2006 GREAT WALL HOVER wheel

Caution:
Do not use the Vaseline to fix the washer.
c. Install the transmission rear housing or adaptor rear housing with the new washer.
Caution:
Refer to the description in section 8.3.17 related installation of output flange assembly (rear wheel drive).
d. Install the transmission rear housing (rear wheel drive) or adaptor rear housing (4WD ) and tighten the bolt.
e. Provide the Loctite202 or equivalent sealant to the rear housing or connector and process the installation. Ensure the bolt is
tightened according to the specification. (Refer to Figure 8.1)
7. Front servo assembly
Caution:
Ensure the front servo clamp ring is installed correctly; ensure the ring spring and spark gap points to the bottom. Refer
to Figure 8.22.
The assembly procedure of front servo assembly (Refer to Figure 8.22) is shown as follows:
a. Use the automatic transmission liquid to lubricate the housing O-ring and install it on the housing.
b. Use the automatic transmission liquid to lubricate the housing O-ring and install it on the piston.
c. Install the piston, brake lever, spring, washer, base and fixing ring.
d. Install the piston brake lever assembly on the front servo housing.
e. Install the front servo plug and spring in the box.
f. Install the front servo assembly in the box.
g. Press down the servo housing and install the fixing ring spring of servo housing. Align the spark gap and coil track and ensure
it is installed in the groove properly. Figure 8.22 front servo and brake belt
8. Brake belt assembly
The assembly process of brake belt assembly is shown as follows:
a. Install the reaction reinforcement lever on the housing.
b. Check the brake belt for crack or damage; check the bush and metal back.
c. Install the support retainer on the brake belt (Refer to Figure 8.23).Note that the later transmission modes will not adopt the
support retainer.
Caution:
Place the new brake belt in the automatic transmission liquid for about 5 minutes before install it.

o. Maintain the horizontal position of cylinder , install the sleeve and clutch disk assembly on the cylinder; ensure the top of
washer and external hole of cylinder are in order until the sleeve can contact the C2 wave plate.
Caution:
For the C2 wave spring is compressed and the clutch disk can endure the weight of 19.6N. The dimension form the lower
side of C2 pressure disc to the gear selection steel plate is 1.4
1.8mm. if the clutch need to start the accuracy from the
top of pressure plate, then the accurate value should be the actual size of pressure plate plus 1.4
1.8mm.
p. Use the special tools to check the C4 clutch assembly. Refer to Figure 8.25.
Caution:
It should take out the clutch clearance assembly before immerse the assembly into the automatic transmission fluid
(ATF).
q. Use the gear selection plate to reach the correct specification. If need to install the new friction disk, it should remove the
clutch assembly and immerse the friction disk in the automatic transmission fluid for 5 minutes at least before the installation.
Reinstall the sleeve and clutch assembly and place it in the cylinder. Ensure the wave washer is arranged consisting with the
cylinder hole.
Install the clutch C2 disk in the cylinder according to the following procedure:
friction disk
steel disc
friction disk
steel disc
The steel disc transmission use the G32 model engine; the 5th friction disk should replace the steel disc (reference table 9.3).
steel disc (optional)
friction disk
steel disc (optional)
friction disk
Caution:
For the clutch assembly can endure the weight of 19.6N, the dimension from the clutch C3 wheel axle to the friction disk
should be within 0.80-1.05mm.
r. Use the tool to test the clutch assembly; ensure the weight is in the acceptable range. Refer to Figure 8.26.
C3 hub positioning
clutch C2 loading
Figure 8.26 C2clutch assembly

