GREAT WALL HOVER 2006 Service Repair Manual

e. If need to install the new friction disk, please remove the clutch assembly and immerse the friction assembly into the
transmission fluid for 5 minutes at least before the installation.
f. Check whether the clutch C1 wheel axle is matched with the overspeed shaft. It should replace the wheel axle and wheel axle
assembly if loose.
g. Coat the small nylon thrust insulation plate with the Vaseline and installs it on the overspeed shaft. Refer to Figure 8.19.
h. It should be carefully when install the overspeed shaft on the C1 cylinder to avoid the damage of sealing ring.
i. Use the Vaseline to install the small copper C1 wheel axle thrust washer, shown as Figure 8.19.
j. Check the input shaft for problem. Install the input shaft on the cylinder and use the ring spring to install the wire safety of
input shaft and cylinder. Ensure the coil is in groove completely.
k. Use the petroleum jelly to install the gasket and place it on the input shaft.
l. Assemble the C1/C2/C4 clutch, clutch C3 and sun gear, shown as figure 8.24, 8.32
m. Install the assembly in the transmission case.
Figure 8.32 and 8.33 assembly number: 6 bearing and pressure disc to clutch C3 assembly
13. Pump housing and torque support
Caution:
a. Do not clean the solenoid valve by solvent.
b. Ensure the O-ring is installed in the correct position.
c. Do not blow off the first drop and mix it with the ball spring blowed off by the torque converter. ( only for the condition of
installing the transmission to STD pump housing)
d. Do not damage the line bearing on the assembly; avoid any impact for bearing during the loading.
e. Check the end floating of transmission; it is help for the lose and incorrect assembly of any assembly.
Caution: Figure 8.35 The orientation of crossing part is shown in Figure 8.36 to 8.42.
The assembly procedure of pump housing and torque converter is as follows:
a. Check the pump for damage, chip and abnormity; check whether the sleeve of drive gear is fixed.
b. Wash the pump and pump gear carefully; remove all redundant oil and dirt.
c. Install the pump gear and pump. Use the micrometer to measure the depth from the surface of pump to gear surface. The
measured value is the side clearance of pump. The side clearance should be in the range of 0.020-0.040mm.
d. Remove the pump gear from the pump.
e. If had been removed, please replace the pump sealing. Ensure the cleanness of pump sealing.
f. Use the transmission liquid to lubricate the pump gear, pump, washer and sealing and install the pump gear on the pump.

Figure 8.34 pump, cover and torque converter support
g. Use the automatic transmission liquid to lubricate the pump O-ring and
install it on the pump. Place the pump on the other side.
h. Ensure the pump housing cavity and hole are not blocked.
Figure 8.35 Assembly of pump cover
i. Use the automatic transmission liquid to lubricate all loose part before
the installation.
g. Install the primary regulating valve on the pump housing, ensure the
valve slide freely; then install the plug of regulating valve and O-ring.
Refer to Figure 8.36.
k. Install the fixed bolt, install the torque conversion clutch regulating valve,
plug and O-ring. Refer to Figure 8.37
l. Install the fixed bolt. Refer to Figure 8.39
m. Install the torque conversion clutch control valve, spring and O-ring.
Refer to Figure 8.38pump cover assembly
pump housing cover
oil seal
pump assembly
o-ring (pump )
n. Install the fixed bolt, shown as Figure 8.39
o. Install the torque converter detection ball spool and spring, shown as Figure 8.41
p. Install the washer on the pump body. Install the housing disc and solenoid wire maintaining cover on the pump housing; ensure
the edge of disc close to the pump housing.
Shown as Figure 8.34, Tighten the bolt according to the sequence of (1-5), shown as Figure 8.42.
Caution:
Check the smooth of wire and connector. To ensure whether the wire and connector have connection and abrasion on the
input shaft or clutch C1/ C2 cylinder; check the wire and connector for over extension.
q. Tighten the screw of solenoid valve 7.Refer to Figure 8.39
r. Install the pump on the pump housing, tighten all bolts; ensure the pump can be washed without pump housing. Tighten
the bolt in certain sequence; shown as figure 8.42.

Figure 8.36 Primary regulating valve
Figure 8.37 Torque converter clutch regulating valve
s. Install the pump on the washer of transfer case of housing.
t . Make the O-ring is proper for the external diameter of pump.
u. Ensure the pump housing hole in main housing is clean and without dirt.
v. Ensure the plastic connector of solenoid valve 7 is installed on the correct position of main housing.
w. Install the pump and pump housing on the input shaft carefully and avoid the damage of gasket spring. Tighten the pump
housing spring. Refer to Figure 8.43 Figure 8.44.
x. Check whether the transmission end float is fixed in the clearance of part 9.2. Refer to It the end float without filling metal plate
is more than that in instruction, then the metal plate should be placed in surface of NO.4 bolt and input shaft bolt. Refer to
Figure 8.19. if the end float is less than 0.5mm or more than 0.8mm; then the transmission can not be installed correctly and
is beyond the specification partly.
Check the end floating by executing the following procedure:
Connect the disc indicator to the front end of the transmission; place the pointer on the end of input shaft.
Apply about 250N or 25kg force on the input shaft.
Zero the indicating pointer.
Install a small lever on rear of the front clutch cylinder.
The recorded measuring value is the end floating value or called as the clearance of No.4 bearing on torque converter
tube support.
After the completion of the process, adjust the front and rear brake belt according to the specification of details in part 8.4.

