2006 GREAT WALL HOVER torque

Automatic transmission-39
Power transmission locking of automatic and manual 3rd-Gear
When the automatic 3rd-Gear and manual 3rd-Gear is locked, the drive of transmission is basically same as that in automatic 3rd-
Gear. But it provide the variable torque drive without slide for the application of torque converter locking clutch.
Control:
The control for the automatic 3
rd-Gear locking and manual 3rd-Gear locking is basically same as that for automatic 3rd –Gear. But
it should be described additionally that the automatic 3
rd-Gear and manual 3rd-gear locking needs the action for variable torque
clutch loop by solenoid valve S7.
When the solenoid valve S7 is opened, the variable torque clutch control valve is closed and allow the oil feed of S7 loop pass
through the solenoid valve S7 to drainage port. It makes the control valve moves to the clutch combination position.
The loop oil from the line 500 flows into the combination part of variable torque clutch through the converter clutch control
valve through the action of variable torque clutch control valve.
The variable torque clutch release oil is drained from the variable torque clutch control valve.
The torque converter loop oil flows into the oil cooler and lubrication loop through the variable clutch control valve.
Refer to Figure 5.7 and table 5.8.
Table 5.8Participating condition of each unit in automatic and manual 3rd-Gear locking
Automatic 3rd-Gear locking and
manual 3
rd-gear locking
Name of participation unit

Automatic transmission-43
Power transmissionAutomatic 4th-Gear locking
In automatic 4th –gear locking, the drive of transmission is same as that in automatic 4th –gear basically. But for the application of
variable torque locking clutch, it provides the variable torque drive without slide.
Control:
The automatic 4th –Gear locking is same as that in automatic 4th-Gear basically. But it should be described that when the automatic
4
th-Gear is locked, it has the action for variable torque loop by solenoid valve S7.
When the solenoid valve S7 is opened, the variable torque clutch control valve is closed and allow the S7 loop oil flows to the
drainage port through the solenoid valve S7, then control the valve to move to the clutch engagement position.
The line pressure loop regulating oil from the torque converter clutch regulating valve flows into the combination side of torque
converter clutch directly.
The release oil of torque converter clutch is drained from the control valve of torque converter clutch..
The torque converter loop oil flows into the oil cooler and lubrication loop directly through the control valve of torque
converter clutch..
Refer to Figure 5.9 and Table 5.10.
Table 5.10
The participating condition of each unit in automatic 4th-gear locking
Clutch
Name of participation unit

Automatic transmission-46
Pin
No. Type 2W D Description
A24 CAN (-ve) I/O ○ CAN hidden communication end
A23 CAN (+ve) I/O ○ CAN exposed communication end
A22 K line communication
connection I/O ● Diagnosis information and car code
A21 Nonuse ―― ○ －－－－－
A20 Nonuse ―― ○ －－－－－
A19 Shaft speed sensor
signal IP ○ The sensor sends the shaft speed signal to T CU
A18 Nonuse ―― ○ －－－－－
A17 Nonuse ―― ○ －－－－－
A16 Nonuse ―― ○ －－－－－
A15 Nonuse ―― ○ －－－－－
B6 Gear-position IP ● T h e sw itch ha s th e variab le-vo ltage ; in dicate the
gear-position steering colum n selected (PRND321). The
vo ltage is variab le in the ran ge o f 0 V --5 V .
B5 transm ission fluid
temperature IP ● The sensor indicates the transmission fluid temperature.
High R=Low temperature
Low R= High temperature
The voltage is variable in the range of 0V to 5V
B 4 so leno id va lve 4 O P ● N /O FF no rm al-op ened so leno id valve , co m b ined w ith the
O N /O FF w itch o f so len oid valve 3; en sure the sh ifting
quality and sequence
B 3 so leno id va lve 1 O P ● ON/OFF normal-opened solenoid valve; combined with
o the r so leno id va lve; u sed to determ ine the selected
gear-position.
B2 Nonuse ―― ○ －－－－－
B1 R e tu rn so len oid va lve
5 IP ● Using for grounding of VPS and current of circuit can be
detected, then process the feedback control for the VPS.
B14 Gear-position －
grounding GND ● PRND321 Gear-position switch grounding
B13 transm ission fluid
temperature －
grounding GND ● Connected to grounding pin of temperature sensor.
B12 solenoid valve 6 OP ● ON/OFF normal-opened solenoid valve, determine the
high or low of line pressure
B11 solenoid valve 2 OP ● O N /O FF norm al-o pened so leno id va lve, co m bined w ith
o the r so leno id valves; u sed to d eterm ine the selected
gear-position.
B10 solenoid valve 3 OP ● O N /O FF norm al-o pened so leno id va lve, co m bined w ith
the O N /O FF sw itch of solenoid valve 4; ensure the
shifting quality and sequence
B 9 so leno id va lve 7 O P ● ON/OFF normal-opened solenoid valve, hydraulic torque
converter locking; increase the efficiency of medium
speed run.
B8 Nonuse ―― ○ －－－－－
B 7 so leno id va lve 5 (+ ve) O P ● It is the so leno id va lve w hich can ch an ge th e p ressu re
d urin g the sh iftin g a nd on /o ff o f so leno id valve .
●= connected line ○= unconnected line ＊=only
OP= output IP=input I/O=input/output
GND=grounding REF=reference PWR=power
Table 6.1.1 Description of TCU pin

