clutch GREAT WALL HOVER 2006 Service Workshop 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.

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.

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.

l. Reverse the clutch cylinder on the pressure machine; and remove the clutch C1 reset spring with same method.
m. Send the compressed air into the cylinder through the cylinder hole, remove the clutch piston from the clutch cylinder. Refer
to Figure 8.6.
4.clutch C3 cylinder
The procedure of removal of clutch C3 cylinder is shown as follows:

a. Remove the front sun gear assembly, thrust bearing and thrust washer from the clutch C3 cylinder asse bly , shown as Figure
8.7.
b. Remove the nylon thrust bearing, bearing block, needle thrust bearing and thrust bearing . From the clutch cylinder hub.
Figure 8.5 Impressed clutch reset spring
Figure 8.7 Clutch C3 and central gear assemblyFigure 8.6 Removal of C1, C2 and clutch C4 piston

Figure 8.8 Removal of clutch C3 piston
c. Install the clutch assembly on the special tools, press down the piston out-back spring; take out the retainer and release spring.
Caution:
Ensure the spring keeping device does not be clamped in the spring groove and all spring pressure is released.
d. Take out the tools, retainer, retainer and spring.
e. Take out the gasket from the clutch C3 cylinder.
f. Take out the clutch disk fixed spring ring and take out the clutch disk.
g. Send the compressed air into the hole between the iron sealing ring and support shaft neck of cylinder; remove the clutch piston
from the clutch cylinder. Refer to Figure 8.8.
h. Take out the cylinder forms the reverse sun gear and C3 washer.
5. Planet carrier and central support
The disassembly procedure of planet carrier and central support, the procedure is shown as follows:
a. Separate the planet carrier and central support from the output shaft; remove the thrust bearing and planet carrier form the
output shaft.
b. Rotate the planet carrier in anticlockwise and separate the central bracket.
c. Raise the one-way clutch form the planet carrier
d. Remove the spring ring on the planet carrier; maintain the periphery of one-way clutch on the planet carrier and take it out.
Refer to Figure 8.9.
e. Remove the one-way clutch fixed mount form the planet carrier.
Figure 8.9 Planet carrier and external race way

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.

connecting housing (4WD)connecting housing
Figure 8.20 planet carrier assembly and central support
eCheck whether the socket has the proper central support, then install the central support on the one-way clutch, ensure the
support can rotate in anticlockwise. Refer to Figure 8.20
f. Use the Vaseline to lubricate the NO.9 needle thrust bearing and thrust washer, and install it on the rear of planet carrier. Refer
to Figure 8.19
g. Install the planet assembly and central support on the box and align the central support installation bolt hole.
h. Install and tighten the central support bolt.
i. Install the ring spring fixing plate; ensure the ring spring is installed in the box correctly.
j. Remove the central support bolt and provide the Loctite243 or similar material for screw; install and tighten the bolt to
specified standard.
6.Ttransmission rear housing assembly
The installation procedure of transmission rear housing assembly is shown as follows:
a. Check the condition of transmission rear housing roller bearing (2WD and Chairman mode), replace it if necessary (rear drive
mode). Install the new bearing form the end of transmission rear housing; only can press the bearing side with mark.
b. Install the new sealing material on the transmission rear housing or adaptor rear housing. Refer to Figure 8.21.
Figure 8.21 Connecting and extension housing
output shaft
o-ring
locking nut
oil seal
needle bearing oil seal
gasket

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 8.25 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