automatic transmission GREAT WALL HOVER 2006 Service Workshop Manual

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.

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.

3. Oil filling of service after sales
Set the liquid level position correctly; the procedure is shown as follows:
a. Shut down the engine; place the gear-position in the P-Gear.
b . Lift the vehicle (or place it above the trench).
c. Clean the around of plug before remove it. Remove the oil plug and check the O-ring for damage, finally connect the oil filling
pump to the oil filling hole.
d. Lower the vehicle and oil filling pump to the ground; fill with the transmission fluid partially. The general oil filling amount
is shown as follows:
If in the status of transmission hydraulic torque converter is empty: 8.0 L
If in the status of transmission hydraulic torque converter is full: 3.8 L
e. When start the vehicle in P-Gear, 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. Then fill with 0.5L transmission fluid (ATF) additionally.
g. Shut off the engine, lift the vehicle; take off the pump and replace the plug. Ensure the plug is tightened according to the
specification.
h. Then pull the vehicle throttle position for slight opening to make the vehicle runs for 3.5
4.5km; the rotary speed of engine
is no more than 2500r/min; then the transmission fluid temperature will in the scope of 50
60.
i. The engine is in idle-speed; pull the hand brake to make the shifting lever circuits in each gear-position horizontal status.
k. Remove the filling plug 3 minutes after the engine is shut off, but must 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 (ATF) to meet the requirement.
l. Reinsert the transmission fluid plug, remove the residual transmission fluid around the vehicle and transmission; tighten the
plug to the specified torque.
4. Replace the ATF
Please notice that the color of TQ95 automatic transmission oil will be faded in the normal operation of transmission; it will be
turn into the deep brown or even in black. It will not affect the performance of ATF. It means that the fading of transmission
fluid not always means to replace the transmission fluid.
If the transmission temperature is raised, the ATF will be burnt. In this condition, ATF will change into black and with special
sulfur smell. The smell of the ATF means the oil is burnt.
If the ATF is burnt, it will cause the damage of transmission (the clutch assembly is damaged at least).At this time, it should
disassembly the transmission and process the necessary detection.
Electronic calibration
1. Idle-speed calibration
The idle-speed calibration is introduced in detail in the vehicle factory manual.
2 Calibration of position of throttle position

If the throttle position information stored in TCU is lost or not in application scope. It can be reestablished according to the
following program as the diagnosis error information.
a. Check whether the engine idle speed is in required range.
b. In the status of shutting off of air-condition, make the engine is in “D” –Gear for 60s,then the reference point with opening
degree of 0
of throttle position is reset in TCU.
Shut off the engine; switch on the ignition device, step the accelerator pedal to bottom for 60s, then the reference point with opening
degree of 100
of throttle position is reset in TCU.
3. Clear of throttle position

The clear process set by learning throttle position is necessary for M88 transmission TCU.
4. Car code

For M88 transmission, the car code is unnecessary.

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.

Figure 8.19 Position of thrust bearing and sealing pad
4. Rear servo assembly
Install the rear servo assembly (Refer to Figure 8.18), the procedure is shown as follows:
a. Check the servo piston O-ring and washer for damage.
b. Use the transmission fluid to lubricate the servo piston O-ring and install the O-ring on the piston groove.
c. Install the piston on the housing; ensure the O-ring is compressed to position, but do not excess.
d. Adjust the spring and piston sleeve; then install the rear servo brake bar on the sleeve.
Caution:
Do not coat the washer with the Vaseline.
e. Install the housing installed with washer on the case.
f. Provide the bolt with the Loctite567 sealant and install it; ensure the bolt is tightened according to the specification.
5. Planet carrier assembly and central support
The installation process of planet carrier assembly and central support is shown as follows:
a. Check the bracket and planet assembly for damage or abnormal and ensure all pinion rotates freely and the pinion axle end
floats in the allowable range; described as 9.2.
b. Install the one-way clutch fixing plate on the planet carrier and ensure the internal edge points to the downwardly. Check the
one-way clutch and brake accessory for damage; replace it according to the requirement.
c. Install the external race on the drum. Press sown the ring race to bottom of drum and install the fixing ring spring. Ensure the
ring spring is installed in the groove stably. Refer to Figure 8.20.
d. Install the one-way brake on the external race with the lip upwardly. Use the automatic transmission liquid to lubricate the
brake accessories. Refer to Figure 8.20.

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 8.25 C4 clutch assembly
Caution:
The diameter of spring wire bunch is 4.3mm.
f. Install the piston out and back spring on the piston and install the spring fixing plate on the spring.
g. Use the special tools and press down the spring to ensure the installation for fixing ring spring. And ensure the spring is fixed
in the groove tightly, then remove the tools.
h. Check the C1 piston detection valve for damage and free movement. Ensure the cleanness of cylinder oil inlet.
Caution:
Ensure the O-ring is not bent in the groove.
i. Use the automatic transmission liquid to lubricate the O-ring and install it in the respective groove.
j. with the clutch C1 hole upwardly, installs the cylinder. Install the piston into the cylinder until the external diameter of piston
enters into the inner diameter of cylinder.
Caution:
The diameter of wire bunch of spring is 5.26mm.
k. Install the spring and spring fixing plate on the piston. Use the special tools and press down the spring to ensure the
installation of fixing ring spring, then remove the tools.
l. Install the C2 wave washer on the cylinder; ensure one of wave washers cab cover the C2 piston drainage outlet.
m. Measure and record the thickness of C2 sleeve ring flange. Refer to Figure 8.25.
n. Install the clutch C4 disc and wave washer on the clutch C2 sleeve. Ensure the round edge steel disc is disassembled according
to the following sequence:
friction disk
steel disc
friction disk
steel disc
friction disk
Wave washer
C2 pressure disc
pressure disc housing load is 3500N
clutch C4 load