42 GWFLORID Maintenance Manual

Transmission

037A Transmission’s Overall External Schematics............. 43

Main Technical Parameters ................................................ 43
Transmission's Proper Use and Care.................................. 44
Technical Specifications for Transmission Installation
and Adjustment.................................................................... 44
Areas of Importance............................................................ 45
Troubleshooting................................................................... 46
037A Transmission Structural Schematics.......................... 47
Clutch.................................................................................. 48
Gear Shift Fork and Fork Shaft........................................... 49
Transmission Case.............................................................. 50
Disassembling the Input Shaft Subassembly...................... 56

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Disassembling the Output Shaft Subassembly................... 60
Disassembling the Shift Cover Subassembly...................... 64
Disassembling the Differential Subassembly...................... 68
 Transmission 43

037A Transmission’s Overall External Schematics

The 037A transmission is a step mechanical transmission with differential, two-shaft front wheel drive
application. The forward gear has adopted the inertia synchronizer gear-shifting mechanism, which offers
smooth and easy gear shifting, reduces noise dramatically, and improves the service life of the gear - important
in achieving the overall economical efficiency. Regarding its control mechanism, the set steel ball and spring
allow the shifting gear to be quick, accurate with solid handling. The 5th gear transmission is equipped with an
interlocking mechanism to prevent accidental switching to reverse, to improve driving comfort and reliability.

Main Technical Parameters

Basic parameters of the 037A transmission
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Max. input torque 115 N·m/4400-5200 rpm
Speed ratio for each gear
3.545 1.913 1.310 0.973 0.804 3.214
Main deceleration ratio 3.944
Odometer speed ratio 31/35 (currently no driven gear)
Center distance (mm) 65
Lubricant capacity (L) 1.8
Control method Remote cable control
Netweight (kg) 28
Match engine GW413EF
44 GWFLORID Maintenance Manual

Transmission's Proper Use and Care

1. Transmission's proper operation
1.1 Shift the gear gently, not excessively.
1.2 Do not start with high speed.
1.3 To avoid premature abrasion of the gear shift fork, do not rest your hand on the gear lever while driving.
2. Model number of the lubricant to be used:
GL-4 80W-90 (For China domestic model)
GL-4 75W-90 (For alpine region model)
GL-5 140 (For high-temperature region model)
Caution: Please only use the lubricant with model numbers specified by the Great Wall Motor Co., Ltd.
Do not mix lubricants with different model numbers. Only fill with clean lubricant.
3. Areas of importance for new vehicle usage:
3.1 Before using a new vehicle, be sure to check the transmission and all exposed connectors and fastening
pieces, so as to avoid failure due to faulty installation or loose connections.
3.2 Since the new vehicle is still in the run-in period, the transmission's lubricant should be replaced after 5000 km
distance.
4. Transmission three-level maintenance:
4.1 Transmission level-one maintenance: During the first level of maintenance, the liquid level of the lubricant
should be checked to ensure that it is up to the oil-filling mouth. Add more if insufficient. Excessive low

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oil level can lead to ineffective lubrication, as well as burning of the bearings and gears. Excessive high oil
level, however, can overheat the transmission or cause oil to leak. In addition, during the first level of main-
tenance, the breather plug should be checked and cleaned. If the breather plug is clogged, internal pressure
will build up and oil will leak from the transmission.
4.2 Transmission level-two maintenance: The transmission's lubricant should be replaced the first time that the
vehicle undergoes the second level of maintenance. Clean the transmission with kerosene. The quality of the
lubricant should be inspected during the future second level of maintenance practises. The lubricant should
be replaced if diluted, gummy, or dirty.
4.3 Transmission level-three maintenance: During the third level of maintenance, it should be removed for in-
spection, cleaning, and oil changing.

