2006 GREAT WALL HOVER parking brake

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 pinFigure 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.

Figure 8.11 Rear servo barCaution:
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 7Figure 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.

Axle drving assembly
Removal of semiaxle
1. Remove the wheel.
2. Disconnect the manual brake pull-wire from the
carriage; loose the small bracket.
3. Remove the brake caliper; remove the brake disc .
4. Remove the rear halfaxle assembly from the rear
axle housing
a. Use the bolt to connect the special tools to the semiaxle flange
surface.
b. Use the hammer of special tools to remove the rear axle.
brake caliper assembly
brake disc
circlip
oil seal base
bearing
oil seal
oil seal pressing block
parking brake assembly
rear axle
N
m: Specified torque
Used component which can not be used any more.
pull-wire assembly
5. Remove the circlip from the halfaxle assembly.
Use the circlip pliers to remove the circlip.

Brake-1
Chapter 8
Brake
Cautions...................................................................................... 2
Troubleshooting............................................................................2
Check and adjustment..................................................................5
Brake pedal..................................................................................7
Parking brake...............................................................................8
Front brake...................................................................................9
Rear brake...................................................................................16
Rear parking brake......................................................................22
Sensor load proportional valve.....................................................29
Antilock Braking System (ABS)..................................................31

Brake-2
Troubleshooting
Cautions

Failure cause Inspection content



Pedal is low or soft brake pad is worn
brake block is worn
brake system is leaked
master pump has failure
Brake system has air
Brake pump has failure
Auto adjuster of rear brake has failure Replace the brake shoe
Replace the brake block
Repair the leakage
Repair or replace the master pump
Drain the air from brake system
Replace the brake pump
Repair or replace the adjuster




Lag of brake Parking brake is adjusted badly.
Pull wire of parking brake is locked
Assist push rod is adjust badly
Extension spring or return spring has fault
Pipeline is blocked
brake pad is broken or deformed
brake block is broken or deformed
Auto adjuster is damaged
Master pump has failure. Adjust the parking brake
Repair if necessary
Adjust the push rod
Repla ce the extension spring
Repair if necessary
Replace the brake shoe
Replace the brake block
Repla ce the a djuster
Repla ce the master pump





Brake is stagnant Improper inflation of tyre
There is grease spot or lubricant oil on the
brake shoe or brake block.
The brake shoe is deformed ; the brake pad
is worn or smoothed
The brake block is deformed, worn or
smoothed
The brake drum or brake disc is deformed
Extension spring or return spring has failure
Wheel pump has failure
Pump has failure
Brake block is blocked Charge the tyre to the proper pressure.
Find out the cause. Replace the brake shoe or block.
Replace the brake shoe
Replace the brake block
Replace the brake drum or brake disc
Repla ce the spring
Repair the wheel pump
Replace
Replace the brake block





brake pedal is hard There is the grease spot or lubrication oil on
the brake disc or brake block.
The brake shoe is deformed; the brake pad is
worn or s moothed
The brake block is deformed, worn or
smoothed
Brake pump has failure.
Brake assist has failure
Improper vacuum degree
The brake pipeline is blocked. Find out the caus e .
Replace the brake shoe or brake block
Replace the brake block
Replace
Replace the assist
Repair if necessary
Repair if necessary