Great Wall Hover. Service Manual - part 11

thickness           Component No.    thickness         Component No.

Adjustment of front and rear brake belt

1. Setting procedure of brake belt

The setting procedure of brake belt is shown as follows:

a. For the calculating method of front servo mechanism thrust lever refer to Figure 8.62,  dimension; standard A.

.Allow the air pressure is in 650/700kPa in the operating area of front servo mechanism  (external of B1),  (refer to

Figure 8.63).

. The forward dimension of thrust lever minus 3mm.

Dimension requirement for selection of shim:

Caution:

The small shim requires that the shim size is 1mm always; the available thickness is listed in Table 8.2.

.

Release air.

b.  Proper shim to end of thrust lever pole.

Check the shim for damage, worn or corrosion; replace it if necessary.

The shim is installed on the support surface between the transmission and pole flange, refer to Figure 8.62.

Install the shim by hand, and not the hammer or pressure.

Press the shim by hand until has the click the noise. The noise means the shim is clamped by the housing correctly.

     c.   Recheck the stroke of thrust lever 3mm

0.25mm.

2. Setting procedure of rear brake belt

The setting procedure of rear brake belt is shown as follows:

a. The setting of distance A is form the back surface of servo piston to inner surface of transmission, use the vernier caliper. Refer

to Figure 8.64.

A allows the air pressure of 650/700kPa is in the front servo mechanism operating area (external of B2),  (refer to Figure

8.63).

Deduct 3.75mm from the movement of piston and use the 2.5 mm shim to divide the rest distance.

Caution:

The small shim requires that the shim size is 1mm always; the available thickness is listed in Table 8.2.

. Release air.

b.  Select the proper shim for end of thrust lever pole.

Check the shim for damage, worn or corrosion; replace it if necessary.

The shim is installed on the support surface between the transmission and pole flange, refer to Figure 8.64.

Install the shim by hand, and not the hammer or pressure.

Press the shim by hand until has the click the noise. The noise means the shim is clamped by the housing correctly.

c.  Recheck the stroke of piston for 3.75mm

0.625mm.

Table 8.2   Effective thickness of shim

Figure 8.62  Setting of brake belt

  Figure 8.63  External port position of B1 and B2

Figure 8.64  Setting of rear brake belt

O il filling procedure 

According to the procedure described in 7.2. 

Specification and special tools 

T ype and specification 

hydraulic torque converter   

    maximum torque multiplier factor 

          179K  

    stalled speed (80 to 100  ℃  rpm)  

       (179K torque converter )  

Specification 

 

2.00:    1 

 

2090 

G ear  ratio 

First gear   

Second gear   

Third gear 

Fourth gear   

Reverse gear   

 

2.393:1 

1.450:1 

1.000:1 

0.677:1 

2.093:1 

Lubricant   

 type 

 dry system 

 alternative of maintenance  

Castrol T Q95 

9.0 L (approximation)   

4.5L (approximation)   

Axial movement of gear assembly 

0.50-0.65 mm 

Fixed pinion axle movement   

0.10-0.50 mm 

Table 9.1－ Type specification 

Pressing factor of clutch 

 0588-000001 

C1 

  structure (friction disk )  

      steel   

5 

5 (2)   

C2 

  structure (friction disk )  

      steel   

5 

4 (2)   

 

 

C3 

  structure (friction disk )  

      steel   

4 

4 (2)   

C4 

  structure (friction disk )  

      steel   

3 

4 (1)   

Table 9.2 Shifting point of clutch assembly details 

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

    Chapter 6

             Drive shaft

Cautions

Do not clamp the drive shaft bushing too tightened by the bench

vice to avoid the deformation.

                         

failure Possible 

causes 

Method 

Noise 

The spline of universal-joint fork is worn 

The intermediate bearing is worn 

The cross-axle bearing is worn or jammed 

Replace the universal-joint 

fork  

Replace the intermediate 

bearing  

Replace the cross-axle bearing   

vibration 

Runout of drive shaft   

Unbalance of drive shaft   

The rear bearing bushing of transmission 

extended housing is worn 

The spline of universal-joint fork is jammed 

Replace the drive shaft   

Replace the drive shaft   

Replace the bushing 

Replace the universal-joint 

fork  

Front axle propeller shaft (4WD) assembly

Rear axle propeller shaft (4WD) assembly

 

