brake fluid GREAT WALL HOVER 2006 Service Repair Manual

Clutch-3
Inspection and adjustment of clutch pedal
1. Check the correctness of pedal height and stroke of push rod
The pedal height starting from the meter: LHD 157.5mm
The push pole travel at the top of the pedal: RHD 151.0mm
If not correct, adjust the pedal height and push rod stroke.
2. Adjust the pedal height and stroke of push bar if necessary
a. Screw off the locknut, rotate the locking bolt until to the correct
height.
Screw on the locknut.
b. Screw off the locknut, rotate the push rod until the stroke of push
rod is correct.
Screw on the locknut.
3. Check the correctness of free stroke of pedal
Step on the pedal lightly until fell the clutch start to generate the
resistance.
Free stroke of pedal: 5
15mm
4. Adjust the free stroke of pedal if necessary
a. Screw off the locknut, rotate the push rod until the free stroke is
correct.
b. Tighten the lock nut
c. Check the height of the pedal after adjusts the free stroke of pedal.
d. On the condition that ensure the free stroke of clutch pedal assembly:
The height difference between the brake pedal, clutch pedal and the
front apron is 0
8mm.
Air discharge of clutch
Remarks: It should discharge the air if there is residual air in the
clutch system.
Caution: Do not leave the clutch liquid on the painted surface,
otherwise it should be washed off immediately.
Fill the brake fluid in the clutch storage tank
Check the liquid tank frequently. Filling if necessary.
the adjustment
point of push rod
stroke
the adjustment
point of pedal height
pedal height
front wall
free stroke
push rod stroke

Clutch-5
Removal of clutch master cylinder, clutch cylinder
1. Use the No. 16 open-end wrench to remove the hose connecting
bleed bolt, use the cloth to cover the oil outlet of auxiliary pump
to avoid the splash of 0brake fluid; step on the clutch pedal for
several times to drain the clutch.
Cautions for installation of clutch operation device:
1. Installation of clutch hard pipe : Check the hard pipe for
deformation, check to see whether the curling at the port of
connection pipe is complete and without damage, if there is no
problem after confirmation, it can be installed and fixed in the
front wall clip and hard-tube clip.
2. Coat each rotary parts of peal with the lithium base grease.
3. Check the surface of clutch hoes, no surface cracking, oil leakage
and dog leg is allowed, use the split washer and spring clip to fix
the clutch hose on the support frame of car body.
4. Connect the joints of the general pump oil pipe and the general
2. Remove the split pin and cylinder pin connected the master
pump connecting fork to the pedal; use the No. 13 socket spanner
to remove two nuts Q32008 which is used to install the master
pump. Check the clutch master cylinder, replace the complete
master pump if the internal of master pump has the abnormal
noise and damage of leakage etc.
pump and sub pump according to the required tightening torque.
5. The air in the clutch oil path needs to be exhausted after filling
oil (except the vacuum filling): step on the clutch pedal after
fillingthe oil tank, when feeling difficult in stepping, use the
open-end wrench with specification of 11 to loosen the air bleed
plug screw to exhaust the air, then tighten the plug screw,
repeat the operation for several times. Tighten the air bleed
plug screw of the sub pump when there is no foam in the
flowing oil liquid. Supplement the oil of the oil tank to the
level between the Max and the Min.

Automatic transmission-14
The main box includes:
z BIR blow-off valve
1. Valve
Figure 3.7 shows the valve unit in the view of transmission fluid tank. Figure 3.8 illustrates the pump cover.
2. Manual-operated valve
The manual-operated valve (refer to Figure 3.9) is connected to the car gear selection mechanism. It controls the transmission
fluid flow to the forward or reverse loop. Except in manual 1st-Gear position, the function of manual-operated valve is same
in all forward gear. In manual 1st-Gear, the transmission fluid will enter into the shift valve 1
2 to make the rear brake belt
and C4 overspeed gear clutch is engaged respectively. The hydraulic control system is located in the valve, pump and main box.
The valve includes the following types:
zManual-operated valve
z Three shift valves
zsequence valve
z electromagnetic pressure control valve
zline pressure control valve
zclutch connection regulating valve
zbrake belt connection regulating valve
zsolenoid valve 1 to solenoid valve 6
zreverse lock valve
The pump includes the following types:
zprimary regulating valve (control line pressure)
ztorque converter clutch regulating valve
ztorque converter clutch control valve
z
solenoid valve 7 Hydraulic control system

