2006 GREAT WALL HOVER torque

3. Oil filling of service after sales
Set the liquid level position correctly; the procedure is shown as follows:
a. Shut down the engine; place the gear-position in the P-Gear.
b . Lift the vehicle (or place it above the trench).
c. Clean the around of plug before remove it. Remove the oil plug and check the O-ring for damage, finally connect the oil filling
pump to the oil filling hole.
d. Lower the vehicle and oil filling pump to the ground; fill with the transmission fluid partially. The general oil filling amount
is shown as follows:
If in the status of transmission hydraulic torque converter is empty: 8.0 L
If in the status of transmission hydraulic torque converter is full: 3.8 L
e. When start the vehicle in P-Gear, 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. Then fill with 0.5L transmission fluid (ATF) additionally.
g. Shut off the engine, lift the vehicle; take off the pump and replace the plug. Ensure the plug is tightened according to the
specification.
h. Then pull the vehicle throttle position for slight opening to make the vehicle runs for 3.5
4.5km; the rotary speed of engine
is no more than 2500r/min; then the transmission fluid temperature will in the scope of 50
60.
i. The engine is in idle-speed; pull the hand brake to make the shifting lever circuits in each gear-position horizontal status.
k. Remove the filling plug 3 minutes after the engine is shut off, but must 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 (ATF) to meet the requirement.
l. Reinsert the transmission fluid plug, remove the residual transmission fluid around the vehicle and transmission; tighten the
plug to the specified torque.
4. Replace the ATF
Please notice that the color of TQ95 automatic transmission oil will be faded in the normal operation of transmission; it will be
turn into the deep brown or even in black. It will not affect the performance of ATF. It means that the fading of transmission
fluid not always means to replace the transmission fluid.
If the transmission temperature is raised, the ATF will be burnt. In this condition, ATF will change into black and with special
sulfur smell. The smell of the ATF means the oil is burnt.
If the ATF is burnt, it will cause the damage of transmission (the clutch assembly is damaged at least).At this time, it should
disassembly the transmission and process the necessary detection.
Electronic calibration
1. Idle-speed calibration
The idle-speed calibration is introduced in detail in the vehicle factory manual.
2 Calibration of position of throttle position

If the throttle position information stored in TCU is lost or not in application scope. It can be reestablished according to the
following program as the diagnosis error information.
a. Check whether the engine idle speed is in required range.
b. In the status of shutting off of air-condition, make the engine is in “D” –Gear for 60s,then the reference point with opening
degree of 0
of throttle position is reset in TCU.
Shut off the engine; switch on the ignition device, step the accelerator pedal to bottom for 60s, then the reference point with opening
degree of 100
of throttle position is reset in TCU.
3. Clear of throttle position

The clear process set by learning throttle position is necessary for M88 transmission TCU.
4. Car code

For M88 transmission, the car code is unnecessary.

Figure 8.1 Removal of typical pump
Disassembly /assembly
Cautions for assembly
It should notice the following items before reassemble the transmission system:
1. Ensure the cooler pipeline is washed and all chip is removed when replace the transmission. It can
be realized by using the compressed air to enter into the rear cooler pipeline to remove the oil and
all foreign material in the front cooler.
2. It should check the cooler after the transmission is installed. Ensure the front and rear cooler
pipeline is connected to the proper container. Rotate the vehicle in P-Gear in idle-speed, measure
the flow rate within 15s.
3. The flow within 15s should be more than 1L.
4. It should avoid any water entering into the transmission. This will cause the transmission fluid to
generate the foam or make the transmission fluid flows out form the respirator.
5. Ensure that two grounding wires in vehicle (one end to battery, one end to vehicle) are connected
before the installation of the anode of battery.
6. If the power control module and transmission control unit is exchanged, then calibrate the pro-
gram refer to related throttle position in Part
Removal
1. Transmission
Caution:
It should remove the gear-position sensor before wash the transmission in solvent or hot abluent.
When need to remove the transmission from the vehicle, it should drainage the transmission fluid,
and use the special removal tools.
The removal of the transmission should be processed in module method, the details of removal of each module is described
in following section in detail. Refer to details of special tools listed in table 9.10 and 9.6 when remove it.
The technician needs a set of quality tools when inspect the transmission, especially for dual hexagon spanner of model
30, 40, 50 and 8mm, 10mm, 12mm.
It should abide by the following procedure when disassemble the transmission:
a. Remove the shell of torque converter and torque converter.
b. Place the transmission on the saddle platform.
c. Remove the oil pan and oil pan sealing.
d. Remove the filter retainer of each valve and remove the filter.
e. Remove the wire on solenoid valve, place it in side.
f. Remove the protection screw in the valve and remove the valve from the main housing (remove the model Z connecting bar).
g. Remove the front servo circlip, cover and piston.
Caution:
The plastic servo block on used for piston return spring.
h. Remove the flange shaft fork, then remove the transmission housing (2WD and Chairman).
Use the 8mm hexagon wrench to move the pump to the housing bolt.

