2006 GREAT WALL HOVER oil

dustproof seal
guide bushingoil seal
transfer case housingball bearingfront output shaft
ball bearing
bowel patch
circlips for hole
rear input shaft
auxiliary gear
disk spring
circlips for shaft
spacing ring
duplicate ball bearing
circlips for
shaft oil seal
back plate
Transfer case assembly (three)
Disassembly of transfer case assembly
4.Remove the shouldered lock screw plug
Use the wrench to remove the shouldered lock screw plug M16
1.512
Caution: The tightening torque is 26-36N
m when install the
shouldered lock screw plug M16
1.512.
5.Remove the upper and lower drive switch M12
1.25
Caution: When install the upper and lower drive switch M12
1.
25, the tightening torque is within 26-36N
m
6.Remove the 2nd/4th drive switch M14
1.25
Caution: When install the 2nd/4th drive switch M14
1.25, the
tightening torque is with in 26-36N
m
N m: specified torque
Used component which can not be used any more.

Transmission-35
Disassembly of rear output shaft assembly
a. Use the special tools to remove the lock nut
Caution: The tightening torque is 87-120N
m when in-
stall the lock nut.
b. Remove the ball bearing
Rear output shaft assembly
cRemove the oil guide plate
circlips for shafthigh and low
gear sleeve
needle bearing
high and low gear hub
needle bearing
low-speed driven gear
rear output shaft
ball bearing
spacing platesecond/ fourth drive gear hub
second/fourth
drive geared sleeve
sprocket needle bearing bushing
needle
bearing
drive sprocket
spacer of
drive sprocket
oil guide plate assembly
ball bearing
assembly
87-120
N m: specified torque
Used component which can not be used any more.
Use the special tools
dRemove the spacing ring

Automatic transmission-2
Instruction for automatic transmission
1. M88 4-speed automatic transmission is equipped with the hydraulic torque converter and electric control system with locking.
When keep the stable forward status, the hydraulic torque converter can be locked automatically when the engine operates in low
speed, then reduce the unnecessary slide.
Figure 1.1 Electric automatic transmission control system
Figure 1.2 M88 4 speeds automatic transmission appearance figure (applied to 2 wheels driving)
2. The main advantage of the transmission is the application of transmission control unit (TCU). The control unit is the control
system based on the microprocessor system.. TCU control the shifting sensing and realize the Gear position shifting through the
signal of opening degree of throttle position, opening frequency of throttle position, engine speed, vehicle speed, transmission oil
temperature, gear position, mode selection and forced Gear reduction application.
3. TCU drives a variable pressure regulating solenoid valve to control three regulation valves and control the feeling of shifting.
Different transmission fluid temperatures are taken as one the main parameters to control the output pressure of the solenoid
valve, so as to keep consistent feeling of shifting within the normal operation scope.
4. The planning of shifting is very flexible. According to the car model, the different shifting plan is stored in the same TCU.
Generally speaking, the “economical mode” can increase the economical efficiency of the fuel and the driving performance of the
car to the maximum limit. The “dynamic mode” can bring into full play the drive performance of the car to the maximum limit. The
“winter mode” can make the car starting from shift 2.

Automatic transmission-3
8. Use two bolts to install the back device on the extended case of the transmission, these lengths are important. If it is too long,
it will hinder the end of the bolt and affect the threads on the case. Ensure the proper length and special torque of the bolt.
9. Pay attention that the height of the oil has been determined before delivery from the ION Company. The oil height needs not
checking or correction, except that improper oil is suspected to be used, or additional oil is needed because of leakage.

Automatic transmission-4
10. The gross weight of the transmission is 76kg; mostly weight is on the front of the transmission (side of torque converter). This
should be considered when design the handling/assembly tools.
11. The crankshaft speed/position sensor is installed on the top of transmission torque converter housing which must be installed
after the transmission is installed on the engine. The sensor will be damaged if it is installed before the installation of
transmission.
12. The transmission use the breathing tube connected to rear end of transmission. The tube must not be restricted or blocked
otherwise the air pressure in transmission will be increased. It is unallowable that the water/dirty/dust enters into the
breathing tube; otherwise the transmission will be damaged.
Removal of transmission
If the transmission needs removing for any reasons, following is the preventive measure to help the remove.
1. Must not only support the oil pan in middle of transmission for it will be deformed and leaked. The oil pan will not be deformed
when supports its external edge.
2. It must not allow the transmission to connect to the engine when the rear end is without connection, otherwise the exhaust
system of vehicle will be damaged.
3. Remove all torque converter bolts and push back the torque converter before remove the bolt connected the torque converter
housing to engine. Once all bolts connected the torque converter housing to engine are removed, use the torque converter the
push the transmission from the location pin, then ensure the torque converter is on the transmission and the transmission is
separated form location pin.
4. Install the dustproof cover on the cooler connector rapidly after open the oil cooler pipe; otherwise the oil leakage from the
torque converter will be 2L. The odometer dustproof cover can prevent the dirty from entering into the transmission and avoids
the leakage of oil form transmission.
5. The engine speed sensor is installed on the top of transmission and should be removed before the transmission is removed form
the engine, for the sensor will be damaged during the removal process of the transmission.
Figure 2.1 Gear selection interface
mode selection
gear selection
indicationgear slide way
Operation and display interface
The four-speed automatic transmission has three types of operation display interface which are shown as follows:
Gear selection
The transmission uses the traditional gear selection shifting handle, which is shown in figure. The gear rod can be moved on the gear
slide way according to the requirement. The relationship between the related gear and its function.

