oil GREAT WALL HOVER 2006 Service Workshop Manual

Figure 8.34 pump, cover and torque converter support
g. Use the automatic transmission liquid to lubricate the pump O-ring and
install it on the pump. Place the pump on the other side.
h. Ensure the pump housing cavity and hole are not blocked.
Figure 8.35 Assembly of pump cover
i. Use the automatic transmission liquid to lubricate all loose part before
the installation.
g. Install the primary regulating valve on the pump housing, ensure the
valve slide freely; then install the plug of regulating valve and O-ring.
Refer to Figure 8.36.
k. Install the fixed bolt, install the torque conversion clutch regulating valve,
plug and O-ring. Refer to Figure 8.37
l. Install the fixed bolt. Refer to Figure 8.39
m. Install the torque conversion clutch control valve, spring and O-ring.
Refer to Figure 8.38pump cover assembly
pump housing cover
oil seal
pump assembly
o-ring (pump )
n. Install the fixed bolt, shown as Figure 8.39
o. Install the torque converter detection ball spool and spring, shown as Figure 8.41
p. Install the washer on the pump body. Install the housing disc and solenoid wire maintaining cover on the pump housing; ensure
the edge of disc close to the pump housing.
Shown as Figure 8.34, Tighten the bolt according to the sequence of (1-5), shown as Figure 8.42.
Caution:
Check the smooth of wire and connector. To ensure whether the wire and connector have connection and abrasion on the
input shaft or clutch C1/ C2 cylinder; check the wire and connector for over extension.
q. Tighten the screw of solenoid valve 7.Refer to Figure 8.39
r. Install the pump on the pump housing, tighten all bolts; ensure the pump can be washed without pump housing. Tighten
the bolt in certain sequence; shown as figure 8.42.

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 8.58 Tighten sequence of bolt form valve to box
15. Installation of oil filter and oil bottom shell
Caution:
a. It should replace the filter when a important mechanical component is damaged and assemble a transmission.
b. To assist the assembly of sealing gasket groove, please coat the surface of oil pan and washer with thin Vaseline to
ensure the sealing gasket is in the groove. Do not rotate the washer, otherwise it will cause the distort or incline of
groove.

Figure 8.59 Bushing of engine oil filter
Figure 8.60 Installation of engine oil filter
Figure 8.61 Tightening sequence of oil pan bolt
It should abide by follows when assemble the oil filter and oil sump tank (Refer to Figure 8.59and Figure 8.60):
a. Use the automatic transmission liquid to lubricate the spring ring of gasket of lubrication oil.
b. Install the oil filter on the valve carefully. During the installation, the socket must be inclined. Refer to Figure 8.59.
c. Fix the oil cleaner assembly.
d. Check whether the magnet is installed in the recess on the corner of oil bottom shell.
e. Assemble the groove on the oil bottom shell. The groove must be bent during the installation.

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

Shifting point
Opening
degree of
throttle
position Shifting
1/2 2/3 3/4 4L Opening
degree of
throttle
position shifting
1/2 2/3 3/4 4L
0% 10 20 34 63 0% 14 26 41 87
40% 26 47 82 95 40% 30 56 76 113
100% (WOT) 53 93 126 150 100%
(WOT) 53
94 127 152
decreasing 55 89 137 152 decreasing 55 96 137 152
Table 9.3- Shifting point-km/h
Maximum speed of typical Gear-decreasing of vehicle
The Gear-decreasing will be disabled when beyond the following speed.
Gear-decreasing type Speed point for disable of Gear-decreasing
Manual 2-1 In 59 km/h
Manual 3-2 89 km/h
Manual 4-3 119 km/h
Manual 4-2 (4-2 direct) 68 km/h
Manual 4-2 (sequence of 4-3-2) 89 km/h
Figure 9.4 - Special tools for maximum disable speed of manual Gear-decreasing
Special tools
tools Part No.
Platform bracket of transmission
oil pump remover
Cross shaft disassembly /installation
(brake lever)
clutch spring compressing tools
clutch assembly clearance positioning tools
Shaft end floating connector
Shaft end floating measuring tools
cross shaft seal disassembly tools
cross shaft seal installation tools
Pump sealing installation tools
Sealing ring expander extender /compressor
Cross shaft lever disassembly /installation
(disable switch)
solenoid valve /electric heating regulator,
electric meter
solenoid valve, platform meter
Assembly ball spool
Sealing gasket disc
Figure 9.5 Special tools

Annex
Description for oil inlet hole of main housing

Troubleshooting
Failure Cause Repair cont ent
Floating/pulling The t yre is worn or charged improperly.