6. Pump
Cautions: the following valves are installed in the pump cover:
solenoid valve 7
C1 eccentric valve ( only for early stage mode, no valve in M88)
torque converter control valve
torque converter regulating valve
primary regulating valve
The disassembly procedure of pump is shown as follows:
a. Remove the wire bunch fixing disc and use the special tools T30 to remove the solenoid valve 7.
b. Use the 8mm sleeve to remove 5 bolts and washers.
c. Use the tool NO.30 to remove 5 screws form the cover plate. It should notice that the odd number screw has the function of
connecting the pump body to the pump cover plate.
Caution:
Do not release the pump by the method of knocking the torque converter support.
d. Separate the pump body from the pump cover.
e. Lift the pump cover disc form the pump cover.
f. Remove two ball spool detection valves and a spring from the pump cover.
Caution:
Some valves and plugs are connected by the spring and may fall down form the housing when remove the pin.
g. Press down the socket inwardly to remove the fixed pin of 4 valves.
h. Take out 4 valves, plugs and springs.
i. Take out the pump gear form the gear.
j. Remove the edge sealing from front of pump when replace it.
7. Valve
The removal procedure of valve is shown as follows:
a. Use the special tools T40 T orxbit to remove the ratchet spring and retainer plate.
Caution:
The manual-operated valve may fall down form the valve.
b. Slide the manual-operated valve to out of lower valve.
c. Pay attention to the angle relationship between the electromagnetic end and valve, remove the solenoid valve and valve
assembly according to the following procedure :
Solenoid valve 1
Solenoid valve 2
Solenoid valve 3
Solenoid valve 4
Solenoid valve 5
Solenoid valve 6
d. Place the valve on the platform with the top upwardly.
e. Use the model NO.30 Special tools to remove the 24 fixing screw. Lift the upper valve and separating disk to separate the
upper valve form the lower valve
f. Reverse the upper part, place the separating disk on the platform upwardly.
g. Lift the separating disk and washer from the upper valve.
h. Remove 5 exposed nylon detection ball spools of valve.
i. Remove the locking nut disc, spring and reverse lock valve.
j. Remove two cleaners (and large nylon detection ball spool ) from the lower valve.
Caution:
Once the pin is removed, the disc in the valve may be loose and slid form the valve when reverse the valve.
k. Remove the locking nut disc and bolt form 1-2, 2-3, 3-4, BAR,CAR valve; the bolt can be removed by the bolt.
l. Remove the 1-2, 2-3 and 3-4 shift valve.

Caution:
Some valves are pulled by the spring and may fall down form the valve.
m. Press down the plug of 4-3 sequence valve and take out the locking nut disc.
n. Take out the plug, valve and spring.
o. Press down the solenoid valve 5 gate. Remove the fixed pin, valve and spring.
Caution:
The valve is pulled by the spring and may fall down form the valve.
p . Press down the line pressure blow-off valve , then remove the fixed pin, disc (if proper) spring and valve.
q. Take out the roller pin and remove the spring and ball spool detection valve adjacent BAR.
Assembly
The transmission is assembled in the method of module. The detailed assembly process of each module is described in the
following chapter in detail.
Refer to Table 8.1 (end of section 8.3) for the description of used torque specification. The Table 9.10 in section 9.6 describes
the necessary special tools for assembly.
The technician also needs to select the quality Torx tools, especially for the two-screw socket wrench with code of 40, 50,
8mm,10mm and 12mm to detect the transmission completely.
1.Transmission
Caution:
Ensure the BIR retainer is proper for the case (otherwise, the valve will damage the separation disk).
Ensure the E clip is installed on the cross shaft.
Ensure all parts of parking machine can operate normally.
The assembly procedure of transmission is shown as follows:
a. Place the upper transmission on the platform upwardly and place it on the transmission bracket.
b. Install all accessories, bolts and bleed devices. Paint the sealant on the sealing place. Tighten all components according
to the specification. Ensure the cleanness of all bleed devices. Ensure the rear oil filling nozzle of housing is correct and
without blocking material. Refer to Figure 8.19.
c. Assemble the BIR valve and spring; ensure the retainer is installed correctly, refer to Figure
8.10. Ensure the
retainer is fixed in the groove completely.
d. Install the rear servo bar and pin shaft. Refer to Figure 8.11.
Caution: Ensure the crown bar can rotates freely.

