sensor GREAT WALL HOVER 2006 Service User Guide

Automatic transmission-51
Table 6.2.3Shifting quality failure
Bad 1→2 Gear
shifting quality The throttle position sensor has failure.
T he brake b elt is adjusted incorrectly.
The front servo piston O-ring is damaged.
The variable pressure solenoid valve (S5) is damaged or
has failure.
S1, S4 has the failure.
The brake belt combination regulating valve (BAR) has
the failur e.
The front servo release spring is installed incorrectly. Detect the resistance, replace the sensor if
necessary.
Detect and replace the rake belt if necessary.
Detect and r epla ce the O -ring if necessary.
Detect, repair or repla ce the S5 if necessary.
Detect, repair or repla ce the S1, S4 if
necessary.
Detect, repair or repla ce the B AR if
necessary.
Detect and repair it if necessary.
Bad 2→3 Gear
shifting quality B1brake belt release valve is blocked.
S3, S2 has the failure.
The clutch combination regulating valve has failure.
The clutch combination oil feed ball spool is lost or
damaged.
The input shaft oil seal is damaged.
C1 piston O-ring is damaged.
C1 piston oil feed ball spool is damaged. Detect the blow-off valve. Replace or
maintain it if necessary.
Detect the S3, S2.Replace or maintain it if
necessary.
Detect the r egulating valve. R eplace or
maintain it if necessary.
Detect the ball spool .Reinstall or replace it if
necessary.
Detect the sealing ring. Reinstall or replace it
if necessary.
Detect the O -ring .R einstall or replace it if
necessary.
Detect the ball spool .Reinstall or replace it if
necessary.
Bad 3→4 Gear
shifting quality S1, S4 has failure.
B1brake belt release valve is blocked.
T he brake b elt is adjusted incorrectly.
The front servo piston O-ring is damaged.
The variable pressure solenoid valve (S5) is damaged or
has failure.
The brake belt combination regulating valve has failure. Detect the S1, S4.R einstall or replace it if
necessary.
Detect the blow-off valve. Replace or repair
it if necessary.
Detect the brake belt. Adjust it if necessary.
Detect the O -ring .R eplace or maintain it if
necessary.
Detect the S5.R epla ce or maintain it if
necessary.
Detect the r egulating valve. R eplace or
maintain it if necessary.
The engine has
the
extinguishing
co nd itio n
when select
the automatic
gear or R-gear. The torque converter clutch control valve is blocked or
solenoid valve 7 has failure. Detect and clean the torque converter clutch
valve (CCCV)
Has unstable
vibration
co nd itio n. S7 has the failure. Process the necessary detection, maintenance
and replacement according to the
requirem ent.

Adjustment
Hydraulic system
Following parts is the detailed description for self-detection procedure pointed to the condition occurred in chapter
6. including the condition indicated the failure, to point the problem existed in the hydraulic system.
It should select the proper procedure from the following primary detection when adjust the transmission.
Detection process of transmission fluid
Detect the manual linkage adjusting system(refer to factory manual of car)
Detect the engine idle speed
Anchoring test (beyond the scope of the maintenance manual)
On-road test (beyond the scope of the maintenance manual)
Detection procedure of transmission fluid level
1. General

The process is used to detect the level of vehicle transmission fluid. It will cause the failure or delay of transmission shifting if
the level is low than required value and the vehicle does not reach the drive temperature.
Firstly, process the transmission diagnosis information detection for vehicle (refer to chapter 6). If found the failure of sensor,
then it maybe caused by transmission fluid level is less than specified value.
It should detect whether has the abnormal delay and Gear-position condition when select the forward or reverse-gear by driving
the vehicle. One feature of oil level less than normal value is that the vehicle has the gear-position delay and lack condition when
the vehicle is in steering. The previous problem will occur when the transmission fluid temperature is low.
When the oil temperature is medium and vehicle speed failure is recorded, the gear-position lose condition
will not occurs any longer, it means that needs to fill the transmission with the transmission fluid.
2. Detection of transmission fluid level

