Great Wall V200. Service Manual

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Automatic transmission-41

In automatic 4

-Gear (overspeed gear), the drive of transmission is sent to the front clutch cylinder through the input shaft. The

operation principle of each function assembly of transmission is shown as follows:

The engagement of clutch C1 drives the planetary gear carrier rotates in clockwise rotation.

The engagement of B1 brake belt makes the reverse sun gear to stop.
When the planetary gear carrier rotates, the long planetary gear rotates around the static reverse sun gear, at the same time, it
rotates around its axial line to drive the gear ring and output shaft to generate the forward movement in the speed higher than
that of input shaft (i.e. overspeed) clockwise.

The forward central gear rotates in the speed higher than input shaft and is more than the speed when 3-4 one-way clutch

(OWC) is engaged.
The engagement of clutch C2 is used to reduce the speed difference generated by 3-4 one-way clutch (OWC).

Control:

In the stable status, the status of solenoid valve and valve is shown as follows:

The solenoid valve S1 is powered on ; S2 is powered off.
When the solenoid valve S1 is powered on, the small end of 3-4 shift valve is in 4

-Gear position for the pressure of line 500.

When the solenoid valve S2 is powered off, the large opening of 2-3 shifting valve is in 4

- Gear position for the pressure of

line 500.
The 1-2 Gear shifting valve is kept in 4

-Gear position for the pressure of S2 oil loop.

The 2

-Gear loop oil (line pressure) from the 1-2 shift valve flows into the brake belt combination regulating valve and 2-3

shift valve directly.
The brake belt combination regulating valve provides the 2

-Gear loop oil for the brake belt attachment loop (BAF) (adjusted

by product of line pressure and valve ratio)

The brake belt combination lip oil is directly supplied to:

External combination part of front servo
Enter into the internal combination part of front servo piston through 3-4 shift valve
The 1st-Gear-2 switch valve provides a oil-drain port when the transmission is switched to 1st-Gear.
The 2nd-Gear loop oil in 2-3shift valve flows into the 3rd-Gear loop directly.
The 3rd-Gear loop oil from the 2-3 shift valve flows into the clutch combination regulating valve and 4th-Gear-3 sequence
valve directly
The clutch combination regulator valve supplies the oil for the clutch combination loop (CAF) (Regulated by the product of
line pressure and valve rate)
CAF oil is directly supplied to:

clutch C1
4th-Gear-3 sequence valve
The drive oil(line pressure) form the manual-operated valve forces the engagement of clutch C2

Refer to Figure 5.8 and Table 5.9.

Table 5.9

Participating condition of each unit in automatic 4

–Gear (overspeed Gear)

clutch

Name of participation unit

Automatic 4

-Gear

(overspeed Gear)

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Automatic transmission-43

Power transmission

Automatic 4

-Gear locking

In automatic 4

–gear locking, the drive of transmission is same as that in automatic 4

–gear basically. But for the application of

variable torque locking clutch, it provides the variable torque drive without slide.

Control:

The automatic 4

–Gear locking is same as that in automatic 4

-Gear basically. But it should be described that when the automatic

-Gear is locked, it has the action for variable torque loop by solenoid valve S7.

When the solenoid valve S7 is opened, the variable torque clutch control valve is closed and allow the S7 loop oil flows to the

drainage port through the solenoid valve S7, then control the valve to move to the clutch engagement position.

The line pressure loop regulating oil from the torque converter clutch regulating valve flows into the combination side of torque

converter clutch directly.

The release oil of torque converter clutch is drained from the control valve of torque converter clutch..

The torque converter loop oil flows into the oil cooler and lubrication loop directly through the control valve of torque

converter clutch..

Refer to Figure 5.9 and Table 5.10.

Table 5.10

The participating condition of each unit in automatic 4

-gear locking

Clutch

Name of participation unit

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Automatic transmission-45

Diagnosis and test

Test system

1. Recommended test equipment and program

The test equipment and control unit for design will be used for the test of all vehicles. The parts for transmission test includes:

Tester for service after sales
Special vehicle for test

2. Tester for service after sales

After the special programming, the tester equipped with special car test software can be used to test the specified system and unit.
The program allows the normal communication between the transmission control units (TCUs) .
The computer needs the required information from the customer and select the necessary data through the manual. For example:
view the code, clear the error code and make the real-time operation. For detailed operating instruction refer to user’s manual.
The equipment can be used by the trained specialized persons, such as technician, machinist to test the electronic and loop
problem related to transmission. The testable information includes: the engine speed, rode (shaft speed), transmission fluid
temperature, position of throttle position, status of solenoid valve and gear and position of operating lever. Additionally, it can be
used to detect the current and stored problem.