Technical Specifications for Transmission Installation and Adjustment

Inspect the axial play (δ) between the synchronizer ring and the gear shaft
Gear (δ1) (δ2) (δ3) (δ4) (δ5)
Standard axial play (mm) 0.7-1.7 0.7-1.7 0.7-1.7 0.7-1.7 0.7-1.7

Check the axial play (δ) between each gear

Gear (δ1) (δ2) (δ3) (δ4) (δ5)
Standard axial play (mm) 0.1-0.4 0.1-0.6 0.1-0.4 0.1-0.6 0.1-0.55
 Transmission 45

Thread fastening piece tightening torque table

Tighten-
Use parts Bolt code Specifications Quantity ing torque
(N·m)
Differential case × differential ring gear 037-2303309 M12 × 1.0 6 123.6
Clutch housing × reverse gear arm
037-1702073 M8 × 1.25 2 17.2
bracket subassembly
No. 1 gear shift fork shaft × No. 1 gear
037-1702056 M6 × 0.75 1 15.7
shift fork
No. 2 gear shift fork shaft × No. 2 gear
037-1702056 M6 × 0.75 1 15.7
shift fork
Transmission case × clutch housing 037-1701012 M8 × 1.25 13 29.4
Transmission case × manipulation lid
037-1702051 M8 × 1.25 4 12.0
subassembly
Transmission case × position mechanism
037-1702042 M18 × 1.5 1 36.8
component
Transmission case × reverse gear idler
037-1701404 M8 × 1.25 1 29.4
shaft × sealing ring

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Transmission case × hexagon head plug 037-1701016 M18 × 1.5 2 39.2
Transmission case × reverse gear switch
037-1701022 M18 × 1.5 1 40.2
subassembly
Transmission case × cable bracket 037-1701019 M8 × 1.25 4 11.3
Clutch housing × clutch slave cylinder
037-1601019 M8 × 1.25 2 11.3
subassembly
Select lever assembly × gear shifting
037-1702027 M8 × 1.25 1 38.0
block
Clutch housing × release fork support
037-1601011 M10 × 1.25 1 36.8
nail
Counterweight component × shift lever
037-1702030 M8 × 1.25 2 20.0
component
Release fork support nail 1 29.4

Areas of Importance
Removal
During removal, all components should be gently handled to avoid knocking, especially the joint surface.
All components should be placed in the proper order to avoid misplacing and mistaking.
Installation
1. Clean all parts before installation (except rubber pieces and gaskets).
2. All oil seals, shaft retainers, and elastic pins should not be reused.
3. All rubbing surfaces should be coated with lubricant, and the lips of all oil seals should be coated with
grease.
4. During installation of the bearings, do not use any kind of rolling element to transmit pressure, and
make sure not to tilt it.
5. During the installation of synchronizer components, the two sides of the spring piston's openings
should alternate.
6. When the transmission is operating under normal working conditions, there should be no lubricant
leakage from any of the parts.
Transportation and storage
1. When transporting a transmission, make sure the conditions are dustproof and rainproof, as well as
take proper care not to damage it due to jolting, shaking, removal, or installation.
2. Transmission assembly should be stored in a ventilated, dustproof, and dry place.
3. Users with special transportation or storage requirements should have another discussion to reach an
agreement on this matter in the supply contract.
46 GWFLORID Maintenance Manual

Troubleshooting
Common problems Possible causes Solving methods
Difficult gear Not applying clutch Use correct driving methods
engagement Insufficient clutch separation Inspection & adjustment
Serious abrasion of the synchronizer ring Replace component
Positioning spring is too hard Replace component
Noise is too loud or Oil level is too low Fill oil to the specified level
abnormal Lubricant is of poor quality Replace the specified oil
Untimely oil changes Replace oil and damaged part

Improper gear axial position and clearance Inspect and adjust

Damaged bearing Replace component

Gear has a burr or has been knocked Repair or replace gear
Oil leakage Too much oil is added, oil level too high. Fill the oil level to the specified position.
Reassemble and screw in according to regu-
Bolt loose or missing