N 

m:      Specified torque

universal-joint fork

front section of

rear axle propeller

shaft

intermediate sup-

port assembly

universal-

joint fork

shim

nut

circlip

cross-axle assembly

rear section assembly of

rear axle propeller shaft

flange fork

circlip

cross-axle assembly

axle tube assembly

front axle drive shaft assembly

N 

m:        Specified torque

universal-joint fork

circlip

cross-axle

assembly

drive shaft axle

pipe assembly

N 

m:    Specified torque

flange fork

transmission

drive shaft assembly

rear axle assembly

front axle drive shaft assembly

transmission

rear axle drive
shaft assembly

transfer case

rear axle assembly

Disassembly of drive shaft:

Remove the intermediate support bolt of drive shaft firstly (CC6460KY

is without intermediate support connecting bolt ), then remove the

connecting bolt between the drive shaft and rear axle , lastly, pull out

the drive shaft assembly from the transmission output spline shaft and

remove it in integral.

Installation of drive shaft:

1

. Firstly, check the drive shaft for damage, spline for corrosion

and connecting surface for deficiency of damage or sand hole by

itself.

2

Install the connecting spline bushing of drive shaft on the

transmission output spline shaft carefully; then install the drive

shaft intermediate support on the intermediate support bracket

of carriage.

3

.  Use the special drive shaft bolt, nut and spring shim to connect

the drive shaft to the vehicle axle ring flange and tighten it. The

tightening torque is 78

5N

m

4

. Tighten the drive shaft intermediate support nut, the tightening

torque is 63

5N

m (the front and rear drive shaft in

CC6460KY model are the integral and has the installation

content)

Chapter 7

Suspension and vehicle axle

Rear suspension …………………………………112

Troubleshooting 

Failure Cause 

Repair 

content 

Floating/pulling 

The tyre 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 connected unsound or worn. 

Charge the tyre to the proper pressure or 

replace the tyre. 

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 tyre is charged improperly 

The stabilizer bar is bend or damaged 

The vibration damper is worn 

Charge the tyre to the proper pressure 

Replace the stabilizer bar   

Replace the vibration damper     

Front wheel vibration 

The tyre 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 

Replace the tyre or charge it to the proper 

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 tyre is charged improperly 

The vibration damper is worn 

The front wheel alignment is badly 

 

The suspension part is worn 

Charge the tyre to the proper pressure 

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 

replace the oil   

Replace the oil seal     

Tighten or replace the flange 

The axle has the noise 

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 bearing of rear axle half shaft is worn. 

The differential bearing is loose 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 wheel alignment

1. Process the following inspection and eliminate

    all problems

a. Check the wear condition of tyre and proper inflation.

Tyre inflation pressure:   230kPa

b. Check the wheel bearing of front wheel for loose.

c. Check the front suspension for loose.

d. Check the steering drive device for loose.

e.   Process the standard elastic test; check thefrontvibration damper

for normal operation.

3. Install the 4-Wheel alignment instrument

Processed according to the detailed description of equipment

manufacturer.

4. Adjust the wheel angle

Remove the cover of spacing bolt of steering knuckle; check the internal

wheel’s steering angle A.

Internal wheel’s steering angle:   

32

Caution: The wheel should not touch the brake hose of car body

when the steering wheel is rotated to limit.

2. Adjust the height of car

A:Adjust the height of car to the standard value for theconvenience of

processing the front wheel alignmentinspection.

B: Front fixed bolt of lower suspension arm

The standard no-load height is: the center of front fixed boltof lower

suspension arm is 295

1mm away form theground.

6. Adjust the wheel toe

Adjust the wheel toe according to the following method

a. Shake the car upwardly and downwardly to make the suspension

reach the stable status.

 b.  Push the car forwardly for 5m in flat ground when the front

 wheel is in the straight forward position.

c.   Mark the center of each rear wheel; measure the distance “B”

  between the marks of left and right tyre.

d.  Push the car forwardly to move the mark on the back of tyre to

 the position of front instrument.

Remarks: if the tyre moves too far, repeat the procedure (b).

e.  Measure the distance “A” ‘between the marks on front of tyre.

f.   Measure the toe of wheel.

 toe =B-A

 Inspection standard: 0-2mm

 If the toe does not consist with the specified value, it can be

 adjusted by the left and right draw-bar.

 Move the vehicle forwardly

g. Adjustment of toe: the standard value is 0

2mm.  The toe is

adjusted by rotating the cross draw-bar. When adjust the toe, it

should rotate the cross draw-bar on left and right side uniformly.

After the adjustment, tighten the lock nut, the tightening torque

is 55

65N

m.

h. Check the sideslip

Sideslip: Within 

5m/km

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 shim

brake 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