When fill up or replace the transmission fluid, it must use the Castrol TQ95 automatic transmission fluid (ATF) or other
permissive oil. It will damage the performance and service life of transmission if use the unpermissive transmission fluid.
Please ensure the transmission fluid level is correct. The transmission also can be damaged if the transmission fluid level is
incorrect.
The setting procedure of transmission fluid level is shown as follows:
Caution:
When the transmission is in operating temperature, the hot transmission fluid may flow out form the
housing if remove the filling plug.
a. If the vehicle is in operating temperature, allow two hours time for cooling before add the transmission fluid, but
it must not more than 4 hours (this will make the transmission locate in the correct temperature range). When the
temperature is overheating, the transmission fluid level will higher than the plug port. Removal of plug will cause
the transmission fluid flows out from the oil filling port, then cause the low level of transmission fluid.
b. The gear-position of transmission is in parking-Gear (P-Gear), shut off the engine.
c. Lifting the vehicle (or parking above the trench).
d. Clean the around of plug when remove it. Then remove and clean the plug and check the O-ring for damage. Install
the oil filling pump in the oil filling hole.
e. Lower the vehicle; the oil filling pump will be connected to the vehicle at this time. Fill the transmission with the
oil partially. Then start the vehicle in P-Gear to rotate the engine in idle speed. Step down the foot brake, pull the
shifting lever in each gear-position in circulation and add the transmission fluid until the action of each gear-
position can be sensed.
f. Shut down the engine; lift the vehicle; ensure the vehicle is always in horizontal.
g. Remove the filling plug 3 minutes after the engine is shut off, but must not be no more than1 hour. At this time, the
correct level position should be in the bottom of oil filling hole. If does not reach the liquid level position, then fill
with few transmission fluid to make it reach the correct level.
h. Replace the transmission; clean the residual transmission fluid on the transmission and
vehicle.
i. Tighten the transmission plug to the specified torque of 30
35Nm.

Figure 8.1 Removal of typical pump
Disassembly /assembly
Cautions for assembly
It should notice the following items before reassemble the transmission system:
1. Ensure the cooler pipeline is washed and all chip is removed when replace the transmission. It can
be realized by using the compressed air to enter into the rear cooler pipeline to remove the oil and
all foreign material in the front cooler.
2. It should check the cooler after the transmission is installed. Ensure the front and rear cooler
pipeline is connected to the proper container. Rotate the vehicle in P-Gear in idle-speed, measure
the flow rate within 15s.
3. The flow within 15s should be more than 1L.
4. It should avoid any water entering into the transmission. This will cause the transmission fluid to
generate the foam or make the transmission fluid flows out form the respirator.
5. Ensure that two grounding wires in vehicle (one end to battery, one end to vehicle) are connected
before the installation of the anode of battery.
6. If the power control module and transmission control unit is exchanged, then calibrate the pro-
gram refer to related throttle position in Part
Removal
1. Transmission
Caution:
It should remove the gear-position sensor before wash the transmission in solvent or hot abluent.
When need to remove the transmission from the vehicle, it should drainage the transmission fluid,
and use the special removal tools.
The removal of the transmission should be processed in module method, the details of removal of each module is described
in following section in detail. Refer to details of special tools listed in table 9.10 and 9.6 when remove it.
The technician needs a set of quality tools when inspect the transmission, especially for dual hexagon spanner of model
30, 40, 50 and 8mm, 10mm, 12mm.
It should abide by the following procedure when disassemble the transmission:
a. Remove the shell of torque converter and torque converter.
b. Place the transmission on the saddle platform.
c. Remove the oil pan and oil pan sealing.
d. Remove the filter retainer of each valve and remove the filter.
e. Remove the wire on solenoid valve, place it in side.
f. Remove the protection screw in the valve and remove the valve from the main housing (remove the model Z connecting bar).
g. Remove the front servo circlip, cover and piston.
Caution:
The plastic servo block on used for piston return spring.
h. Remove the flange shaft fork, then remove the transmission housing (2WD and Chairman).
Use the 8mm hexagon wrench to move the pump to the housing bolt.

