shoe loose or damaged, and
high humidity, crack on flange of brake bottom plate
snowing, saltness or
mud. The occasional
squeak sound would
neither lead to fatal
error of the brake, nor
to degradation of
effectiveness of the
brake.

BR-4 Braking system — Troubleshooting
Continuous Adjustment error of brake pedal or booster push rod Check and adjustment
squealing and squeak Poor return of brake booster or master cylinder or Check, repair or replacement
sound is heard when wheel cylinder
brake is not working (Disc brake)
Piston rusting or stuck Check and fill up lubricant as
required
Improper position of brake stop inside brake caliper Repair or replacement
Friction of rotor cover against cover of brake caliper Repair or replacement
Inappropriate installation of brake stop supporting Repair or replacement
plate inside disc brake
Brake stop abrasion indicator interfering with rotor Replacement
due to wear of brake stop
(Drum brake)
Compression spring of brake shoe soft, damaged and Replacement
inappropriate
Crack on flange of brake bottom plate Repair or replacement
Interference between brake drum and bending or Repair or replacement
warping brake bottom plate
Inappropriate processing of brake drum which leads Replace the brake drum
to its interference with brake bottom plate or brake
shoe
Continuous Other parts of braking system:
squealing and squeak Loose or redundant parts in braking system Check, maintenance and
sound is heard when replacement as required
brake is not working Brake lining burnishing due to rear brake drum too Check, maintenance and
tight replacement as required
Wear, damage or insufficient lubrication of wheel Check, maintenance and
bearing replacement as required
Creak, clatter or Stones or foreign bodies involved in interior of Remove the foreign bodies, e.g.
cluck sound is heard wheel protecting cover the stones
when brake is not Wheel hub nut loose Tighten it to stipulated torque and
working replace it if bolt hole is expanded
Improper adjustment of brake pedal or booster push Check and adjustment
rod
Wear, damage or insufficient lubrication of wheel Check, oiling or replacement
bearing
(Disc brake)
Curling on brake stop supporting plate or brake stop Check, repair or replacement
outer end
Poor silencer sheet Check, replacement as required
Wear of sliding sleeve Check, replacement as required
Holddown bolt loose Check, tightening as required
Poor return of piston Check, repair or replacement
(Drum brake)
Parts loose or redundant Check it, take it off or repair it

Braking system — Troubleshooting BR-5
Serious leakage of master Oil leakage of master cylinder, wheel Eliminate leaking places
cylinder oil storage cylinder or hydraulic pipeline
Insufficient vacuum boost, no Vacuum leak of vacuum booster not in Check and replace the damaged
boost after engine flame out that operation parts
can lead to unstable idle speed Front and rear housing of booster unsealed Replace the vacuum booster
of engine when serious Front and rear air seal of booster out of Replace the vacuum booster
work
Leakage of vacuum cone way valve Replace the vacuum cone way
valve assembly
Brake pedal heavy, no boost Vacuum leak of vacuum booster not in Replace the front and rear air
effect operation seal and the booster diaphragm
Breakage of booster diaphragm Replace the vacuum booster
Breakage of control valve ring cup Replace the control valve
assembly
When stepping pedal several Compensate opening of master cylinder Check the brake fluid
times in a row, pedal changes jammed specification
successively till blocked Adjust the position of the hitch
yoke
Vehicles can not be stopped by Cable loose Adjust the self-locking nut of
pulling up manual brake the manual to strain the cable
Cable break Replace the cable
Breakage of cable cartridge or crack on Replace the damaged parts
balancing plate slot of manual brake
Damage of manual brake mechanism due to Replace the manual brake
incorrect manipulation mechanism
Parking brake indicator lamp is Parking brake indicator lamp damaged Replace the parts
not on Plug of manual brake switch loose Tighten the plug
Manual brake disconnected with its Fix the manual brake switch
foundation
Manual brake rusted or damaged Replace the manual brake
switch
Misplacement of control lever gripper Adjust the control lever gripper
Abnormal sound due to sway of Deformation of manual brake parts due to Replace the manual brake
manual brake incorrect manipulation

BR-6 Braking system — Overhaul of braking system
Brake lamp switch

Overhaul of braking system
Pedal push rod Inspection and adjustment of brake pedal
1. Check that the pedal height is correct
Distance from pedal to lower front wall plate: 152mm
Distance from pedal to lower front wall plate: 152mm
2. Adjust the pedal height if necessary
(a) Disconnect the wire connector of brake lamp, loosen
the lock nuts and rotate the brake switch to screw it out
to such a position that it does not contact the brake pedal
limit block;
(b) Loosen lock nuts of the connecting control lever, rotate
the connecting control lever with slip joint pliers to make
the pedal height reach the standard value; after that tighten
the lock nuts, meanwhile ensure the spare working travel
Pedal height of pedal push rod is 1mm.
(c) Rotate the brake lamp switch until it contacts the brake
pedal limit block, then keep rotating for another 1/2 to 1
circle and tighten the lock nuts;
(d) Connect the brake lamp switch wire connector;
(e) The brake lamp should not be turned on when the brake
pedal is released.
3. Check the free pedal travel

Pedal push rod Free pedal travel: (4-6)mm
Step the brake pedal 2 to 3 times when the engine is off, then
push down the brake pedal after influence of the brake booster
is eliminated until pressure is met to measure the amount of
movement (free travel).
It must meet the requirements of the standard value.
4. Adjust pedal travel if necessary
(a) When amount of travel is incorrect, rotate pedal push
rod to adjust free travel.
(b) Confirm free pedal travel by starting the engine.
(c) Check pedal height after adjustment of free pedal travel.
(d) The relative front wall height difference between brake
pedal and clutch pedal is (0 to 8) mm.
(e) The relative front wall height difference between brake
pedal and accelerator pedal is (45 ± 5) mm.
Free pedal travel
5. When clearance between brake pedal shaft and bush
is too large, dismantle the pedal and replace

Braking system — Overhaul of braking system BR-7
Inspection and renewal of brake fluid hydraulic system;

Brake fluid affects directly brake performance and 5. Yardstick for completion of rinse: brake fluid that
operating condition and service life of braking system flows out of discharge valve is clear without dirt.
elements. It has a good hydroscopicity and tends to Emptying of hydraulic system
absorb water, thus can lead to corrosion of metal If brake fluid inside the whole hydraulic system is to
parts and deterioration of rubber parts. Deterioration be emptied, loosen all the air bleed screws with each
of brake fluid due to contamination or mix of different one inserted with a hose to let brake fluid flow into
brake fluids often causes boiling and gasification of the container, then slowly step the pedal until only
brake fluid and degradation of brake performance. air overflows. During the process ensure all the valves
Therefore when filling or renewing brake fluid open.
attention must be paid to: Air discharge of hydraulic system
1. The container for holding brake fluid must be
Hydraulic braking system must work in no air
capped and sealed;
condition, for any air that enters the system shall
2. As brake fluid is toxic and harmful to lacquer
cause soft brake or ineffective brake. When operating
finish, those spattered onto surface of vehicle
on braking system or whether there is air inside the
body must be wiped off immediately; braking system is not clear, it is essential to discharge
3. When water or other contaminants are found the air inside the system.
in brake fluid, and piston seal of master cylinder
1. Order of discharge
is already damaged, brake fluid inside braking
(a) When whether there is air inside the braking
system and all the rubber parts including brake
system is not clear, air discharge must be
hose bust be replaced.
performed on master cylinder first;£»
4. Correct brake fluid level inside the fluid (b) Then discharge other valves if installed;£»
reservoir shall be maintained between MAX and (c) Other order principles: discharge in turn from
MIN level.
the wheel brake that is farthest from master
Brake fluid level inside the fluid reservoir shall be
cylinder; the discharge order for vehicles with
checked after 1000KM running, and if the level does
steering wheels on the left: right rear wheel –
not meet the requirements, more brake fluid shall be
left rear wheel – right front wheel – left front
filled into the fluid reservoir until MAX level is wheel.For vehicles with steering wheels on the
reached. right: left rear wheel – right rear wheel – left
Overhaul of hydraulic element and front wheel – right front wheel.
rinse of system 2. Method for air discharge
1. If oil based solvent enters the hydraulic system, (1)Manual discharge
the whole system shall be rinsed and all rubber Take brake pedal and master cylinder as power
parts shall be replaced; sources, discharge brake fluid that contains bubbles
2. Wash hands clean before installation of new from the system when air bleed screws are loosened.
rubber parts or other elements; This is often completed by simultaneous operation
3. During overhaul or rinse of hydraulic elements, of two people with one stepping brake pedal and the
use of normal solvents (e.g. kerosene or other operating air bleed screws. During the process,
gasoline, etc.) is forbidden, and solvents that attention must be paid to:
can be used are confined to degreased alcohol (a) With ignition switch at off position, step the
or brake fluid; pedal for several times in order to remove the
4. After overhaul of elements, brake fluid inside vacuum reserved or hydraulic pressure;
the system shall be discharged, and after the (b) Fill clean brake fluid into master cylinder to
system is rinsed with new brake fluid, fill in new correct (stipulated) level before and after air
brake fluid and discharge the air inside the discharge;

BR-8 Braking system — Overhaul of braking system
(c) Fluid level needs to be checked frequently in (d) Slowly press down the pedal and do not release
order to keep the volume of fluid reservoir above it, observe whether brake fluid that flows out
half of the total volume; of the joints contains bubbles;
(d) Air bleed screws shall only be loosened when (e) Tighten joints of brake line;
the pedal is stepped down, and tightened before (f) Let assistant release the pedal and wait for 15s;
the pedal is released, meanwhile observe (g) Repeat the above mentioned steps until air is
whether brake fluid discharged contains completely discharged;
bubbles; (h) Open joints of brake line at upper front end of
(e) System valves shall not prevent air discharge; master cylinder and repeat the above mentioned
(f) When brake fluid that flows out of hose or steps.
joint contains no bubbles, air inside the system ⑵ Air discharge of wheel brake
has been discharged, while if bubbles come (a) Check brake fluid level of fluid reservoir in
out of the hose inserted into brake fluid with master cylinder, fill more fluid when necessary,
pedal stepped down, air still exists in the system. check repeatedly and fill up in time during air
(g) Keep the free end of hose immersed in brake discharge;
fluid to prevent air from entering when screws (b) Place one end of air discharge hose on air bleed
are loosened; screws and insert the other end below the fluid
(h) During the process of air discharge, that gently level of some of the brake fluid;
knock the casting position of vibrating brake (c) Let assistant slowly step the pedal for several
device with rubber hammer is conducive to times until the pedal can not be pressed down
removal of deep layer bubbles of brake fluid; after successive rises and press feet against
(i) If whether there is air inside the braking system the pedal forcibly;
is not clear, air discharge must be performed (d) Loosen air bleed screws and observe whether
to master cylinder before that of wheel cylinder brake fluid that flows out contains bubbles, at
or brake caliper; the moment the pedal is slowly descending;
(j) Normally air discharge is performed on all the (e) When brake pedal is approaching travel end or
wheels; brake fluid flowing out contains no bubbles,
(k) Hoses for air discharge with cone way valve tighten air bleed screws;
may be used to prevent air from sucked into (f) Let assistant release the pedal and wait for 15s;
the system reversely. (g) Repeat the above mentioned steps until brake
⑵ Pressure discharge fluid flowing out contains no bubbles after air
Pressure air discharge device may be used for air bleed screws are loosened;
discharge of braking system if conditions permit. (h) Perform air discharge to all the wheels with
3. Order of discharge the same method;
⑴ Air discharge of master cylinder (i) Switch on the ignition switch after air discharge
As master cylinder has no air bleed screws, the of the whole system is completed;
following steps may be observed: (j) Check travel of brake pedal and counteracting
(a) Check brake fluid level of fluid reservoir in force of the pedal;
master cylinder, and add brake fluid when (k) Check the indication of brake alarm lamp, and
necessary; eliminate troubles or discharge air repeatedly
(b) Slowly open joints of brake line at upper front when necessary;
end of master cylinder until brake fluid flows (l) Complete air discharge by filling brake fluid
out from the opening; level of fluid reservoir to stipulated level.
(c) Reconnect brake line but do not tighten it;

Braking system — Brake pedal BR-9
Brake pedal
Part drawing
Brake pedal return spring
Brake pedal shaft
Welding assembly of brake pedal bracket

Brake pedal bush
Spring washer
Brake lamp limit block
Braking lamp switch

Nut
Welding assembly of brake pedal arm Pedal cover
Disassembly of brake pedal assembly

1. Dismount nuts and spring washer with hexagon wrench
2. Dismount brake pedal shaft, brake pedal bush, welding

assembly of brake pedal arm, brake lamp limit block,
return spring of brake pedal and welding assembly of
brake pedal bracket.
Grease coating
Assembly of brake pedal assembly
1. Coat interior of brake pedal axle tube and inner wall of
brake pedal bush, and mount the bush into brake pedal
axle tube.