Automatic transmission-16
Figure 3.9 manual-operated valve 3.
1-2 shift valve (refer to Figure 3.10) has two position status. It must be in the position (2, 3, 4) for the convenience of raising
gear in 1
st-Gear. It is using for all 1-2 and 2-1 shift.
Through the power supply of S1 and (or ) S2, the 1-2 shift valve can acquire its On/Off status.
During 1-2 shift period, drive the transmission fluid from manual-operated valve to the 2
nd-Gear loop. During the shifting form
2 to 1, the brake belt is engaged and drain the oil through the 1-2 Gear shift valve.
When in 1
st-gear position, the 1-2 gear shift valve operates with the 3-4gear shift valve (described as follows) combinedly to
separate the clutch C4; if in 2
nd-Gear position, engage the clutch C4. When select the manual Gear-1, the clutch C4 engages with
the rear brake belt (B2).
31-2 shift valve

Automatic transmission-19
Figure 3.15 clutch combination regulating valve
10. Brake belt combination regulating valve
aP-Gear or N-Gear, vehicle speed 3km/h
b
R-Gear , speed 10km/h
c
Speed of engine : 1250rpm
d
Diesel vehicle , Opening degree of throttle position: 25
eGasoline vehicle, opening degree of throttle position: 12
In this condition, the TCU control solenoid valve S1 and S2 are closed. The reverse lock valve is affected by the pressure form
S1-S2 transmission fluid; connect the line pressure to loop B2. The transmission fluid flows to servo internal and external
attachment area, the B2 is engaged.
When none of above condition is met, TCU control the solenoid valve S1 and S2 to be opened. The pressure of S1-S2 is
released and the spring control valve body is in locking status at the same. In this condition, the B2 attachment is prohibited.
The feature can realize the protection for transmission by controlling the B2 in high speed and providing the reverse-gear
locking.
If the transmission is in failure mode, then the rear brake belt will be attached in P-Gear, R-Gear and N-Gear.
Figure 3.16 brake belt combination regulating valve

Automatic transmission-22
Power transmission system
The power transmission system includes:
Torque converter equipped with single lock clutch.
4 multi-plate clutch assemblies
2 brake belts
2 one-way clutches
Planetary gear assembly
parking mechanism
A traditional planetary gear assembly composed by six pinions is used in four-speed transmission. It realizes the 4 Gear power
transmission through the drive gear bracket.
So, the cross arrangement is the main arranging method. In the box, there are four subassemblies, shown as follows:
Gear bank central support
C1-C2-C3-clutch C4 subassembly
Pump assembly
Valve assembly
One piece or one set of optional shim is located between the input shaft flange and center of stator support shaft axle of and used
to control the end flotation of transmission. The structure arrangement allows the inspection for the subassembly during the
product manufacturing period.
For description of power transmission system refer to table 4.1 and Figure 4.1:
When the clutch C2 is engaged and 1-2 one-way clutch is engaged, the gear is in 2nd-Gear at this time. During the 1-2 shifting
process, B1 brake belt is combined and the 1-2 one-way clutch is separated (OWC). During the 2-3 shifting period, the clutch
C1 is engaged and the B1brake belt is released. During the 3-4 shifting period, B1brake belt is engaged and 3-4 one-way clutch
is released. For reverse gear, the clutch C3 and B2brake belt is engaged.
When the gear position is in manual 1st, 2
nd and 3rd gear position, the engagement of the clutch C4 can provide the brake of
engine. Additionally, in the drive scope of 2
nd and 3rd Gear, the engagement of clutch C4 can eliminate the unfavorable freewheel
inertia. In the scope of manual 1
st-Gear, the low speed shifting is realized by the engagement of B2brake belt.
The front and rear servo has the figure surface design which requires the accurate friction and need not the secondary regulating
valve. When use the transmission fluid with new static factor, the design of the friction unit can meet the requirement that need
low shifting energy and high static holding force. The transmission uses the non-asbestos friction material.
LUGear position Gear ratio
1st-Gear 2.393
2
nd-Gear 1.450
3
rd-Gear 1.000
4
th-Gear 0.677
R-Gear 2.093
Manual 1 2.393
C3C4 B1 B2
Name of participated unit
* For operation of specified vehicle refer to user’operation manual.
LU: hydraulic torque converter lock clutch
Table 4.1 Participated unit and gear ratio in different gear position