Automatic transmission-47
4. Operating mode of transmission
TCU realizes the effective control for the transmission according to the accurate information acquired form the input data and
complete control for the output data. To ensure the input and output of TCU is actual and effective, TCU executes the data sense
command for hardware and software. For the failure information found in the following operating mode described in detail, TCU
will give the corresponding response.
Similarly, it exists the possibility that could not find out the failure cause. If encounter the condition, the operation for transmis
sion is determined difficultly.
Following condition will effect the operation of transmission, but will not appear the detection failure information.
a. Power supply failure
The transmission adopts the 3-Gear lame Home Mode (LHM) irrelevant to car speed.
If occur the intermittent power supply, then TCU will start form 4-Gear and is switched to the proper gear to meet the
requirement of current work. At this time, it will not monitor the power supply status.
b. The transmission fluid temperature is higher than 135
If found the transmission temperature is high:

The torque converter lock clutch will start in low speed and the car will have the vibration.

Some cars will have the condition that the mode indicator lamp is flash.
The reason for the condition may be the transmission fluid temperature is high or acquire the inaccurate single form the
temperature sensor. If occurs the temperature failure, it may find the high temperature operating condition.
c. Failure of ON/OFF solenoid valve
If one of the solenoid valves has the mechanical failure, TCU will not find the failure. At this time, the failure operation of
transmission will be determined according to the solenoid valve with failure. The characteristic of different solenoid valve failure
is listed in Table 6.1.2.
reverse pin
gear indication pin
Gear sensor(black)
Figure 6.1.1 Description for wire bundle pin

Automatic transmission-48
s oleno id
valve Condition Transmission operation
1 Opened
always 1st-Gear replaces 2nd-Gear; 4th-Gear replaces 3rd-Gear. It causes the car form the G ear shift of 1
→1→4→4 when accelerate form static. The transmission stay longer time in Gear; worse 1→4
shift feeling.
Closed always 2nd-Gear replaces 1st-Gear; 3rd-Gear replaces 4th-Gear. It causes the car form the G ear shift of 2
→2→3→3 when accelerate form static. It is said that starts form 2nd-Gear.
2 Closed always 4th-Gear replaces 1st-Gear; 3rd-Gear replaces 2nd-Gear. It causes the car form the G ear shift of 2
→2→3→3 when accelerate form static. That is saying that start form 4th-Gear.
Opened
always 2nd-Gear replaces 3rd-Gear; 1st-Gear replace 4th-Gear.
It cause the car is shifted form 1st-Gear to 2nd-Gear, then from 2nd-G ear to Gear when accelerate
form static. It will feel the transmission is in free gear position after 2→1 Gear shift.
1&2 Opened
always Can not realize the reverse gear; only has 1st-Gear operation.
3 Closed always Following shifts are bad. (2→3 is worst ):1→3, 1→4, 2→3, 2→4, 4→2, 4→1
Opened
always Following gear shifts are worse: 3→4, 4→3, 3→2。
It may cause the gear slide when the hydraulic torque converter is locked.
4 Closed always Following gear shifts are worse:
1→2, 1→3, 1→4, 2→3, 2→4, 3→1, 3→2, (including manual) 3→4, 4→1, 4→3
Opened
always Following gear shifts are worse: (1→2 is worst) 2→4, 3→2 It may cause the gear slide when
the hydraulic torque converter is locked.
6 Closed always The line pressure is high always.
Opened
always The line pressure is low always. So it cause the slide between gears. The clutch C1 and brake belt
B1 will be burned.
7 Closed always The hydraulic torque converter is without lock.
Opened
always The hydraulic torque converter is locked in 3rd-Gear and 4th-Gear. It cause the car generates the
vibration in low-speed status.
Table 6.1.2 Operation of transmission when ON/OFF solenoid valve is faulty
Mechanical detection
1.Inspection of transmission on car
It should process the following detections before disassemble the transmission:
process the on-road drive test to determine the failure cause .(according to requirement)
Detect the standard of transmission fluid. (refer to 7.2.1)
Ensure the transmission fluid in not overheated. (Normal color and smell)
Detect the failure information.
Check the battery terminal and grounding for corrosion or loose.
The engine speed is within the specified value in manual.
Check the cooling system for normal operation.
All power supply and plug wires is tight and not loose.
Check the transmission fluid, ensure the oil pan is without other martial material or pollutant.
2. Oil leakage detection
It should wash the polluted part of the transmission before select the oil leakage part, then drive the car.
When detect the leakage part of the rear servo system, it should lift the car by lifter firstly, then switch the gear to reverse
gear within 10s.
When detect the leakage part of front servo system, it should lift the car by lifter firstly, then switch the gear to gear-2
(winter mode).
The time switched to 2nd-Gear should be no more than 10s to avoid the oil in the torque converter is overheated.
3. FAQ table

