Great Wall Hover. Manual - part 33

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 7

Figure 8.17  Installation of 10-pin

connecting plug

2.output shaft and gear assembly

The assembly procedure of  output shaft and gear assembly  (Refer to Figure 8.19),is shown as follows:

a. Check the output shaft bush for damage, replace it if necessary.

b. Check the parking detent on the ring gear for damage ; replace it if necessary.

c. Check the sealing ring groove for damage.

d.  Use the automatic transmission liquid to lubricate the gasket.

e.     Place the scarfing notch upwardly and install the sealing ring on the output shaft.

f. If has been removed., it should use the ring spring for reinforcement when install the ring gear on the output shaft. Ensure the

ring spring is fixed in the groove.

g. Use the Vaseline oil for lubrication; install the thrust bearing assembly NO.10 on the output shaft.

h. It should be carefully when install the output shaft on the box to avoid the damage of sealing ring.

3. Rear brake belt assembly

The assembly procedure of rear brake belt assembly (Refer to Figure 8.18) is shown as follows:

a.  Check the rear brake belt for leakage or damage; check its corresponding bush and metal back .

Figure 8.18  Rear servo and brake belt

b. Install the reaction reinforcement bar on the main box, need not shim.

Caution:

Place the new brake belt in the automatic transmission liquid for about 5 minutes before install it.

c. It should be careful when install the rear brake belt on the transmission. Ensure the brake belt is installed on the correct

position.

d.    Install the application support bar on the rear brake belt, then connect it to the servo motor

      bar.

e. Install the cam disc and tighten the screw according to the instruction.

Figure 8.19  Position of thrust bearing and sealing pad

4. Rear servo assembly

Install the rear servo assembly  (Refer to Figure 8.18), the procedure is shown as follows:

a. Check the servo piston O-ring and washer for damage.

b.  Use the transmission fluid to lubricate the servo piston O-ring and install the O-ring on the piston groove.

c. Install the piston on the housing; ensure the O-ring is compressed to position, but do not excess.

d.  Adjust the spring and piston sleeve; then install the rear servo brake bar on the sleeve.

Caution:

Do not coat the washer with the Vaseline.

e. Install the housing installed with washer on the case.

f. Provide the bolt with the Loctite567 sealant and install it; ensure the bolt is tightened according to the specification.

5. Planet carrier assembly and central support

The installation process of planet carrier assembly and central support is shown as follows:

a. Check the bracket and planet assembly for damage or abnormal and ensure all pinion rotates freely and the pinion axle end

floats in the allowable range; described as 9.2.

b. Install the one-way clutch fixing plate on the planet carrier and ensure the internal edge points to the downwardly. Check the

one-way clutch and brake accessory for damage; replace it according to the requirement.

c. Install the external race on the drum. Press sown the ring race to bottom of drum and install the fixing ring spring. Ensure the

ring spring is installed in the groove stably. Refer to Figure 8.20.

d.  Install the one-way brake on the external race with the lip upwardly. Use the automatic transmission liquid to lubricate the

        brake accessories. Refer to Figure 8.20.

connecting housing (4WD)

connecting housing

Figure 8.20   planet carrier assembly and central support

e

Check whether the socket has the proper central support, then install the central support on the one-way clutch, ensure the

        support can rotate in anticlockwise. Refer to Figure 8.20

f. Use the Vaseline to lubricate the NO.9 needle thrust bearing and thrust washer, and install it on the rear of planet carrier. Refer

to Figure 8.19

g. Install the planet assembly and central support on the box and align the central support installation bolt hole.

h. Install and tighten the central support bolt.

i.

Install the ring spring fixing plate; ensure the ring spring is installed in the box correctly.

j.

Remove the central support bolt and provide the Loctite243 or similar material for screw; install and tighten the bolt to

        specified standard.

6.Ttransmission rear housing assembly

The installation procedure of transmission rear housing assembly is shown as follows:

a. Check the condition of transmission rear housing roller bearing (2WD and Chairman mode), replace it if necessary (rear drive

mode). Install the new bearing form the end of transmission rear housing; only can press the bearing side with mark.

b. Install the new sealing material on the transmission rear housing or adaptor rear housing. Refer to Figure 8.21.

Figure 8.21  Connecting and extension housing

output shaft

o-ring

locking nut

oil seal

needle bearing

oil seal

gasket