BR-10 Braking system — Brake pedal
2. Mount pedal cover, brake lamp limit block and return

spring of brake pedal on welding assembly of brake
pedal arm.
3. Assemble welding assembly of brake pedal bracket and

the assembled brake pedal arm assembly with brake
pedal shaft, nuts and spring washer, and tighten them
with a 30N·m wrench.
Nut

Braking system — Parking lever assembly BR-11
Parking lever assembly

Part drawing
Handle
Self-locking nut
Control lever assembly
Switch
M4 screw
Cable assembly
Disassembly of parking lever assembly

Remark: parking lever is connected to rear parking brake cable
assembly through cable balancing plate, and mounted to vehicle
body floor through 3 connecting bolts, thus other operations
can only be made after the two connections are loosened.
1. Dismount handle
Grip the end of the handle and pull it out.
Remark: the handle and the control lever are bound together
by viscose, thus it is necessary to heat them for disassembly.
2. Dismount cable assembly

Special socket
wrench (M6) Screw special tools for self-locking nuts (M6 special socket
wrench) out of adjusting screw lever of cable assembly; then
Self-locking nut
dismount cable assembly from control lever assembly.
Remark: sealed cowling of cable assembly is connected to
foundation of control lever assembly through 2 barbs.

BR-12 Braking system — Parking lever assembly
3. Dismount switch
Screw off M4 screws that connect switch and foundation
with a philips driver, then pull out the switch.
Assembly of parking brake control lever as-

sembly
1. Assemble switch
Dismount parking brake switch and premount it in location
hole on foundation, then screw tight M4 screws that connect
switch and foundation with a philips driver.
Tightening torque:(2 ± 0.5)N·m
2. Assemble cable assembly

Special socket First let screw lever of cable assembly get through the square
wrench (M6) guide hole of guide plate on control lever assembly, then mount
Self-locking nut sealed cowling on foundation of control lever assembly with
2 barbs; finally screw in self-locking nuts with special tools
(M6 special socket wrench) and adjust them to appropriate
position.
3. Assemble handle
Coat the location where handle contacts control lever with
viscose, then nest handle on control lever.
Remark: control lever has a limit position for handle, thus
handle shall be nested to the bottom.
Technical requirement
1. Control travel of parking lever is (45 ± 1) degree.
2. Parking lever is mounted on floor with 3 connecting bolts.
Tightening torque: (23±2)N·m
3. Pulling up (8 – 10) teeth of parking lever shall have brake
effect.
4. Parking brake control handle force shall not exceed
600N.

Braking system — Vacuum booster with brake cylinder assembly BR-13
Vacuum booster with brake cylinder assembly

Part drawing
Hitch yoke Lock pin

Spacer (riser block)
Pin shaft
Hitch yoke lock nut

Cup cap
Absorbing pad (shim)
Cup
Hexagon flange nut
Booster assembly
Vacuum alarm switch assembly
Hexagon socket cross recessed screw
Master cylinder connecting nut

Master cylinder assembly
Disassembly procedure of vacuum booster

with brake cylinder assembly
Attention: booster is connected and mounted to pedal
bracket on front wall plate with 4 lock nuts, and is
connected to pedal arm through pin shaft and lock pin
directly, thus pipe joint shall be screwed open with S10
open end wrench before dismantle of assembly, then
the connection of lock pin and pin shaft to pedal shall
be disconnected forcibly with pliers, and lock nuts be
loosened, after that operation of booster assembly is
Brake cylinder permissible.
assembly
1. Disassembly of assembly and master cylinder
Dismount two lock nuts with a hexagon head wrench, then
take off master cylinder assembly from booster and place it
on clean cardboard or soft cloth.
Booster assembly
Nut

BR-14 Braking system — Vacuum booster with brake cylinder assembly
2. Disassembly of oil cup assembly and master cylinder

Oil cup assembly
assembly
Screw off cross recessed hexagon head screws with a philips
Slot driver, then pull out slots on the same side of oil cup from
dummy club of master cylinder directly with hands (here do
not overexert), and tilt oil cup in pull-out direction to
Cross recessed
Master cylinder
disassemble.
hexagon head
Dummy club assembly
screw
3. Disassembly of oil cup and oil cup cap

Screw off the cap from oil cup directly with hands.
Cup
Oil cup cap
4. Disassembly of vacuum alarm switch assembly and

Vacuum alarm switch assembly
booster
Screw off vacuum alarm switch assembly from booster
assembly (the two are connected by threads) with special tools.
Booster assembly
5. Disassembly of shim and riser block

Shim
As shim and riser block are directly placed on booster, they
can be taken off by hand.
Riser block
6. Disassembly of pin shaft and lock pin

This location needs to be opened by pliers
Forcibly open the end of lock pin with pliers, take out lock
Lock pin pin, then take off pin shaft from hitch yoke.
Pin shaft
Hitch yoke

Braking system — Front brake BR-15
7. Disassembly of hitch yoke

Hitch yoke lock nut
Hitch yoke When disassembling hitch yoke, please note first measure the
distance between center of hitch yoke and rear housing plane,
and perform assembly according to this distance. To screw
off hitch yoke from control valve rod, first put a shaft whose
diameter is a little smaller than that of hitch yoke hole through
Control valve rod the hole, then grip it and loosen lock nuts of hitch yoke with a
wrench.
Front brake
Part drawing
Copper washer
25-35
Brake hose bolt
Guide pin
50 ± 5
Guide pin gum cover
Caliper body
Anchor pin, guide pin dust cap
25-35
Front brake hose
Piston
Piston dust cap
Air bleed screw cap
7-10
Anchor pin
Rectangular seal ring Anchor pin, guide pin dust cap

Circlip sheet 2 of brake stop
Circlip sheet 1 of brake stop

Inboard silencer sheet compound piece
Tong hold
Inboard brake stop
silencer sheet
Alarm piece for wear limit of brake stop

Outboard silencer sheet
compound piece Circlip sheet 1 of Circlip sheet 2 of brake stop
N ·m : Specified torque brake stop Brake stop assembly
Replacement of brake stop

Remark: in the case of service brake, if continuous squealing
sound is heard from front wheels, check alarm piece for wear
limit of brake stop. In case trace of alarm piece rubbing brake
disc is found, brake stop shall be replaced.
1. Dismount front wheels

BR-16 Braking system — Front brake
2. Check the thickness of brake stop friction material

Check the thickness of brake stop friction material through
sightglass on caliper body, and if it does not fall within stipulated
range, replace the friction material.
Minimum thickness: 2.0mm
3. Raise brake caliper body

(a) Dismount hexagon flange bolts
(b) Raise brake wheel cylinder and hang it up with ropes in

order to protect brake oil pipe.
Remark: do not unscrew brake oil pipe and air bleed plug.
4. Dismount the following parts:

(a) Two brake stops
(b) One silencer sheet
(c) Two silencer sheet compound pieces
(d) One alarm piece for wear limit of brake stop
(e) Four brake stop circlip sheets
5. Measure thickness of brake disc

(see page SA – 18)
6. Measure radial oscillation of brake disc
(see page SA – 18)

7. Install brake stop circlip sheet
8. Install new brake stop

(a) Mount alarm piece for wear limit of brake stop on inboard
brake stop.
(b) Mount one silencer sheet and one silencer sheet
compound piece on inboard brake stop.
(c) Mount only one silencer sheet compound piece on
outboard brake stop.
(d) Install two brake stops to locate alarm piece for wear
limit at interior of brake caliper.
Attention: grease and paint contamination on working
surface of brake stop and brake disc are not allowed.
(e) Suck a small amount of brake fluid out of liquid reservoir

(to prevent brake fluid inside liquid reservoir from
overflowing).
(f) Press in the piston with special tools.
9. Install brake wheel cylinder

Install and tighten hexagon flange bolt.
Remark: replace brake stop on one wheel at a time to avoid
ejection of piston on the other wheel.
10. Install front wheels
Tightening torque of wheel fixing nut: (135 ± 15)N·m

Dismount of brake wheel cylinder

1. Dismount front brake hose
Dismount front brake hose, and hold the brake fluid with a
container.
2. Dismount brake wheel cylinder from caliper bracket

(a) Dismount hexagon flange bolt, anchor pin and guide pin.
(b) Dismount brake wheel cylinder
3. Dismount brake stop

(a) Two brake stops
(b) One silencer sheet
(c) Two silencer sheet compound pieces
(d) One alarm piece for wear limit of brake stop
(e) Four brake stop circlip sheets
Disassembly of brake wheel cylinder

1. Dismount piston from caliper body
(a) Place wooden block between caliper bracket and caliper
body.
(b) Align air gun or air pipe with brake oil pipe hole and
dismount piston from caliper body.
(c) Take out piston with clean duster cloth or other soft
cloth.
Warning: do not put fingers in front of piston when using
compressed air.
2. Dismount piston seal from caliper body
Use paper clips to dismount piston seal.
Attention: do not use sharp tools in order to avoid
scratching of piston seal.

Inspection of front brake parts

1. Measure the thickness of brake stop friction wafer
Standard thickness: 9.0mm
If the thickness is smaller than minimum thickness or trace of
uneven wear is found, replace the brake stop.
2. Measure thickness of brake disc

If brake disc has scratching or abrasion, or its thickness is
smaller than minimum thickness, repair or replace brake disc.
3. Measure radial oscillation of brake disc

Remark: confirm that bearing has been correctly adjusted
before measurement.
Maximum radial oscillation: 0.11mm
4. Replace brake disc if necessary

(a) Dismount caliper bracket from steering knuckle.
(b) Dismount wheel hub and brake disc.
(c) Install new brake disc and tighten connecting bolts
according to stipulated torque.
(d) Install wheel hub and brake disc assembly
(e) Mount caliper bracket on steering knuckle and screw
tight the bolts according to stipulated torque.
Assembly of brake wheel cylinder

1. Preparation
All parts shall be cleaned and dried to eliminate impurities before
assembly. During assembly, coat guide pin and anchor pin
with vacuum silicon-based grease of appropriate amount; and
coat working surface of piston and rectangular seal ring with
rubber lubricant of appropriate amount.

2. Install piston seal in caliper body

(a) Screw air bleed screw into air bleed hole of caliper
body.
(b) Put rectangular seal ring into two – cylinder seal
groove of caliper body after coating its working
surface with rubber lubricant of appropriate
amount.
3. Install piston with dust cap into caliper body

(a) Nest dust cap on piston.
(b) Elongate dust cap and let its edge clamping ring
come out from under the bottom of piston; slip the
edge clamping ring into edge clamping ring slot of
cylinder hole with tools (e.g.: iron wire about Ф
2mm).
Attention: do not use sharp tools in order to avoid
scratching of dust cap.
(c) Then press piston against bottom of cylinder hole
by hand.
4. Mount guide pin and anchor pin on caliper bracket
(a) Mount guide pin dust cap on guide pin and anchor
pin respectively.
(b) Screw guide pin and anchor pin into caliper bracket
respectively.
Attention: do not break guide pin dust cap.
Installment of brake caliper

1. Install brake stop

(a) Install brake wheel cylinder.
(b) Install and tighten hexagon flange bolt.

