2006 GREAT WALL HOVER Service Repair Manual

Figure 8.58 Tighten sequence of bolt form valve to box
15. Installation of oil filter and oil bottom shell
Caution:
a. It should replace the filter when a important mechanical component is damaged and assemble a transmission.
b. To assist the assembly of sealing gasket groove, please coat the surface of oil pan and washer with thin Vaseline to
ensure the sealing gasket is in the groove. Do not rotate the washer, otherwise it will cause the distort or incline of
groove.

Figure 8.59 Bushing of engine oil filter
Figure 8.60 Installation of engine oil filter
Figure 8.61 Tightening sequence of oil pan bolt
It should abide by follows when assemble the oil filter and oil sump tank (Refer to Figure 8.59and Figure 8.60):
a. Use the automatic transmission liquid to lubricate the spring ring of gasket of lubrication oil.
b. Install the oil filter on the valve carefully. During the installation, the socket must be inclined. Refer to Figure 8.59.
c. Fix the oil cleaner assembly.
d. Check whether the magnet is installed in the recess on the corner of oil bottom shell.
e. Assemble the groove on the oil bottom shell. The groove must be bent during the installation.

f. Make the installation of oil bottom shell is proper for transfer case and the tighten the safety valve according to the
specification and sequence (Refer to Figure 8.61). do not distort it.
16.Torque converter and support sleeve assembly
Install the hydraulic torque converter and housing assembly, the procedure is shown as follows:
a. Install the hydraulic torque converter housing on the main case.
Caution:
All hardware should be installed correctly and comply with the specification.
b. Use the Loctite243 or equivalent to fix the torque converter housing; install and tighten it to standard specification.
c. Install the torque converter; ensure the pump gear sealing is installed correctly.
17. Rear wheel drive mode of output ring flange assembly
Assemble the output shaft assembly, the procedure is shown as follows:
a. Place the paw of transmission operating rod on the parking position and lock the output shaft.
b. Wash the output shaft upper line; use the loctite243 or equivalent.
c. Install and tighten the ring flange, O-ring and nut.
Caution: In the heavy steel slide plate, place the ring flange on the upper nut; avoid the damage of bearing.
d. Tighten the nut on the output shaft
Torque type specification N.m Ft/lb
tra n s m iss io n as se m b ly

torque converter housing to
housing M12×32 4, 8or 9 54-68 40-50
rear end housing to housing
-C h a irm a n M12×32 4 54-68 40-50
C onnector housing to housing
-4 W D M8×25 10 35-40 26-30
rear end housing to housing
-2 W D M8×25 10 35-40 26-30
rear servo cover to housing
M8×25 6 30-35 22-26
O il pan to housing
M6×16 9 4-6 3-4.5
O il cooler pipe connection
2 40-45 29.5-33
V alve to housing
M6×26 7 8-13 6-9.5
V alve to housing
M6×45 5 8-13 6-9.5
B rake bar spring
M8×16 1 20-22 15-16
central support to housing
M10×34 2 20-27 15-20
C am disc to housing
M8×16 2 16-22 12-16
G ear-position sensor to
housing 10-24×13 2 4-6 3-4.5
O utput shaft lock nut
M24×1.5 1 100-110 74-81.5
oil filling plug M 20 1 30-35 22-26
Pump housing assembly


Pump to pump cover
M8×55 5 24-27 18-20
Pum p cover to housing
M8×40 6 24-34 18-25
Pum p cover to housing
M8×58 2 24-34 18-25
Pum p cover disc to pum p
cover M6×16 5 13-16 9.5-12
Pum p cover disc to crescent
M6×54 1 13-16 9.5-12
Valve assem bly


U p p e r v a lv e to lo w e r v a lv e
M6×30 24or 25 11-16 8-12
Line socket M 6 1 4-7 3-5
solenoid valve (on/off type
and VPS, including S7) M6×16 7 8-12 6-9
Table 8.1 Torque specification

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 fillin g procedure
According to the procedure described in 7.2.
Specification and special tools
Type and specification
hydraulic torque converter
maximum torque multiplier factor
179K
stalled speed (80 to 100 ℃ rp m)
(179K torque converter ) Specification

2.00: 1

2090
Gear 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 TQ95
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
Tab le 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