2006 GREAT WALL HOVER Service Repair Manual

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

b. Remove the first bearing blocks assembly ; take out the adjusting
shim
Caution: It should select the adjusting shim when install the
adjusting shim
43. Remove the bearing snap ring
44
Remove the intermediate shaft assembly
45. Remove the first shaft assembly
46. Remove the needle bearing
Mark

47. Remove the 3rd/4th-Gear shift fork
Remove the second shaft assembly
a. Use the rubber hammer to knock the second shaft
b. Remove the needle bearing bushing of reverse driven gear
c. Remove the double inner-race ball bearing assembly
d. Remove the second shaft assembly

Secondary shaft assembly
49. Disassembly of second shaft assembly
a. Remove the second shaft rear retainer
Caution: It should select the circlip for shaft when install the
circlip for shaft.
b. Remove the 3rd/4th-Gear synchronizer assembly
c. Remove the 3rd/4th-Gear synchronizer gear ring
Caution: When install the 3rd/4th-Gear synchronizer gear ring, it
should use the plug gage to measure the end surface clearance of
gear ring to ensure it is within 1.25-1.65mm
¦circlips for shaft
3rd/4th-Gear syn-
chronizer assembly
1st/2nd-Gear synchronizer assembly
synchronizer gear ring
3rd-Gear driven gear assemblyneedle bearing
second shaft
2nd-Gear driven gear assembly
2nd-Gear synchronizer gear ring needle bearing
sleeve
1st-Gear synchronizer gear ring1st-Gear driven gear assembly
double inner-race
N m: specified torque
Used component which can not be used any more.

d. Remove the 3rd-Gear driven gear assembly
Caution: When install the 3rd-Gear driven gear assembly, it should
use the plug gage to measure the 3rd-Gear driven gear assembly
axialclearance to ensure it is within 0.17-0.284mm
e. Remove the 3rd-Gear driven gear needle bearing
f. Use the special tools to press the second shaft to remove the inner
race of double inner-race ball bearing.
Remove the 1st-Gear driven gear
Caution: When install the 1st-Gear driven gear, it should use the
plug gage to measure the 1st-Gear driven gear axial clearance to
ensure it is within 0.17-0.284mm.
h. Remove the 1st-Gear driven gear needle bearing

Transmission-23
i. Remove the sleeve
j. Remove the 1st-Gear synchronizer gear ring
k. Remove the 1st/2nd-Gear synchronizer assembly
l. Remove the 2nd-Gear synchronizer gear ring , 2nd-Gear driven gear
and second shaft
Caution: When install the 2nd-Gear driven gear, it should use the
plug gage to measure the 2nd-Gear driven gear axial clearance to
ensure it is within 0.17-0.284mm

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-25
2.Replacement of oil-seal of transfer case
The replacement of transfer case oil seal is shown as figure. Disconnect
the drive shaft from the transfer case, use the flat head screwer to
remove the oil seal
Caution: Do not damage the housing hole during the disassembly.
Then use the special tools to knock the transfer case oil seal into
the transfer case. It should pay attention to the installation dire
tion of oil seal. The oil seal is flush with the port of transfer case.
Shown as figure. Coat the lip of oil seal with the specified general
synthetic gear oil.
3. Disassembly and check of transmission
The preoperation before the removal and after installation of
transmission is : When remove and install the manipulator cover
assembly, drain and fill with the specified transmission and transfer
case lubrication oil. When remove and install the front and rear drive
shaft, separate each plug-in part of transmission from the vehicle.
Inspection of manipulator cover assembly:
The bolt dimension is different for different installation position. Do not
confuse it during the installation. It should install the fixing bolt A firstly.
The tightening torque of bolt A and B bolt is 15
22Nm.
installation position of fastening blot
bolt
bolt bolt
Repair of transmission SC5M4D-C
1. Inspection of oil level of transmission and transfer case:
Screw off the oil drainage screw plug of main box and transfer case;
drain all lubrication oil, tighten the oil drain plug to specified torque.
The torque is: 30
35Nm. Fill the main box and transfer case with
the transmission oil through the oil filling port. The number is hyperbolic
gear oil SAE80W/90, comply with API GL-4. The oil quantities are
main box : 2.2 L, transfer case : 2.7 L. (for high and low temperature
environment refer to maintenance specification). Tighten the oil filling
screw plug to specified torque. The torque is: 30
35Nm.
front output shaft oil
seal (SC
1802504)
rear output shaft oil seal
(SC
1802323)
transmission
transfer case
oil filling screw plug
oil-drain screw-plug assembly
(JK72
1701070) oil filling screw plug