3. Description of TCU pin

The description of TCU pin code had been listed in Table 6.1.1
For description of wire bunch refer to Figure 6.1.1

Pin No.

Function

Type

2WD

description

A14

Public grounding

GND

●

Negative pole of TCU supply, connected to negative pole of

battery.

A13

Nonuse

－－

○

－－－－－

A12

Mode indicator lamp
Snowland mode

●

Indicate that select the “Snowland Mode” operating method.

A11

Parking-Gear indicator lamp

●

The drive instrument panel indicator lamp indicates that is in
the “Parking Gear”

A10

Reverse-Gear indicator lamp

●

The drive instrument panel indicator lamp indicates that is in
“Reverse Gear”

N-Gear indicator lamp

●

The drive instrument panel indicator lamp indicates that is in
“Idle N Gear”

A8 Nonuse

－－

○

－－－－－

A7 Nonuse

－－

○

－－－－－

Mode indicator lamp
dynamic mode

●

Indicate that select the “dynamic mode” operating method.

A5 Nonuse

――

○

－－－

――

A4 Nonuse

――

○

－－－－－

A3 Nonuse

――

○

－－－－－

Mode switch

●

The switch is used to select the “economic mode”, “dynamic
mode” and “snowland mode”. The voltage is variable in
range of 0 V－2V .

A1 Nonuse

――

○

－－－－－

A30

Power supply

PWR

●

Power supply for TCU; is the main power source of drive

unit and solenoid valve.

A29 Nonuse

――

○

－－－－－

A28

-Gear indicator lamp

-Gear position﹡

●

Drive the instrument panel indicator lamp indication, indicate
that the gear-position is in “1

-Gear”

A27

2nd-Gear indicator lamp
/2nd-Gear position

●

Drive the instrument panel indicator lamp indication, indicate
that the gear-position is in “2

-Gear”

A26

-Gear indicator lamp

-Gear position﹡

●

Drive the instrument panel indicator lamp indication, indicate
that the gear-position is in “3

-Gear”

A25

Automatic gear indicator
lamp /4

–Gear position

●

Drive the instrument panel indicator lamp indication, indicate
that the gear-position is in “automatic-Gear”

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Automatic transmission-46

P in

N o .

T yp e

2W D

D escrip tion

A2 4 C A N

(-ve )

I/O

○ CAN

h idd en

co m m u nicatio n

end

A2 3 C A N

(+ ve)

I/O

○

C A N e x posed co m m u nicatio n en d

A2 2

K lin e co m m u n ication
connection

I/O

●

D ia gn osis in form ation and c ar code

A2 1 N on use

― ―

○

－－－－－

A2 0 N on use

― ―

○

－－－－－

A1 9

Sh aft speed se nso r
signal

○

T h e senso r send s the sha ft spe ed sign a l to T C U

A1 8 N on use

― ―

○

－－－－－

A1 7 N on use

― ―

○

－－－－－

A1 6 N on use

― ―

○

－－－－－

A1 5 N on use

― ―

○

－－－－－

B 6 G ear-positio n

●

T h e switch  ha s th e variab le-vo ltage ; in dicate the
ge ar-po sition  steerin g  co lu m n  selected  (P R ND 3 21). T he
vo ltage is variab le in  the ran ge o f 0 V --5 V.

B 5

transm ission flu id
te m pe ra ture

●

T h e senso r ind ica te s the  transm ission   flu id  te m pe ra ture.
H igh  R = L o w  tem pe rature
L o w   R =  High   te m p era tu re
T h e  vo ltage  is  varia b le in  the ran ge o f  0 V  to  5 V

B 4 so leno id

va lve

O P

●

N /O FF no rm al-op ened  so leno id  valve , co m b ined  w ith  the
O N /O FF w itch  o f so len oid  valve  3; en sure  the  sh ifting
q ua lity  an d  sequence

B 3 so leno id

va lve

O P

●

O N /O FF n orm al-o pen ed so len oid valve ; co m bined w ith
o the r so leno id va lve; u sed to determ ine the selected
ge ar-po sition .