v. Install the thrust disc on the cylinder internal wheel axle. Refer to Figure 8.24and 8.19.
w. Connect the C2 /clutch C4 wheel axle assembly in clutch C4 disc, install the clutch C2 disc. Install the C3 wheel axle and
reinforce it by ring spring; ensure the ring spring is installed in the groove fixedly. Please refer to Figure 8.24.
10. Clutch C3 and reverse central gear system
The assembly procedure of clutch C3 and reverse central gear assembly (refer to Figure 8.28) is shown as follows:
Check the cleanness of hole on cylinder. Caution:
It should take out the clutch clearance assembly before immerse the assembly into the automatic transmission fluid
(ATF).
s. Use the gear selection plate to reach the correct specification. It should remove the clutch assembly and immerse the friction
disk in the automatic transmission fluid for 5 minutes at least before the installation if install the new friction disks. Lubricate
and install the 3-4 one-way clutch and install the sleeve on the C2 wheel axle. Adjust the handle rear and install the nylon thrust
washer on the C4 wheel axle. Refer to Figure 8.27.
t . Adjust and install the clutch C4 wheel axle on the clutch C2 and one-way clutch assembly. Check the rotary direction of clutch
C2 wheel axle, when keep the C4 wheel axle in static, C2 wheel axle should rotate in clockwise and is locked in anticlockwise.
Refer to Figure 8.27.
u. Use the Vaseline to lubricate the N0.5 thrust bearing and install it on the C4 gear wheel axle ,separate the clutch C2 disc form
the clutch cylinder.
Figure 8.27 C2 hub rotation

e. If need to install the new friction disk, please remove the clutch assembly and immerse the friction assembly into the
transmission fluid for 5 minutes at least before the installation.
f. Check whether the clutch C1 wheel axle is matched with the overspeed shaft. It should replace the wheel axle and wheel axle
assembly if loose.
g. Coat the small nylon thrust insulation plate with the Vaseline and installs it on the overspeed shaft. Refer to Figure 8.19.
h. It should be carefully when install the overspeed shaft on the C1 cylinder to avoid the damage of sealing ring.
i. Use the Vaseline to install the small copper C1 wheel axle thrust washer, shown as Figure 8.19.
j. Check the input shaft for problem. Install the input shaft on the cylinder and use the ring spring to install the wire safety of
input shaft and cylinder. Ensure the coil is in groove completely.
k. Use the petroleum jelly to install the gasket and place it on the input shaft.
l. Assemble the C1/C2/C4 clutch, clutch C3 and sun gear, shown as figure 8.24, 8.32
m. Install the assembly in the transmission case.
Figure 8.32 and 8.33 assembly number: 6 bearing and pressure disc to clutch C3 assembly
13. Pump housing and torque support
Caution:
a. Do not clean the solenoid valve by solvent.
b. Ensure the O-ring is installed in the correct position.
c. Do not blow off the first drop and mix it with the ball spring blowed off by the torque converter. ( only for the condition of
installing the transmission to STD pump housing)
d. Do not damage the line bearing on the assembly; avoid any impact for bearing during the loading.
e. Check the end floating of transmission; it is help for the lose and incorrect assembly of any assembly.
Caution: Figure 8.35 The orientation of crossing part is shown in Figure 8.36 to 8.42.
The assembly procedure of pump housing and torque converter is as follows:
a. Check the pump for damage, chip and abnormity; check whether the sleeve of drive gear is fixed.
b. Wash the pump and pump gear carefully; remove all redundant oil and dirt.
c. Install the pump gear and pump. Use the micrometer to measure the depth from the surface of pump to gear surface. The
measured value is the side clearance of pump. The side clearance should be in the range of 0.020-0.040mm.
d. Remove the pump gear from the pump.
e. If had been removed, please replace the pump sealing. Ensure the cleanness of pump sealing.
f. Use the transmission liquid to lubricate the pump gear, pump, washer and sealing and install the pump gear on the pump.

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

Troubleshooting
Failure Cause Repair cont ent
Floating/pulling The t yre is worn or charged improperly.

The front wheel alignment is incorrect.