3. Connect front brake hose

Connect front brake hose with caliper body.
4. Fill liquid reservoir of brake with brake fluid and

discharge air in braking system.
5. Check there is no leakage of brake fluid

Attention: discharge air after replacement.
(see page BR -6)

BR-22 Braking system — Rear brake
Rear brake
Part drawing
Wheel cylinder assembly
◆ Drawing arm grip ring

Elastic washer Self – regulating dial piece
Dial piece anchor pin
◆ Elastic shield ring
Return Clearance
Rubber blanking spring
cover adjusting
mechanism
assembly
Compression
spring nutted rod
Brake bottom plate Dial piece

Brake shoe adjusting spring
Brake shoe assembly adjusting
tension spring
Drawing arm pin
Compression spring
Brake drawing arm assembly
N ·m :Specified torque Brake drum
Dismount of rear brake

1. Check the thickness of brake shoe lining
Dismount sightglass plug˘ńand check the thickness of brake
shoe lining through the sightglass. If the thickness is smaller
than minimum value, replace brake shoe.
2. Dismount rear wheels
3. Dismount brake drum

Remark: in case brake drum is difficult to dismount, take the
following measures:
(a) Dismount rubber blanking cover, then insert slotted
screwdriver into the hole on brake bottom plate to pry
self – regulating dial piece away from clearance adjusting
wheel.
(b) Use another slotted screwdriver to screw clearance adjusting
wheel in order to release adjuster of brake shoe assembly.

Braking system — Rear brake BR-23
4. Dismount brake shoe strap drawing arm assembly and

brake shoe strap dial piece assembly
(a) Dismount compression spring on brake shoe strap
drawing arm assembly and brake shoe strap dial piece
assembly respectively, press down compression spring
and rotate it, release when square hole of compression
spring turns parallel with head of compression spring
nutted rod, then dismount compression spring.
(b) Dismount adjusting tension spring from brake shoe strap

dial piece assembly.
(c) Dismount return spring and clearance adjusting

mechanism assembly and brake shoe tension spring from
brake shoe strap drawing arm assembly, then dismount
brake shoe strap dial piece assembly.
(d) Dismount parking brake cable from rear shoe.

(e) Dismount brake shoe strap drawing arm assembly.
5. Disassembly of return spring and clearance adjusting

mechanism assembly
(a) Dismount head of clearance adjusting shaft.
(b) Dismount clearance adjusting wheel.
(c) Dismount return spring.

6. Dismount brake drawing arm assembly

(a) Dismount grip ring of drawing arm with pliers.
(b) Dismount washer.
(c) Dismount drawing arm pin.
(d) Dismount brake drawing arm assembly
7. Dismount self – regulating dial piece

(a) Dismount elastic shield ring with pliers.
(b) Dismount dial piece anchor pin.
(c) Dismount self – regulating dial piece.
8. Dismount brake wheel cylinder

(a) Dismount brake pipeline. Clog pipeline with clean plug.
(b) Dismount wheel cylinder assembly by dismounting two
bolts.
9. Dismount the following parts from wheel cylinder

assembly
(a) Two wheel cylinder shields.
(b) Two pistons.
(c) Two piston cup.
(d) Spring.
(e) Air bleed plug.
(f) Air bleed cap.
Inspection and repair of brake parts

1. Check disassembled parts
Check disassembled parts are not worn, rusted and damaged.
2. Measure inner diameter of brake drum

Standard inner diameter: 295.0mm
Maximum inner diameter: 297.0mm

3. Measure the thickness of brake shoe lining

Brake shoe shall be replaced if its thickness is smaller than
minimum thickness or uneven wear is found.
Remark: if one of brake shoes needs replacing, all rear brake
shoes shall be replaced in order to maintain consistent brake
performance.
4. Test whether brake shoe lining contacts well with brake

drum
In case that brake shoe lining does not contact brake drum
well, replace brake shoe assembly.

Assembly of rear brake
Note: assemble parts according to direction indicated in the figure
Front Front
Left wheel right wheel
1. Assemble brake wheel cylinder

(a) Coat two piston cups with lithium soap based glycol grease
of appropriate amount.
(b) Assemble brake wheel cylinder.
·Mount two piston cups on two pistons.
·Mount two wheel cylinder shields on two pistons.
·Install spring and two piston components into wheel
cylinder body.
Remark: perform correct assembly according to direction
indicated in the figure.
(a) Mount wheel cylinder assembly on brake bottom plate
using two bolts.
Tightening torque: (6.5-10)N·m
(b) Connect brake pipeline to wheel cylinder assembly.
3. Coat the following parts with lithium soap based grease

of appropriate amount
(a) Coat six boss plane where bottom plate contacts brake
shoe with lithium soap based grease of small amount.
(b) Coat brake shoe strap drawing arm assembly and brake
shoe strap dial piece assembly with lithium soap based
grease of small amount (see the area indicated by arrows
in the figure).
Remark: do not contaminate brake shoe lining.

(c) Put return spring through clearance adjusting screw lever,

and coat thread and screw lever of clearance adjusting
wheel, head of clearance adjusting shaft and clearance
adjusting screw lever (see locations indicated by arrows
in the figure) with lithium soap based grease of
appropriate amount.
4. Mount brake drawing arm assembly on brake shoe

assembly
(a) Install parking brake drawing arm assembly and put it
through drawing arm pin.
(b) Nest new elastic washer on drawing arm pin.
(c) Install a new grip ring into drawing arm pin with pliers.
5. Mount self – regulating dial piece on rear brake shoe

(a) Install dial piece anchor pin.
(b) Nest self – regulating dial piece on dial piece anchor pin.
(c) Install a new elastic grip ring into dial piece anchor pin
with pliers.
6. Install brake shoe cable and brake shoe strap drawing

arm assembly
(a) Mount brake cable on brake drawing arm assembly.
(b) Mount brake shoe tension spring on rear brake shoe.

(c) Mount rear brake shoe and insert shoe end into brake
wheel cylinder.
Attention: do not let oil or grease stain brake shoe.

7. Install brake shoe strap dial piece assembly

(a) Mount brake shoe tension spring between brake shoe
strap drawing arm assembly and brake shoe strap dial
piece assembly.
(b) Install brake shoe strap dial piece assembly and insert
shoe end into wheel cylinder assembly.
Attention: do not let oil or grease stain brake shoe lining.
8. Install return spring and clearance adjusting mechanism

assembly
(a) Install head of clearance adjusting shaft into brake shoe
strap dial piece assembly and mount return spring on it.
(b) Mount clearance adjusting screw lever and return spring
on brake shoe strap drawing arm assembly.
Attention: ensure head of clearance adjusting shaft prop
against self – regulating dial piece.
9. Install dial piece adjusting spring

Hook one end of dial piece adjusting tension spring on self –
regulating dial piece, and mount the other end on brake shoe
strap dial piece assembly.
10.Install compression spring

Put compression spring through its nutted rod, press down
and rotate it, then block head of compression spring nutted
rod in compression spring groove.
11.Check operating process of self – regulating mechanism

(a) Check self – regulating screw lever to see whether
it rotates by moving parking lever of rear brake shoe
in directions indicated in the figure. If it can not
rotate, find out which part of rear brake has an
error.
(b) Adjust the length of adjusting mechanism to make
it as short as possible.
(c) Install brake drum.
(d) Pull parking lever to its maximum travel until rattle
sound is not heard.

12. Check clearance between brake shoe and brake drum

(a) Dismount brake drum.
(b) Measure inner diameter of brake drum and outer diameter
of brake shoe, and confirm whether the difference
between them falls within standard range.
Clearance of shoe: 0.6mm
If the clearance is not correct, check parking brake system.
13. Install rear wheels

14. Fill liquid reservoir of brake with brake fluid and

discharge air in braking system
15. Check there is no leakage of brake fluid

BR-30 Braking system — Loading sensing pressure proportioning valve
Loading sensing pressure proportioning valve

Assembly relationship drawing
Lower bracket of loading sensing pressure proportioning valve Loading sensing pressure
proportioning valve assembly
Hexagon flange bolt Upper bracket of loading sensing

pressure proportioning valve
Tube bank fixing bracket
Disassembly and assembly of loading

sensing pressure proportioning valve
1. Place vehicles on lifting support and prop them up (or
perform this in the pit)
2. Disconnect brake pipeline connections (3) on valve body
3. Dismount lock nuts on loading sensing pressure

proportioning valve, and adjusting bolts from lower
bracket

Braking system — Loading sensing pressure proportioning valve BR-31
4. Dismount holddown bolts (2) and take off loading sensing

pressure proportioning valve assembly
5. Perform repair or other overhauls
6. Mount loading sensing pressure proportioning valve on
bracket with holddown bolts
7. Mount adjusting bolts on lower bracket and screw tight
lock nuts
8. Connect each brake pipeline and tighten joint
9. Fill up brake fluid, discharge air in the system, and check
brake pressure and leakage
1. Elongation indicator of loading sensing pressure
proportioning valve L1 (center distance between hooks
at both ends)
L2 L1 L1: 210MM (no load) – 240mm (full load)
2. Adjustment range of bracket L2
L2：20mm
3. Tightening torque at joint of brake pipeline: (16 ± 2)N·
m

SR-1
Steering system
Page
Precautions ................................................................ SR-2

Troubleshooting .......................................................... SR-2
On-vehicle inspection.................................................. SR-3
Steering driving device ................................................ SR-4
Hydraulic power steering system ................................ SR-6
SR

SR-2 Steering system — Precautions,Troubleshooting
Precautions
Always be careful when replacing each part, since any
error shall affect the performance of the steering system
and lead to accidents and dangers during running.
Troubleshooting
Trouble Causes Remedy
Poor returnability 1. Insufficient tire pressure 1. Inflate the tire
2. Change of front wheel alignment 2. Remeasure it and adjust front wheel alignment
3. Steering valve clogged parameters
4. Degradation of performance of 3. Inspect and replace steering gear parts
steering valve torsion bar 4. Replace the steering gear
5. Steering drive pair too tight
5. Replace the drive pair
Steering heavy 1. Low tire pressure 1. Inflate the tire according to standard air pressure
2. Knuckle too tight 2. Inspect knuckle clearance and lubricate the
knuckle
3. Steering gear too tight 3. Inspect and adjust gear and rack clearance
4. Inaccurate front wheel alignment 4. Adjust front wheel alignment
5. Hydraulic system lacking oil 5. Check liquid level in fluid reservoir and replenish
steering fluid as specified
6. Air left in hydraulic system 6. Inspect seal of each oil pipe joint, discharge air
and check liquid level
7. Insufficient oil supply of steering 7. If there is serious internal leakage due to wear of
pump oil pump, replace the steering pump;
if leakage is caused by too low oil viscosity,
replace the steering fluid with qualified new one.
8. Steering drive pair too tight 8. Inspect and adjust meshing clearance of gear and
fill up grease
One way direction 1. Insufficient tire pressure at one 1. Inflate the tire
heavy side
2. Steering gear valve deviated from 2. Repair or replace the steering gear
middle position
3. Left or right fixed pressure 3. Replace the seals
impossible to set up

Steering system — On-vehicle inspection SR-3
On-vehicle inspection
Steering wheel inspection
1. Check steering wheel for clearance or clattering sound.
a
Steering wheel play “a”: (0-30) mm
2. Check to see if bolts and nuts are tightened. Then tighten
them if necessary. If damaged parts are found, repair
or replace them.
Inspection of tension of drive belt

Tension of drive belt: when a 98N force is applied
New belt: (5-7) mm
Tension bolt Old belt: (7-9) mm
Remark:
● “New belt” means its use on the machine does not
exceed 5 minutes.
● “Old belt” means its use on the machine exceeds 5
minutes.
Hexagon hole bolt Inspection and filling of power steering
Fluid
reservoir fluid
Power steering oil pump Hose 1. Park vehicles on flat ground.
2. Check liquid level in oil reservoir is between upper and
Hose
lower scale.
Oil outlet pipe of steering gear
3. Vehicles shall be inspected and filled with hydraulic oil
Reservoir support
for every 6000Km mileage or 3 months.
Oil return pipe of steering gear 4. Replacement of hydraulic oil and exhaust:
(a) Open the cover of oil reservoir, dismount the oil return
hose on oil reservoir and discharge oil to container.
(b) Start the engine and set it to idle. Discharge oil, meanwhile
turn steering wheel to left and right limit positions for
several times until oil inside steering system is completely
discharged.
(c) Shut down the engine.
(d) Install oil return hose and fill new hydraulic oil in oil
reservoir.
(e) Restart the engine and set it to idle, then turn steering
wheel to left and right limit positions for several times,
meanwhile fill oil reservoir with new hydraulic oil until
no foams or feculence are found in oil reservoir. Ensure
liquid level in oil reservoir stays between upper and lower
scale when the engine is shut down.
(f) Screw tight the cover of oil reservoir.
When steering or refilling hydraulic oil, steering wheel
shall not stay at limit positions for more than 5 minutes
in order to avoid damage of steering system.