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lations.
Breather plug fails Replace
Damaged seal Replace
Synchronizer is damaged Excessive gear shifting force Replace synchronizer
Not applying clutch Use correct driving methods
Synchronizer's spring expan-
Replace
sion ring is damaged
Gear disengagement Control mechanism malfunction Inspect and adjust
Retaining spring or steel ball missing Additional assembly
Retaining spring malfunction Replace
Fork groove of the gear sleeve is worn out Replace
Shifting fork is worn out. Replace
Bearing and gear are burnt Oil level is too low Replace part and fill oil
Lubricant is of poor quality. Replace part and lubricant
Untimely oil replacement causes
Replace part and lubricant
the oil to be too dirty
Mixed use of different oils
Replace part and lubricant
or use of additives
Difficulty shifting gears Synchronizer spring malfunction Replace
The internal groove of the syn-
Replace
chronizer ring is worn out
The synchronizer ring is seized
Replace
into the conical surface
Deformed shifting fork or
Replace
shifting fork shaft
Shifting fork is worn out Replace
 Transmission 47

037A Transmission Structural Schematics

1
2
3
4
5 9
6 10
7 11
8 12
76 13
75 14
74 15
73 16
17
72 18
71 19
70 20
21
22
69 23
68 24
67 25
66 26

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65
64
63
27
28
29
62 30
31
61 32
60 33
59
58

57
56
55 34
54 35
53 36
52 37
38
51 39
50 40
49 41
48 42
47 46
45
44
43

1. No. 2 gear sleeve 2. Shaft retainer 3. No. 2 Slider (3) 4. Spring expansion ring (2) 5. No. 2 gear hub 6. 3rd gear synchronizer ring
7. 3rd gear gear assembly 8. Needle bearing 9. With washer bolt 10. Clutch slave cylinder subassembly 11. Release fork protective
cover 12. Release fork spring 13. Bolt for flange face (3) 14. Release fork 15. Clutch housing 16. Release fork support nail 17. Ball
bearing 18. 2nd gear synchronizer ring 19. T oil seal 20. No. 1 gear sleeve 21. No. 1 Slider 22. 1st gear synchronizer ring 23. 1st gear
gear components 24. Needle bearing 25. Release bearing subassembly 26. Tapered roller bearing 27. Guide nozzle 28. 2nd gear gear
assembly 29. No. 1 gear hub 30. Spring expansion ring (2) 31. Bolt for flange face (6) 32. Straight pin 33. Odometer driver 34. T oil
seal 35. Tapered roller bearing 36. Adjusting shim (2) 37. Axle shaft gear (2) 38. Planetary gear (2) 39. Gasket (2) 40. Differential
case 41. Planetary gear shaft 42. Differential ring gear 43. Bolt for flange face (8) 44. Tapered roller bearing 45. Adjusting shim 46.
T oil seal 47. Shaft retainer 48. Retaining ring 49. Needle bearing 50. 3rd driven gear 51. Spacer 52. 4th driven gear 53. 5th driven
gear 54. Shaft retainers 55. Tapered roller bearing 56. Adjusting shim 57. Output shaft 58. 5th gear gear assembly 59. Shaft retainer
60. Retaining ring 61. Spring expansion ring (2) 62. Needle bearing 63. Input shaft 64. Adjusting shim 65. Ball bearing 66. 3rd gear
gear hub 67. 3rd gear Slider (3) 68. 3rd gear gear sleeve 69. 5th gear synchronizer ring 70. Steel ball 71. 5th gear thrust washer 72.
Needle bearing 73. 4th gear components 74. Retaining ring 75. 4th gear synchronizer ring 76. Transmission case
48 GWFLORID Maintenance Manual

Clutch
Components

Release bearing
Cable bracket

Release fork
Bolts with
washer
×5
11.3

Cable bracket
Release fork support nail
29.4

Bolts with washer

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11.3
Release fork dust cover

Differential assembly
Clutch housing Magnetic body

Guide nozzle

Tapered roller
bearings

T oil seal
Output shaft assembly

Input shaft assembly

N·m : Specified torque

 Transmission 49

Gear Shift Fork and Fork Shaft

Components

Clutch housing

No. 1 gear shift fork shaft

Shaft retainers

Set bolt 15.7

Elastic
cylindrical pin

No. 1 gear shift fork

Shaft

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retainers
Elastic
cylindrical pin
Lock pin No. 1
guide block
Pressure spring
No. 3 gear shift
Reverse gear fork shaft
gear shift fork No. 3 guide block Lock pin
No. 2 gear shift fork shaft
No. 3 gear shift fork