Automatic transmission-26
Power transmission
Introduction
It has the following power transmission pointed to different Gear-position:
power transmission N-Gear and P-Gear
power transmission R-Gear
power transmission manual 1
power transmission Automatic 1st-Gear
power transmission Automatic 2nd -Gear
power transmission Automatic 3rd -Gear
power transmission Automatic 3rd-Gear locking
power transmission Automatic 4th -Gear (overspeed -gear)
power transmission Automatic 4th -Gear locking
For description of each kind of power transmission condition, refer to following parts.
Table 5.1 describe the on-off condition of each unit in all gear condition.
Name of participated unit
Position C1 C2 C3 C4 B1 B2 1-2
OWC 3-4
OWC LU
clutch
Parking and neutral position － － － － － X － － －
Reverse － － X － X － － －
Manual 1st -G ear － X － X － X － X
Automatic 1st- Gear － X － － － － X －
Auto 2nd-Gear and manual
2nd -G ear － X － X X － － X － Automatic 3rd –Gear and
manual 3rd-Gear X X － X － － － X － Automatic 3rd-Gear locking
and manual 3rd-Gear
locking X X － X － － － X X
Automatic 4th -Gear
(overspeed -gear) X X － － X － － － －
Automatic 4th -Gear locking
X X － － X － － － X
In P-Gear or N-Gear, the planetary gear assembly has not the drive. The rear brake belt is used to eliminate the voice generated in
engagement with reverse gear and increase the application of 4WD. It is without the engagement of clutch and brake belt.
In parking-Gear, the locking of mechanism is realized through the engagement of brake lever installed on housing and tooth of
output shaft gear ring.
Control
In stabl
e status, to maintain the arrangement, the status of solenoid valve and valve is shown as follows:
solenoid valve S1 and S2 is powered off.
The line (pump) pressure is applied on the primary regulating valve (PRV) and electromagnetic supply valve.
The torque converter, oil cooler and lubrication loop are filled up with the transmission fluid from the primary regulating
valve.
The line pressure 500 loop is filled up with the transmission fluid from the electromagnetic supply valve.

S5 will be filled up with the transmission fluid through the variable pressure

egulating valve (S5) .
The line pressure is prohibited form entering into the drive loop through the manual-operated valve .
B1 loop and all clutch loop are opened to drainage port.

Automatic transmission-31
Power transmission manual 1st-Gear
In manual 1st –Gear, the drive of transmission is send to the rear clutch cylinder through the input shaft. In this
condition, each function unit of transmission is shown as follows:
The clutch C2 is engaged through the 3-4 one-way clutch (OWC) to drive the front sun gear.
The engagement of B2 brake belt make the planetary gear carrier to stop.
The front sun gear drive the short planetary gear to rotate in anticlockwise.
The short planetary gear drive the long planetary gear to rotate in clockwise.
The long planetary gear rotate around its axial to drive the internal gear ring and output
shaft to rotate in clockwise to realize the movement in forward direction.
In overspeed, clutch C4 can provides certain brake force through 3-4 one-way clutch .
Control:
In stable status, the action of solenoid valve and valve is shown as follows:
The solenoid valve S1 and S2 is powered on.
In the action of pressure of line 500, the gear shift valve of 1-2, 2-3, 3-4 gear are kept in position of 1st-Gear.
The manual-operated valve transmission fluid (line pressure ) makes the clutch C2 to engagement.
LO-1st (line pressure) oil flows to the clutch C4 through the 1-2 Gear switching valve to engage the B2 brake belt.
Refer to Figure 5.3 and Table 5.4.
Table 5.4
The participating condition of each unit in manual 1st-Gear
Name of participated unit
X X

Automatic transmission-37
power transmission Automatic 3rd-Gear and manual 3rd-Gear
In automatic and manual 3rd-Gear, the drive of transmission reaches the front cylinder through the input shaft. In this condition,
the operating principle of the transmission is shown as follows:
The engagement of clutch C2 drives the front sun gear
The engagement of clutch C1 drives the planetary gear carrier
The forward central gear and planetary gear carrier rotate in the same speed clockwise. So, there is not relative motion
between the forward central gear and planetary gear.
The gear ring and output shaft rotate in the speed of output shaft, and makes the moves forwardly.
The engagement of clutch C4 is through the 3-4 one-way clutch (OWC) and make the engine to provide the brake force
in overspeed.
Control:
In stable status, the status of solenoid valve and valve is shown as follows:
The solenoid valve S1 is powered off; Solenoid valve S2 is powered off
When the solenoid valve S1 and S2 is powered off, 2-3 and 3-4 shift valve are kept in 3rd-Gear position through the line
pressure 500.
1-2 Gear shifting valve is kept in 3rd-Gear position by the oil pressure of S1 and S2.
The (line pressure)oil form the 1-2 Gear shifting valve flows into the brake belt combination regulating valve directly and
flows into the 2-3 Gear shifting valve.
The brake belt combination regulating valve provides the 2nd-Gear oil (controlled by the product of line pressure and valve)
to the brake belt feed loop(BAF).
The brake belt feed loop directly provides the oil to:
External combination part of front servo
When the transmission is shifted to 1st-Gear, the 1-2 Gear shifting valve provides the oil drainage port.
When the transmission is in 4th –Gear position, it will use the 3-4 Gear shifting valve.
The 2nd-Gear oil of 2-3 Gear shifting valve flows into the 3rd-gear loop directly .
The 3rd-Gear oil from the 2-3 Gear shifting valve flows into the clutch combination regulating valve and sequence valve of
4-3 Gear directly.
The clutch combination regulating valve provides the oil of clutch attachment feed loop (controlled by the product of line
pressure of 500 and valve ratio) (CAF).
CAF directly provides the oil to :
clutch C1
Sequence valve of 4-3 Gear
In 4-3 Gear shifting valve, the CAF oil is changed to the release fluid of B1 (B1R-F), it cause the closing of brake belt 1
through the 3-4 Gear shifting valve to spring bottom of 4-3 gear sequence valve and release side of front servo.
The drive force (line pressure ) is sent to the clutch C4 through the 3-4 Gear shifting valve to engage the clutch C4 .
Refer to Figure 5.6 and Table 5.7.
Table 5.7
Table of participating condition of each unit in automatic and manual 3rd –Gear
Clutch
Name of participation unit
Automatic and manual
3
rd –Gear

