oil GREAT WALL HOVER 2006 Service User Guide

Inspection of SC5M2D-C transmission:
1.Check the oil level of transmission:
Screw off the oil discharge plug of the transmission; discharge all lubri-
cate oil; screw on the oil discharge plug to the specified torque; the
torque is: 30
35Nm. Fill the transmission with the transmission
oil through the oil filling port, oil number is hyperbolic gear oil SAE80W/
90, which meet API GL-4, oil capacity are 2.2L. Tighten the oil-filling
plug to the specified torque of 30
35Nm. (for area with high or
low temperature refer to the maintenance specification)
2. Replacement of oil seal of rear hosing:
The replacement of the oil seal of rear housing is shown in figure.
Disconnect the drive shaft from the rear housing; remove the oil seal
by the flat screwdriver, then use the special tools to knock the rear
housing oil seal in the rear housing. It should pay attention to the
installation of oil seal, shown as figure. Coat the lip of oil seal with the
specified transmission oil.
3. Removal, installation and inspection of transmission
The preoperation before removal and after installation of transmission
is: Remove and install the manipulator cover assembly, drain and fill
the transmission oil accordance with the regulation; after remove and
install the drive shaft. Separate each plug-in part from the vehicle
transmission .
4
Inspection of manipulator cover assembly
Shown as figure, remove the adhesive on the surface before installation,
use the screwdriver( M8
1.25) to clean the adhesive in the screw
hole; coat the installed part of bolt screw with the specified screw
adhesive. Firstly, install two positioning bolts A, then install other
two bolt A and bolt C respectively. The tightening torque of all bolts is
15
22Nm.
oil filling screw plug (SC1701005)
oil-drain screw-plug assembly (JK721701071)
rear housing oil seal
bolt C(SC-1704003)bolt A(SC-1704004)

SC5M2D-C transmission assembly
handle of gearlever
dustproof seal cover
oil seal 39.65210
odometer driven gear assembly
odometer seating lock plate
cylindrical compression spring
1.05.841
bush
select & shift seating
N m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special toolsmanipulator cover assembly
elastic cylindrical pin 6
22
rear housing assembly spring cylindrical pin
reverse lamp switch bracket
bearing housing assembly
clutch housing assembly
location compression
cylindrical pin

Manipulator cover assembly
gearbox assembly (one)
reverse lock assembly nut M8
bulbrubber cover
pin 740
master control lever assembly
bulb basebush
stop plate of main rodbush
bulb jacket
N m: specified torque
Used component which can not be used any more.
Pregummed component N
m: specified torque
Used component which can not be used any more.
bush
6
oil guiding plate
location pin
steel ball 7.
938
aluminum gasket
reverse lamp switch
gearbox
selection and shifting
shaft rubber choke plug
bleed plug assembly
bush
selection and shifting block
elastic cylindrical pin 622

Disassembly of clutch housing assembly /bearing
housing assembly
40. Use the special tools to remove the reverse shaft
Use the magnetic rod to take out 2 interlocking pins
Remove the first bearing block assembly
a. Use the special tools to install 6 M8 bolts.
Caution: When install 6 M8 bolts, the tightening torque is 10-
13N·m
Clutch housing assembly / Bearing housing assembly
bush
oil seal
Used component which can not be used any more.
throwout bearing
assembly washer 8
¦ non-standard spring
first bearing
first shaft assembly
needle bearingsecond shaft assembly
¦circles for shaft
¦adjusting shim
leather cup
separation rocker arm assembly separation rocker arm ball supportclutch cylinder assembly
front space ring of intermediate shaft
intermediate shaft assembly aluminum waher
Specified torque

Transmission-25
2.Replacement of oil-seal of transfer case
The replacement of transfer case oil seal is shown as figure. Disconnect
the drive shaft from the transfer case, use the flat head screwer to
remove the oil seal
Caution: Do not damage the housing hole during the disassembly.
Then use the special tools to knock the transfer case oil seal into
the transfer case. It should pay attention to the installation dire
tion of oil seal. The oil seal is flush with the port of transfer case.
Shown as figure. Coat the lip of oil seal with the specified general
synthetic gear oil.
3. Disassembly and check of transmission
The preoperation before the removal and after installation of
transmission is : When remove and install the manipulator cover
assembly, drain and fill with the specified transmission and transfer
case lubrication oil. When remove and install the front and rear drive
shaft, separate each plug-in part of transmission from the vehicle.
Inspection of manipulator cover assembly:
The bolt dimension is different for different installation position. Do not
confuse it during the installation. It should install the fixing bolt A firstly.
The tightening torque of bolt A and B bolt is 15
22Nm.
installation position of fastening blot
bolt
bolt bolt
Repair of transmission SC5M4D-C
1. Inspection of oil level of transmission and transfer case:
Screw off the oil drainage screw plug of main box and transfer case;
drain all lubrication oil, tighten the oil drain plug to specified torque.
The torque is: 30
35Nm. Fill the main box and transfer case with
the transmission oil through the oil filling port. The number is hyperbolic
gear oil SAE80W/90, comply with API GL-4. The oil quantities are
main box : 2.2 L, transfer case : 2.7 L. (for high and low temperature
environment refer to maintenance specification). Tighten the oil filling
screw plug to specified torque. The torque is: 30
35Nm.
front output shaft oil
seal (SC
1802504)
rear output shaft oil seal
(SC
1802323)
transmission
transfer case
oil filling screw plug
oil-drain screw-plug assembly
(JK72
1701070) oil filling screw plug

