2006 GREAT WALL HOVER clutch

Disassembly of clutch housing assembly /bearing
housing assembly
40. Use the special tools to remove the reverse shaft
Use the magnetic rod to take out 2 interlocking pins
Remove the first bearing block assembly
a. Use the special tools to install 6 M8 bolts.
Caution: When install 6 M8 bolts, the tightening torque is 10-
13N·m
Clutch housing assembly / Bearing housing assembly
bush
oil seal
Used component which can not be used any more.
throwout bearing
assembly washer 8
¦ non-standard spring
first bearing
first shaft assembly
needle bearingsecond shaft assembly
¦circles for shaft
¦adjusting shim
leather cup
separation rocker arm assembly separation rocker arm ball supportclutch cylinder assembly
front space ring of intermediate shaft
intermediate shaft assembly aluminum waher
Specified torque

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-29
Transfer case assembly (one)
Transfer case assembly
transfer case
housing assembly
rear output
shaft assembly
transfer case cover
26-36
30-35
aluminum gasket 18
30-35
waved springhigh speed gear chain
front output shaft assembly
15-20
side cover plate
bush
thrust washer
needle bearing
needle bearing
spacing ring
O-RING
rear intermediate shaft
high/low gear
duplicate gear
thrust washerlock plate
14-19
high/low gear
declutch shift shaft high/low gear shift fork assembly
2nd/4th drive
declutch shift shaft
pin 526
2nd/4th drive
shifting blockinterlocking
cylinder pin
spacing ring2nd/4th drive
shift fork
cylindrical compression spring
spring base
split retainer
aluminum
gasket 18
N
m: specified torque
Used component which can not be used any more.
Pregummed component
transfer case housing assembly
N
m: specified torque
Used component which can not be used any more.

c. Remove the high/low drive declutch shift shaft elastic cylindrical pin
d. Remove the 2
nd/4th declutch shift shaft elastic cylindrical pin
e. Use the circlip pliers to remove the bearing snap ring
f. Use the rubber hammer to knock out the transfer case cover assembly
slightly and remove the transfer case cover assembly. b. Remove the select & shift seating elastic cylindrical pin

Transmission-33
10. Remove the high and low gear drive declutch shift shaft
11.Remove the second and fourth drive declutch shift shaft
12. Use the plastic hammer to knock out the rear output shaft
assembly, front output shaft assembly and chain out slightly
13. Remove the second/fourth shift block and high and low gear
shift fork
14. Remove the housing of transfer case
a. Use the wrench to remove 4 bolts M10
1.2535 and 2 nuts
M10
1.25 connected the gearbox and tranafer case housing
Caution: The tightening torque is 30
42 N•m when install
the connecting bolt of gearbox and housing of transfer case

Automatic transmission-5
Table 2.1 Gear selection and its function
Gear selection function
1st-Gear
(manual 1
st-Gear ) The first gear is using for climbing and braking. It is a function which limits the speed of
the car. The speed limitation by engine is realized by reduce the opening degree of
throttle position.
2nd-Gear (automatic, manual
2
nd-Gear) In economic mode, it can process the 1
st and 2nd shifting operation when engage the 2nd
–Gear. The limitation of vehicle speed by engine is realized through reducing the
opening of throttle position. in 4WD 4 high, , the transmission will maintain 2
nd-Gear
position The manual mode and winter-Mode will only maintain 2nd-Gear 。
3rd-Gear
(automatic, manual 3rd-Gea) In economic mode and dynamic mode, it can process the shifting operation of 1
st, 2nd
and 3rd-Gear when engage the 3rd-Gear, and can reaches the very high vehicle speed. At
this time the locking clutch can process the locking action, refer to vehicle user manual.
The limitation of vehicle speed by engine is realized by reduce the opening of throttle
position. In 4WD 4 low, the transmission should be maintained in 3
rd –Gear position.
Under manual mode, the transmission will be kept in 3rd-Gear.
D-gear
(drive) It can process the 1
st, 2nd, 3rd and 4th –Gear position operation and gear-shifting operation
of (1-2), (1-3), (2-3), (2-4), (3-4), (4-3), (4-2), (3-1) and (2-1). This shifting operation is
processed by taking the vehicle speed, throttle position, throttle position switching
frequency (or forced Gear-decreasing) as the parameter. The locking clutch can process
the locking action in 3rd –Gear, 4
th-Gear according to the type of vehicle. Refer to user
manual of vehicle.
N-Gear
(neutral gear) Only the rear brake belt is engaged at this time. It determines whether the function can
be realized according to the vehicle speed, engine speed and throttle position. But the
gear-position sensor allows the starting of engine. Allow the slide of N-Gear.
R-Gear
(reverse gear) Set the anti-misoperation in forward function according to the vehicle speed, engine
speed and throttle position opening to realize the reverse operation. The gear-position
sensor can start the revers e lamp.
P-gear
(parking gear) Only the rear brake belt is engaged at this time. The function can be determined
according to the vehicle speed, engine speed and throttle position. The output shaft of
transmission is locked. The gear-position sensor can start the engine.