B 2 N on use

― ―

○

－－－－－

B 1

R e tu rn so len oid va lve
5

●

U sin g fo r groun din g o f V P S a nd curren t o f c ircu it can be
d etected , then process the feedback contro l fo r th e V P S .

B 1 4

G ear-positio n

－

groun din g

G N D

●

P R N D 3 21 Gea r-positio n sw itch groun din g

B 1 3

transm ission flu id
te m pe ra ture －
groun din g

G N D

●

C o nnec te d to ground in g pin o f te m p erature sen so r.

B 1 2 so leno id

va lve

O P

●

O N /O FF no rm al-op ene d so len oid valve, determ in e the
h igh or lo w o f lin e p ressu re

B 1 1 so leno id

va lve

O P

●

O N /O FF norm al-o pened so leno id va lve, co m bined w ith
o the r so leno id valves; u sed to d eterm ine the selected
ge ar-po sition .

B 1 0 so leno id

va lve

O P

●

O N /O FF norm al-o pened  so leno id  va lve, co m bined  w ith
the O N /O FF  sw itch  o f so leno id  va lve 4 ; en sure the
shiftin g  quality  and   seq uence

B 9 so leno id

va lve

O P

●

O N /O FF  n orm a l-o pen ed   so leno id   valve ,  h yd raulic  torq ue
con verter  loc kin g;  in cre ase  th e  e fficienc y  o f  m ed iu m
speed   ru n .

B 8 N on use

― ―

○

－－－－－

B 7 so leno id

va lve

5 (+ve)

O P

●

It is the so leno id va lve w hich can ch an ge th e p ressu re
d urin g the sh iftin g a nd on /o ff o f so leno id valve .

● = connected line                                                        ○ = unconnected line                     ＊ =only
O P =  ou tpu t                                                                    IP =in put                                                I/O = in pu t/o utp ut
G N D = gro und in g                                                            R E F= refere nce                                      P W R=p o w er

Table 6.1.1 Description of TCU pin

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Automatic transmission-47

4. Operating mode of transmission

TCU realizes the effective control for the transmission according to the accurate information acquired form the input data and

complete control for the output data. To ensure the input and output of TCU is actual and effective, TCU executes the data sense

command for hardware and software. For the failure information found in the following operating mode described in detail, TCU

will give the corresponding response.

Similarly, it exists the possibility that could not find out the failure cause. If encounter the condition, the operation for transmis

sion is determined difficultly.

Following condition will effect the operation of transmission, but will not appear the detection failure information.

a. Power supply failure

The transmission adopts the 3-Gear lame Home Mode (LHM) irrelevant to car speed.

If occur the intermittent power supply, then TCU will start form 4-Gear and is switched to the proper gear to meet the

requirement of current work. At this time, it will not monitor the power supply status.

b. The transmission fluid temperature is higher than 135

If found the transmission temperature is high:

The torque converter lock clutch will start in low speed and the car will have the vibration.

Some cars will have the condition that the mode indicator lamp is flash.

The reason for the condition may be the transmission fluid temperature is high or acquire the inaccurate single form the

temperature sensor. If occurs the temperature failure, it may find the high temperature operating condition.

c. Failure of ON/OFF solenoid valve

If one of the solenoid valves has the mechanical failure, TCU will not find the failure. At this time, the failure operation of

transmission will be determined according to the solenoid valve with failure. The characteristic of different solenoid valve failure

is listed in Table 6.1.2.

reverse pin

gear indication pin

Gear sensor(black)

Figure 6.1.1 Description for wire bundle pin

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Automatic transmission-48

solenoid

valve

Condition Transmission

operation

Opened

always

1st-Gear replaces 2nd-Gear; 4th-Gear replaces 3rd-Gear. It causes the car form the G ear shift of 1
→1→4→4 when accelerate form static. The transmission stay longer time in Gear; worse 1→4
shift feeling.

Closed

always

2nd-Gear replaces 1st-Gear; 3rd-Gear replaces 4th-Gear. It causes the car form the G ear shift of 2
→2→3→3 when accelerate form static. It is said that starts form 2nd-Gear.

2 Closed

always

4th-Gear replaces 1st-Gear; 3rd-Gear replaces 2nd-Gear. It causes the car form the G ear shift of 2
→2→3→3 when accelerate form static. That is saying that start form 4th-Gear.

Opened

always

2nd-Gear replaces 3rd-Gear; 1st-Gear replace 4th-Gear.
It cause the car is shifted form 1st-Gear to 2nd-Gear, then from 2nd-G ear to Gear when accelerate
form static. It will feel the transmission is in free gear position after 2→1 Gear shift.