SR-4 Steering system — Steering driving device
Steering driving device

Part drawing
Steering wheel body assembly
Rubber joint Steering column assembly
Coupling
Steering wheel cover sheet assembly
Middle drive shaft
Fixed bolt of cover sheet
Lower drive shaft

55 ± 5
Steering drive pair
Hexagon hole bolt

55 ± 5 Flexible universal joint
Seal washer
25 ± 3 Steering fluid reservoir
Hose
Power steering pump assembly

Low pressure pipeline
High pressure pipeline
◆ shape rubber sealing ring
Power steering gear assembly
90 ± 10

Steering system — Steering driving device SR-5
1. Tightening torque of holddown bolts of power steering
gear assembly is (90 ± 10)N.m
2. Tightening torque of connecting bolts between steering
drive pair assembly and power steering gear assembly
is (25 ± 3)N·m
3. Tightening torque of connecting bolts between steering
drive pair assembly and left side member of the frame
is (55 ± 5)N·m
4. Tightening torque of hexagon hole bolts of power
steering pump and high pressure pipe is 30N·m
5. Tension of 4PK1100 multi-wedge belt is (500 ± 50)N
6. Centering of steering wheel: put front wheels right ahead,
take off steering wheel without changing position of
steering rod, then install steering wheel in alignment with
the center. At this moment webs of steering wheel shall
be symmetric on the left and right, and the Changcheng
logo on steering wheel shall be at the front view position
of the driver. Tighten the nuts, here tightening torque is
(25-35)N·m
7. Inspection of steering wheel free clearance
When steered to the right direction, and engine is flamed out,
apply a force of about 5N to steering wheel along its
circumferential direction to turn it to the left, and if resistance
is generated and is increasing, stop applying the force; then
turn steering wheel to the right, if resistance is generated and
is increasing, stop applying the force; the measured value of
the angle turned of circumference of steering wheel is regarded
as free clearance of steering wheel which shall be smaller
than 20°. Angles to right from middle position shall not exceed
10°.

SR-6 Steering system — Hydraulic power steering system
Hydraulic power steering system

Control valve
Fuel pipe
Power steering gear assembly Power steering oil pump

assembly
Fluid reservoir
Steering system and power steering principle

Power steering system consists of steering oil pump, fluid
res ervoir , power st eering gear and oil pi pe.
With the aid of belt drive, the engine drives steering oil pump
to produce hydraulic pressure. Hydraulic pressure is applied
Oil return chamber on the piston of power steering gear which generates a auxiliary
Valve core Connected to force to push the rack of steering gear. The value of this
one side of
hydraulic
auxiliary force depends on pressure on the piston. Variation of
cylinder piston pressure is completed by control valve in steering gear.
Straight driving condition
Pressure oil
In straight driving condition control valve core in power
steering gear does not move and stays in middle position.
Torsion bar
Connected to the other side of hydraulic cylinder piston
Hydraulic oil supplied by oil pump does not flow to hydraulic
cylinder but returns to oil reservoir through the loop directly
Connected to from control valve. At this moment pressure on both sides of
Valve core one side of piston of steering gear is equivalent, and piston shall not move.
hydraulic
Oil return cylinder piston Steering process
chamber
When turning steering wheel, torsion bar in control valve shall
be twisted and deformed, and control valve core that is
connected to torsion bar shall rotate accordingly. Open oil
Torsion bar Pressure oil channel at one side and close oil channel at the other side, let
Connected to the other side of hydraulic cylinder piston hydraulic oil flow to one side of hydraulic cylinder to activate
the piston, thus realizing front wheel steering by moving of
racks.
Return process
After steering is completed, the force on steering wheel shall
disappear, deformed torsion bar shall recover its original shape,
and control valve core shall also turn back to middle position.
Hydraulic oil supplied by oil pump does not flow to hydraulic
cylinder but returns to oil reservoir through the loop directly
from control valve. At this moment pressure on both sides of

Steering system — Hydraulic power steering system SR-7
piston is equivalent. In the presence of front wheel alignment

parameters, vehicles shall return to straight driving
automatically. During the process of returning to straight
driving, the piston moves and oil at one side of the piston
flows to the other side through control valve channel.
Road feel effect

Road feel effect refers to drivers’ feeling of steering resistance
on road surface when steering. When the driver applies forces
on steering wheel, torsion bar shall be deformed. The larger
the steering resistance on road surface, the heavier deformation
the torsion bar. In order to protect torsion bar from damage,
limit mechanism is installed. When deformation of torsion bar
reaches a certain degree, limit mechanism shall functions, so
that torsional force is transferred to steering gear then rack no
longer through torsion bar but directly through valve core. At
the moment steering resistance on road surface is directly
transferred to drivers without torsion bar as a media. Therefore
drivers may judge variation of resistance according to
resistance on steering wheel.

BE-1
Vehicle body electrical system

Page
Instruction for electrical system ................................... BE-2

Wire harness .............................................................. BE-3
Exploded view of vehicle circuit ................................... BE-9
Central door lock ......................................................... BE-19
Audio system .............................................................. BE-22

BE-2 Vehicle body electrical system — Instruction for electrical system
Instruction for electrical system

Vehicle body electrical system is basically the same as that of “Hover”. Front headlights are converted to 2 high
beam lights, and air bag is also an option. In order to facilitate understanding of details of this section, apart from
schematic diagram of operating principles of electrical equipment provided, schematic diagram of connection of wire
harnesses and relevant plug-in units and terminal box are also introduced. Where the terminal box inside engine room
is labeled No.1, while that inside instrument panel labeled No.2. The following instruction is made for introduction of
circuits in sequence.
Operating instruction
1. A special plug-in unit symbol is added in connection drawing of wire harnesses, see figure 1 below.
2. In order to reduce the number of symbols of special plug-in unit, all plug-in units between wire harness
and load are illustrated by words.
3. See figure 2 for symbol of wire plug-in unit on boot, where the number above is wire number, and the
letters below represent color of wire.
In addition: double-color wire is represented by a slash (/) between letters representing the two colors, where
letters on the left of (/) indicate color of wire, and letters on the right of it indicate color of another fine wire on the
wire. For example: L/R means blue wire with red fine wire; Br/Gr means brown wire with gray fine wire.
4. Pin number of plug-in unit is subject to the direction in which wire and plug-in unit are inserted in boot.
Plug units are numbered from left to right, while plug jack units are numbered from right to left, see
figure 3.
See the table below for letters representing wire color
B –Black Br—Brown G----Green Gr---Gray L----Blue Lg—Light green
Or--Orange P---Pink R---Red V---Violet W---White Y---Yellow
Wire number
Plug jack end Plug end

Wire color
Figure 1 Figure 2
Boot view direction Boot view direction
Pin number direction at anode end of plug Pin number direction at cathode end of plug
Figure 3

Vehicle body electrical system — Wire harness BE-3
分两页布置 Wire harness
Relations between wire harnesses and plug-in unit connection number drawing

BE-4 Vehicle body electrical system — Wire harness
Wire harness
middle wire connection serial number function diagram 1
Connected to engine Connected to engine

room wire harness A wire harness A

room wire harness B wire harness B

room wire harness C wire harness C

Connected to instru- Connected to engine

ment wire harness A room wire harness A

ment wire harness B room wire harness B

ment wire harness C room wire harness C

Connected to dome Connected to instru-

wire harness ment wire harness
Connected to engine Connected to instru-

room wire harness ment wire harness
Connected to transmis- Connected to instru-

sion wire harness ment wire harness
Connected to Connected to instrument

floor wire harness panel wire harness

Connected to instrument Connected to right left door

wire harness assembly A wire harness assembly A
Connected to instrument Connected to right left door

wire harness assembly B wire harness assembly B
Connected to instrument Connected to right front door

wire harness assembly B wire harness assembly B
Connected to instrument Connected to right front door

wire harness assembly A wire harness assembly A

Connected to Chassis wire Connected to floor wire

harness assembly harnessassembly
Connected to Connected to left rear

floor wire harness door wire harness assembly
Connected to Connected to right rear

floor wire harness door wire harness assembly
Connected to Air bag Connected to instrument

wire harness(Yellow) panel wire harness(Yellow)

Vehicle body electrical system — Exploded view of vehicle circuit BE-9
Exploded view of vehicle circuit

Power generation and starting system

BE-10 Vehicle body electrical system — Exploded view of vehicle circuit
Engine electronic control system

Illumination and signal system

Combined instrument system

4WD electric controlled transmission and electric clutch system

Entertainment and air conditioner system

Cigarette lighter, power plug, wiper and power mirror system

ABS system

Air bag

Central controller and riser system

Vehicle body electrical system — Central door lock BE-19
Central door lock

Definition of wire harness of central door lock controller
1. Headlight detection
It is connected to anode wire of high beam light which produces an output voltage of 12V during operation.
2. Right turn light
It is connected to anode wire of right turn light which produces an output voltage of 12V during operation.
3. Positive output of power window
It is connected to power window relay. When the key turns to ON gear, an output voltage of 12V is produced, and
after the key is pulled out, a 60-second 12V voltage time delay is delivered.
4. Roof output
It is connected to negative trigger of roof controller, which produces a 1-second negative signal output after the
system enters remote control door state. (reserved)
5. Unlock output of central door lock
It is connected to unlock wire of actuator of central door lock, and a voltage output of 12V is produced when
unlocking.
6. Lock output of central door lock
It is connected to unlock wire of actuator of central door lock, and a voltage output of 12V is produced when
locking.
7. Detection of key insert
It is connected to check line of lock head, and electric potential is lowered when key insert is detected.
8. Left turn light
It is connected to anode wire of left turn light which produces an output voltage of 12V during operation.
9. Reading lamp output
It is connected to negative trigger line of front reading lamp, which produces low electric potential during operation,
and at the moment reading lamp is on.
10. Detection of lock switch
Connected to internal lock switch of left front door. When the lock is unlocked its internal switch is switched on.
This wire has low electric potential.
11.Tachometer detection
It is connected to output line of tachometer detection line. Central door lock is locked automatically when traveling
speed reaches 15 km/h. The door shall be unlocked automatically after flame out of engine.
12.ON power source detection
It is connected to ON gear wire of ignition switch which produces a voltage output of 12V when the key is turned
to ON position.
13. Cathode of power source
This wire is earthed. (this wire too long shall produce interference source)
16. Anode of power source
It is connected to anode of battery and is covered by 20A insurance.
17. Air bag signal

BE-20 Vehicle body electrical system — Central door lock
This wire is connected to unlock signal of air bag.