Automatic transmission-7
Indicator lamp
Figure 2.2
control system
General
The transmission has two sets of control system, a electric control system and a hydraulic control system. The electric control
system monitors the vehicle parameter and adjusts the transmission performance; the hydraulic control system executes the
command of electric control system.
Electric control system
The electric control system consists of the sensor, TCU and 7 solenoid valves. TCU read in the data and make the output under the
control of software based on the value stored in Read Only Memory (ROM).
TCU controls the hydraulic control system and the control is realized through the valve and pump assembly. The system includes
7 solenoid valves, in which 6 valves are used to control the line pressure, operate the shift valve and hydraulic torque converter lock
clutch and switch on and off two regulating valves (Two regulating valves control the shift feel). The seventh solenoid valve is the
pressure regulating solenoid valve (VPS) which controls the shift feel with other three regulating valves. Figure 3.1 is the typical TCU
control system plan.
The figure includes all elements of electric control system involved in the section.
throttle position
open sensor
Engine speed
vehicle speed
Transmission
fluid temperature
mode selection
(instrument panel
/console )
Gear sensor
Forced step-
decreasingK line
shifting
logic
shifting
sensing
line
pressurehydraulic
control
system
Solenoid valve 1
Solenoid valve 2
Solenoid valve 3
Solenoid valve 4
Solenoid valve 5
Solenoid valve 6
Solenoid valve 7
pressure regulating
solenoid valve
Mode indicator lamp
Gear indicator lamp
set and other
necessary equipment
indication

Automatic transmission-11
Diagnosis input
solenoid valve
1and 2 S1 and S2 is the normal open solenoid valve, which is used to set the gear-position with other switch
solenoid valve. It determines the static gear-position by operating the gear shift valve. Refer to Table 3.5,
S1 and S2 also send the pressure single to allow or prohibit the engagement with rear brake belt.
solenoid valve
3and 4 S3 and S4 are the normal-opened solenoid valve which is used to control the shifting quality and sequence in
combination. S3 control the open or close of the clutch. S4 is used to control the on and off of the front brake
belt regulating valve.
solenoid valve 5 S5 is the variable pressure solenoid valve which can release the pressure of gear-position shifting. It provides
the pressure signal to the clutch and brake belt regulator and controls the shifting pressure. S5 also provides
the pressure single to the torque converter clutch regulating valve.
solenoid valve 6 S6 is the normal-opened solenoid valve, which is used to the set the H/L level of pipeline pressure. The
pipeline pressure is high when the solenoid valve is closed.
solenoid valve 7 S7 is the normal-opened solenoid valve which is used to control the engagement status of torque converter
licking clutch. It makes the clutch to generate the action when the S7 is in opened status.
Table 3.4 Status and function of solenoid valve

Gear-position S1 S2
1st-Gear On On
2nd-Gear Off On
3rd-Gear Off Off
4th-Gear On Off
R-Gear One of them is in On position
at least.
N-Gear Off Off
P-Gear Off Off
Table 3.5 Logic status of solenoid valve in static gear-position