Transmission-27
Manipulator cover assembly
Rear housing assembly
nut
reverse lock
assembly
manipulator
cover assembly
ball head
rubber cover
auxiliary steering
column stop platebush
ball head basewasher
pin
auxiliary steering
column assembly
handle of transfer case
ball head
hood
ball head
rubber cover
stop plate of
main bar
bush
ball head base
pin
washer
master control lever assembly
handle of
gearlever
N m: specified torque
Used component which can not be used any more.
odometer driven gear
assembly
odometer seating lock plate
14-19
14-19
oil seal
dustproof seal
guide bushing
rear housing
adjusting shim
24-33
26-36
aluminum gasket
mushroom lock spring
aluminum gasket
24-33
mushroom lock spring
26-3630-42
N m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special tools
steel ball 7.938 (3)

dustproof seal
guide bushingoil seal
transfer case housingball bearingfront output shaft
ball bearing
bowel patch
circlips for hole
rear input shaft
auxiliary gear
disk spring
circlips for shaft
spacing ring
duplicate ball bearing
circlips for
shaft oil seal
back plate
Transfer case assembly (three)
Disassembly of transfer case assembly
4.Remove the shouldered lock screw plug
Use the wrench to remove the shouldered lock screw plug M16
1.512
Caution: The tightening torque is 26-36N
m when install the
shouldered lock screw plug M16
1.512.
5.Remove the upper and lower drive switch M12
1.25
Caution: When install the upper and lower drive switch M12
1.
25, the tightening torque is within 26-36N
m
6.Remove the 2nd/4th drive switch M14
1.25
Caution: When install the 2nd/4th drive switch M14
1.25, the
tightening torque is with in 26-36N
m
N m: specified torque
Used component which can not be used any more.

Transmission-35
Disassembly of rear output shaft assembly
a. Use the special tools to remove the lock nut
Caution: The tightening torque is 87-120N
m when in-
stall the lock nut.
b. Remove the ball bearing
Rear output shaft assembly
cRemove the oil guide plate
circlips for shafthigh and low
gear sleeve
needle bearing
high and low gear hub
needle bearing
low-speed driven gear
rear output shaft
ball bearing
spacing platesecond/ fourth drive gear hub
second/fourth
drive geared sleeve
sprocket needle bearing bushing
needle
bearing
drive sprocket
spacer of
drive sprocket
oil guide plate assembly
ball bearing
assembly
87-120
N m: specified torque
Used component which can not be used any more.
Use the special tools
dRemove the spacing ring

Automatic transmission-2
Instruction for automatic transmission
1. M88 4-speed automatic transmission is equipped with the hydraulic torque converter and electric control system with locking.
When keep the stable forward status, the hydraulic torque converter can be locked automatically when the engine operates in low
speed, then reduce the unnecessary slide.
Figure 1.1 Electric automatic transmission control system
Figure 1.2 M88 4 speeds automatic transmission appearance figure (applied to 2 wheels driving)
2. The main advantage of the transmission is the application of transmission control unit (TCU). The control unit is the control
system based on the microprocessor system.. TCU control the shifting sensing and realize the Gear position shifting through the
signal of opening degree of throttle position, opening frequency of throttle position, engine speed, vehicle speed, transmission oil
temperature, gear position, mode selection and forced Gear reduction application.
3. TCU drives a variable pressure regulating solenoid valve to control three regulation valves and control the feeling of shifting.
Different transmission fluid temperatures are taken as one the main parameters to control the output pressure of the solenoid
valve, so as to keep consistent feeling of shifting within the normal operation scope.
4. The planning of shifting is very flexible. According to the car model, the different shifting plan is stored in the same TCU.
Generally speaking, the “economical mode” can increase the economical efficiency of the fuel and the driving performance of the
car to the maximum limit. The “dynamic mode” can bring into full play the drive performance of the car to the maximum limit. The
“winter mode” can make the car starting from shift 2.

Automatic transmission-3
8. Use two bolts to install the back device on the extended case of the transmission, these lengths are important. If it is too long,
it will hinder the end of the bolt and affect the threads on the case. Ensure the proper length and special torque of the bolt.
9. Pay attention that the height of the oil has been determined before delivery from the ION Company. The oil height needs not
checking or correction, except that improper oil is suspected to be used, or additional oil is needed because of leakage.