Shaft retainers Set bolt

Bracket bolt 15.7

17.2
Shaft retainers

Reverse gear arm No. 2 gear shift fork

bracket assembly

Reverse gear
idler assembly

Reverse gear
idler shaft Output shaft assembly
Bolt for flange face
29.4
Gasket
Input shaft assembly

N·m : Specified torque

50 GWFLORID Maintenance Manual

Transmission Case
Components

Bolt for flange face 12.0

Clip
Clip

Clip

Reverse gear

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Shift lever assembly
switch subassembly

Pressure torsion spring Washer

Oil drain slot

Tapered roller bearings

Bush

Adjusting shim

Adjusting shim Transmission case

Position mechanism
assembly
36.8 39.2
Hexagon head plug

Hexagon head plug

39.2 Washer Washer

Bolt for flange face ×8

N·m : Specified torque 29.4
Transmission 51

Shift System Removal

1. Remove 4 bolts for flange face from the manipulation
lid.

2. Remove the set bolts from the sides of the transmis-

sion case.

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3. Separate the clutch housing and the transmission
case.
(a) Remove 8 bolts for flange face from the transmission
case and clutch housing.
(b) Remove 5 bolts for flange face from the clutch housing
and transmission case.
(c) Pound the housing's protruding parts with a soft ham-
mer to remove the transmission case.

4. Remove the reverse gear idler shaft and the reverse

gear idler assembly.
52 GWFLORID Maintenance Manual

5. Remove the reverse gear arm bracket assembly.

6. Remove the No. 1 gear shift fork shaft and the set
bolts.

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7. Remove the elastic cylindrical pin from the No. 1 guide
block.

8. Remove the No. 1 gear shift fork, No. 1 gear shift fork
shaft, and No. 1 guide block.
Transmission 53

9. Remove the elastic cylindrical pin from the No. 3 gear

shift fork.

10. Remove the elastic cylindrical pin from the No. 3 guide
block.

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11. Remove the No. 3 gear shift fork, compression spring,
and No. 3 guide block.

12. Remove the set bolts from the No. 2 gear shift fork
shaft.
54 GWFLORID Maintenance Manual

13. Remove the No. 2 gear shift fork shaft, No. 2 gear shift
fork, and No. 2 guide block.

14. Remove the input and output shaft subassembly.

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15. Remove the differential subassembly.

16. Remove the magnetic body from the inside of the

clutch housing.
Transmission 55

17. Remove the oil drain slot from the inside of the transmis-
sion case.

18. Remove the T oil seal with a screwdriver from the

clutch housing.

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19. Remove the release fork and the release bearing from
the clutch housing.

20. Remove the set bolts of the release fork from the
clutch housing.
56 GWFLORID Maintenance Manual

Disassembling the Input Shaft Subassembly

Components

Needle bearing 4th gear subassembly

Rear ball bearing 4th gear synchronizer ring

Retaining ring

Spring expansion
ring Shaft retainer

Spring expansion ring

No. 3 Slider
No. 3 gear sleeve/

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No. 3 gear hub
No. 2 gear sleeve/No. 2
gear hub
5th gear
synchronizer ring No. 2 Slider
Spring expansion ring
Spring expansion
ring
5th gear gear
subassembly Needle bearing 3rd gear
synchronizer ring

Retaining ring

3rd gear gear subassembly

Shaft retainer

Input shaft Needle bearing

Steel ball
Front ball bearing
5th gear thrust washer

1. Remove the input shaft's ball bearing.

Transmission 57

2. Remove each component from the 3rd synchronizer.

3. Remove the 5th gear needle bearing.

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4. Remove the retaining ring.

5. Remove the shaft retainer.

58 GWFLORID Maintenance Manual

6. Remove the input shaft's 5th gear thrust washer.

7. Remove the steel balls from the 5th gear thrust washer
of the input shaft.

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8. Remove the 4th gear subassembly, 4th gear needle
bearing, 4th gear synchronizer ring, and the 4th gear
bearing washer (4 types of part).

9. Remove the shaft retainer from the input shaft's No. 2

synchronizer gear hub.
Transmission 59

10. Remove each component of the input shaft's No.2 syn-

chronizer.

