belt GREAT WALL HOVER 2006 Service Owner's Manual

Automatic transmission-52
Failure Reason Corresponding measures
C2 is burnt.
T operation lever linkage is beyond the
normal adjusting scope.

S6 is invalid.-Operating lever is hard.

The over speed Gear/output shaft sealing
ring is damaged. Monitor and repair the C2 if necessary and
adjust the linkage device.
Repair the C2; detect, repair or replace the
S6 if necessary.
Repair the C2; detect and replace the
sealing ring or shaft if necessary.
C4 is burnt. The clutch C4 assembly clearance is
incorrect.

The over speed Gear/output shaft sealing
ring is damaged.
3→4 one-way clutch is in rear position.

The over speed clutch (OC) /1
st-Gear low
speed ball spool has displacement. Detect the C4. Det ect and adjust the clutch
C4 assembly clearance if necessary.
Repair the C4; detect and replace the oil
seal or shaft.
Repair the C4, detect or modify the OWC
if necessary.
Repair the C4, detect or modify the ball
spool if necessary.
B1 is burnt. B1R spring is damaged.

The dimension of oil inlet hole of front
servo is large and has the possibility of
loose.
The input shaft sealing ring is damaged.
C1/B1R ball spool has displacement. Detect and repair the or replace the spring
if necessary.
Replace the socket if necessary and detect
the C3 piston O-ring.
Replace the sealing ring.
Repair the B1; modify the ball spool if
necessary.
C1 is burnt. B1Rspring / plug is lost.

The over speed Gear/input shaft sealing
ring is damaged

4→3 sequence valve is in rear position.

Clutch attachment oil feed inlet (CAF).
B1Rball spool is lost. Detect and repair C1 or replace the spring
if necessary.
Repair the C1; detect and replace the
sealing ring or shaft if necessary.
Repair the C1; detect and modify the valve
if necessary.
Repair the C1; detect and replace the ball
spool if necessary.
B2 brake belt is burnt. In
R-Gear- without manual
1
st-Gear. The rear brake belt is adjusted incorrectly or
damaged.
The low speed R-Gear /1
st-Gear ball spool
has displacement. Detect and adjust the brake belt if
necessary.
Detect and reinstall the ball spool if
necessary.
The torque converter is
locked hardly or is not
locked. The torque converter combination regulator
is in rear position. Detect and modify the valve if
necessary.

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.

2.output shaft and gear assembly
The assembly procedure of output shaft and gear assembly (Refer to Figure 8.19),is shown as follows:
a. Check the output shaft bush for damage, replace it if necessary.
b. Check the parking detent on the ring gear for damage ; replace it if necessary.
c. Check the sealing ring groove for damage.
d. Use the automatic transmission liquid to lubricate the gasket.
e. Place the scarfing notch upwardly and install the sealing ring on the output shaft.
f. If has been removed., it should use the ring spring for reinforcement when install the ring gear on the output shaft. Ensure the
ring spring is fixed in the groove.
g. Use the Vaseline oil for lubrication; install the thrust bearing assembly NO.10 on the output shaft.
h. It should be carefully when install the output shaft on the box to avoid the damage of sealing ring.
3. Rear brake belt assembly
The assembly procedure of rear brake belt assembly (Refer to Figure 8.18) is shown as follows:
a. Check the rear brake belt for leakage or damage; check its corresponding bush and metal back .
Figure 8.18 Rear servo and brake belt
b. Install the reaction reinforcement bar on the main box, need not shim.
Caution:
Place the new brake belt in the automatic transmission liquid for about 5 minutes before install it.
c. It should be careful when install the rear brake belt on the transmission. Ensure the brake belt is installed on the correct
position.
d. Install the application support bar on the rear brake belt, then connect it to the servo motor
bar.
e. Install the cam disc and tighten the screw according to the instruction.