Figure 8.15 manual-operated valve brake lever
k. Install the manual-operated valve detent connecting rod (shown as Figure 8.15), align it with the cross shaft hole.
l. Push the shaft by the positioning operating lever, until start from one side of box operating lever.
m. Use the special tools to install the operating lever drive bolt on the shaft, and ensure the adaptor covers the bolt.
n. Press the bolt into the shaft until the tools reaches the bottom.
o. Take out the tools and install the spring fixing ring spring on the shaft
p . Use the tools to install the new cross shaft seal.
q. Install the Gear-position sensor on the box; install the screw according to the specified torque. Use the tools to press the bolt
on the shaft.
r. Check the connection of wire bunch port completely to ensure the normal operation.
s. Install the wire bunch and install the connecting point of solenoid valve 7 and ring flange matched to the pump. Refer to Figure
8.16. The connecting wire of solenoid valve 7 is organized under the parking lever and in box cross shaft.
t . Install the 10-pin connecting socket in the box, ensure the flange of connecting socket matches to the notch on box.
u. Pull out the wire bunch part form the box and prohibition switches; install the 10-pin connecting socket on the wire bunch
bracket (only for rear-wheel drive mode).
Figure 8.16 Connecting position of coil 7Figure 8.17 Installation of 10-pin
connecting plug

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.

Figure 8.34 pump, cover and torque converter support
g. Use the automatic transmission liquid to lubricate the pump O-ring and
install it on the pump. Place the pump on the other side.
h. Ensure the pump housing cavity and hole are not blocked.
Figure 8.35 Assembly of pump cover
i. Use the automatic transmission liquid to lubricate all loose part before
the installation.
g. Install the primary regulating valve on the pump housing, ensure the
valve slide freely; then install the plug of regulating valve and O-ring.
Refer to Figure 8.36.
k. Install the fixed bolt, install the torque conversion clutch regulating valve,
plug and O-ring. Refer to Figure 8.37
l. Install the fixed bolt. Refer to Figure 8.39
m. Install the torque conversion clutch control valve, spring and O-ring.
Refer to Figure 8.38pump cover assembly
pump housing cover
oil seal
pump assembly
o-ring (pump )
n. Install the fixed bolt, shown as Figure 8.39
o. Install the torque converter detection ball spool and spring, shown as Figure 8.41
p. Install the washer on the pump body. Install the housing disc and solenoid wire maintaining cover on the pump housing; ensure
the edge of disc close to the pump housing.
Shown as Figure 8.34, Tighten the bolt according to the sequence of (1-5), shown as Figure 8.42.
Caution:
Check the smooth of wire and connector. To ensure whether the wire and connector have connection and abrasion on the
input shaft or clutch C1/ C2 cylinder; check the wire and connector for over extension.
q. Tighten the screw of solenoid valve 7.Refer to Figure 8.39
r. Install the pump on the pump housing, tighten all bolts; ensure the pump can be washed without pump housing. Tighten
the bolt in certain sequence; shown as figure 8.42.

Figure 8.36 Primary regulating valve
Figure 8.37 Torque converter clutch regulating valve
s. Install the pump on the washer of transfer case of housing.
t . Make the O-ring is proper for the external diameter of pump.
u. Ensure the pump housing hole in main housing is clean and without dirt.
v. Ensure the plastic connector of solenoid valve 7 is installed on the correct position of main housing.
w. Install the pump and pump housing on the input shaft carefully and avoid the damage of gasket spring. Tighten the pump
housing spring. Refer to Figure 8.43 Figure 8.44.
x. Check whether the transmission end float is fixed in the clearance of part 9.2. Refer to It the end float without filling metal plate
is more than that in instruction, then the metal plate should be placed in surface of NO.4 bolt and input shaft bolt. Refer to
Figure 8.19. if the end float is less than 0.5mm or more than 0.8mm; then the transmission can not be installed correctly and
is beyond the specification partly.
Check the end floating by executing the following procedure:
Connect the disc indicator to the front end of the transmission; place the pointer on the end of input shaft.
Apply about 250N or 25kg force on the input shaft.
Zero the indicating pointer.
Install a small lever on rear of the front clutch cylinder.
The recorded measuring value is the end floating value or called as the clearance of No.4 bearing on torque converter
tube support.
After the completion of the process, adjust the front and rear brake belt according to the specification of details in part 8.4.