Automatic transmission-13
Symbol of solenoid valve (On/off solenoid valve)
Figure 3.5 Normal-opened type
1.Variable pressure regulating valve regulating system
The shifting pressure of abrasion unit is controlled by the variable pressure regulating valve.
The line pressure is independent of the shifting pressure and determined by the thro
position, shifting status and engine speed.
S5 is a proportional or variable pressure regulating valve which provides the pressure signal control shifting pressure for
the clutch and brake belt regulating valve.
In automatic shifting period, it process the integral times enlarging and contracting
regulation for the clutch regulating valve, brake belt regulating valve, torque converter regulating valve and VPS.
The hydraulic pressure generated by variable pressure regulating valve is in inverse ratio with current. During the shifting, TCU
will increase or decrease the current of solenoid valve according to the program. The current is variable in the range of 200mA
to 1000mA. The increasing of the current will decrease the S5 output pressure; the decreasing of current will increase the output
pressure of S5.
Lin 500 pressure (about 440 to 560kPa) is the reference pressure of VPS, meanwhile, the VPS output pressure equals to the
pressure on line 500 always.
When the VPS is in waiting status, it means there is not the generation of shifting action. VPS current is 200mA. At this time,
it gives the maximum output pressure.
In stable status, the brake belt and clutch regulating solenoid valve is in closed status. In this condition, the pressure of line 500
is applied on the piston. For the line 500 pressure is more than S5 pressure always, so it pushed the oil in S5 to the place
between the regulating valve and piston. At this time, oil pressure applied on the friction unit equals to the product of pressure
on line 500 and magnification factor.
During the starting of shifting, the used on/off solenoid valve is in opened status which cut off the oil loop supply from line 500
to piston.
At the same time, VPS pressure is decreased to starting pressure valve, pressure set by regulating valve and pressure setting
value required by execution of VPS by pushing the piston from the valve. The shifting is finished through the on/off solenoid
valve, VPS returns to the waiting status
Pointed to each gear-position, the system can make the brake belt; clutch or both realize
the electronic control.
Mode indicator lamp: the mode indicator lamp can be used to indicate the current selected and whether the overpeed status
exists. The mode indicator lamp is located in instrument panel generally. (Refer to Part 2.3)

Automatic transmission-16
Figure 3.9 manual-operated valve 3.
1-2 shift valve (refer to Figure 3.10) has two position status. It must be in the position (2, 3, 4) for the convenience of raising
gear in 1
st-Gear. It is using for all 1-2 and 2-1 shift.
Through the power supply of S1 and (or ) S2, the 1-2 shift valve can acquire its On/Off status.
During 1-2 shift period, drive the transmission fluid from manual-operated valve to the 2
nd-Gear loop. During the shifting form
2 to 1, the brake belt is engaged and drain the oil through the 1-2 Gear shift valve.
When in 1
st-gear position, the 1-2 gear shift valve operates with the 3-4gear shift valve (described as follows) combinedly to
separate the clutch C4; if in 2
nd-Gear position, engage the clutch C4. When select the manual Gear-1, the clutch C4 engages with
the rear brake belt (B2).
31-2 shift valve

Automatic transmission-17
Figure 3.10 1-2 gear shift valve
Clutch combination regulating valve (refer to Figure 3.15) is a constant ratio regulating valve which provide the regulating pressure
of clutch C1 to control the change ratio of shifting quality clutch status. The ratio is about 2.25:1.
When the S3 is opened, the oil of 3
rd-Gear is provided to the valve and adjust the pressure (CAF) to 2.25 times of S5 signal
pressure. When S3 is in closed status, the output pressure is 2.25 times of pressure of line 500.
9. Clutch combination regulating valve