Automatic transmission-51
Table 6.2.3Shifting quality failure
Bad 1→2 Gear
shifting quality The throttle position sensor has failure.
T he brake b elt is adjusted incorrectly.
The front servo piston O-ring is damaged.
The variable pressure solenoid valve (S5) is damaged or
has failure.
S1, S4 has the failure.
The brake belt combination regulating valve (BAR) has
the failur e.
The front servo release spring is installed incorrectly. Detect the resistance, replace the sensor if
necessary.
Detect and replace the rake belt if necessary.
Detect and r epla ce the O -ring if necessary.
Detect, repair or repla ce the S5 if necessary.
Detect, repair or repla ce the S1, S4 if
necessary.
Detect, repair or repla ce the B AR if
necessary.
Detect and repair it if necessary.
Bad 2→3 Gear
shifting quality B1brake belt release valve is blocked.
S3, S2 has the failure.
The clutch combination regulating valve has failure.
The clutch combination oil feed ball spool is lost or
damaged.
The input shaft oil seal is damaged.
C1 piston O-ring is damaged.
C1 piston oil feed ball spool is damaged. Detect the blow-off valve. Replace or
maintain it if necessary.
Detect the S3, S2.Replace or maintain it if
necessary.
Detect the r egulating valve. R eplace or
maintain it if necessary.
Detect the ball spool .Reinstall or replace it if
necessary.
Detect the sealing ring. Reinstall or replace it
if necessary.
Detect the O -ring .R einstall or replace it if
necessary.
Detect the ball spool .Reinstall or replace it if
necessary.
Bad 3→4 Gear
shifting quality S1, S4 has failure.
B1brake belt release valve is blocked.
T he brake b elt is adjusted incorrectly.
The front servo piston O-ring is damaged.
The variable pressure solenoid valve (S5) is damaged or
has failure.
The brake belt combination regulating valve has failure. Detect the S1, S4.R einstall or replace it if
necessary.
Detect the blow-off valve. Replace or repair
it if necessary.
Detect the brake belt. Adjust it if necessary.
Detect the O -ring .R eplace or maintain it if
necessary.
Detect the S5.R epla ce or maintain it if
necessary.
Detect the r egulating valve. R eplace or
maintain it if necessary.
The engine has
the
extinguishing
co nd itio n
when select
the automatic
gear or R-gear. The torque converter clutch control valve is blocked or
solenoid valve 7 has failure. Detect and clean the torque converter clutch
valve (CCCV)
Has unstable
vibration
co nd itio n. S7 has the failure. Process the necessary detection, maintenance
and replacement according to the
requirem ent.

Automatic transmission-52
Failure Reason Corresponding measures
C2 is burnt.
T operation lever linkage is beyond the
normal adjusting scope.

S6 is invalid.-Operating lever is hard.

The over speed Gear/output shaft sealing
ring is damaged. Monitor and repair the C2 if necessary and
adjust the linkage device.
Repair the C2; detect, repair or replace the
S6 if necessary.
Repair the C2; detect and replace the
sealing ring or shaft if necessary.
C4 is burnt. The clutch C4 assembly clearance is
incorrect.

The over speed Gear/output shaft sealing
ring is damaged.
3→4 one-way clutch is in rear position.

The over speed clutch (OC) /1
st-Gear low
speed ball spool has displacement. Detect the C4. Det ect and adjust the clutch
C4 assembly clearance if necessary.
Repair the C4; detect and replace the oil
seal or shaft.
Repair the C4, detect or modify the OWC
if necessary.
Repair the C4, detect or modify the ball
spool if necessary.
B1 is burnt. B1R spring is damaged.

