Great Wall Hover. Service Manual - part 9

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 pin

Figure 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 assembly

Figure 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

6. Pump

Cautions: the following valves are installed in the pump cover:

solenoid valve 7

C1 eccentric valve ( only for early stage mode, no valve in M88)

torque converter control valve

torque converter regulating valve

primary regulating valve

The disassembly procedure of pump is shown as follows:

a. Remove the wire bunch fixing disc and use the special tools T30 to remove the solenoid valve 7.

b. Use the 8mm sleeve to remove 5 bolts and washers.

c. Use the tool NO.30 to remove 5 screws form the cover plate. It should notice that the odd number screw has the function of

connecting the pump body to the pump cover plate.

Caution:

Do not release the pump by the method of knocking the torque converter support.

d. Separate the pump body from the pump cover.

e. Lift the pump cover disc form the pump cover.

f. Remove two ball spool detection valves and a spring from the pump cover.

Caution:

Some valves and plugs are connected by the spring and may fall down form the housing when remove the pin.

g. Press down the socket inwardly to remove the fixed pin of 4 valves.

h. Take out 4 valves, plugs and springs.

i.

Take out the pump gear form the gear.

j. Remove the edge sealing from front of pump when replace it.

7. Valve

The removal procedure of valve is shown as follows:

a. Use the special tools T40 T orxbit to remove the ratchet spring and retainer plate.

Caution:

The manual-operated valve may fall down form the valve.

b. Slide the manual-operated valve to out of lower valve.

c. Pay attention to the angle relationship between the electromagnetic end and valve, remove the solenoid valve and valve

assembly according to the following procedure :

Solenoid valve 1

Solenoid valve 2

Solenoid valve 3

Solenoid valve 4

Solenoid valve 5

Solenoid valve 6

d.  Place the valve on the platform with the top upwardly.

e.  Use the model NO.30 Special tools to remove the 24 fixing screw. Lift the upper valve and separating disk to separate the

upper valve form the lower valve

f. Reverse the upper part, place the separating disk on the platform upwardly.

g. Lift the separating disk and washer from the upper valve.

h. Remove 5 exposed nylon detection ball spools of valve.

i.

Remove the locking nut disc, spring and reverse lock valve.

j.

Remove two cleaners  (and large nylon detection ball spool ) from the lower valve.

Caution:

Once the pin is removed, the disc in the valve may be loose and slid form the valve when reverse the valve.

k. Remove the locking nut disc and bolt form 1-2, 2-3, 3-4, BAR,CAR valve; the bolt can be removed by the bolt.

l.

Remove the 1-2, 2-3 and 3-4 shift valve.

Caution:

Some valves are pulled by the spring and may fall down form the valve.

m.  Press down the plug of 4-3 sequence valve and take out the locking nut disc.

n. Take out the plug, valve and spring.

o. Press down the solenoid valve 5 gate. Remove the fixed pin, valve and spring.

Caution:

The valve is pulled by the spring and may fall down form the valve.

p. Press down the line pressure blow-off valve , then remove the fixed pin, disc (if proper) spring and valve.

q. Take out the roller pin and remove the spring and ball spool detection valve adjacent BAR.

Assembly

The transmission is assembled in the method of module. The detailed assembly process of each module is described in the

following chapter in detail.

Refer to Table 8.1 (end of section 8.3) for the description of used torque specification. The Table 9.10 in section 9.6 describes

the necessary special tools for assembly.

The technician also needs to select the quality Torx tools, especially for the two-screw socket wrench with code of 40, 50,

8mm,10mm and 12mm to detect the transmission completely.

1.Transmission

Caution:

Ensure the BIR retainer is proper for the case (otherwise, the valve will damage the separation disk).

Ensure the E clip is installed on the cross shaft.

Ensure all parts of parking machine can operate normally.

The assembly procedure of transmission is shown as follows:

a.

Place the upper transmission on the platform upwardly and place it on the transmission bracket.

b.

Install all accessories, bolts and bleed devices. Paint the sealant on the sealing place. Tighten all components according

to the specification. Ensure the cleanness of all bleed devices. Ensure the rear oil filling nozzle of housing is correct and

without blocking material. Refer to Figure 8.19.

c.

Assemble the BIR valve and spring; ensure the retainer is installed correctly, refer to Figure 

 8.10. Ensure the

retainer is fixed in the groove completely.

  d.    Install the rear servo bar and pin shaft. Refer to Figure 8.11.

Caution: Ensure the crown bar can rotates freely.

Figure 8.11  Rear servo bar

Caution:

Pay attention to do not coat the sealant between the bolt and crown bar.

e.   Install the parking operating lever (as Figure 8.12), including the return spring and shaft pin. Coat the external end of shaft pin

with small sealant.

f. Use the circlip to protect the shaft pin. Pay attention to ensure the operating lever can rotate around the shaft pin freely and

the spring can make the parking operating lever returns to the correct position.

g. Install the parking brake lever pin and spring. Refer to Figure 8.13.Caution:  ensure the rake lever can rotate freely.

h. Connect the parking brake lever to the manual-operated valve connecting rod. Shown as Figure 8.14. Ensure the spring and cam

axle ring are installed on the connecting rod fixedly.

i.

