GREAT WALL HOVER 2006 Service Manual PDF

d. Remove the 3rd-Gear driven gear assembly
Caution: When install the 3rd-Gear driven gear assembly, it should
use the plug gage to measure the 3rd-Gear driven gear assembly
axialclearance to ensure it is within 0.17-0.284mm
e. Remove the 3rd-Gear driven gear needle bearing
f. Use the special tools to press the second shaft to remove the inner
race of double inner-race ball bearing.
Remove the 1st-Gear driven gear
Caution: When install the 1st-Gear driven gear, it should use the
plug gage to measure the 1st-Gear driven gear axial clearance to
ensure it is within 0.17-0.284mm.
h. Remove the 1st-Gear driven gear needle bearing

Transmission-23
i. Remove the sleeve
j. Remove the 1st-Gear synchronizer gear ring
k. Remove the 1st/2nd-Gear synchronizer assembly
l. Remove the 2nd-Gear synchronizer gear ring , 2nd-Gear driven gear
and second shaft
Caution: When install the 2nd-Gear driven gear, it should use the
plug gage to measure the 2nd-Gear driven gear axial clearance to
ensure it is within 0.17-0.284mm

2. Operation of 4WD
The operating auxiliary steering column can be shifted to 4WD status.
For position of auxiliary steering column and corresponding operating
condition refer to table.
3. Caution for operation:
a. Do not use 4WD in good surface, otherwise the tyre and components
of drive system will be damaged easily and increase the consumption
of fuel, and cause the noise of drive system.
b. Please run in 1st-Gear under “4L” gear position when run in very
low speed in field.
Operating instruction of transmission SC5M4D-C
1.The schematic diagram of transmission operating gear position
is on the handle of steering column.
During the process after vehicle is started and in traveling, it must
step the clutch pedal to bottom before the shifting. If need shift from
5
th-Gear to reverse-Gear, it should move the shifting bar to the neutral
position of 3rd/4th-Gear. Shift to R-Gear after stop the vehicle stably,
otherwise, it can not shift.
During the traveling process. It should always pay attention to the
shifting to make the vehicle matches to the speed of engine. The
correct shifting can improve the economical efficiency and prolong
the service life of engine. Do not shift from high-Gear to low-Gear on
the condition that the pointer of tachometer may enter into red area,
otherwise, the engine will be damaged.
Warning: Do not shift to reverse-Gear when the vehicle moves
forwardly, otherwise the transmission will be damaged.
hand hall of main steering column
hand ball of auxiliary steering column
Auxiliary steering
column position drive Operating condition
2H 2WD Use this gear position when run in the general railway and high speed highway.
4H High speed 4WD Use this gear position when run in the deep snowland, sand ground or uneven road
in normal speed.
N Neutral gear When use the gear position during using of winch, it could not drive the vehicle.
4L Low speed 4WD Use this gear-position when run in uneven road such as mud land or climbing or
downward （especially when need increas e the power）.

Transmission-25
2.Replacement of oil-seal of transfer case
The replacement of transfer case oil seal is shown as figure. Disconnect
the drive shaft from the transfer case, use the flat head screwer to
remove the oil seal
Caution: Do not damage the housing hole during the disassembly.
Then use the special tools to knock the transfer case oil seal into
the transfer case. It should pay attention to the installation dire
tion of oil seal. The oil seal is flush with the port of transfer case.
Shown as figure. Coat the lip of oil seal with the specified general
synthetic gear oil.
3. Disassembly and check of transmission
The preoperation before the removal and after installation of
transmission is : When remove and install the manipulator cover
assembly, drain and fill with the specified transmission and transfer
case lubrication oil. When remove and install the front and rear drive
shaft, separate each plug-in part of transmission from the vehicle.
Inspection of manipulator cover assembly:
The bolt dimension is different for different installation position. Do not
confuse it during the installation. It should install the fixing bolt A firstly.
The tightening torque of bolt A and B bolt is 15
22Nm.
installation position of fastening blot
bolt
bolt bolt
Repair of transmission SC5M4D-C
1. Inspection of oil level of transmission and transfer case:
Screw off the oil drainage screw plug of main box and transfer case;
drain all lubrication oil, tighten the oil drain plug to specified torque.
The torque is: 30
35Nm. Fill the main box and transfer case with
the transmission oil through the oil filling port. The number is hyperbolic
gear oil SAE80W/90, comply with API GL-4. The oil quantities are
main box : 2.2 L, transfer case : 2.7 L. (for high and low temperature
environment refer to maintenance specification). Tighten the oil filling
screw plug to specified torque. The torque is: 30
35Nm.
front output shaft oil
seal (SC
1802504)
rear output shaft oil seal
(SC
1802323)
transmission
transfer case
oil filling screw plug
oil-drain screw-plug assembly
(JK72
1701070) oil filling screw plug

