Great Wall Hover. Manual - part 31

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.

Caution:

Do not take out the central support by knocking the output shaft , otherwise, it will damage the surface of thrust bearing

permanently

         o. Remove the central support, 1-2 one-way clutch and planetary gear block.

         p. Use the T40 special tools to remove the parking lever cum disc.

         q. Remove the rear brake belt support and rear brake belt.

         r.  Remove the output shaft assembly.

2. Transmission case

It should follow the following procedure when remove the transmission:

         a. Use the tools to take out the fixed pin from one side of cross shaft gear sensor (2WD and 4WD mode).

         b. Remove the gear sensor from the case. Use the special tools to take out the cross shaft seal.

         c. Take out the circlip from the cross shaft. Pull up the cross shaft and take out the drive pin from the sector gear-position

             selection plate.

          d. Use the tools, press down the cross-shaft pin and take out the shaft , reset spring and bolt from the housing. Refer to Figure

             8.3.

Figure 8.3  Installation and disassembly of cross-axle pin

Figure 8.2  central support retainer

      i.   Use the pump remover to remove the pump, refer to Figure 8.1.

      g.   Remove the input shaft , front clutch cylinder and overspeed –Gear shaft as an integral. Take it out from the front of housing.

      k.  Remove the clutch C3 cylinder and central gear .

      l.   Remove the brake belt support and brake belt.

      m. Use the 50 special tools to remove two central support connecting bolts.

      n.  Remove the central support retainer, refer to Figure 8.2.

e. Take out the manual-operated valve operating lever and parking operating lever.

f. Take out the 10 pin socket connector form the wire bunch bracket adjacent gear sensor.

     g.    Press down the raised part of 10-pin plug and take out the 10-pin connecting plug from the box.

h. Separate the NO.7 solenoid valve wire bunch form the front end of  housing.

i.

Remove the brake bar pivot, brake shaft and spring.

j.

Remove the shaft and rear servo operating lever.

k. Remove the rear servo cover and piston assembly.

l.

Remove the BIR circlip, valve and spring.

m. Remove two brake belt adjusting shims.

n. Check the output shaft bush in box, replace it if necessary.

o. Check the cooler pipeline, replace it if necessary.

p.  Check the box for damage.

Caution:

It must not remove the operating lever of parking gear in normal condition.

q. It needs to remove the P-Gear operating lever: take out the circlip from the pivot, knock the external of shaft until it can move

freely in box. Then use a width and thin object to table out the bolt form the box, operating lever and spring.

3. Front clutch cylinder

When take out the front clutch cylinder, please refer to Figure 8.4. The procedure is shown as follows:

Figure 8.4   Assembly of front clutch cylinder

a. Place the assembly on a level surface.

b. Remove the thrust bearing and adjusting shim from the input shaft .

c. Remove the retainer and input shaft form the front end of clutch .

d. Remove the overspeed gear shaft and clutch C1 hub assembly from the clutch cylinder.

e. Take out the clutch disk C1 form the cylinder.

f. Take out the retainer which fix the clutch C3 hub on the rear end of clutch cylinder, then take out the hub.

g. Take out the C2\clutch C4 hub assembly and remove the thrust bearing form the C4 hub.

h. Take out the clutch C2 disc.

i.

Reverse the clutch cylinder and take out the clutch C4 sleeve, clutch disk and two wave washers. The 3-4 one-way clutches is

located between the C2 and clutch C4 hub. The other wheel axle can be taken out by rotating a  wheel axle in clockwise.

j.

Remove the thrust block form the clutch C4 cylinder hub.

Caution

Ensure the spring keeping device does not be clamped in the spring groove and all spring pressure is released.

k. Put end surface of C2\clutch C4 upwardly, connect the clutch cylinder with the tools. Pressed down the piston reset spring,

take out the spring fixing retainer (Refer to Figure 8.5). Remove the tools and take out the ring spring, fixing part and spring.

     l.   Reverse the clutch cylinder on the pressure machine; and remove the clutch C1 reset spring with same method.

     m. Send the compressed air into the cylinder through the cylinder hole, remove the clutch piston from the clutch  cylinder. Refer

to Figure 8.6.

4.clutch C3  cylinder

The procedure of removal of clutch C3 cylinder is shown as follows:

    

a.   Remove the front sun gear assembly, thrust bearing and thrust washer from the clutch C3 cylinder asse  bly , shown as Figure

  8.7.

      b.  Remove the nylon thrust bearing, bearing block, needle thrust bearing and thrust bearing . From the clutch  cylinder hub.

Figure 8.5  Impressed clutch reset spring

Figure 8.7  Clutch C3 and central gear assembly

Figure 8.6  Removal of C1, C2 and clutch C4 piston