Caution:
Do not use the Vaseline to fix the washer.
c. Install the transmission rear housing or adaptor rear housing with the new washer.
Caution:
Refer to the description in section 8.3.17 related installation of output flange assembly (rear wheel drive).
d. Install the transmission rear housing (rear wheel drive) or adaptor rear housing (4WD ) and tighten the bolt.
e. Provide the Loctite202 or equivalent sealant to the rear housing or connector and process the installation. Ensure the bolt is
tightened according to the specification. (Refer to Figure 8.1)
7. Front servo assembly
Caution:
Ensure the front servo clamp ring is installed correctly; ensure the ring spring and spark gap points to the bottom. Refer
to Figure 8.22.
The assembly procedure of front servo assembly (Refer to Figure 8.22) is shown as follows:
a. Use the automatic transmission liquid to lubricate the housing O-ring and install it on the housing.
b. Use the automatic transmission liquid to lubricate the housing O-ring and install it on the piston.
c. Install the piston, brake lever, spring, washer, base and fixing ring.
d. Install the piston brake lever assembly on the front servo housing.
e. Install the front servo plug and spring in the box.
f. Install the front servo assembly in the box.
g. Press down the servo housing and install the fixing ring spring of servo housing. Align the spark gap and coil track and ensure
it is installed in the groove properly. Figure 8.22 front servo and brake belt
8. Brake belt assembly
The assembly process of brake belt assembly is shown as follows:
a. Install the reaction reinforcement lever on the housing.
b. Check the brake belt for crack or damage; check the bush and metal back.
c. Install the support retainer on the brake belt (Refer to Figure 8.23).Note that the later transmission modes will not adopt the
support retainer.
Caution:
Place the new brake belt in the automatic transmission liquid for about 5 minutes before install it.

Figure 8.23 Installation of brake belt press lever
d. Install the brake belt on the transmission, ensure it is installed on the correct position.
e. Install the reaction support on the fixing plate and connect it to the brake belt and reinforcement lever. Install the application
support on thea fixing plate and connect it to the brake belt and servo piston bar.
9.C2/clutch C4 assembly
Caution:
Check the piston for crack, especially for piston C2.
Must not mix the clutch piston out and back spring.
Ensure the correct installation of clip ring
The assembly procedure of C2/clutch C4 assembly (refer to 8.24) is shown as follows:
a. Ensure the cleanness of internal oil inlet of cylinder; check the discharge outlet of piston C2 for cleanness; use the transmission
liquid to lubricate the O-ring.
Caution:
The O-ring must not be winded in groove.
Figure 8.24 Typical C2/C4clutch assembly
b. Install the small O-ring in the inner groove; install the large O-ring in the external groove of piston; check the discharge outlet
of C4 piston for cleanness.
c. Use the transmission liquid to lubricate the O-ring; install the small O-ring in the inner groove; install the large O-ring in the
external groove of piston.
d. Make the C2/clutch C4 hole face upwardly; install the clutch cylinder; place the C4 piston in the original position proper for
C2 piston during the calibration..
e. Install the C2/C4 piston assembly on the cylinder; ensure the external hole of cylinder align with the discharge outlet of piston,
until the external diameter of C2 piston enters into the internal diameter of cylinder.

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.

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 8.48 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

thickness Component No. thickness Component No.
Adjustment of front and rear brake belt
1. Setting procedure of brake belt
The setting procedure of brake belt is shown as follows:
a. For the calculating method of front servo mechanism thrust lever refer to Figure 8.62, dimension; standard A.
.Allow the air pressure is in 650/700kPa in the operating area of front servo mechanism (external of B1), (refer to
Figure 8.63).
. The forward dimension of thrust lever minus 3mm.
Dimension requirement for selection of shim:
Caution:
The small shim requires that the shim size is 1mm always; the available thickness is listed in Table 8.2.
. Release air.
b. Proper shim to end of thrust lever pole.
Check the shim for damage, worn or corrosion; replace it if necessary.
The shim is installed on the support surface between the transmission and pole flange, refer to Figure 8.62.
Install the shim by hand, and not the hammer or pressure.
Press the shim by hand until has the click the noise. The noise means the shim is clamped by the housing correctly.
c. Recheck the stroke of thrust lever 3mm
0.25mm.
2. Setting procedure of rear brake belt
The setting procedure of rear brake belt is shown as follows:
a. The setting of distance A is form the back surface of servo piston to inner surface of transmission, use the vernier caliper. Refer
to Figure 8.64.
A allows the air pressure of 650/700kPa is in the front servo mechanism operating area (external of B2), (refer to Figure
8.63).
Deduct 3.75mm from the movement of piston and use the 2.5 mm shim to divide the rest distance.
Caution:
The small shim requires that the shim size is 1mm always; the available thickness is listed in Table 8.2.
. Release air.
b. Select the proper shim for end of thrust lever pole.
Check the shim for damage, worn or corrosion; replace it if necessary.
The shim is installed on the support surface between the transmission and pole flange, refer to Figure 8.64.
Install the shim by hand, and not the hammer or pressure.
Press the shim by hand until has the click the noise. The noise means the shim is clamped by the housing correctly.
c. Recheck the stroke of piston for 3.75mm
0.625mm.
Table 8.2 Effective thickness of shim