2006 GREAT WALL HOVER Service Repair Manual

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.

Manipulator cover assembly
gearbox assembly (one)
reverse lock assembly nut M8
bulbrubber cover
pin 740
master control lever assembly
bulb basebush
stop plate of main rodbush
bulb jacket
N m: specified torque
Used component which can not be used any more.
Pregummed component N
m: specified torque
Used component which can not be used any more.
bush
6
oil guiding plate
location pin
steel ball 7.
938
aluminum gasket
reverse lamp switch
gearbox
selection and shifting
shaft rubber choke plug
bleed plug assembly
bush
selection and shifting block
elastic cylindrical pin 622

N m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special tools
aluminum
washer
lower cover plate assembly
bushgear 5 drive gear ball bearing
circlip for shaft
steel ball
odometer drive gear
circlip for shaft
ball bearing
circlip for shaft
reverse gear 5
shift fork
in 622
declutch shift shaft for
first and secondea
gear 3/4 declutch
shift shaft

declutch shift shaft
pin 522
gear 1/2 shift-
ing block
gear 3/4 shifting
block
earbox assembly (three)
steel ball 4.762
pin 622
gear 1/2 shift fork
adjusting shim
spacing ring
reverse drive gear
reverse shaft
needle bearing
reverse gear thrust washer
split pin
grease baffle of air duct
support axial lock plate
reverse needle bearing bushing
needle bearing
thrust washer
gear 5 needle
bearing bushingsynchronizer gear ring
reverse gear 5 synchronizer assembly
N m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special tools
gear 3/4
shift forkreverse driven gear assembly
needle bearinggear 5 driven
gear assembly

5. Remove the reverse lamp switch M12×1.25
Caution: When install the reverse lamp switch M12×1.25, the
tightening torque is 26-36 N·m
6. Remove the gearbox
a.Use the wrench to remove the 5 M8×55 bolts, 1 M8×6 bolt and 2
M8×110 bolts
Caution: When install 5 M8×55 bolts, 1 M8×6 bolt and 2 M8×110
bolts. tightening torque is
b. Remove the gearbox assembly
7. Use the circlip pliers to remove the circlip for shaft
8. Remove the odometer drive gear