The wheel bearing is adjusted too tightened.
The front /rear suspension components is loose or
damaged
The steering linkage is loose or worn
The steering device is connect ed unsound or worn. Charge the t yre to the prop er pressur e or
repla ce the t yre.
Check the condition of front wheel
alignment.
Adjust the wheel bearing
Tighten or replace the suspension
partTighten or replace the steering
linkage
Adjust or replace the steering device
Subsidence of vehicle body Overload of vehicle
vibration damper is worn
spring is weak Check the load weight
Replace the vibration damper
Replace the spring
Left-right swing/up-down
bounce The t yre is charged improperly
The stabilizer bar is bend or damaged
The vibration damper is worn Charge the t yre to the prop er pressur e
Replace the stabilizer bar
Replace the vibration damper
Front wheel vibration The t yre is worn or is charged improperly

Unbalance of each wheel
The vibration damper is worn
The front wheel alignment is incorrect

The wheel bearing is worn or adjusted badly
The ball joint or bushing is worn
The steering system is loose or worn
The steering mechanism is adjusted badly or damaged Repla ce the t yr e or char ge it to the prop er
pressure.
Balance all wheels
Replace the vibration damper
Check the condition of front wheel
alignment
Replace or adjust the wheel bearing
Check the ball joint or bushing
Tighten or replace the steering linkage
Adjust or repair the steering device
Abnormal abrasion of tyre The t yre is charged improperly
The vibration damper is worn
The front wheel alignment is badly

The suspension part is worn Charge the t yre to the prop er pressur e
Replace the vibration damper
Check the condition of front wheel
alignment
Replace the suspension part
Oil leakage of differential High oil level or incorrect oil grade

The oil seal is worn or damaged
The matching flange is loose or damaged Drain the oil to the specified level or
repla ce the oil
Replace the oil seal
Tighten or replace the flange
The axle has the nois e The oil grade is low or incorrect

The clearance of the pinion, ring gear or side gear is
large.
The ring, pinion gear or side gear is worn or broken
The pinion gear bearing is worn
The b earing of rear axle half shaft is worn.
The differential b earing is loos e or worn Fill with the lubrication oil or replace the
oil according to the specification
Check the clearance

Check each gear
Replace the bearing
Replace the bearing
Tighten or replace the bearing

Front wheel alignment
1. Process the following inspection and eliminate
all problems
a. Check the wear condition of tyre and proper inflation.
Tyre inflation pressure: 230kPa
b. Check the wheel bearing of front wheel for loose.
c. Check the front suspension for loose.
d. Check the steering drive device for loose.
e. Process the standard elastic test; check thefrontvibration damper
for normal operation.
3. Install the 4-Wheel alignment instrument
Processed according to the detailed description of equipment
manufacturer.
4. Adjust the wheel angle
Remove the cover of spacing bolt of steering knuckle; check the internal
wheel’s steering angle A.
Internal wheel’s steering angle:
32
Caution: The wheel should not touch the brake hose of car body
when the steering wheel is rotated to limit.
2. Adjust the height of car
A:Adjust the height of car to the standard value for theconvenience of
processing the front wheel alignmentinspection.
B: Front fixed bolt of lower suspension arm
The standard no-load height is: the center of front fixed boltof lower
suspension arm is 295
1mm away form theground.

6. Adjust the wheel toe
Adjust the wheel toe according to the following method
a. Shake the car upwardly and downwardly to make the suspension
reach the stable status.
b. Push the car forwardly for 5m in flat ground when the front
wheel is in the straight forward position.
c. Mark the center of each rear wheel; measure the distance “B”
between the marks of left and right tyre.
d. Push the car forwardly to move the mark on the back of tyre to
the position of front instrument.
Remarks: if the tyre moves too far, repeat the procedure (b).
e. Measure the distance “A” ‘between the marks on front of tyre.
f. Measure the toe of wheel.
toe =B-A
Inspection standard: 0-2mm
If the toe does not consist with the specified value, it can be
adjusted by the left and right draw-bar.
Move the vehicle forwardly
g. Adjustment of toe: the standard value is 02mm. The toe is
adjusted by rotating the cross draw-bar. When adjust the toe, it
should rotate the cross draw-bar on left and right side uniformly.
After the adjustment, tighten the lock nut, the tightening torque
is 55
65Nm.