Transmission SC5M4DC assembly
N m: specified torque
Used component which can not be used any more.
transmission
separated case
spring cylindrical pin
cylindrical
compression spring
steel ball 6.35 cylindrical compression spring
reverse lamp
switch bracket
wire clip
elastic cylindrical
pin
manipulator cover assembly
washer
test switch bracket
select & shift seating
washer
location spring
cylindrical pin
cylindrical compression spring
bush
wire clip
stud M101.25

Transmission-27
Manipulator cover assembly
Rear housing assembly
nut
reverse lock
assembly
manipulator
cover assembly
ball head
rubber cover
auxiliary steering
column stop platebush
ball head basewasher
pin
auxiliary steering
column assembly
handle of transfer case
ball head
hood
ball head
rubber cover
stop plate of
main bar
bush
ball head base
pin
washer
master control lever assembly
handle of
gearlever
N m: specified torque
Used component which can not be used any more.
odometer driven gear
assembly
odometer seating lock plate
14-19
14-19
oil seal
dustproof seal
guide bushing
rear housing
adjusting shim
24-33
26-36
aluminum gasket
mushroom lock spring
aluminum gasket
24-33
mushroom lock spring
26-3630-42
N m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special tools
steel ball 7.938 (3)

Disassembly of rear housing assembly
1.Remove the M8
18 hexagon bolt and the lock plate
Caution: When install the M8
18 hexagon bolt, the tightening
torque is 14-19N
m
2.Remove the odometer driven gear assembly
Use the special tools to remove the odometer driven gear assembly
3.Remove the rear cover assembly
Caution: When install 6 M10
1.2530 hexagon bolts, the tightening
torque is 14-19N
m
b.Use the plastic hammer to knock the rear cover slightly and take out
the rear cover
c.Take out the adjusting shim
Caution: It should select the adjusting shim as follows when
install it.
mark

Transmission-29
Transfer case assembly (one)
Transfer case assembly
transfer case
housing assembly
rear output
shaft assembly
transfer case cover
26-36
30-35
aluminum gasket 18
30-35
waved springhigh speed gear chain
front output shaft assembly
15-20
side cover plate
bush
thrust washer
needle bearing
needle bearing
spacing ring
O-RING
rear intermediate shaft
high/low gear
duplicate gear
thrust washerlock plate
14-19
high/low gear
declutch shift shaft high/low gear shift fork assembly
2nd/4th drive
declutch shift shaft
pin 526
2nd/4th drive
shifting blockinterlocking
cylinder pin
spacing ring2nd/4th drive
shift fork
cylindrical compression spring
spring base
split retainer
aluminum
gasket 18
N
m: specified torque
Used component which can not be used any more.
Pregummed component
transfer case housing assembly
N
m: specified torque
Used component which can not be used any more.

dustproof seal
guide bushingoil seal
transfer case housingball bearingfront output shaft
ball bearing
bowel patch
circlips for hole
rear input shaft
auxiliary gear
disk spring
circlips for shaft
spacing ring
duplicate ball bearing
circlips for
shaft oil seal
back plate
Transfer case assembly (three)
Disassembly of transfer case assembly
4.Remove the shouldered lock screw plug
Use the wrench to remove the shouldered lock screw plug M16
1.512
Caution: The tightening torque is 26-36N
m when install the
shouldered lock screw plug M16
1.512.
5.Remove the upper and lower drive switch M12
1.25
Caution: When install the upper and lower drive switch M12
1.
25, the tightening torque is within 26-36N
m
6.Remove the 2nd/4th drive switch M14
1.25
Caution: When install the 2nd/4th drive switch M14
1.25, the
tightening torque is with in 26-36N
m
N m: specified torque
Used component which can not be used any more.

Transmission-31
7.Remove the shouldered lock screw plug M141.510
Caution: When install the shouldered lock screw plug M14
1.5
10, the tightening torque is within 26-36Nm
8.Remove the shouldered lock screw plug
a. Use the wrench to remove the shouldered lock screw plug M12
1.2510
Caution: When install the shouldered lock screw plug M14
1.5
10, the tightening torque is within 26-36Nm
b.Takeout mushroom lock spring
c. Use the magnetic rod to take out the steel ball.
9.Remove the transfer case cover
a. Use the wrench to remove 12 connecting bolts M10
1.2565
between the transfer case cover and tranafer case housing.
Caution: The tightening torque is 26-36N
m when install the
bolt M10
1.2565.