Great Wall Hover. Manual - part 34

Caution:

Do not use the Vaseline to fix the washer.

c. Install the transmission rear housing or adaptor rear housing with the new washer.

Caution:

Refer to the description in section 8.3.17 related installation of output flange assembly (rear wheel drive).

d. Install the transmission rear housing  (rear wheel drive) or adaptor rear housing (4WD ) and tighten the bolt.

e. Provide the Loctite202 or equivalent sealant to the rear housing or connector and process the installation. Ensure the bolt is

    tightened according to the specification. (Refer to Figure 8.1)

7. Front servo assembly

Caution:

Ensure the front servo clamp ring is installed correctly; ensure the ring spring and spark gap points to the bottom. Refer

to Figure 8.22.

The assembly procedure of front servo assembly (Refer to Figure 8.22) is shown as follows:

a. Use the automatic transmission liquid to lubricate the housing O-ring and install it on the housing.

b. Use the automatic transmission liquid to lubricate the housing O-ring and install it on the piston.

c. Install the piston, brake lever, spring, washer, base and fixing ring.

d. Install the piston brake lever assembly on the front servo housing.

e. Install the front servo plug and spring in the box.

f. Install the front servo assembly in the box.

g. Press down the servo housing and install the fixing ring spring of servo housing. Align the spark gap and coil track and ensure

    it is installed in the groove properly. Figure 8.22 front servo and brake belt

8. Brake belt assembly

The assembly process of brake belt assembly is shown as follows:

a. Install the reaction reinforcement lever on the housing.

b. Check the brake belt for crack or damage; check the bush and metal back.

c. Install the support retainer on the brake belt (Refer to Figure 8.23).Note that the later transmission modes will not adopt the

support retainer.

Caution:

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

Figure 8.23  Installation of brake belt press lever

d. Install the brake belt on the transmission, ensure it is installed on the correct position.

e. Install the reaction support on the fixing plate and connect it to the brake belt and reinforcement lever. Install the application

support on thea fixing plate and connect it to the brake belt and servo piston bar.

9.C2/clutch C4 assembly

Caution:

Check the piston for crack, especially for piston C2.

Must not mix the clutch piston out and back spring.

Ensure the correct installation of clip ring

The assembly procedure of C2/clutch C4 assembly (refer to 8.24) is shown as follows:

a. Ensure the cleanness of internal oil inlet of cylinder; check the discharge outlet of piston C2 for cleanness; use the transmission

   liquid to lubricate the O-ring.

Caution:

The O-ring must not be winded in groove.

Figure 8.24  Typical C2/C4clutch assembly

b. Install the small O-ring in the inner groove; install the large O-ring in the external groove of piston; check the discharge outlet

of C4 piston for cleanness.

c. Use the transmission liquid to lubricate the O-ring; install the small O-ring in the inner groove; install the large O-ring in the

external groove of piston.

d. Make the C2/clutch C4 hole face upwardly; install the clutch cylinder; place the C4 piston in the original position proper for

C2 piston during the calibration..

      e.    Install the C2/C4 piston assembly on the cylinder; ensure the external hole of cylinder align with the discharge outlet of piston,

    until the external diameter of C2 piston enters into the internal diameter of cylinder.

Figure 8.25  C4 clutch assembly

Caution:

The diameter of spring wire bunch is 4.3mm.

f. Install the piston out and back spring on the piston and install the spring fixing plate on the spring.

g. Use the special tools and press down the spring to ensure the installation for fixing ring spring. And ensure the spring is fixed

in the groove tightly, then remove the tools.

h. Check the C1 piston detection valve for damage and free movement. Ensure the cleanness of cylinder oil inlet.

Caution:

Ensure the O-ring is not bent in the groove.

i.

Use the automatic transmission liquid to lubricate the O-ring and install it in the respective groove.

j.

with the clutch C1 hole upwardly, installs the cylinder. Install the piston into the cylinder until the external diameter of piston

enters into the inner diameter of cylinder.

Caution:

The diameter of wire bunch of spring is 5.26mm.

k. Install the spring and spring fixing plate on the piston. Use the special tools and press down the spring to ensure the

installation of fixing ring spring, then remove the tools.

l.

Install the C2 wave washer on the cylinder; ensure one of wave washers cab cover the C2 piston drainage outlet.

m. Measure and record the thickness of C2 sleeve ring flange. Refer to Figure 8.25.

n. Install the clutch C4 disc and wave washer on the clutch C2 sleeve. Ensure the round edge   steel disc is disassembled according

to the following sequence:

friction disk

steel disc

friction disk

steel disc

friction disk

   Wave washer

C2 pressure disc

pressure disc housing load is 3500N

clutch C4 load

o. Maintain the horizontal position of cylinder , install the sleeve and clutch disk assembly on the cylinder; ensure the top of

washer and external hole of cylinder are in order until the sleeve can contact the C2 wave plate.

Caution:

For the C2 wave spring is compressed and the clutch disk can endure the weight of 19.6N. The dimension form the lower
side of C2 pressure disc to the gear selection steel plate is 1.4

1.8mm. if the clutch need to start the accuracy  from the

top of pressure plate, then the accurate value should be the actual size of pressure plate plus 1.4

1.8mm.

p. Use the special tools to check the C4 clutch assembly. Refer to Figure 8.25.

Caution:

It should take out the clutch clearance assembly before immerse the assembly into the automatic transmission fluid
(ATF).

q.  Use the gear selection plate to reach the correct specification. If need to install the new friction disk, it should remove the

clutch assembly and immerse the  friction disk in the automatic transmission fluid for 5 minutes at least before the installation.
Reinstall the sleeve and clutch assembly and place it in the cylinder. Ensure the wave washer is arranged consisting with the
cylinder hole.

Install the clutch C2 disk in the cylinder according to the following procedure:

friction disk

steel disc

friction disk

steel disc

 The steel disc transmission use the G32 model engine; the 5

th

 friction disk should replace the steel disc (reference table 9.3).

steel disc  (optional)

friction disk

steel disc  (optional)

friction disk

Caution:

For the clutch assembly can endure the weight of 19.6N, the dimension from the clutch C3   wheel axle to the friction disk
should be within 0.80-1.05mm.

      r.   Use the tool to test the clutch assembly; ensure the weight is in the acceptable range. Refer to Figure 8.26.

C3 hub positioning

clutch C2 loading

Figure 8.26  C2clutch assembly