11. Remove the input shaft's 3rd gear synchronizer ring

and the 3rd gear subassembly.

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12. Remove the needle bearing from the 3rd gear of input
shaft.
60 GWFLORID Maintenance Manual

Disassembling the Output Shaft Subassembly

Components

Rear tapered
1st gear roller bearing
synchronizer ring

Shaft retainer

5th driven gear

1st gear gear
subassembly
4th driven gear

Needle bearing

Spacer

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3rd driven gear

Retaining ring
Shaft retainer

Needle bearing

Output shaft
2nd gear gear subassembly

2nd gear synchronizer ring

Spring expansion ring

No. 1 Slider

No. 1 gear sleeve/No. 1

Front tapered gear hub
roller bearing

1. Remove the output shaft's rear tapered roller bearing.

Transmission 61

2. Remove the output shaft's 5th driven gear shaft retainer.

3. Remove together the output shaft's 5th and 4th gear

driven gear.

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4. Remove the output shaft spacer.

5. Remove the output shaft's 3rd driven gear and the 2nd
gear subassembly spacer.
62 GWFLORID Maintenance Manual

6. Remove the output shaft's 2nd gear synchronizer ring,

2nd gear needle bearing, and the 2nd gear subassem-
bly retaining ring.

7. Remove the shaft retainer from the No. 1 synchronizer

gear hub of the output shaft.

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8. Remove the output shaft's No. 1 synchronizer compo-
nents and the 1st driven gear.

9. Remove the needle bearing from the output shaft's 1st

driven gear subassembly.
Transmission 63

10. Remove each component of output shaft's No. 1 syn-

chronizer.

11. Remove the front tapered roller bearing.

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64 GWFLORID Maintenance Manual

Disassembling the Shift Cover Subassembly

Components

Gear shifting block

Shift lever assembly

Dust cover
T oil seal
38.0 Set bolt

No. 2 spring seat

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Pressure spring

Manipulation lid

Shaft retainer
T oil seal

Select lever subassembly

Shift guide block

Gasket

Lock plate Shaft retainer

Elastic cylindrical pin

N·m : Specified torque

1. Remove the shift lever's elastic cylindrical pin.

Transmission 65

2. Remove the shaft retainer on the shift lever and the se-
lect lever.

3. Remove the lock plate.

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4. Remove the pressure torsion spring.

5. Remove the No. 2 spring seat.

66 GWFLORID Maintenance Manual

6. Remove the set bolts and the select lever assembly.

7. Remove the select lever subassembly.

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8. Remove the shaft retainer on the shift shaft and the se-
lect lever.
Caution: Use a cord to fasten the shift lever in order to
Cord make the operation convenient.

9. Remove the shift shaft and the shift shaft dust cover.
Transmission 67

10. Remove the shaft retainer from the shift shaft.

11. Remove the shift shaft T oil seal from the manipulation
lid.

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12. Remove the T oil seal from the manipulation lid.
68 GWFLORID Maintenance Manual

Disassembling the Differential Subassembly

Components

T oil seal
Clutch housing

Tapered roller bearings

Elastic cylindrical pin Differential case

Odometer drive gear

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Gasket

Planetary gear
Adjusting shim Differential ring gear

Axle shaft gear

Axle shaft gear
Planetary gear shaft Bolt for flange face
Adjusting shim
Planetary gear 123.6

Gasket

Tapered roller bearings

T oil seal
Adjusting shim

Transmission case

N·m : Specified torque

Transmission 69

1. Remove the tapered roller bearings of the left differen-

tial.

2. Remove the odometer drive gear from the differential.

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3. Remove the tapered roller bearings of the right differen-
tial.

4. Remove the bolts for flange face of the differential ring

gear and the differential case.
70 GWFLORID Maintenance Manual

5. After removing bolts for flange face from the differential

ring gear and the differential case, gently pound to re-
move the differential ring gear with a soft hammer.

6. Remove the elastic cylindrical pins from the differential

case and the gear shaft.

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7. Remove 2 planetary gears, 2 axle shaft gears, 2 ad-
justing shims, and 2 gaskets from the inside of the dif-
ferential case.