GREAT WALL HOVER 2006 Service Manual PDF

c. Remove the high/low drive declutch shift shaft elastic cylindrical pin
d. Remove the 2
nd/4th declutch shift shaft elastic cylindrical pin
e. Use the circlip pliers to remove the bearing snap ring
f. Use the rubber hammer to knock out the transfer case cover assembly
slightly and remove the transfer case cover assembly. b. Remove the select & shift seating elastic cylindrical pin

Transmission-33
10. Remove the high and low gear drive declutch shift shaft
11.Remove the second and fourth drive declutch shift shaft
12. Use the plastic hammer to knock out the rear output shaft
assembly, front output shaft assembly and chain out slightly
13. Remove the second/fourth shift block and high and low gear
shift fork
14. Remove the housing of transfer case
a. Use the wrench to remove 4 bolts M10
1.2535 and 2 nuts
M10
1.25 connected the gearbox and tranafer case housing
Caution: The tightening torque is 30
42 N•m when install
the connecting bolt of gearbox and housing of transfer case

b. Remove the housing of transfer case
15.Remove a location pin
For the disassembly of gearbox refer to “Disassembly of gearbox in
SC5M2D
C”

Transmission-35
Disassembly of rear output shaft assembly
a. Use the special tools to remove the lock nut
Caution: The tightening torque is 87-120N
m when in-
stall the lock nut.
b. Remove the ball bearing
Rear output shaft assembly
cRemove the oil guide plate
circlips for shafthigh and low
gear sleeve
needle bearing
high and low gear hub
needle bearing
low-speed driven gear
rear output shaft
ball bearing
spacing platesecond/ fourth drive gear hub
second/fourth
drive geared sleeve
sprocket needle bearing bushing
needle
bearing
drive sprocket
spacer of
drive sprocket
oil guide plate assembly
ball bearing
assembly
87-120
N m: specified torque
Used component which can not be used any more.
Use the special tools
dRemove the spacing ring

e. Use the magnetic rod to remove the steel ball.
f. Remove the drive sprocket and needle bearing
Caution: When install the drive sprocket, it should use the plug
gage to measure the drive sprocket axial clearance and ensure
within 0.19-0.338mm
g Remove the drive geared sleeve
h. Use the magnetic rod to remove the steel ball.
i. Dismantle the drive gear sleeve.

Transmission-37
jRemove the gear hub
k
Remove the spacing plate
l. Use the circlip pliers to remove the circlip.
Caution: It should select the circlip for shaft according the angle
when install it.
m.Remove the high and low geared sleeve and gear hub
n. Remove the low-speed driven gear, needle bearing and rear output
shaft
Caution: When install the low-speed driven gear, it should use the
plug gage to measure the axial clearance of low-speed driven gear
axial clearance to ensure the axial clearance is 0.17-0.284 mm
Mark
Thickness (mm)
White
Blue
Green

Automatic transmission-1
Chapter 5
Automatic transmission (M88)
Instruction for automatic transmission .........................................2
Operation and display interface ..................................................5
Control system...........................................................................7
Power transmission system..........................................................22
Power transmission ...................................................................26
Diagnosis and test.......................................................................45
Adjustment................................................................................53
Disassembly /Assembly...............................................................55
Specification and special tools ...................................................90
Annex.........................................................................................92

Automatic transmission-2
Instruction for automatic transmission
1. M88 4-speed automatic transmission is equipped with the hydraulic torque converter and electric control system with locking.
When keep the stable forward status, the hydraulic torque converter can be locked automatically when the engine operates in low
speed, then reduce the unnecessary slide.
Figure 1.1 Electric automatic transmission control system
Figure 1.2 M88 4 speeds automatic transmission appearance figure (applied to 2 wheels driving)
2. The main advantage of the transmission is the application of transmission control unit (TCU). The control unit is the control
system based on the microprocessor system.. TCU control the shifting sensing and realize the Gear position shifting through the
signal of opening degree of throttle position, opening frequency of throttle position, engine speed, vehicle speed, transmission oil
temperature, gear position, mode selection and forced Gear reduction application.
3. TCU drives a variable pressure regulating solenoid valve to control three regulation valves and control the feeling of shifting.
Different transmission fluid temperatures are taken as one the main parameters to control the output pressure of the solenoid
valve, so as to keep consistent feeling of shifting within the normal operation scope.
4. The planning of shifting is very flexible. According to the car model, the different shifting plan is stored in the same TCU.
Generally speaking, the “economical mode” can increase the economical efficiency of the fuel and the driving performance of the
car to the maximum limit. The “dynamic mode” can bring into full play the drive performance of the car to the maximum limit. The
“winter mode” can make the car starting from shift 2.

Automatic transmission-3
8. Use two bolts to install the back device on the extended case of the transmission, these lengths are important. If it is too long,
it will hinder the end of the bolt and affect the threads on the case. Ensure the proper length and special torque of the bolt.
9. Pay attention that the height of the oil has been determined before delivery from the ION Company. The oil height needs not
checking or correction, except that improper oil is suspected to be used, or additional oil is needed because of leakage.

Automatic transmission-4
10. The gross weight of the transmission is 76kg; mostly weight is on the front of the transmission (side of torque converter). This
should be considered when design the handling/assembly tools.
11. The crankshaft speed/position sensor is installed on the top of transmission torque converter housing which must be installed
after the transmission is installed on the engine. The sensor will be damaged if it is installed before the installation of
transmission.
12. The transmission use the breathing tube connected to rear end of transmission. The tube must not be restricted or blocked
otherwise the air pressure in transmission will be increased. It is unallowable that the water/dirty/dust enters into the
breathing tube; otherwise the transmission will be damaged.
Removal of transmission
If the transmission needs removing for any reasons, following is the preventive measure to help the remove.
1. Must not only support the oil pan in middle of transmission for it will be deformed and leaked. The oil pan will not be deformed
when supports its external edge.
2. It must not allow the transmission to connect to the engine when the rear end is without connection, otherwise the exhaust
system of vehicle will be damaged.
3. Remove all torque converter bolts and push back the torque converter before remove the bolt connected the torque converter
housing to engine. Once all bolts connected the torque converter housing to engine are removed, use the torque converter the
push the transmission from the location pin, then ensure the torque converter is on the transmission and the transmission is
separated form location pin.
4. Install the dustproof cover on the cooler connector rapidly after open the oil cooler pipe; otherwise the oil leakage from the
torque converter will be 2L. The odometer dustproof cover can prevent the dirty from entering into the transmission and avoids
the leakage of oil form transmission.
5. The engine speed sensor is installed on the top of transmission and should be removed before the transmission is removed form
the engine, for the sensor will be damaged during the removal process of the transmission.
Figure 2.1 Gear selection interface
mode selection
gear selection
indicationgear slide way
Operation and display interface
The four-speed automatic transmission has three types of operation display interface which are shown as follows:
Gear selection
The transmission uses the traditional gear selection shifting handle, which is shown in figure. The gear rod can be moved on the gear
slide way according to the requirement. The relationship between the related gear and its function.