1&2

Opened

always

Can not realize the reverse gear; only has 1st-Gear operation.

Closed always

Following shifts are bad. (2→3 is worst ):1→3, 1→4, 2→3, 2→4, 4→2, 4→1

Opened

always

Following gear shifts are worse: 3→4, 4→3, 3→2。
It may cause the gear slide when the hydraulic torque converter is locked.

4 Closed

always

Following gear shifts are worse:
1→2, 1→3, 1→4, 2→3, 2→4, 3→1, 3→2, (including manual) 3→4, 4→1, 4→3

Opened

always

Following gear shifts are worse: (1→2 is worst) 2→4, 3→2 It may cause the gear slide when
the hydraulic torque converter is locked.

Closed always

The line pressure is high always.

Opened

always

The line pressure is low always. So it cause the slide between gears. The clutch C1 and brake belt

B1 will be burned.

Closed always

The hydraulic torque converter is without lock.

Opened

always

The hydraulic torque converter is locked in 3rd-Gear and 4th-Gear. It cause the car generates the
vibration in low-speed status.

Table 6.1.2 Operation of transmission when ON/OFF solenoid valve is faulty

Mechanical detection

1.Inspection of transmission on car

It should process the following detections before disassemble the transmission:

process the on-road drive test to determine the failure cause .(according to requirement)

Detect the standard of transmission fluid. (refer to 7.2.1)

Ensure the transmission fluid in not overheated. (Normal color and smell)

Detect the failure information.

Check the battery terminal and grounding for corrosion or loose.

The engine speed is within the specified value in manual.

Check the cooling system for normal operation.

All power supply and plug wires is tight and not loose.

Check the transmission fluid, ensure the oil pan is without other martial material or pollutant.

2. Oil leakage detection

It should wash the polluted part of the transmission before select the oil leakage part, then drive the car.

When detect the leakage part of the rear servo system, it should lift the car by lifter firstly, then switch the gear to reverse

gear within 10s.

When detect the leakage part of front servo system, it should lift the car by lifter firstly, then switch the gear to gear-2

(winter mode).

The time switched to 2nd-Gear should be no more than 10s to avoid the oil in the torque converter is overheated.

3. FAQ table

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Automatic transmission-49

The distribution of FAQ table is shown as follows:

Table 6.2.1 Drive failure

Table 6.2.3 Shift quality failure

Table 6.2.2 Shift mode failure

Table 6.2.4 Disassembly failure

failure Possible

reason

Corresponding

measure

“D”-Gear operation

has not drive

The automatic transmission fluid is insufficient.

The oil-entering of C1/C2 piston is blocked.

The “Z” is assembled incorrectly.

The primary regulating valve plug is opened.

The overspeed shaft or input shaft sealing ring is

failure.

3→4, 1→2 single-way clutch is installed in reverse or

failure.

Check the liquid level. Fill it up if necessary.

Check and wash the C1/C2 oil inlet device.

Reinstall the “Z” connection.

Remove, wash and reinstall the primary

regulating valve.

Check and replace it if necessary.

The reverse shifting

operation is without

drive.

The manual 1

-Gear

has not engine

brake.

The engine brake is

normal in manual

-Gear.

The input shaft oil seal ring is damaged.

The rear brake belt or servo system is faulty.

C3, C3 wheel shaft or C1/C2 cylinder are out of work.

Check and replace it if necessary.

Test the servo system or replace the rear brake

belt according to the requirement.

Test the failure C3, C3 wheel axle or C1/C2

cylinder.

Repair it in time if necessary.

“D” –Gear and reverse

–Gear operation is

without drive.

The primary regulating valve is blocked.

The pump gear is damaged.

Take out the output shaft clasp.

Detect and clean the primary regulating valve.

Check and replace the pump gear if necessary.

Check and repair it if necessary.

Only can 2→3 shifting

(can not realize the

-Gear and 1

-Gear)

S1 is closed always.

Test the S1. Repair or replace it if necessary.

Test the failure of S1 12V power supply

voltage or wire bundle.

Only can 1→4 shifting

1→3→4 shifting (1

→2 shifting delay).

S1 is opened always

Test the S1. Repair or replace it if necessary.

Test the failure of S1 12V power supply

voltage or wire bundle.

Only can 4→3 shifting

S2 is closed always.

