brake GREAT WALL HOVER 2006 Service Owner's Manual

Automatic transmission-29
In reverse-Gear position, the drive of transmission is sent to the clutch hub through the input shaft and rear clutch piston. In this
condition, the description of each function unit of transmission is shown as follows:
The clutch C3 is engaged and drive the reverse central gear to rotate in clockwise.
The engagement of B2 brake belt cause the rest of the planetary gear carrier, then make the long planetary gear rotates
around its shaft anticlockwise.
The long planetary gear drives the internal gear ring rotates anticlockwise .
Use the spline to connect the inner gear ring to the output shaft and drive the gear ring rotate anticlockwise or in reverse.
Control:
In stable status, to maintain the arrangement, the action of solenoid valve and valve is shown as follows:
A solenoid valve S1 or S2 is closed at least. (Refer to the part in section 3.3.11, related to condition when S1 and S2 is
closed.)
The line pressure reaches the internal surface and external surface of rear servo piston through the reverse lock valve
directly.
The line pressure urges the reverse-Gear loop oil pass through the manual-operated valve.
The reverse-Gear loop oil is circuited to clutch C3 through the manual-operated valve.
In the transmission whiteout HP pump shell, the reverse-Gear loop also can reaches the spring end of the primary
regulating valve to support the spring and push the line-pressure regulating valve.
The oil loop of execution line of all other clutches and brake belts is opened to leaking port.
Refer to Figure 5.2 and Table 5.3.
Table 5.3 The participating condition of each unit in reverse-Gear position
Gear-position
Reverse gear
Name of participated unit

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-35
Power transmission automatic 2nd-Gear and manual 2
In automatic 1st and manual 2nd-Gear, the drive of transmission reaches the front clutch cylinder through the input shaft. In this
condition, the operating principle of each functional unit of transmission is shown as follows:
The engagement of clutch C2 drives the forward central gear.
The forward central gear drives the short planetary gear to rotate in anticlockwise.
The short planetary gear drives the long planetary gear to rotate clockwise.
The engagement of brake belt B1 makes the stop of reverse central gear to make the long planetary gear rotates around the
reverse central gear, then make the internal gear and output shaft rotates in clockwise to make the vehicle moves forwardly.
The clutch C4 is engaged through the 3-4 one-way clutch (OWC) and provides the brake force of engine during overspeed.
Control:
In stable status, the status action of solenoid valve and valve is shown as follows:
The solenoid valve S1 is powered off ; The solenoid valve S2 is powered on.
The drive oil (line pressure) from the manual-operated valve makes the engagement of clutch C2.
When the solenoid valve S1 is powered off, the S1 oil pressure form line pressure 500 pushes the 3-4 Gear shifting valve
moves to left. At the same time, the S1 oil flows into the 1-2 Gear shifting valve to push the 1-2 Gear shifting valve to the
2
nd –Gear.
The line pressure oil from the 1-2 Gear shifting valve flows into the brake belt combination regulating valve, and 2-3 Gar
shifting valve.
The brake belt engagement regulator valve provides the 2nd-Gear oil (controlled by product of line pressure and valve rate)
to brake belt feed loop (BAF).
The brake belt engagement feed loop directly provides the oil to:
External engagement part of front servo piston.
1-2 Gear shifting valve can provide a oil drainage port when the transmission is shifted to 1st-Gear.
Use the 3-4 Gear shifting valve when the transmission is in 4
th-Gear position.
The drive force (line pressure) is sent to the clutch C4 through the 3-4 Gear shifting valve to realize the engagement of
clutch C4.
Refer to Figure 5.5 and table 5.6
Table 5.6The participating condition of each unit in automatic 2nd-Gear and manual 2nd-Gear
Automatic 2nd-Gear and manual
2
nd-Gear

