Great Wall Hover. Manual — part 66
Reducer
Replace the oil seal on the car
1. Disconnect the reducer from the drive shaft.
a. Make the assembly mark on two flanges.
b. Remove four bolts and nuts.
2. Remove the flange and dustproof cover assembly
3. Remove the oil seal
Use the special tools to remove the oil seal.
bearing spacer
adjusting washer
rear bearing
drive bevel gear
adjusting ring
side bearing
driven bevel gear
differential housing
locking plate
plain washer
flange
dustproof cover
oil seal
oil baffle disc
front bearing
bearing gland
stop plate
lock washer with
double ears
N
m: Specified torque
Used component which can not be used any more.
assembly mark
4. Install the new oil seal
a. Coat the lip of oil seal with the HP-R grease.
b. Use the special tools to knock in the new oil seal.
Insertion depth of oil seal: 1.0mm
5. Install the flange and dustproof cover assembly
6. Rivet the drive bevel gear nut.
7. Connect the drive shaft flange to the reducer
flange Align the assembly mark ; then connect them
by bolt.
Tightening force: 78
5N
m
8. Check the oil level of reducerReplace the hyperbolic
gear oil if necessary.
Oil number : GL-5 hyperbolic gear
Viscosity : SAE80W/90
Amount: Filled with oil until the oil flows out form oil filling
port.
Removal of reducer
1.Remove the oil drain plug; drain the oil from the
reducer
2. Remove the rear axle
(Refer to Step 2 in “Disassembly of Rear Axle”)
3. Disconnect the drive shaft from the reducer
(Refer to step 1 in “Replace the Oil Seal on Car”)
4
Remove the assembly of reducer.
special tools
insertion depth
: 1mm
assembly mark
assembly mark
Disassembly of reducer
Remarks: If the noise of differential is loud, process the follow-
ing inspection before disassembles the differential to determine
its reason. When the differential has serious problems, it can be
disassembled for repair if necessary.
1. Check the internal clearance of driven bevel gear.
If the clearance is beyond the specified range; adjust the preapplied
load of bearing or repair if necessary.
(Refer to step 13 “Assembly of Reducer”)
Standard internal clearance: 0.15-0.25mm
2. Check the intertooth contact of drive bevel gear
and driven bevel gear.
(Refer to Step 14 in “Assembly of Reducer”)
Record the contact position of tooth.
3. Check the clearance between the thrust plate of
axle shaft gear and differential housing.
Use the feeler to measure the clearance between the thrust plate
of axle shaft gear and differential housing.
Standard clearance: 0.45-0.75mm
It should be replaced by the proper thrust washer if the clearance
is beyond the specified range.
(Refer to Step 2 in “Replacement of Differential Components”)
4. Measure the pre-applied load of drive bevel gear
Use the torsion meter to measure the pre-applied load on the
internal clearance between the drive small gear and driven bevel
gear.
Pre-applied load: 0.4-0.6N
m
5. Total pre-applied load
Use the torsion meter to measure the total pre-applied load.
Pre-applied load : 0.9-1.3N
m
6. Remove the differential and driven bevel gear
a. Make the assembly mark on the differential bearing gland and
reducer housing.
b.Remove two stop plates.
c.Remove two bearing glands and two adjusting rings.
d.Remove the bearing outer race.
e.Remove the differential form the reducer housing.
Remarks: Mark the label on the removed components to indi-
cate the position of reassembly.
7. Remove the flange and dustproof cover assembly
a.Use the hammer and chisel to loose the riveted part of nut.
b.Use the special tools to clamps the flange; then remove the nut.
Caution: The used nut can not be used any more.
c.Remove the flange and dustproof cover assembly.
8. Remove the oil seal
Use the tools to pry out the oil seal.
9. Remove the drive bevel gear and spacer
Remove the drive bevel gear, bearing and spacer from the reducer
housing.
10. Remove the oil baffle disc and front bearing inner
race
11. Replace the rear bearing of drive bevel gear
a. Use the press machine and special tools to pull out the rear
bearing from the drive bevel gear.
special tools
special tools
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