Test the S2. Repair or replace it if necessary.

Test the failure of circuit break or wire bundle.

1→2→neutral position

shifting (1

-Gear

transition)

S2 is opened always

Test the S2. Repair or replace it if necessary.

Test the failure of circuit break or wire bundle.

Only can 1→3 shifting

B1 is out of work

The brake belt is loose.

The front servo piston or oil seal is out of work.

S1/S2 ball spool is reinstalled in wrong place.

Test and adjust it according to the requirement.

Test and maintain it according to the

requirement.

Test and replace or reinstall it according

to the requirement.

Only can 1→3→4

shifting

The small O-ring of front servo piston is invalid or

lost.

2→3 Gear position shifting valve is blocked.

Detect the O-ring. Process the replacement or

reinstallation if necessary. Detect the 2→3

Gear shifting valve; Process the maintenance

or replacement according to the requirement.

Only can 1→2→1

shifting

C1 is invalid or 3

-Gear and 4

-Gear is loose. (give

to 1

-Gear in 3

-gear; give to 2

-Gear in 4

-Gear)

Detect the clutch C1. Repair or replace it if

necessary.

Can not realize the

manual 4→3, 3→2, 2

→1

Overspeed clutch /ball spool has displacement.

C4 is invalid.

Detect the ball spool. Process the replacement

or reinstallation according to the requirement.

Detect the C4. Repair C4 or replace the C4

wave pan according to the necessary.

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Automatic transmission-50

O n ly ca n 1 → 3 → 4

s h if tin g

T h e s m a ll O -rin g o f fr o n t ser v o p is to n is in v a lid o r lo s t.

2 → 3 G ea r p s itio n s h ifti n g v a lv e is b lo ck ed .

D et e ct th e O -r in g . P r o c es s  th e rep la c e m e n t o r
r ein s ta lla tio n  if   n e c es s a ry . D et e ct th e 2 → 3
G ea r  s h iftin g   v a lv e;  P ro c es s   th e  m a in t en a n c e
o r  r ep la c e m en t   a c co r d in g   t o   th e  r eq u ir e m e n t.

O n ly ca n 1 → 2 → 1

s h if tin g

C 1 is in v a lid o r 3

- G ea r a n d 4

- G ea r is lo o s e . (g iv e t o

-G ear in 3

-g ea r; g iv e to 2

n d

-G ea r in 4

-G ea r)

D et e ct th e clu tc h C 1 . R ep a ir o r r ep la c e it if
n e c es s a r y.

C a n n o t r ea liz e t h e

m a n u a l 4 → 3 , 3 → 2 , 2

→ 1

O v er sp e ed clu tc h /b a ll s p o o l h a s d isp la c e m en t.
C 4 is in v a lid .

D et e ct th e b a ll s p o o l. P r o c es s th e r ep la c e m en t

o r r ein s ta lla tio n a c co r d i n g to th e r eq u ire m e n t.

D et e ct th e C 4 . R ep a ir C 4 o r r ep la c e th e C 4
w a v e p a n a c c o r d in g to th e n e c es sa r y .

W ith o u t m a n u a l

- G ea r

T h e r ea r b ra k e b e lt is lo o s e w h en th e t e m p era tu r e i s
h ig h .
T h e R -G ea r /L o w s p e e d 1

-G ea r b a ll s p o o l h a s

d is p la c e m e n t.

T h e in t ern a l “ O ” – rin g o f r ea r s er v o is l o s t.
C 4 is in v a lid .

D et e ct  th e  r ea r  b ra k e  b elt,  a d j u s t  id   n e c es s a ry.
D et e ct t h e b a ll sp o o l, R ein s ta ll o r r ep la c e it if
n e c es s a r y.
D et e ct  th e  O - rin g ,  R e in s ta ll  o r  r ep la c e   it  if
n e c es s a r y.
D et e ct th e C 4 . R ep a ir o r r ep la c e it if  n e c ess a r y.

O n ly ca n 1 → 2 → 2 → 4

g ea r .

T h e   d im en s io n   o f   so ck et   o f   f ro n t  s er v o   is   la r g e .  H a s   th e
p o s s ib ilit y  o f   lo o s e  o f  p l u g .
It  h a s  th e tre n d  th a t  ca n  n o t rea liz e  th e r e v ers e-G ear  if
d riv e   th e  v e h ic le  in   th is   co n d itio n   co n t in u o u sl y .