Name of participation unit

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-41
In automatic 4th-Gear (overspeed gear), the drive of transmission is sent to the front clutch cylinder through the input shaft. The
operation principle of each function assembly of transmission is shown as follows:
The engagement of clutch C1 drives the planetary gear carrier rotates in clockwise rotation.
The engagement of B1 brake belt makes the reverse sun gear to stop.
When the planetary gear carrier rotates, the long planetary gear rotates around the static reverse sun gear, at the same time, it
rotates around its axial line to drive the gear ring and output shaft to generate the forward movement in the speed higher than
that of input shaft (i.e. overspeed) clockwise.
The forward central gear rotates in the speed higher than input shaft and is more than the speed when 3-4 one-way clutch
(OWC) is engaged.
The engagement of clutch C2 is used to reduce the speed difference generated by 3-4 one-way clutch (OWC).
Control:
In the stable status, the status of solenoid valve and valve is shown as follows:
The solenoid valve S1 is powered on ; S2 is powered off.
When the solenoid valve S1 is powered on, the small end of 3-4 shift valve is in 4th-Gear position for the pressure of line 500.
When the solenoid valve S2 is powered off, the large opening of 2-3 shifting valve is in 4th- Gear position for the pressure of
line 500.
The 1-2 Gear shifting valve is kept in 4th-Gear position for the pressure of S2 oil loop.
The 2nd-Gear loop oil (line pressure) from the 1-2 shift valve flows into the brake belt combination regulating valve and 2-3
shift valve directly.
The brake belt combination regulating valve provides the 2nd-Gear loop oil for the brake belt attachment loop (BAF) (adjusted
by product of line pressure and valve ratio)
The brake belt combination lip oil is directly supplied to:
External combination part of front servo
Enter into the internal combination part of front servo piston through 3-4 shift valve
The 1st-Gear-2 switch valve provides a oil-drain port when the transmission is switched to 1st-Gear.
The 2nd-Gear loop oil in 2-3shift valve flows into the 3rd-Gear loop directly.
The 3rd-Gear loop oil from the 2-3 shift valve flows into the clutch combination regulating valve and 4th-Gear-3 sequence
valve directly
The clutch combination regulator valve supplies the oil for the clutch combination loop (CAF) (Regulated by the product of
line pressure and valve rate)
CAF oil is directly supplied to:
clutch C1
4th-Gear-3 sequence valve
The drive oil(line pressure) form the manual-operated valve forces the engagement of clutch C2
Refer to Figure 5.8 and Table 5.9.
Table 5.9
Participating condition of each unit in automatic 4th –Gear (overspeed Gear)
clutch
Name of participation unit
Automatic 4
th-Gear
(overspeed 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

Automatic transmission-49
The distribution of FAQ table is shown as follows:
Table 6.2.1 Drive failure Table 6.2.3 Shift quality failure
Table 6.2.2 Shift mode failure Table 6.2.4 Disassembly failure
failure Possible reason Corresponding measure
“D”-Gear operation
has not drive The automatic transmission fluid is insufficient.
The oil-entering of C1/C2 piston is blocked.
The “Z” is assembled incorrectly.
The primary regulating valve plug is opened.
The overspeed shaft or input shaft sealing ring is
failure.
3→4, 1→2 single-way clut ch is installed in revers e or
failure. Check the liquid level. Fill it up if necessary.
Check and wash the C1/C2 oil inlet device.
Reinstall the “Z” connection.
Remove, wash and reinstall the primary
regulating valve.
Check and replace it if necessary.
Check and replace it if necessary.
The reverse shifting
operation is without
drive.
The manual 1
st-Gear
has not engine
brake.
The engine brake is
normal in manual
1
st-Gear. The input shaft oil seal ring is damaged.
The rear brake belt or servo system is faulty.
C3, C3 wheel shaft or C1/C2 cylinder are out of work. Check and replace it if necessary.
Test the servo system or replace the rear brake
belt according to the requirement.
Test the failure C3, C3 wheel axle or C1/C2
cylinder.
Repair it in time if necessary.
“D” –Gear and reverse
–Gear operation is
without drive. The primary regulating valve is blocked.
The pump gear is damaged.
Take out the output shaft clasp. Det ect and clean the primary regulating valve.
Check and replace the pump gear if necessary.
Check and repair it if necessary.
Only can 2→3 shifting
(can not realize the
4
th-Gear and 1st-Gear) S1 is closed always. Test the S1. Repair or replace it if necessary.
Test the failure of S1 12V power supply
voltage or wire bundle.
Only can 1→4 shifting
1→3→4 shifting (1
→2 shifting delay). S1 is opened always Test the S1. Repair or replace it if necessary.
Test the failure of S1 12V power supply
voltage or wire bundle.
Only can 4→3 shifting S2 is closed always.
Test the S2. Repair or replace it if necessary.
Test the failure of circuit break or wire bundle.
1→2→neutral position
shifting (1st-Gear
transition) S2 is opened always Test the S2. Repair or replace it if necessary.
Test the failure of circuit break or wire bundle.
Only can 1→3 shifting B1 is out of work
The brake belt is loose.
The front servo piston or oil s eal is out of work.
S1/S2 ball spool is reinstalled in wrong place. Test and adjust it according to the requirement.
Test and maintain it according to the
requirement. Test and replace or reinstall it according
to the requirement.