19. Manual lock signal
It is connected to lock control wire of central door lock of left front door, and is to be connected to cathode of
power source (earth) during operation.
20.Manual unlock signal
It is connected to unlock control wire of central door lock of left front door, and is to be connected to cathode of
power source (earth) during operation.
21.Left front door switch
This wire is connected to control wire of left front door switch, and is connected to cathode of power source
(earth) during operation.
22.Right front door switch
This wire is connected to control wire of right front door switch, and is connected to cathode of power source
(earth) during operation.
Functional description of central door lock controller
1. Locking
After all the doors are closed, press “LOCK” key of controller once. Turn light shall flash and central door lock
shall be locked.
2. Unlocking
Press “UNLOCK” key of controller once in locking condition. Turn light shall flash twice and central door lock
shall be unlocked.
3. Panic function
Press “UNLOCK” key of controller once in locking condition. Turn light shall flash 10 times in a very short time.
Press “UNLOCK” key of controller to quit panic function.
4. Automatic protection function
In locking condition, press “UNLOCK” key of controller to unlock the door. If the door has not been opened, it
shall be locked automatically after 30 seconds.
5. Automatic locking during running
When traveling speed increases from 0 km/h to 15 km/h, central door lock shall lock itself. After IG gear of
ignition switch is disconnected, the door shall be unlocked automatically.
When JP1 is connected to H, automatic locking function is open; when JP1 is connected to L, automatic locking
function is closed.
6. Pause of remote control function
When the key is inserted into ignition lock, remote controller shall not work, but the host can work normally.
7. Manual unlocking and locking of door lock
Unlocking or locking may be controlled manually.
8. Clear and registration of remote controller
Open the door, insert the key into ignition lock and switch OFF gear to ON gear for 5 times in a short time, finally
maintain ON gear. Here one flash of the light means learning function is started. By pressing any of the keys of
remote controller, registration of remote controller is completed which is indicated by two flashes of the light. By
repeated operation a maximum of 4 remote controllers may be registered: if no key of remote controller is pressed
in 10 seconds, system shall quit learning function automatically. Registration of new remote controllers shall clear
the earliest registrations in condition that there are already 4 remote controllers registered.
9. Reading lamp time delay function
(a) By opening the door then closing it, the light shall be on for 10 seconds. If the key is inserted into ignition
switch within the 10 seconds, reading lamp shall go out immediately.

Vehicle body electrical system — Central door lock BE-21
(b) By opening the door then closing it, the light shall be on for 10 seconds. If the door is locked within the 10
seconds, reading lamp shall go out immediately.
(c) By pulling out the key from ignition switch, the light shall be on for 1 minute. If the key is inserted into
ignition switch again, reading lamp shall go out immediately.
(d) By pulling out the key from ignition switch, the light shall be on for 1 minute. If the door is locked, reading
lamp shall go out immediately.
10. Buzz function
(a) The key is inserted (low) and is not at ON gear (high). Opening of any door shall cause intermittent buzz of
the buzzer;
(b) When the key is not inserted, high beam light is on and one of the doors is open, the buzzer shall give a long
buzz.
11. Mains supply of riser time delay
After the key is pulled out form ignition lock, central controller shall provide control switch of riser with one-
minute power source to close windows (windows are to be raised by pressing riser switch). If windows have not
been raised in one minute, by inserting the key into ignition switch then pulling it out again another one-minute
power source is obtained.

BE-22 Vehicle body electrical system — Audio system
Audio system
Precautions:
1. When radio player is in CD mode, in order to avoid abnormal damage of instrument due to too high
temperature, it shall start thermal protection function automatically and turn down the sound volume.
2. If CD player can not work normally, press（▲）key for more than 5 seconds to reset it to normal
condition.
Troubleshooting
System Trouble Remedy
Cassette Display is blank when switch is 1 Check fuse at the back of the player is not loose
system turned on 2 Check fuse is not open circuit
3 If new fuse is blown again, send the player to special
technicians for repair
No broadcasting station can be
Check antenna or antenna socket at the back of the player is
received either through FM or
not loose
through AM
Left or right sound track out of 1 Press balancing potentiometer, spin it from left to right,
function and turn it to central position
2 Check each contact pin of socket at the back of the player
is in good contact
Impure acoustics of broadcasting Manually search broadcasting stations to obtain pure
stations acquired by auto-search acoustics
CD player CD player indicates “ERROR” CD disc may be placed in wrong direction – it shall be
system placed in CD player with its face down
Engine produces “toot” sound as Check power line is connected
that of motor during operation Check earth wire of the player is connected to that of the
vehicle
No sound output and blank display Check power line is connected
Check all the fuses
Check all the power lines
The player is overheated under Check earth wire of the player is connected to that of the
normal sound volume vehicle
Antenna no signal Check connecting wire of antenna
Sound output is weak, bass is The reason is that loudspeakers are out of phase. Check
abnormal and left and right side is audio connecting line.
unbalanced
Front and rear loudspeaker control
Check the wire connected to loudspeaker
out of function

Vehicle body electrical system — Audio system BE-23
Composition and function of CC1031PS40/60 audio system

Audio system of this model is equipped with either CD player or cassette player.
Standard equipment: cassette player + 2 front door loudspeakers + 2 back door loudspeakers +
telescopic antenna.
Advanced equipment: single disc CD player + 2 front door loudspeakers + 2 back door loudspeakers
+ 2 front door high pitch loudspeaker + telescopic antenna.
1. Cassette player
This series of models feature phase locking loop type electronic tuning, FM/AM stereo digital display radio player,
and such functions as tone control circuit and automatic reverse, etc. Preselecting stations: 30 (18FM + 12AM).
2. CD player
This model features an audio system with PLL electronic tuning radio and CD player, and can receive AM, FM and
FM stereo broadcasting as well as play CD disc. Preselecting stations: 30 (18FM + 12AM). It also features EAS
electronic anti-knock function.
Operating principle of CC1031PS40/60 audio system

1. Cassette player
(a) Host is connected to loudspeaker: PA of host is 4-track BTL output, maximum output power is 4 x 15W;
each loudspeaker shall have a special line, and its phase and position shall be connected accurately; please
switch off the power source before connecting loudspeaker to avoid short circuit of wire.
(b) Host is connected to antenna: insert coaxial cable plug of antenna into socket of host antenna; the joint of
antenna socket shall be firm and reliable.
Attention: unreliable joint of antenna shall lead to failure of radio function.
2. CD player
(a) Host is connected to loudspeaker: PA of host is 4-track BTL output, maximum output power is 4 x 30W;
each loudspeaker shall have a special line, and its phase and position shall be connected accurately; please
switch off the power source before connecting loudspeaker to avoid short circuit of wire.
(b) Host is connected to antenna: insert coaxial cable plug of antenna into socket of host antenna; the joint of
antenna socket shall be firm and reliable.
Attention: unreliable joint of antenna shall lead to failure of radio function.
3. Definition of system foot
Definition of foot
No.
Ⅰ Ⅱ
1 R.R(+)
2 R.R(-)
3 R.F(+)
4 ACC+ R.F(-)
5 ANTENNA L.F(+)
6 ILLUMINATION L.F(-)
7 BATTERY L.R(+)
8 GNT L.R(-)

BE-24 Vehicle body electrical system — Audio system
技术参数
System Item Technical parameter
Cassette playerMains voltage 12V
Current consumption 2.5A
Rated power 4×6W(load 4Ω)
Tape speed error ＜±1.5%
S/N 50dB
Frequency response (100～8000)Hz
Frequency range FM：(87.5～108.0)MHz AM：(531～1629)KHz
S/N FM：55dB AM：50dB
CD player Power source 14.4V minus earth DC power source
Input current Maximum 10A
Output power Maximum 4×30W
Bass control ±10dB at 100Hz
High pitch control ±10dB at 10KHz
S/N >70dB
Degree of separation for>55dB
sound track
Range of frequency response
(20～20)KHz
Degree of distortion <0.2%
Frequency range FM：(87.5～108)MHz AM：(531～1629)KHz
S/N FM：60dB AM：40dB
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AC-1
Air conditioning system

page
Troubleshooting .......................................................... AC-2

Air conditioning system ............................................... AC-5
Daily maintenance of air conditioning system .............. AC-6
Vacuum pumping and filling of refrigerant .................... AC-7
Maintenance and replacement of pipeline .................... AC-8
Amount of refrigeration oil to be filled and method for filling
.............................................. AC-9

AC-2 Air conditioning system—Troubleshooting
Troubleshooting
Location Trouble Causes
Air Compressor does Fuse blown, compressor relay damaged
conditioning not suck Contact of pressure switch disconnected, short circuit or open circuit
system out Electromagnetic clutch coil of compressor open circuit
of function Burn-out of switch
Burn-out of main relay
Clutch skidding
Fracture or loose of compressor belt
Compressor error
Insufficient secondary refrigerant, system pressure below 0.196MP
System pressure over 3.14MP
Water temperature of engine too high
Clutch voltage below 7V
Compressor Normally open contact of compressor relay sticky; no secondary refrigerant
sucks in system due to serious leakage
Blower sending no wind
Blower sending Fuse blown
no wind Motor and brush of blower damaged
Blower switch damaged
Wiring connector disconnected or circuit open
Speed adjustment module damaged
Blower sending no wind at high speed; high speed relay damaged
Intermittent Compressor in Refrigerating system frozen-up
refrigeration normal condition Failure of thermistor or temperature sensing package
of Poor contact of A/C switch
refrigerating Condensing fan damaged
system Compressor in Clutch skidding
abnormal Clutch coil loose
condition Poor earth of clutch coil
Insufficient Small air outlet Blower fan in normal condition: blast pipe damaged
refrigeration Air cooler abnormal:
(1) Blower switch abnormal
(2) Low pressure of power source
(3) Speed adjustment module damaged
Appropriate air Compressor in normal condition
outlet (1) Low pressure at both high and low tension side
(a) Expansion valve clogged
(b) Opening of expansion valve too small
(2) High pressure at both high and low tension side
(a) Failure of high pressure pipeline; flow encumbered
(b) Thermistor ineffective
(c) Opening of expansion valve too large
(d) Excessive refrigeration oil
(e) Excessive refrigerant
(f) Poor heat radiation of condenser

Air conditioning system—Troubleshooting AC-3
Insufficient Appropria Compressor in normal condition
refrigeration te air (3) Pressure at high tension side too low
outlet (a) Damage of low pressure pipeline
(b) Low pressure pipeline clogged
(4) Pressure at low tension side too low
(a) Frosting of evaporator
(b) Expansion valve clogged
(c) Low pressure pipeline clogged
(d) Speed adjustment thermistor ineffective
(5) Low tension side sometimes normal, sometimes negative pressure; water in
refrigerating system and freeze-up
(6) Low tension side negative pressure, high tension side pressure too low,
refrigerating system clogged
(7) Low tension side pressure too low, high tension side pressure too high
(a) Interior of fluid dryer clogged
(b) High pressure pipeline clogged
(8) Low tension side pressure too high, high tension side pressure too low
(a) Leakage of compressor
(b) Compressor valve damaged
(9) Poor radiation of condenser due to small air output of condensing fan
Compressor in abnormal condition
(1) Compressor internal fault
(2) Compressor belt too loose and skid
(3) Electromagnetic clutch fault
(a) Low mains voltage
(b) Interference of stator and rotor
(c) Stable idle amplifier fault
(d) Open circuit, connecting part disconnected
(e) Switch and relay in poor working condition
(f) Open circuit, short circuit
(g) Poor earth
Other reasons
Poor sealing of vehicle body
Noise of Noise too Belt too loose or excessively worn
refrigerating loud Set screws of compressor mounting bracket loose
system Damage of compressor mounting bracket
Internal parts of compressor damaged
Lack or absence of refrigeration oil
Clutch skid noise
Clutch bearing lacking oil or damaged
Motor bearing of blower damaged
Fracture or loose of blower bracket
Fracture or loose of blower blade
Friction of blower blade and other parts

AC-4 Air conditioning system—Troubleshooting
Heating No heating or Blower of air conditioner out of function
system insufficient heating Blower relay damaged
Hot water pipe clogged
Cooling water pipe clogged
Cool and warm air door cable damaged
Insufficient coolant
Blower out of Fuse blown or poor contact of switch
function Burn-out of blower motor
High speed relay of blower open circuit
Speed adjustment resistor damaged
Circuit open
Water leakage Aging of heater pipe and loose of joint
Overheat Speed adjustment resistor of fan damaged
Cool and warm air door cable damaged
Insufficient hot air Mode cable damaged
for defrosting Inappropriate position of door
Air outlet clogged
Insufficient heating
Inappropriate installation of tunnel
Circuit open

Air conditioning system — Air conditioning system AC-5
Air conditioning system

Component Chart
Evaporator
Low pressure hose
Compressor
High pressure hose

Fluid reservoir
Condenser
Basic component of CC1031PS40/60 air

conditioning system
The air conditioning system of CC1031PS40/60C model is a
manually controlled system featuring an integration of
ventilation, heating and refrigeration. Cool and warm air is
separated with silent air outlet. Air cleaning equipment is also
equipped.
Basic components: heater assembly, compressor assembly,
blower assembly, condenser assembly, evaporator assembly,
pipeline, air conditioner control panel assembly, defrosting
system, heating system and ventilation system, etc.
Operating principle of CC1031PS40/60 air

conditioning system
1. This system is manually controlled air conditioning
system. Internal and external circulation, air blowing
mode and temperature regulation are all controlled by
cables of control panel.
Attention: when starting compressor, air regulating knob
must be open, otherwise compressor can not be started.