The front wheel alignment is incorrect.

The wheel bearing is adjusted too tightened.
The front /rear suspension components is loose or
damaged
The steering linkage is loose or worn
The steering device is connect ed unsound or worn. Charge the t yre to the prop er pressur e or
repla ce the t yre.
Check the condition of front wheel
alignment.
Adjust the wheel bearing
Tighten or replace the suspension
partTighten or replace the steering
linkage
Adjust or replace the steering device
Subsidence of vehicle body Overload of vehicle
vibration damper is worn
spring is weak Check the load weight
Replace the vibration damper
Replace the spring
Left-right swing/up-down
bounce The t yre is charged improperly
The stabilizer bar is bend or damaged
The vibration damper is worn Charge the t yre to the prop er pressur e
Replace the stabilizer bar
Replace the vibration damper
Front wheel vibration The t yre is worn or is charged improperly

Unbalance of each wheel
The vibration damper is worn
The front wheel alignment is incorrect

The wheel bearing is worn or adjusted badly
The ball joint or bushing is worn
The steering system is loose or worn
The steering mechanism is adjusted badly or damaged Repla ce the t yr e or char ge it to the prop er
pressure.
Balance all wheels
Replace the vibration damper
Check the condition of front wheel
alignment
Replace or adjust the wheel bearing
Check the ball joint or bushing
Tighten or replace the steering linkage
Adjust or repair the steering device
Abnormal abrasion of tyre The t yre is charged improperly
The vibration damper is worn
The front wheel alignment is badly

The suspension part is worn Charge the t yre to the prop er pressur e
Replace the vibration damper
Check the condition of front wheel
alignment
Replace the suspension part
Oil leakage of differential High oil level or incorrect oil grade

The oil seal is worn or damaged
The matching flange is loose or damaged Drain the oil to the specified level or
repla ce the oil
Replace the oil seal
Tighten or replace the flange
The axle has the nois e The oil grade is low or incorrect

The clearance of the pinion, ring gear or side gear is
large.
The ring, pinion gear or side gear is worn or broken
The pinion gear bearing is worn
The b earing of rear axle half shaft is worn.
The differential b earing is loos e or worn Fill with the lubrication oil or replace the
oil according to the specification
Check the clearance

Check each gear
Replace the bearing
Replace the bearing
Tighten or replace the bearing

Front hub and steering knuckle (2WD)
stabilizer bar
connecting rod
of stabilizer bar
flat shim
disk shim
fill block
shim
fill block
disk shim
absorber
bearing
hub cap
brake cover
spring shim
split pin
lower suspension arm
split pin
upper suspension arm
spring shimbrake caliper assembly
steering knuckle
tight nut
lock washer
screw
oil seal
bearing
hub and brake disc flat shim
N
m: specified torque
Used component which can not be used any more
precoated component

special tools
diagram of special tools
grease
4. Remove the oil seal and inner bearing
a. Use the screwdriver to pry out the oil seal.
b .Remove the inner race of inner bearing from the hub.
Check and repair of front hub
1. Check each bearing
Wash the inner and outer race of each bearing and check them for
damage or wear.
2. Replace the bearing outer race
a. Use the brass bar and hand hammer to knock out the bearing outer
race.
b. Use the special tools to knock in the new bearing outer race.
Assembly of front hub
1. Coat the inner surface of hub and bearing outer race
with the grease.
The grease is the Jin HP-R grease or the grease met the requirement in
following table.
Item Typical data
Dropping point, C
289
Leakage amount (104
C, 6h), g 0.48
EP performance OK value , N
178