2006 GREAT WALL HOVER transmission

Structure diagram of SC5M2D-C and SC5M4D-C transmission: shown in figure
Structure diagram of SC5M2D-C transmission
Structure diagram of SC5M4D-C transmission
Specification of transmission

1. Speed ratio of transmissio

Gear Ⅰ Ⅱ Ⅲ Ⅳ Ⅴ R
Speed ratio 3.967 2.136 1.360 1.000 0.856 3.578

2. Speed ratio of transfer case SC5M4D-C

Gear synchronizer H L
Speed ratio 1.000 1.925

3. Central distance of main shaft
transmission 72 mm
transfer case 222.25 mm
4. Instruction for repair specification of transmission

Inspection item Repair specification
End clearance of gear of Axle 1 (mm) 0～0.06 Adjusted by axial retainer.
Clearance b etween b earing block and bearing of Axle 1 (mm) 0～0.1 Adjusted by adjusting shim.
End clearance of gear hub of Gear 3/ 4 synchronizer (mm) 0～0.08 Adjusted by axial retainer.
Clearance of rear end cone b earing of int ermediate s haft (mm) 0～0.05 Adjusted by adjusting shim.
End clearance of gear hub of high and low gear (mm)
SC5M4D-C 0～0.08 Adjusted by axial retainer.
Clearance between the rear output shaft rear bearing and back
cover (mm) SC5M4D-C 0～0.1 Adjusted by adjusting shim.
Clearance of rear input shaft bearing (mm) SC5M4D-C 0～0.06 Adjusted by adjusting shim.

Inspection of SC5M2D-C transmission:
1.Check the oil level of transmission:
Screw off the oil discharge plug of the transmission; discharge all lubri-
cate oil; screw on the oil discharge plug to the specified torque; the
torque is: 30
35Nm. Fill the transmission with the transmission
oil through the oil filling port, oil number is hyperbolic gear oil SAE80W/
90, which meet API GL-4, oil capacity are 2.2L. Tighten the oil-filling
plug to the specified torque of 30
35Nm. (for area with high or
low temperature refer to the maintenance specification)
2. Replacement of oil seal of rear hosing:
The replacement of the oil seal of rear housing is shown in figure.
Disconnect the drive shaft from the rear housing; remove the oil seal
by the flat screwdriver, then use the special tools to knock the rear
housing oil seal in the rear housing. It should pay attention to the
installation of oil seal, shown as figure. Coat the lip of oil seal with the
specified transmission oil.
3. Removal, installation and inspection of transmission
The preoperation before removal and after installation of transmission
is: Remove and install the manipulator cover assembly, drain and fill
the transmission oil accordance with the regulation; after remove and
install the drive shaft. Separate each plug-in part from the vehicle
transmission .
4
Inspection of manipulator cover assembly
Shown as figure, remove the adhesive on the surface before installation,
use the screwdriver( M8
1.25) to clean the adhesive in the screw
hole; coat the installed part of bolt screw with the specified screw
adhesive. Firstly, install two positioning bolts A, then install other
two bolt A and bolt C respectively. The tightening torque of all bolts is
15
22Nm.
oil filling screw plug (SC1701005)
oil-drain screw-plug assembly (JK721701071)
rear housing oil seal
bolt C(SC-1704003)bolt A(SC-1704004)

SC5M2D-C transmission assembly
handle of gearlever
dustproof seal cover
oil seal 39.65210
odometer driven gear assembly
odometer seating lock plate
cylindrical compression spring
1.05.841
bush
select & shift seating
N m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special toolsmanipulator cover assembly
elastic cylindrical pin 6
22
rear housing assembly spring cylindrical pin
reverse lamp switch bracket
bearing housing assembly
clutch housing assembly
location compression
cylindrical pin

Disassembly of transmission (SC5M2D-C)
1.Remove the hexagon bolt M818 and lock plate.
Caution: The tightening torque is 14-19N
m when install the
hexagon bolt;
2.Remove the odometer driven gear assembly
Use the special tools to remove the odometer driven gear assembly
3.Remove the rear housing assembly
a. Remove 6 M10
1.2530 hexagon bolts
Caution: The tightening torque is 14-19N
m when installs 6
M10
1.2530 hexagon bolts.
b. Use the rubber hammer to knock the rear housing and take out the
rear housing assembly.
4. Remove 2 location pins and bushes.

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