R ep a ir  o r   r ep la c e  it  if  n eces s a r y.
D et e ct  th e  C 3   p is to n   O -rin g ,  r ep la c e   it  if
n e c es s a r y.

O n ly a n 1

- g ea r,

n d

-G ea r, 4

-G ea r o r

-G ea r , 2

n d

-G ea r a n d

r d

-G ea r.(3

r d

-G ear is

tig h te n ed )

T h e g ea r s e n s o r h a s fa ilu r e, o n ly ca n 1 → 2 → 3 s h iftin g .
3 → 4 G ea r s h iftin g v a lv e is b lo c k ed .

D et e ct th e g ea r- p o s itio n s e n s o r. R ep a ir o r

rep la ce   it   if  n e c es s a ry .  D ete ct  th e   3 → 4   g ea r
s h iftin g  v a lv e. R ep a ir  o r r ep la c e it if
n e c ess a r y.

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Automatic transmission-51

Table 6.2.3

Shifting quality failure

Bad 1→2 Gear
shifting quality

The throttle position sensor has failure.
The brake belt is adjusted incorrectly.
The front servo piston O-ring is damaged.
The variable pressure solenoid valve (S5) is damaged or
has failure.
S1, S4 has the failure.
The brake belt combination regulating valve (BAR) has
the failure.
The front servo release spring is installed incorrectly.

Detect the resistance, replace the sensor if
necessary.
Detect and replace the rake belt if necessary.
Detect and replace the O-ring if necessary.
Detect, repair or replace the S5 if necessary.
Detect, repair or replace the S1, S4 if
necessary.
Detect, repair or replace the BAR if
necessary.
Detect and repair it if necessary.

Bad 2→3 Gear
shifting quality

B1brake belt release valve is blocked.
S3, S2 has the failure.
The clutch combination regulating valve has failure.
The clutch combination oil feed ball spool is lost or
damaged.
The input shaft oil seal is damaged.
C1 piston O-ring is damaged.
C1 piston oil feed ball spool is damaged.

Detect the blow-off valve. Replace or
maintain it if necessary.
Detect the S3, S2.Replace or maintain it if
necessary.
Detect the regulating valve. Replace or
maintain it if necessary.
Detect the ball spool .Reinstall or replace it if
necessary.
Detect the sealing ring. Reinstall or replace it
if necessary.
Detect the O-ring .Reinstall or replace it if
necessary.
Detect the ball spool .Reinstall or replace it if
necessary.

Bad 3→4 Gear
shifting quality

S1, S4 has failure.
B1brake belt release valve is blocked.
The brake belt is adjusted incorrectly.
The front servo piston O-ring is damaged.
The variable pressure solenoid valve (S5) is damaged or
has failure.
The brake belt combination regulating valve has failure.

Detect the S1, S4.Reinstall or replace it if
necessary.
Detect the blow-off valve. Replace or repair
it if necessary.
Detect the brake belt. Adjust it if necessary.
Detect the O-ring .Replace or maintain it if
necessary.
Detect the S5.Replace or maintain it if
necessary.
Detect the regulating valve. Replace or

maintain it if necessary.

The engine has

the

extinguishing

condition

when select

the automatic

gear or R-gear.

The torque converter clutch control valve is blocked or
solenoid valve 7 has failure.

Detect and clean the torque converter clutch
valve (CCCV)

Has unstable

vibration

condition.

S7 has the failure.

Process the necessary detection, maintenance
and replacement according to the
requirement.

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Automatic transmission-52

Failure Reason Corresponding

measures

C2 is burnt.

T operation lever linkage is beyond the

normal adjusting scope.

S6 is invalid.-Operating lever is hard.

The over speed Gear/output shaft sealing

ring is damaged.

Monitor and repair the C2 if necessary and

adjust the linkage device.

Repair the C2; detect, repair or replace the

S6 if necessary.

Repair the C2; detect and replace the

sealing ring or shaft if necessary.

C4 is burnt.

The clutch C4 assembly clearance is

incorrect.

The over speed Gear/output shaft sealing

ring is damaged.

3→4 one-way clutch is in rear position.

The over speed clutch (OC) /1

-Gear low

speed ball spool has displacement.

Detect the C4. Detect and adjust the clutch

C4 assembly clearance if necessary.

Repair the C4; detect and replace the oil

seal or shaft.

Repair the C4, detect or modify the OWC

if necessary.