Caution:
Do not take out the central support by knocking the output shaft , otherwise, it will damage the surface of thrust bearing
permanently
o. Remove the central support, 1-2 one-way clutch and planetary gear block.
p. Use the T40 special tools to remove the parking lever cum disc.
q. Remove the rear brake belt support and rear brake belt.
r. Remove the output shaft assembly.
2. Transmission case
It should follow the following procedure when remove the transmission:
a. Use the tools to take out the fixed pin from one side of cross shaft gear sensor (2WD and 4WD mode).
b. Remove the gear sensor from the case. Use the special tools to take out the cross shaft seal.
c. Take out the circlip from the cross shaft. Pull up the cross shaft and take out the drive pin from the sector gear-position
selection plate.
d. Use the tools, press down the cross-shaft pin and take out the shaft , reset spring and bolt from the housing. Refer to Figure
8.3.
Figure 8.3 Installation and disassembly of cross-axle pinFigure 8.2 central support retainer
i. Use the pump remover to remove the pump, refer to Figure 8.1.
g. Remove the input shaft , front clutch cylinder and overspeed –Gear shaft as an integral. Take it out from the front of housing.
k. Remove the clutch C3 cylinder and central gear .
l. Remove the brake belt support and brake belt.
m. Use the 50 special tools to remove two central support connecting bolts.
n. Remove the central support retainer, refer to Figure 8.2.

e. Take out the manual-operated valve operating lever and parking operating lever.
f. Take out the 10 pin socket connector form the wire bunch bracket adjacent gear sensor.
g. Press down the raised part of 10-pin plug and take out the 10-pin connecting plug from the box.
h. Separate the NO.7 solenoid valve wire bunch form the front end of housing.
i. Remove the brake bar pivot, brake shaft and spring.
j. Remove the shaft and rear servo operating lever.
k. Remove the rear servo cover and piston assembly.
l. Remove the BIR circlip, valve and spring.
m. Remove two brake belt adjusting shims.
n. Check the output shaft bush in box, replace it if necessary.
o. Check the cooler pipeline, replace it if necessary.
p. Check the box for damage.
Caution:
It must not remove the operating lever of parking gear in normal condition.
q. It needs to remove the P-Gear operating lever: take out the circlip from the pivot, knock the external of shaft until it can move
freely in box. Then use a width and thin object to table out the bolt form the box, operating lever and spring.
3. Front clutch cylinder
When take out the front clutch cylinder, please refer to Figure 8.4. The procedure is shown as follows:
Figure 8.4 Assembly of front clutch cylinder
a. Place the assembly on a level surface.
b. Remove the thrust bearing and adjusting shim from the input shaft .
c. Remove the retainer and input shaft form the front end of clutch .
d. Remove the overspeed gear shaft and clutch C1 hub assembly from the clutch cylinder.
e. Take out the clutch disk C1 form the cylinder.
f. Take out the retainer which fix the clutch C3 hub on the rear end of clutch cylinder, then take out the hub.
g. Take out the C2\clutch C4 hub assembly and remove the thrust bearing form the C4 hub.
h. Take out the clutch C2 disc.
i. Reverse the clutch cylinder and take out the clutch C4 sleeve, clutch disk and two wave washers. The 3-4 one-way clutches is
located between the C2 and clutch C4 hub. The other wheel axle can be taken out by rotating a wheel axle in clockwise.
j. Remove the thrust block form the clutch C4 cylinder hub.
Caution
Ensure the spring keeping device does not be clamped in the spring groove and all spring pressure is released.
k. Put end surface of C2\clutch C4 upwardly, connect the clutch cylinder with the tools. Pressed down the piston reset spring,
take out the spring fixing retainer (Refer to Figure 8.5). Remove the tools and take out the ring spring, fixing part and spring.