AC-6 Air conditioning system — Daily maintenance of air conditioning syste
2. Definition of each terminal of air conditioning system.
Blower air outlet switch Control panel input
1 1 Gear position 1 Defrosting signal input 7 Null

2 Common port 2 Backlight + 8 Request signal output terminal
3 Signal terminal 3 Backlight - 9 Defrosting relay output terminal
4 4 Gear position 4 Request signal output term inal 10 Com mon earth terminal
5 3 Gear position 5 Null 11 Earth terminal
6 2 Gear position 6 Null 12 Input terminal
Three state
pressure switch Speed adjustment resistor Blower motor
Evaporator temperature sensor
1 AC 2 Earth First and second terminals connected to medium voltage

3 Compressor relay Third and fourth terminals connected to high voltage
3. Check drive belt. Belt between compressor and

Daily maintenance of air con-
engine shall be strained.
ditioning system 4. Check that air conditioning system does not
In order to ensure normal operation of air produce abnormal noise and smell.
conditioning system, maintenance shall be 5. Check that temperature difference at air inlet and
performed regularly. Daily maintenance of outlet of compressor is normal.
air conditioning system is as follows: 6. Check appearance of hose of refrigeration system
1. Check and clean condenser of air is normal and connection at each joint is tight.
conditioning system to the effect that 7. Check refrigeration system pipeline does not
radiating fin is clean and no stemming contact other parts and there is no trace of oil
remains among radiating fins. After leakage at each joint.
running in rain or on muddy road, check 8. Check circuit connection of refrigeration system is
there is no mud, sand or stones in rel iab l e and the re is no op en circ uit and
condenser fan, otherwise clean the fan disconnection.
in time. 9. Check binding bolts of compressor are tight and
2. Check the amount of working medium not fractured.
of ref rigeration system; w hen air
conditioning unit is in normal condition,
observe the fluid sight glass which in
normal condition does not contain
bubbles.

Air conditioning system—Vacuum pumping and filling of refrigerant AC-7
Low pressure
High pressure Vacuum pumping and filling of refrigerant
Manifold gauge
Low pressure Blue Connect air conditioner (Compressor) pipeline and multi-
Red
pipe purpose joint of vacuum pump with pressure manifold gauge,
Snap fitting High pressure pipe and then start vacuum pumping. Before vacuum pumping,
open high and low pressure valve of pressure manifold gauge
Snap fitting as well as end valve of vacuum pump (if any), then press
Vacuum pump
“ON” button to start vacuum pump and keep vacuum pump
in operation for more than 20 minutes. When pressure manifold
gauge indicates –760mmHg or even lower, close high and
Manifold gauge low valve as well as end valve of vacuum pump (if it is open),
Low pressure gauge High pressure gauge and switch off vacuum pump.
Air tightness inspection

Continue to check readings of pressure manifold gauge after
Yellow vacuum pump is switched off.
If pressure reading remains constant for 20 minutes after stop
Blue Yellow Red
of vacuum pump, it demonstrates that refrigeration system is
not leaking and it is possible to carry out next work. Change
of reading indicates there is still leakage in system. Check and
repair leaking part, and then start vacuum pumping again.
Filling of refrigerant
1. After air tightness of system is confirmed, connect
refrigerant reservoir (or gas cylinder) to one end of yellow
inflated hose. The other end of yellow inflated hose is
connected to filler port in the middle of pressure manifold
gauge. Ensure nuts on refrigerant reservoir and inflated
hose are tightened, and then open valve of refrigerant
Air purge close
reservoir. At the moment high and low pressure valve is
Red
closed. Press on valve core on side port with pin
Yellow
screwdriver or similar tools for 1 to 2 seconds to
Blue
discharge air in inflated hose and manifold gauge.
Refrigerant reservoir
2. Open high pressure valve of pressure manifold gauge,
and fill system with refrigerant through high pressure
Low pressure High pressure
pipeline. Here note readings of high and low pressure
close gauge and confirm that both two readings have
Open
Blue increased. If pressure does not increase when
Red
refrigerant is filled, it can be inferred that joint of pipeline
Yellow is loose or seal is damaged. After reasons are found
out and repair is done, refill refrigerant. When pressure
stops increasing, close high pressure valve of pressure
Refrigerant reservoir manifold gauge then start the engine.

AC-8 Air conditioning system — Maintenance and replacement of pipeline
Low pressure High pressure Perform open and close operation accord-
Open
Blue Open ing to the following procedures
Red Turn up speed adjustment switch of blower to its limit,
turn temperature control switch to coldest position,
Yellow
press A/C switch, and select internal circulation mode for
internal/external circulation,
Refrigerant reservoir and keep doors and windows open during the process.
Regulate engine speed to idle as specified.
Erect refrigerant reservoir or gas cylinder (to let refrigerant
flow into refrigeration system in gaseous form), and open
low pressure valve of pressure manifold gauge.
Do not open high pressure valve when compressor is running.
Before inspection of refrigeration level, refrigerant volume to
be filled according to stipulations of air conditioning system
shall be determined.
When filling refrigerant, carefully observe high tension side of
pressure manifold gauge, for flow status of refrigerant (clear,
foaming, turbid) can be observed from inspection window,
so that appropriate time to stop filling can be determined (by
Pressure at
high tension closing low pressure valve).
side Before determining volume of refrigerant to be filled, please
（M P a ） Appropriate
pressure
set up according to the following operating conditions.
Temperature of engine water tank: stable
(Appropriate fill) (Surfeit fill) Engine speed: normal idle
A/C switch: ON
Refrigerant volume (g)
Speed adjustment switch of blower: maximum gear
Temperature controller: air return temperature inside vehicle
body is at the middle position.
Control of first of the air: internal circulation
Door: completely open
Window: completely open
Maintenance and replacement of pipe-

Switch off
line
1. Before installation of parts, cathode of batteries must
be disconnected.

Air conditioning system—Amount of refrigeration oil to be filled and method for filling AC-9
2. When air inlets of refrigeration system, water tank of

engine and air conditioner are open, be sure to cover
Protective cap
each opening with a cap to prevent dust, external
Hard hat impurity and water from entering.
3. Mount protective cap on end of each pipe until pipe is
connected to refrigeration system.
Protective cap must be installed
4. When connecting pipes, add some compressor oil to O

ring and tighten nuts with two wrenches. Note not to spray
compressor oil onto painted or plastic parts to avoid
defilement. If it is already sprayed onto these parts, clean
them immediately.
Compressor oil Tightening with 5. W hen connecting pipes, tighten screws or nuts
2 wrenches at according to torques specified in the following table.
one time
Diameter (mm) Tightening torque (N·m)
￠8 12-15
￠16 30-35
Amount of refrigeration oil to be filled and method for filling

1. CC1031PS40/60 air conditioning system is equipped with JSS-D14 compressor manufactured by
Chongqin Construction. The stipulated refrigeration oil type is RS-20, and use of other types of
refrigeration oil shall damage parts of the compressor. Refrigeration oil must be replenished when
some of parts need replacing during repair: evaporator, condenser: 30mll; dryer: 20ml; pipeline: 10ml.
2. There are two ways of filling refrigeration oil: direct filling and vacuum suction
(a) Direct filling: ① Remove oil filler plug and fill up refrigeration oil of the stipulated RS-20 type; ② Observe
through hole of oil filler plug and rotate front panel of clutch to locate connecting rod of piston in the very
middle position of hole of oil filler plug; ③ Insert dip stick to the right of connecting rod of piston until end
of dip stick contacts cover of compressor; ④ Take out dip stick and check scale (marking) of refrigeration
oil which shall be between 4 and 6; ⑤ Tighten oil plug to a torque of (14.7 ± 4.9)N.m
(b) Vacuum suction: first vacuumize refrigeration system to 0.2X105 Pa, then start to fill RS-20 refrigeration oil
according to the following procedures: ① Close high pressure manual valve and auxiliary valve; ②
Dismount the hose on high tension side from manifold pressure gauge and insert it into oil cup; ③ Open
auxiliary valve and let refrigeration oil sucked into refrigeration system from oil cup; ④ When refrigeration
oil in oil cup is nearly pumped out, close auxiliary valve immediately to avoid air being sucked into system;
⑤ Screw hose connection on high tension side on manifold pressure gauge, and start vacuum pump to open
high pressure manual valve, then open auxiliary valve to vacuumize the system to 0.2X105Pa and proceed
for another 15 minutes so as to discharge air in the system.
Attention:
1. When replacing old compressor with new one, some oil must be discharged to match the amount in the
old one, so that impair of refrigeration effect due to excessive oil can be avoided.
2. If old or repaired compressors are used, oil volume of these compressors shall be equal to that of new
compressors.

B0-1
Vehicle body
Page
General ....................................................................... BO-2

Engine hood ................................................................ BO-3
Front door ................................................................... BO-4
Back door ................................................................... BO-10
Vehicle body chafing strip ............................................ BO-15
Wheel trim .................................................................. BO-17
Front windshield glass ................................................ BO-18
Rear windshield glass ................................................. BO-20
Trunk rear panel assembly .......................................... BO-22
Instrument panel ......................................................... BO-23
Seat belt ..................................................................... BO-26
Seat ............................................................................ BO-28
Body dimension .......................................................... BO-29
BO

B0-2 Vehicle body — General
General
In the case of damage of vehicle body and parts, first take
measures to protect vehicles from damage before repair.
For example:
1. During disassembly and installation, protective tape shall
be affixed to relevant parts of the body.
2. Before prying open vehicle body parts with screwdriver

or scraper, their head or blade shall be wrapped with
tape to prevent paint coat or body from damage.
Protect the tape
If rust inhibitor is damaged when repairing other parts, it

Peeling off shall be repaired.
For example:
1. If sealant, paint coat or primer coat of vehicle body is
damaged due to falling off and crack, etc., repair shall
be made using relevant rust inhibitor.
Crack
2. If hinge or external board is loosened or removed, rust

inhibition shall be coated after repair.
Rust depressant

Vehicle body — Engine hood B0-3
Engine hood
Adjustment of engine hood
1. Adjustment of engine hood in front/rear and left/right
directions
Unscrew bolts of engine hood hinge and adjust engine hood.
2. Adjustment of leading edge of engine hood in vertical

direction
Rotate buffer slab to adjust engine hood.
3. Adjustment of lock catch of engine hood

Unscrew bolts and adjust lock catch.

B0-4 Vehicle body—Front door
Front door
Part drawing
Right front door glass mud chute

Right front door glass assembly
Right front door external

water bar
Right outside rearview mirror assembly
Right front door glass guide rail assembly
Right front door glass rear guide rail
Right side door lock

Front door internal buckle assembly
hinge
Right front side door external handle assembly

Front door check
Right front side door lock assembly
Lock hook assembly

Right front door electric
window regulator assembly
Right front door joint strip
Internal set square of outside rearview mirror
Right front door internal water bar
Right front inner door

trim assembly (electric)
Right front inner door trim
assembly (manual)
Outer trim frame of right Switch panel of right front door

side internal buckle window regulator
Regulator handle

Vehicle body—Front door B0-5
Adjustment of front door

1. Adjustment of door in front/rear and vertical directions
Adjust the door after holding down bolts of door side
hinge are unscrewed.
2. Adjustment of door in left/right and vertical directions

djust the door after holding down bolts of door side hinge
are unscrewed.
3. Adjustment of door lock catch

(a) Check adjustment of installation of door and match of
door lock is completed.
(b) Gently unscrew holddown bolts of lock catch and beat
the lock catch with a rawhide hammer to adjust its
position.
(c) Then tighten set screws of lock catch.
Disassembly of front door

1. Remove regulator handle
Open spring clip with a slotted screwdriver and remove
regulator handle and diaphragm.
2. Dismount of inside door handle

(a) Remove screws and slide the handle forward.
(b) Separate the handle from control lever and remove the
handle.
3. Remove internal decorative set square
Pry loose clip joint with a screwdriver and remove internal
decorative set square.
Attention: before screwdriver is used, its head must be
wrapped with tape.
4. Dismount of rearview mirror
Remove 3 nuts and outside rearview mirror.