The dimension of oil inlet hole of front
servo is large and has the possibility of
loose.
The input shaft sealing ring is damaged.
C1/B1R ball spool has displacement. Detect and repair the or replace the spring
if necessary.
Replace the socket if necessary and detect
the C3 piston O-ring.
Replace the sealing ring.
Repair the B1; modify the ball spool if
necessary.
C1 is burnt. B1Rspring / plug is lost.

The over speed Gear/input shaft sealing
ring is damaged

4→3 sequence valve is in rear position.

Clutch attachment oil feed inlet (CAF).
B1Rball spool is lost. Detect and repair C1 or replace the spring
if necessary.
Repair the C1; detect and replace the
sealing ring or shaft if necessary.
Repair the C1; detect and modify the valve
if necessary.
Repair the C1; detect and replace the ball
spool if necessary.
B2 brake belt is burnt. In
R-Gear- without manual
1
st-Gear. The rear brake belt is adjusted incorrectly or
damaged.
The low speed R-Gear /1
st-Gear ball spool
has displacement. Detect and adjust the brake belt if
necessary.
Detect and reinstall the ball spool if
necessary.
The torque converter is
locked hardly or is not
locked. The torque converter combination regulator
is in rear position. Detect and modify the valve if
necessary.

Adjustment
Hydraulic system
Following parts is the detailed description for self-detection procedure pointed to the condition occurred in chapter
6. including the condition indicated the failure, to point the problem existed in the hydraulic system.
It should select the proper procedure from the following primary detection when adjust the transmission.
Detection process of transmission fluid
Detect the manual linkage adjusting system(refer to factory manual of car)
Detect the engine idle speed
Anchoring test (beyond the scope of the maintenance manual)
On-road test (beyond the scope of the maintenance manual)
Detection procedure of transmission fluid level
1. General

The process is used to detect the level of vehicle transmission fluid. It will cause the failure or delay of transmission shifting if
the level is low than required value and the vehicle does not reach the drive temperature.
Firstly, process the transmission diagnosis information detection for vehicle (refer to chapter 6). If found the failure of sensor,
then it maybe caused by transmission fluid level is less than specified value.
It should detect whether has the abnormal delay and Gear-position condition when select the forward or reverse-gear by driving
the vehicle. One feature of oil level less than normal value is that the vehicle has the gear-position delay and lack condition when
the vehicle is in steering. The previous problem will occur when the transmission fluid temperature is low.
When the oil temperature is medium and vehicle speed failure is recorded, the gear-position lose condition
will not occurs any longer, it means that needs to fill the transmission with the transmission fluid.
2. Detection of transmission fluid level

When fill up or replace the transmission fluid, it must use the Castrol TQ95 automatic transmission fluid (ATF) or other
permissive oil. It will damage the performance and service life of transmission if use the unpermissive transmission fluid.
Please ensure the transmission fluid level is correct. The transmission also can be damaged if the transmission fluid level is
incorrect.
The setting procedure of transmission fluid level is shown as follows:
Caution:
When the transmission is in operating temperature, the hot transmission fluid may flow out form the
housing if remove the filling plug.
a. If the vehicle is in operating temperature, allow two hours time for cooling before add the transmission fluid, but
it must not more than 4 hours (this will make the transmission locate in the correct temperature range). When the
temperature is overheating, the transmission fluid level will higher than the plug port. Removal of plug will cause
the transmission fluid flows out from the oil filling port, then cause the low level of transmission fluid.
b. The gear-position of transmission is in parking-Gear (P-Gear), shut off the engine.
c. Lifting the vehicle (or parking above the trench).
d. Clean the around of plug when remove it. Then remove and clean the plug and check the O-ring for damage. Install
the oil filling pump in the oil filling hole.
e. Lower the vehicle; the oil filling pump will be connected to the vehicle at this time. Fill the transmission with the
oil partially. Then start the vehicle in P-Gear to rotate the engine in idle speed. Step down the foot brake, pull the
shifting lever in each gear-position in circulation and add the transmission fluid until the action of each gear-
position can be sensed.
f. Shut down the engine; lift the vehicle; ensure the vehicle is always in horizontal.
g. Remove the filling plug 3 minutes after the engine is shut off, but must not be no more than1 hour. At this time, the
correct level position should be in the bottom of oil filling hole. If does not reach the liquid level position, then fill
with few transmission fluid to make it reach the correct level.
h. Replace the transmission; clean the residual transmission fluid on the transmission and
vehicle.
i. Tighten the transmission plug to the specified torque of 30
35Nm.