Figure 8.11 Rear servo barCaution:
Pay attention to do not coat the sealant between the bolt and crown bar.
e. Install the parking operating lever (as Figure 8.12), including the return spring and shaft pin. Coat the external end of shaft pin
with small sealant.
f. Use the circlip to protect the shaft pin. Pay attention to ensure the operating lever can rotate around the shaft pin freely and
the spring can make the parking operating lever returns to the correct position.
g. Install the parking brake lever pin and spring. Refer to Figure 8.13.Caution: ensure the rake lever can rotate freely.
h. Connect the parking brake lever to the manual-operated valve connecting rod. Shown as Figure 8.14. Ensure the spring and cam
axle ring are installed on the connecting rod fixedly.
i. Check the cam axle ring for smooth sliding on rod.
j. Install the cross shaft in the box in reverse direction of Gear-position sensor, then install the concussion spring on the shaft.Figure 8.12 Parking operating lever
Figure 8.13 Typical parking brake shaft pin and spring
Figure 8.14 Parking lever and manual shaft

Figure 8.15 manual-operated valve brake lever
k. Install the manual-operated valve detent connecting rod (shown as Figure 8.15), align it with the cross shaft hole.
l. Push the shaft by the positioning operating lever, until start from one side of box operating lever.
m. Use the special tools to install the operating lever drive bolt on the shaft, and ensure the adaptor covers the bolt.
n. Press the bolt into the shaft until the tools reaches the bottom.
o. Take out the tools and install the spring fixing ring spring on the shaft
p . Use the tools to install the new cross shaft seal.
q. Install the Gear-position sensor on the box; install the screw according to the specified torque. Use the tools to press the bolt
on the shaft.
r. Check the connection of wire bunch port completely to ensure the normal operation.
s. Install the wire bunch and install the connecting point of solenoid valve 7 and ring flange matched to the pump. Refer to Figure
8.16. The connecting wire of solenoid valve 7 is organized under the parking lever and in box cross shaft.
t . Install the 10-pin connecting socket in the box, ensure the flange of connecting socket matches to the notch on box.
u. Pull out the wire bunch part form the box and prohibition switches; install the 10-pin connecting socket on the wire bunch
bracket (only for rear-wheel drive mode).
Figure 8.16 Connecting position of coil 7Figure 8.17 Installation of 10-pin
connecting plug

f. Make the installation of oil bottom shell is proper for transfer case and the tighten the safety valve according to the
specification and sequence (Refer to Figure 8.61). do not distort it.
16.Torque converter and support sleeve assembly
Install the hydraulic torque converter and housing assembly, the procedure is shown as follows:
a. Install the hydraulic torque converter housing on the main case.
Caution:
All hardware should be installed correctly and comply with the specification.
b. Use the Loctite243 or equivalent to fix the torque converter housing; install and tighten it to standard specification.
c. Install the torque converter; ensure the pump gear sealing is installed correctly.
17. Rear wheel drive mode of output ring flange assembly
Assemble the output shaft assembly, the procedure is shown as follows:
a. Place the paw of transmission operating rod on the parking position and lock the output shaft.
b. Wash the output shaft upper line; use the loctite243 or equivalent.
c. Install and tighten the ring flange, O-ring and nut.
Caution: In the heavy steel slide plate, place the ring flange on the upper nut; avoid the damage of bearing.
d. Tighten the nut on the output shaft
Torque type specification N.m Ft/lb
tra n s m iss io n as se m b ly