Figure 8.39 Valve fixing plug and pin
Figure 8.40 Torque converter release ball and spring

Figure 8.41 Position of test ball
Figure 8.42 Tighten the pump bolt in the sequence shown in figure
Figure 8.43 Connect the pump to the housing in the sequence shown in figure

14. Valve
Caution:
a. Must not clean the solenoid valve pipe port by solvent.
b. Pay attention to the position of ball on upper of valve.
c. Pay attention to the position of 1-2 Gear and 3-4 Gear gear shift valve which may be exchanged.
d. Check the 4-3 Gear sequence valve and spring for position.
e. Check the 12mm ball on the lower of valve.
f. It should ensure install the correct pump housing (HPPC). Please must not mix the 1
st-Gearlow position ball spool
with the torque converter ball spool .
g. Check the rag of line pressure relief valve and pay attention to replace the iron shim.
h. The hole on the valve is used for fixation and safety and could not be extended.
i . When repair the transmission, it should ensure the solenoid 5 damp coil spring is not broken.
The installation procedure of valve is shown as follows:
a. Use the cleaning solvent (refer to 8.45, 8.46) to wash the upper and lower valve completely and dry it by air; check the valve
cavity, port and hole for damage or block.
b. Install the cushioning baffle positioning bolt and clean all loose parts completely.
c. Check all valves for smooth sliding on its position.
d. Install the proper pump housing, spring and ball. Check the valve and rolling bolt.
e. Install the 1-2 Gear gear shift valve, plug and fixed bolt. Refer to Figure 8.48. Install the 3-4 Gear gear shift valve and fixed bolt.
Refer to Figure 8.49.
Install the 2-3 Gear gear shift valve and fixed bolt. Refer to Figure 8.50. Install the 4-3 sequence valve, spring, plug and fixed
disc.
Refer to Figure 8.51.
f. Install the brake belt action regulating valve (BAR) spring, piston and fixed bolt. Refer to Figure 8-52
g. Install the force and action regulation valve (CAR)spring, piston and fixed bolt. Refer to Figure 8-53
Caution: The aluminum valve is damaged easily.
h. Install the solenoid pressure-supply valve, spring and fixed disc. Refer to Figure 8.54.
i. Install the solenoid valve 6 bolt , spring and fixed bolt.

Figure 8.45 Lower valve
Figure 8.46 Position of upper valve and detection ball
Figure 8.47 solenoid valve 5 and damper

Figure 8.48 12gear shift valve
Figure 8.49 3
4 gear shift valve
Figure 8.50 solenoid 2 and 2
3gear shift valve
Figure 8.51 4
3sequence valve
Figure 8.52 brake belt combination regulating valve and solenoid 4

Figure 8.53 clutch combination regulating valve and solenoid 3
Figure 8.54 solenoid combination valve and solenoid 6
Figure 8.55 reverse lock valve
j. Position the 3rd feed ball (large nylon ) on the valve and solenoid supply valve filter, shown as Figure 8.54.
k. Check the separating disk for abrasion, repair or replace if necessary.
l. Check the washer of upper and lower valve for damage, replace it if necessary
m. Install the upper shim of lower position valve.
n. Install the reverse lock valve, spring and fixed disc; ensure the correct installation of valve; shown as Figure 8.55.
o. Install 5 nylon balls on the upper valve, shown as Figure 8.46. Install the upper valve shim; install the separating disk on the
upper valve.
p . Lift the separating disk to the upper valve; prevent the detection ball from falling ; install the upper valve on the low pressure
valve. Tighten all screws. Refer to Figure 8.56.

Figure 8.56 The tighten sequence of valve bolt from upper to lower
q. Install the solenoid valve 1, 2, 3, 4 and 6. Ensure the solenoid valve is clamped by the clip tightly and the bolt is tightened to
the specified torque.
Caution:
The wire harness ground wire port is protected by the solenoid valve fixing plate
r. Install the solenoid valve 5. Ensure the solenoid valve close to valve through the clip.
s. When install the valve with line pressure relief valve, it should install the tapering port of line pressure relief valve, then install
and fix the spring and disc.
t . Install the pin spring; ensure the screw is tightened to the specified torque. Check the damaged spring.
u. Install the manual gear shift valve .Refer to Figure 8.57.
Figure 8.57 Manual gear shift valve
v. It should ensure the position lever is in the position of manual 1st-Gear before install the valve on the transmission.
w. Adjust the valve on the transfer case and install the connection of manual-operated valve steering column and manual-operated
valve. Make the long end of connecting object is proper for the 1
st manual-operated valve. Install the protecting spring and
tighten it according to the specification. Refer to Figure 8.58.
x. Check the positioning drum and manual-operated valve .
Caution:
All hardware must be installed and meet the specification.
y . Connect the wire of connecting solenoid according to the following details:
Solenoid valve 1
red
Solenoid valve 2
blue
Solenoid valve 3
yellow
Solenoid valve 4
orange
Solenoid valve 5
green
Solenoid valve 6
purple
Refer to Figure 8.58.