Check the cam axle ring for smooth sliding on rod.

j.

Install the cross shaft in the box in reverse direction of Gear-position sensor, then install the concussion spring on the shaft.

Figure 8.12   Parking operating lever

Figure 8.13  Typical parking brake shaft pin and spring

Figure 8.14   Parking lever and manual shaft

Figure 8.15   manual-operated valve brake lever

k. Install the manual-operated valve detent connecting rod (shown as Figure 8.15), align it with the cross shaft hole.

l.

Push the shaft by the positioning operating lever, until start from one side of box operating lever.

m. Use the special tools to install the operating lever drive bolt on the shaft, and ensure the adaptor covers the bolt.

n. Press the bolt into the shaft until the tools reaches the bottom.

o. Take out the tools and install the spring fixing ring spring on the shaft

p. Use the tools to install the new cross shaft seal.

q. Install the Gear-position sensor on the box; install the screw according to the specified torque. Use the tools to press the bolt

on the shaft.

r. Check the connection of wire bunch port completely to ensure the normal operation.

s. Install the wire bunch and install the connecting point of solenoid valve 7 and ring flange matched to the pump. Refer to Figure

8.16. The connecting wire of solenoid valve 7 is organized under the parking lever and in box cross shaft.

t. Install the 10-pin connecting socket in the box, ensure the flange of connecting socket matches to the notch on box.

u.  Pull out the wire bunch part form the box and prohibition switches; install the 10-pin connecting socket on the wire bunch

bracket (only for rear-wheel drive mode).

Figure 8.16  Connecting position of coil 7

Figure 8.17  Installation of 10-pin

connecting plug

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.

connecting housing (4WD)

connecting housing

Figure 8.20   planet carrier assembly and central support

e

Check 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

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 8.23  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

o. Maintain the horizontal position of cylinder , install the sleeve and clutch disk assembly on the cylinder; ensure the top of

washer and external hole of cylinder are in order until the sleeve can contact the C2 wave plate.

Caution:

For the C2 wave spring is compressed and the clutch disk can endure the weight of 19.6N. The dimension form the lower
side of C2 pressure disc to the gear selection steel plate is 1.4

1.8mm. if the clutch need to start the accuracy  from the

top of pressure plate, then the accurate value should be the actual size of pressure plate plus 1.4

1.8mm.

p. Use the special tools to check the C4 clutch assembly. Refer to Figure 8.25.

Caution:

It should take out the clutch clearance assembly before immerse the assembly into the automatic transmission fluid
(ATF).

q.  Use the gear selection plate to reach the correct specification. If need to install the new friction disk, it should remove the

clutch assembly and immerse the  friction disk in the automatic transmission fluid for 5 minutes at least before the installation.
Reinstall the sleeve and clutch assembly and place it in the cylinder. Ensure the wave washer is arranged consisting with the
cylinder hole.

Install the clutch C2 disk in the cylinder according to the following procedure:

friction disk

steel disc

friction disk

steel disc

 The steel disc transmission use the G32 model engine; the 5

th

 friction disk should replace the steel disc (reference table 9.3).

steel disc  (optional)

friction disk

steel disc  (optional)

friction disk

Caution:

For the clutch assembly can endure the weight of 19.6N, the dimension from the clutch C3   wheel axle to the friction disk
should be within 0.80-1.05mm.

      r.   Use the tool to test the clutch assembly; ensure the weight is in the acceptable range. Refer to Figure 8.26.

C3 hub positioning

clutch C2 loading

Figure 8.26  C2clutch assembly

v.    Install the thrust disc on the cylinder internal wheel axle. Refer to Figure 8.24and 8.19.

w.   Connect the C2 /clutch C4  wheel axle assembly in clutch C4 disc, install the clutch C2 disc. Install the C3 wheel axle and

         reinforce it by ring spring; ensure the ring spring is installed in the groove fixedly. Please refer to Figure 8.24.

10. Clutch C3 and reverse central gear system

The assembly procedure of clutch C3 and reverse central gear assembly  (refer to Figure 8.28) is shown as follows:

 Check the cleanness of hole on cylinder.

Caution:

It should take out the clutch clearance assembly before immerse the assembly into the automatic transmission fluid

(ATF).

s.     Use the gear selection plate to reach the correct specification. It should remove the clutch assembly and immerse the friction

disk in the automatic transmission fluid for 5 minutes at least before the installation if install the new friction disks. Lubricate

and install the 3-4 one-way clutch and install the sleeve on the C2 wheel axle. Adjust the handle rear and install the nylon thrust

washer on the C4 wheel axle. Refer to Figure 8.27.

t. Adjust and install the clutch C4 wheel axle on the clutch C2 and one-way clutch assembly. Check the rotary direction of clutch

C2 wheel axle, when keep the C4 wheel axle in static, C2 wheel axle should rotate in clockwise and is locked in anticlockwise.

Refer to Figure 8.27.

u.    Use the Vaseline to lubricate the N0.5 thrust bearing and install it on the C4 gear wheel axle ,separate the clutch C2 disc form

        the clutch cylinder.

Figure 8.27 C2 hub rotation