torque converter housing to
housing M12×32 4, 8or 9 54-68 40-50
rear end housing to housing
-C h a irm a n M12×32 4 54-68 40-50
C onnector housing to housing
-4 W D M8×25 10 35-40 26-30
rear end housing to housing
-2 W D M8×25 10 35-40 26-30
rear servo cover to housing
M8×25 6 30-35 22-26
O il pan to housing
M6×16 9 4-6 3-4.5
O il cooler pipe connection
2 40-45 29.5-33
V alve to housing
M6×26 7 8-13 6-9.5
V alve to housing
M6×45 5 8-13 6-9.5
B rake bar spring
M8×16 1 20-22 15-16
central support to housing
M10×34 2 20-27 15-20
C am disc to housing
M8×16 2 16-22 12-16
G ear-position sensor to
housing 10-24×13 2 4-6 3-4.5
O utput shaft lock nut
M24×1.5 1 100-110 74-81.5
oil filling plug M 20 1 30-35 22-26
Pump housing assembly


Pump to pump cover
M8×55 5 24-27 18-20
Pum p cover to housing
M8×40 6 24-34 18-25
Pum p cover to housing
M8×58 2 24-34 18-25
Pum p cover disc to pum p
cover M6×16 5 13-16 9.5-12
Pum p cover disc to crescent
M6×54 1 13-16 9.5-12
Valve assem bly


U p p e r v a lv e to lo w e r v a lv e
M6×30 24or 25 11-16 8-12
Line socket M 6 1 4-7 3-5
solenoid valve (on/off type
and VPS, including S7) M6×16 7 8-12 6-9
Table 8.1 Torque specification

Brake-1
Chapter 8
Brake
Cautions...................................................................................... 2
Troubleshooting............................................................................2
Check and adjustment..................................................................5
Brake pedal..................................................................................7
Parking brake...............................................................................8
Front brake...................................................................................9
Rear brake...................................................................................16
Rear parking brake......................................................................22
Sensor load proportional valve.....................................................29
Antilock Braking System (ABS)..................................................31

Brake-31
Antilock Braking System (ABS)
Cautions
1. It must not remove or install the electric elements and wire bunch plug when the ignition switch is in ON to avoid
the damage of ECU. It should turn off the ignition switch if needs disassembly.
2. Pay attention to do not knock or impact the ABS ECU during the maintenance and repair, for it will damage the
ABS ECU easily.
3. The wheel speed sensor and hydraulic unit (integrated with ECU) of BOSCH ABS8.0 can not be repaired, it should
be replaced in integral if damaged.
4. After the brake system is maintained, the brake pedal maybe soft. Discharge the air according to the normal brake
system.
5. It must use the brake fluid from original manufacturer; the brake fluid of different number cannot be used in mixed,
otherwise it will cause the failure of brake system. Select the tyre of original type as most as possible
Repair of Antilock Braking System (ABS)
1. It should process the failure diagnosis for the brake system before process the ABS failure diagnosis. It can
diagnose out the failure rapidly by using Table 1. In Table 1, the small number means the failure which occurs most
possibly. Check each element according to the sequence and maintain or replace it if necessary.
2. Check the following elements for normal operation before the diagnosis:
Brake fluid level and brake fluid quality
Pressure of tyre, size of tyre, shape and depth of tyre figure
Other brake component
These components will affect the brake effect of the ABS. Check the system sensor, connecting wire and connector for correct
installation, arrangement and connection. Ensure the completeness of fuse, repair or replace it if necessary.
3. Process the analysis and diagnosis according to the ABS advanced by owner. Use the diagnosis instrument (Annex
1) for final check and confirmation. It must process the run inspection after the competition of all ABS maintenance.
The test condition is shown as follows:
a. Confirm the tyre complies with the requirement, the tyre pressure is normal.
b. The brake system (including brake light ) is normal
c. The brake system is without leakage.
d. The position and installation of wheel speed sensor is correct.
e. All fuses are normal.
4. test method:
Run for 1 min at least when the vehicle speed is beyond 40Km/h, process a proper brake. Then read out the failure code to
ensure the ABS is without failure code.