Inner manual door trim 5. Dismount of inner door trim

Inner manual door trim:
(a) Remove internal buckle bolts and internal buckle.
(b) Remove bolts of door arm rest.
(c) Insert screwdriver between fixed clip and inner door trim
and pry it loose.
○ 8 clips wrapped with tape.
Inner plate of electric door (d) Remove inner door trim.
Inner electric door trim:
(b) Remove bolts of motor switch panel.
(c) Remove motor switch and panel.
(d) Insert screwdriver between fixed clip and inner door trim
and pry it loose.
○ 8 clips wrapped with tape.
(e) Remove inner door trim.
6. Dismount of front door external water bar

Lower the glass to appropriate position, grip external water
bar by hand and pull it up with force to remove it.
7. Dismount of front door glass assembly

(a) Adjust front door glass to align fixed bolts of glass bracket
with installation holes of inner panel, and remove 2 fixed
bolts of glass bracket.
(b) Pull glass up and remove it by tilting it.
8. Dismount of door glass mud chute
9. Dismount of rear assembly of front door glass guide rail

Dismount guide rail by removing its fixed bolts.

10. Dismount of window regulator

(a) Remove 4 fixed bolt of regulator and 2 fixing nuts of
regulator.
(b) Remove regulator through auxiliary hole.
11. Dismount of locking button inside vehicles

Relieve control lever and dismount locking button inside
vehicles.
12. Dismount of door lock and outside door handle with lock
cylinder
(a) Separate control lever from outside door handle with lock
cylinder.
(b) Remove 3 screws and door lock.
(c) Remove 2 bolts and outside door handle with lock cylinder.
(d) Remove spring clip and lock cylinder.
Replacement of front door glass
1. Adjust front door glass to align fixed bolts of glass bracket
with installation holes of inner panel.
2. Remove fixed bolts of glass bracket and take out the

glass.
Assembly of front door

1. Before installation of parts, coat them with MP grease.
(a) Coat sliding plane and gear of glass regulator with MP
grease.
Attention: do not coat spring of window regulator with
MP grease.
(b) Coat sliding plane of door lock with MP grease.
2. Installation of outside door handle and door lock

(a) Mount lock cylinder on outside door handle with spring
clip.
(b) Install outside door handle and lock cylinder with 2 bolts.
(c) Install door lock with 3 bolts.
(d) Connect control lever to outside door handle.
3. Installation of locking button inside the door
Install locking button inside vehicles and connect control lever.

4. Installation of rear assembly of front door glass guide

rail
5. Installation of window regulator

(a) Install regulator through auxiliary hole.
(b) Install 4 fixed bolt of regulator and 2 fixing nuts of
regulator.
6. Installation of front door glass mud chute
7. Installation of front door glass assembly

Adjust bracket arm of window regulator to align fixed holes
of glass bracket with installation holes of inner panel. Install
glass in glass mud chute, and mount glass bracket on bracket
arm of the regulator with 2 bolts.
8. Installation of front door external water bar
Lower glass to appropriate position and mount external water
bar on rabbet of outer panel of the door.
9. Installation of outside rearview mirror
Inner manual door trim 10. Installation of inner door trim

Inner manual door trim
(a) First mount handle on control lever, then take it out from
handle hole inside the door.
(b) Use fixing clip to install inner plate of door to
corresponding hole by gently beat.
(c) Fix door arm rest with 2 bolts.
○ 8 clips (d) Install internal buckle with 1 bolt.
Inner plate of electric door
Inner plate of electric door
(a) First mount handle on control lever, then take it out from
handle hole inside the door.
(b) Use fixing clip to install inner door trim to corresponding
hole by gently beat.
(c) Install motor switch and panel with 2 bolts.
(d) Install internal buckle with 1 bolt.
○ 8 clips

11. Installation of inside door handle

(a) Push door handle into panel board of the door and slide it
backward.
(b) Tighten screws.
12.Installation of regulator handle
In case doors and windows are all closed, install panel board
and regulator handle with spring clip according to the drawing.

B0-10 Vehicle body — Back door
Back door
Part drawing
Right back door glass mud chute Right back door external water bar Right back door glass assembly
Right front door glass front guide rail
Rear check
Right side door lock
internal buckle assembly Right front door glass rear guide rail
Right back side door
Back door hinge outside handle assembly
Lock hook assembly
Right back door lock assembly
Right back door electric window regulator assembly
Right back door joint strip
Right back door internal water bar
Switch panel of right

back door regulator
Right front inner door trim assembly (electric)
Right front inner door trim assembly (manual)

Outer trim frame of right side internal buckle
Regulator handle

Vehicle body — Back door B0-11
Adjustment of back door

The same as adjustment of front door
Disassembly of back door

1. Dismount of regulator handle
Open spring clip with a slotted screwdriver and remove
regulator handle and diaphragm.
2. Dismount of inside door handle

(a) Remove screws and slide the handle forward.
(b) Separate the handle from control lever and remove the
handle.
Inner manual door trim 3. Dismount of inner door trim

Inner manual door trim
(b) Remove bolts of door arm rest.
(c) Insert screwdriver between fixed clip and inner door trim
and pry it loose.
wrapped with tape.
○ 7 clips (d) Remove inner door trim.
Inner plate of electric door Inner plate of electric door
(b) Remove bolts of motor switch panel.
(c) Remove motor switch and panel.
(d) Insert screwdriver between fixed clip and inner door trim
and pry it loose.
wrapped with tape.
○ 7 clips
(e) Remove inner door trim.

4. Dismount of back door external water bar

Lower the glass to appropriate position, grip external water
bar by hand and pull it up with force to remove it.
5. Dismount of back door glass assembly

(a) Adjust glass to align fixed bolts of glass bracket with
installation holes of inner panel, and remove 2 fixed bolts
of glass bracket.
(b) Pull glass up and remove it by tilting it.
6. Dismount of back door glass mud chute
7. Dismount of back door glass guide rail assembly
8. Dismount of window regulator

(a) Remove 5 fixed bolts of regulator bracket.
(b) Remove regulator through auxiliary hole.
9. Dismount of locking button inside vehicles

Relieve control lever and dismount locking button inside
vehicles.
10. Dismount of door lock and outside door handle with lock
cylinder
(a) Remove 3 screws and door lock.
(b) Remove 2 bolts and outside door handle with lock cylinder.
(c) Remove spring clip and lock cylinder.
Replacement of back door glass assembly

1. Adjust front door glass to align fixed bolts of glass bracket
with installation holes of inner panel.
2. Remove fixed bolts of glass bracket and take out the

glass.
278mm

Vehicle body — Back door B0-13
Assembly of back door

1. Before installation of parts, coat them with MP grease.
(a) Coat sliding plane and gear of glass regulator with MP
grease.
Attention: do not coat spring of window regulator with
MP grease.
(b) Coat sliding plane of door lock with MP grease.
2. Installation of outside door handle and door lock

(a) Mount lock cylinder on outside door handle with spring
clip.
(b) Install outside door handle and lock cylinder with 2 bolts.
(c) Install door lock with 3 bolts.
(d) Connect control lever to outside door handle.
3. Installation of locking button inside the door

Install locking button inside vehicles and connect control lever.
4. Installation of window regulator
(a) Install regulator through auxiliary hole
(b) Install 3 fixed bolts of regulator.
(c) Install 4 fixed bolts of regulator bracket.
5. Installation of back door glass guide rail assembly

Install guide rail and bolts.
6. Installation of back door glass mud chute

7. Installation of back door glass assembly

Install glass into door chamber, and mount glass on window
regulator with 2 bolts.
8. Installation of back door external water bar

Lower glass to appropriate position and mount external water
bar on rabbet of outer panel of the door.
9. Installation of inner door trim
10. Installation of inside door handle

(a) Push door handle into panel board of the door and slide it
backward.
(b) Tighten screws.
11. Installation of regulator handle
In case doors and windows are all closed, install panel board
and regulator handle with spring clip according to the drawing.

Vehicle body — Vehicle body chafing strip B0-15
Vehicle body chafing strip
Precautions for storage of vehicle body chafing strip:

1. It shall be stored at a cool place to avoid direct sunshine, high temperature and dust.
2. As vehicle body chafing strip is PP+EPDM-T30 product, do not let it contact paint thinner, other solvents
or boiling water.
3. The time limit for storage of vehicle body chafing strip is about 9 months.
Part drawing
Front side door chafing strip Back side door chafing strip Trunk chafing strip
AB：6.5mm
C D ：9 m m
EF: 87mm
Note: Permissible clearance error between AB and CD 1mm
Permissible clearance error between EF

B0-16 Vehicle body — Vehicle body chafing strip
Dismount of vehicle body chafing strip

1. Remove the end of chafing strip
Pry loose a 30mm-long part of the end of chafing strip with a
scraper.
Attention: before scraper is used, its head must be
wrapped with tape.
2. Dismount chafing strip and remove binders

(a) Cut off binders with a cutting knife and pull down chafing
strip.
(b) Scrape off binders from vehicle body with a cutting knife
or emery paper.
Remark: do not reuse removed chafing strip.
Installation of vehicle body chafing strip

1. Clean the plate-work fitting surface of chafing strip
Wipe off dirt with cleaning tools.
2. Pull out parting paper from 3M tape of chafing strip
Remark: when peeling off parting paper, note not to let dirt
and dust enter non-exposed parts.
3. Install chafing strip along stamping line of vehicle body

Affix chafing strip along stamping line of vehicle body as
indicated in the drawing.
Remark: lower edge line of chafing strip is in accordance with
stamping line.
Attention:
● Press on chafing strip with thumb and apply a
certain pressure to ensure it is firmly installed.
● After installation, do not clean the vehicle within 24
hours.

Vehicle body — Wheel trim B0-17
Wheel trim
Installation site of parts
Front part of front fender trim bar
Front fender trim bar
Rear fender trim bar
Replacement of front fender trim bar and front

part of front fender trim bar
1. Dismount of front part of front fender trim bar
Remove 3 nuts and take off front part of front fender trim
bar.
2. Dismount of front fender trim bar
Remove 6 screws and take off 5 clips.
3. Installation of front part of front fender trim bar
Mount front part of front fender trim bar on front bumper and
fix it with 3 nuts.
4. Installation of front fender trim bar
(a) First fix 5 clips to fender trim bar, then mount clip seat
on fender, finally install fender trim bar on fender.
(b) Install 6 screws.
Replacement of rear fender trim bar

1. Dismount of rear fender trim bar
Remove 5 screws and take off fender trim bar.
2. Installation of rear fender trim bar
(a) First fix 5 clips to rear fender trim bar, then mount clip
seat on outer panel of the trunk, finally install fender trim
bar on outer panel of the trunk.
(b) Install 5 screws.

B0-18 Vehicle body—Front windshield glass
Front windshield glass

Upper trim bar of front windshield
Right clip bar of front windshield
Front windshield glass assy.

Wiper
Left clip bar of front windshield
Cover sheet of wiper
Dismount of front windshield glass assem-

bly
1. Dismount the following parts
(a) Wiper arm
(b) Left and right clip bar of front windshield
(c) Front wiper cover sheet
2. Dismount front windshield glass assembly

Prick a small hole in sealant between glass and vehicle body
and insert a small gauge wire into it, then two people cooperate
to pull the wire to separate glass from vehicle body completely
by sawing off the sealant, finally pull glass outward and
dismount it.
Attention: operate carefully to avoid damage of glass
and vehicle body.