Automatic transmission-48
s oleno id
valve Condition Transmission operation
1 Opened
always 1st-Gear replaces 2nd-Gear; 4th-Gear replaces 3rd-Gear. It causes the car form the G ear shift of 1
→1→4→4 when accelerate form static. The transmission stay longer time in Gear; worse 1→4
shift feeling.
Closed always 2nd-Gear replaces 1st-Gear; 3rd-Gear replaces 4th-Gear. It causes the car form the G ear shift of 2
→2→3→3 when accelerate form static. It is said that starts form 2nd-Gear.
2 Closed always 4th-Gear replaces 1st-Gear; 3rd-Gear replaces 2nd-Gear. It causes the car form the G ear shift of 2
→2→3→3 when accelerate form static. That is saying that start form 4th-Gear.
Opened
always 2nd-Gear replaces 3rd-Gear; 1st-Gear replace 4th-Gear.
It cause the car is shifted form 1st-Gear to 2nd-Gear, then from 2nd-G ear to Gear when accelerate
form static. It will feel the transmission is in free gear position after 2→1 Gear shift.
1&2 Opened
always Can not realize the reverse gear; only has 1st-Gear operation.
3 Closed always Following shifts are bad. (2→3 is worst ):1→3, 1→4, 2→3, 2→4, 4→2, 4→1
Opened
always Following gear shifts are worse: 3→4, 4→3, 3→2。
It may cause the gear slide when the hydraulic torque converter is locked.
4 Closed always Following gear shifts are worse:
1→2, 1→3, 1→4, 2→3, 2→4, 3→1, 3→2, (including manual) 3→4, 4→1, 4→3
Opened
always Following gear shifts are worse: (1→2 is worst) 2→4, 3→2 It may cause the gear slide when
the hydraulic torque converter is locked.
6 Closed always The line pressure is high always.
Opened
always The line pressure is low always. So it cause the slide between gears. The clutch C1 and brake belt
B1 will be burned.
7 Closed always The hydraulic torque converter is without lock.
Opened
always The hydraulic torque converter is locked in 3rd-Gear and 4th-Gear. It cause the car generates the
vibration in low-speed status.
Table 6.1.2 Operation of transmission when ON/OFF solenoid valve is faulty
Mechanical detection
1.Inspection of transmission on car
It should process the following detections before disassemble the transmission:
process the on-road drive test to determine the failure cause .(according to requirement)
Detect the standard of transmission fluid. (refer to 7.2.1)
Ensure the transmission fluid in not overheated. (Normal color and smell)
Detect the failure information.
Check the battery terminal and grounding for corrosion or loose.
The engine speed is within the specified value in manual.
Check the cooling system for normal operation.
All power supply and plug wires is tight and not loose.
Check the transmission fluid, ensure the oil pan is without other martial material or pollutant.
2. Oil leakage detection
It should wash the polluted part of the transmission before select the oil leakage part, then drive the car.
When detect the leakage part of the rear servo system, it should lift the car by lifter firstly, then switch the gear to reverse
gear within 10s.
When detect the leakage part of front servo system, it should lift the car by lifter firstly, then switch the gear to gear-2
(winter mode).
The time switched to 2nd-Gear should be no more than 10s to avoid the oil in the torque converter is overheated.
3. FAQ table