Only can 1→3→4
shifting The small O-ring of front s ervo piston is invalid or
lost.
2→3 Gear position shifting valve is blocked. Det ect the O-ring. Process the replacement or
reinstallation if necessary. Detect the 2→3
Gear shifting valve; Process the maintenance
or replacement according to the requirement.
Only can 1→2→1
shifting C1 is invalid or 3rd-Gear and 4th-Gear is loose. (give
to 1st-Gear in 3rd-gear; give to 2nd-Gear in 4th-Gear) Det ect the clutch C1. Repair or replace it if
necessary.
Can not realize the
man ual 4→3, 3→2, 2
→1 Overspeed clutch /ball spool has displacement.
C4 is invalid. Detect the ball spool. Process the replacement
or reinstallation according to the requirement.
Det ect the C4. Repair C4 or r eplace the C4
wave pan according to the necessary.

Automatic transmission-50
Only can 1→3→4
shifting The sm all O -ring of front servo piston is invalid or lost.
2→3 G ear psition shifting valve is blocked. D etect the O -ring. P rocess the replacem ent or
reinstallatio n if n ecessary. D etect th e 2→3
G ear shifting valve; Process the maintenance
or replacem ent according to the requirem ent.
Only can 1→2→1
shifting C1 is invalid or 3rd-G ear and 4th- G ea r is lo o s e . (g iv e t o
1st-G ear in 3rd-gear; give to 2nd-G ear in 4th-G ear) D etect th e clutch C 1 . R ep air or rep la ce it if
necessary.
Can not realize the
manual 4→3, 3→2, 2
→1 O verspeed clutch /ball spool has displacem ent.
C4 is invalid. D etect the ball spool. Process the replacem ent
or reinstallation according to the req uirem ent.
D etect the C4. R epair C4 or replace the C 4
wave pan according to the necessary.
W itho ut m an ual
1st-G ear The rear brake belt is loose when the tem perature is
high.
The R -G ear/Low speed 1
st-G ear ball spool has
displacem ent.
The internal “O ” –ring of rear servo is lost.
C4 is invalid. D etect the rear brake b elt, adjust id necessary.
D et e ct t h e b a ll sp o o l, R ein s ta ll o r r ep la c e it if
necessary.
D etect the O -ring, R einstall or replace it if
necessary.
D et e ct th e C 4 . R ep a ir o r r ep la c e it if n e c ess a r y.
Only can 1→2→2→4
gear. The dim ension of socket of front servo is large. H as the
possibility of loose of plug.
It has the trend that ca n n ot realize th e reverse-G ear if
drive the vehicle in this condition continuously. Repair or replace it if necessary.
Detect the C3 piston O -ring, replace it if
necessary.
Only an 1st-gear,
2nd-G ear, 4th-G ear or
1st-G ear, 2nd-G ear an d
3rd-G ear.(3rd-G ear is
tightened) The gear sensor has failure, only can1→2→3 shifting.
3→4 Gear shifting valve is blocked. D etect the gear-position sensor. R epair or
replace it if necessary. D etect the 3→4 gear
shiftin g va lv e. R ep air or r ep la ce it if
necessary.

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.

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.