Vehicle body—Front windshield glass B0-19
Installation of front windshield glass assem-

bly
1. Clean vehicle body and glass
Remove the glass cement on surface of vehicle body and glass,
then clean contact surface between vehicle body and glass
with cleaning tools.
2. Mount upper trim bar of front windshield on glass
3. Install front windshield glass assembly
(a) Place two suction cups on surface of front windshield
glass, and put glass upside down on work bench.
(b) Coat cleaning activators along inner edge (glass black
edge) of front windshield glass and dry it (usually 10 to
15 minutes), then paint primer coat on cleaning activators
and dry it (usually 15 to 20 minutes), finally smear glass
cement along circumference of glass evenly.
(c) Wipe windshield rabbet of vehicle body with cotton yarn,
and clean it completely with cleaning agent and dry it
(usually 10 to 15 minutes), then paint the primer coat
and dry it (usually 15 to 20 minutes), finally affix front
windshield glass on the rabbet.
(d) Then smear glass cement along circumference of glass
evenly.
Attention: when smearing glass cement, no paraclase
shall exist at butt joint of glass cement.
(e) At last affix front windshield glass on the rabbet, and
adjust it by tapping on surroundings of glass cement by
hand to make it firm.
(f) Bind upper edge of front windshield glass and vehicle
body together with scotch tape in order to avoid loose of
glass.
Attention:
● Dip cloth in cleaning agent and use it to wipe off
redundant glass cement on vehicle body.
● Usually after 4 hours of placement in summer and
8 hours in winter shall the vehicle be put into
running.
4. Install the following parts

(a) Cover sheet of wiper.
(b) Wiper arm.
(c) (Left and right) clip bar of front windshield.
5. Check for leakage and repair

(a) Perform leakage test.
(b) Seal leaking parts with glass cement.

B0-20 Vehicle body — Rear windshield glass
Rear windshield glass

Rear windshield glass
Dismount of rear windshield glass assembly

Prick a small hole in sealant between glass and vehicle body
with a tool and insert a steel wire into it, then two people
cooperate to pull the wire to separate glass from vehicle body
completely by sawing off the sealant, finally pull glass outward
and dismount it.
Installation of rear windshield glass assem-

bly
1. Clean vehicle body and glass
Remove the glass cement on surface of vehicle body and glass,
then clean contact surface between vehicle body and glass
with cleaning tools.

Vehicle body — Rear windshield glass B0-21
2. Install rear windshield glass assembly

(a) Place two suction cups on surface of rear windshield
glass, and put glass upside down on work bench.
(b) Coat cleaning activators along inner edge (glass black
edge) of rear windshield glass and dry it (usually 5 to 15
minutes), then paint primer coat on cleaning activators
and dry it (usually 15 to 20 minutes).
(c) Wipe windshield rabbet of vehicle body with cotton yarn,
and clean it completely with cleaning agent and dry it
(usually 10 to 15 minutes), then paint the primer coat
and dry it (usually 15 to 20 minutes).
(d) Then smear glass cement along circumference of glass
evenly.
Attention: when smearing glass cement, no paraclase
shall exist at butt joint of glass cement.
(e) Affix rear windshield: first align reference column of rear
windshield with vehicle body hole, then affix rear
windshield on the rebbet, and adjust it by tapping on
surroundings of glass cement by hand to make it firm.
(f) Bind upper edge of rear windshield glass and vehicle body
together with scotch tape in order to avoid loose of glass.
Attention:
● Dip cloth in cleaning agent and use it to wipe off
redundant glass cement on vehicle body.
● Usually after 4 hours of placement in summer and
8 hours in winter shall the vehicle be put into
running.
3. Check for leakage and repair

(a) Perform leakage test.
(b) Seal leaking parts with glass cement.

B0-22 Vehicle body — Trunk rear panel assembly
Trunk rear panel assembly

Right connecting rod Outside handle assembly
Left connecting rod

Right hinge assembly of trunk back door Lock body assembly
Center hinge fixed Fixing bracket assembly of trunk

leaf assembly of check
trunk back door Lock catch assembly
of left lock
Center hinge fixed leaf of

trunk back door
Trunk check joint plate assembly
Inner plate closure plate
of trunk back plate
Left hinge assembly of trunk back door
Dismount of trunk back door lock assembly

1. Remove 12 screws and take off inner plate closure plate
of trunk back plate
2. Separate left/right connecting rod from outside handle
3. Remove trunk back door lock assembly from trunk back
plate assembly
Remove 2 hexagon flange bolts and trunk back door lock
assembly
Installation of trunk back door lock assembly

1. Mount trunk back door lock assembly on trunk back plate
assembly
Install trunk back door lock assembly with 2 hexagon flange
bolts
2. Connect left/right rod and outside handle assembly
3. Install inner plate closure plate of trunk back plate
Install inner plate closure plate of trunk back plate with 12
extension buckles and screws

Vehicle body — Instrument panel B0-23
Instrument panel
Part drawing
Central mask left and right

ventilation port assembly Air bag cover plate
Central mask assembly
Instrument panel right ventilation port assembly
Upper cover plate of instrument panel

Instrument embellisher Instrument panel right side cover plate
Upper cover plate of instrument panel
Upper cover plate of

instrument panel
Instrument panel left
ventilation port assembly
Glove box lock cylinder assembly
Glove box assembly
Ashtray assembly
Instrument panel
Instrument panel left side cover plate
Transmission embellisher assembly
Left low plate assembly

Manual brake lever embellisher assembly
Fuse block cover block

B0-24 Vehicle body — Instrument panel
Dismount of instrument panel

1. Disconnect battery cable from the cathode (-)
2. Dismount steering wheel
3. Dismount engine hood lock switch
Remove 2 screws and engine hood lock cable.
4. Dismount combination switch mask component
Remove the 3 screws.
5. Dismount manual brake lever embellisher assembly

6. Dismount transmission embellisher assembly
7. Dismount left low plate assembly

(a) Remove 1 screw and mask.
(b) Disconnect connectors.
8. Dismount instrument mask assembly

(a) Pull out instrument mask.
(b) Disconnect connectors
9. Dismount combined instrument

(a) Remove the 3 screws.
(c) Dismount combined instrument.
10. Dismount ashtray

Vehicle body — Instrument panel B0-25
11. Dismount central mask assembly

(a) Pry out central mask with a screwdriver according to
the drawing and dismount it.
wrapped with tape.
12. Dismount air conditioner panel

(a) Remove 2 screws and pull out air conditioner panel.
13. Dismount CD and music center

(a) Remove the 4 screws.
(b) Disconnect wireless cable and connectors.
(c) Dismount CD and music center.
14. Dismount glove box assembly

Remove 2 screws and glove box assembly.
15. Dismount instrument panel
(a) Remove upper cover plates of instrument panel (3) and
left/right side cover plate of instrument panel.
(b) Remove 3 nuts and 2 bolts connecting instrument panel
and vehicle body.
(c) Remove 4 bolts connecting buttress brace of instrument
panel and vehicle body.
(d) Remove the combination of instrument panel and buttress
brace.
(e) Remove 4 fixed bolts of buttress brace of instrument
panel and instrument panel assembly.
(f) Remove tunnel and engine room wire harness.
(g) Remove instrument panel.
Installation of instrument panel
Install instrument panel parts according to reverse procedures
of dismount

B0-26 Vehicle body — seat belt
seat belt
Part drawing
Front seat belt
50 ± 5
50 ± 5
50 ± 5
50 ± 5
Rear seat belt
50 ± 5
50 ± 5
50 ± 5

Vehicle body — seat belt B0-27
Inspection of seat belt

Attention: seat b elt system must b e insp ected
systematically after each accident, and if the following
parts are found damaged, users must be informed to
replace seat belts. In case users refuse to replace
damaged seat belts, details must be recorded.
1. Inspect seat belt
2. Inspect inertia wheel (locking effect)
3. Visually inspect locking mechanism
4. Inspect functionality of seat belt locking mechanism
5. Inspect guiding mechanism of seat belt and dead bolt
6. Inspect fasteners and connecting points
7. Inspect spool of lap belt
Running test (in safe place)

1. Tighten front seat belt.
2. Run vehicles at 16 km/h and perform emergency stop.
3. Check seat belt is tightened and can not extend.
Remark: carry out this test in a safe place. If seat belt is not
tightened, dismount parts of seat belt mechanism and carry
out the following static test. In addition, whenever new seat
belt parts are installed, appropriate inspection shall be
performed before installation.
Static test
1 5° 1. Dismount locking retractor parts.
＞
27
° 2. Slowly tilt the retractor.
3. Check the retraction of seat belt. Seat belt shall be able
to be pulled out when tilt angle is 12° or is below 15°; it
shall not be pulled out when tilt angle is over 27°.
Two point seat belt (manual)

Test
1. Adjust seat belt to appropriate length.
2. Apply stable load on seat belt.
3. Check seat belt which shall not extend at the moment.

B0-28 Vehicle body — Seat
Seat
Part drawing
Front row seat
85 ± 5
85 ± 5
85 ± 5 85 ± 5
85 ± 5
85 ± 5
Rear row seat
85 ± 5
85 ± 5
85 ± 5
85 ± 5

Vehicle body — Vehicle body dimension B0-29
Vehicle body dimension

Head light bed plate
(3D distance point dimension)
1051
A 1055 a
B 1045 b
Unit：mm
Symbol Description Diameter (mm ) Symbol Description Diam eter (m m)
A,a Installation hole of head light ￠7 B,b Installation hole of horn ￠9
Engine room
A a
153 7
7 153
552
552
B b
Unit：mm
Symbol Description Diameter Symbol Description Diameter

(mm) (mm)
A,a Installation through hole of head light ￠13 B,b Installation through hole of hinge ￠13

B0-30 Vehicle body — Vehicle body dimension
Windshield opening
a C
A
8
142
748.5
748.5
D
B b
Unit：mm
Symbol Description Diameter (mm) Symbol Description Diameter (mm)

A,a Technological cut of tonneau —— B,b Installation hole of wiper cover plate ￠8
Connecting part of tonneau/side Connecting part of front wall upper
C —— D ——
panel outer plate part/side panel outer plate
Side plate
A
1074
119
7 E
718 G
1 22 8
B
6 86
946 D
C f
Unit：mm
Installation through hole of
A ￠10 B Basic location hole ￠25
fender
C,D Technological cut —— E Basic location hole ￠36
Upper/lower cutting edge of back Corresponding point of rear
F,f —— G ——
door colum n outer plate

Vehicle body — Vehicle body dimension B0-31
Engine room
A a
308
308
298 C c 298 b
B
Unit：mm
A Location hole of tonneau glass ￠6 B,b Corresponding point on rear panel ——
a Location hole of tonneau glass 6×8 slotted hole C,c Outer edge of rear panel ——

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Preface

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

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How to use this manual

Front reducer assembly

Explain the repair procedures step by step:

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This format can help experienced technical personnel quickly find

Identification number position

Frame number (VIN)

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Integrated repair instruction

● Before removing or disassembling parts, inspect them carefully

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

● Assemble parts as the regulations in maintenance standard with

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● Parts no longer for use after service

● Use parts and lubricants produced by original factory. When

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

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

● Disassemble the hose clip

● Brake fluid and hydraulic element

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Trouble shooting instruction on electrical

3. Repair method of harness joint terminal

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4. Dismounting of the harness

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● Assembling and disassembling of the clip

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Small clip detacher

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Complete Vehicle parameters

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Complete vehicle type

Complete vehicle basic parameters

Wheel Front wheel camber 0°±30′ 0°±30′ 0°±30′

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Complete vehicle basic performance parameters

Fuel supply Fuel tank Plastic fuel tank: 70L

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Main assembly structure and parameters of chassis

Steering Steering gear type Hydraulic power rack-and-pinion

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Vehicle body structure type

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Electrical system structure and parameters

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Vehicle body dimension schematic diagram

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(Two-dimensional distance size)

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Fuel supply system and exhaust

Fuel supply system:

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Fuel supply system

Accelerator pedal bracket

★ Fuel pump gland