Repair the C4, detect or modify the ball

spool if necessary.

B1 is burnt.

B1R spring is damaged.

The dimension of oil inlet hole of front

servo is large and has the possibility of

loose.

The input shaft sealing ring is damaged.

C1/B1R ball spool has displacement.

Detect and repair the or replace the spring

if necessary.

Replace the socket if necessary and detect

the C3 piston O-ring.

Replace the sealing ring.

Repair the B1; modify the ball spool if

necessary.

C1 is burnt.

B1Rspring / plug is lost.

The over speed Gear/input shaft sealing

ring is damaged

4→3 sequence valve is in rear position.

Clutch attachment oil feed inlet (CAF).

B1Rball spool is lost.

Detect and repair C1 or replace the spring

if necessary.

Repair the C1; detect and replace the

sealing ring or shaft if necessary.

Repair the C1; detect and modify the valve

if necessary.

Repair the C1; detect and replace the ball

spool if necessary.

B2 brake belt is burnt. In

R-Gear- without manual

-Gear.

The rear brake belt is adjusted incorrectly or

damaged.

The low speed R-Gear /1

-Gear ball spool

has displacement.

Detect and adjust the brake belt if

necessary.

Detect and reinstall the ball spool if

necessary.

The torque converter is

locked hardly or is not

locked.

The torque converter combination regulator

is in rear position.

Detect and modify the valve if

necessary.

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Adjustment

Hydraulic system

Following parts is the detailed description for self-detection procedure pointed to the condition occurred in chapter

6. including the condition indicated the failure, to point the problem existed in the hydraulic system.

It should select the proper procedure from the following primary detection when adjust the transmission.

Detection process of transmission fluid

Detect the manual linkage adjusting system(refer to factory manual of car)

Detect the engine idle speed

Anchoring test (beyond the scope of the maintenance manual)

On-road test (beyond the scope of the maintenance manual)

Detection procedure of transmission fluid level
1. General

The process is used to detect the level of vehicle transmission fluid. It will cause the failure or delay of transmission shifting if

the level is low than required value and the vehicle does not reach the drive temperature.

Firstly, process the transmission diagnosis information detection for vehicle (refer to chapter 6). If found the failure of sensor,

then it maybe caused by transmission fluid level is less than specified value.

It should detect whether has the abnormal delay and Gear-position condition when select the forward or reverse-gear by driving

the vehicle. One feature of oil level less than normal value is that the vehicle has the gear-position delay and lack condition when

the vehicle is in steering. The previous problem will occur when the transmission fluid temperature is low.

When the oil temperature is medium and vehicle speed failure is recorded, the gear-position lose condition

will not occurs any longer, it means that needs to fill the transmission with the transmission fluid.

2. Detection of transmission fluid level

When fill up or replace the transmission fluid, it must use the Castrol TQ95 automatic transmission fluid (ATF) or other

permissive oil. It will damage the performance and service life of transmission if use the unpermissive transmission fluid.

Please ensure the transmission fluid level is correct. The transmission also can be damaged if the transmission fluid level is

incorrect.

The setting procedure of transmission fluid level is shown as follows:

Caution:
When the transmission is in operating temperature, the hot transmission fluid may flow out form the
housing if remove the filling plug.

a. If the vehicle is in operating temperature, allow two hours time for cooling before add the transmission fluid, but

it must not more than 4 hours (this will make the transmission locate in the correct temperature range). When the

temperature is overheating, the transmission fluid level will higher than the plug port. Removal of plug will cause

the transmission fluid flows out from the oil filling port, then cause the low level of transmission fluid.

b. The gear-position of transmission is in parking-Gear (P-Gear), shut off the engine.

c. Lifting the vehicle (or parking above the trench).

d. Clean the around of plug when remove it. Then remove and clean the plug and check the O-ring for damage. Install

the oil filling pump in the oil filling hole.

e. Lower the vehicle; the oil filling pump will be connected to the vehicle at this time. Fill the transmission with the

oil partially. Then start the vehicle in P-Gear to 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. Shut down the engine; lift the vehicle; ensure the vehicle is always in horizontal.

g. Remove the filling plug 3 minutes after the engine is shut off, but must not 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 to make it reach the correct level.

h. Replace the transmission; clean the residual transmission fluid on the transmission and

vehicle.

i. Tighten the transmission plug to the specified torque of 30

35N

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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

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.

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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.

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Great Wall V200. Service Manual - part 8