Great Wall Hover. Service Manual — part 4
e. Remove the gear 3/4 declutch shift shaft assembly
f. Remove the reverse gear 5 shift fork
18. Remove the lock nut of intermediate shaft
Caution: When install the lock nut of intermediate shaft , the
tightening torque is 160-190N·m
19.Remove the Gear 1/2 declutch shift shaft assembly, intermediate
shaft rear ball bearing, 5th-Gear drive gear
20. Remove the Gear 1/2 shift fork
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21.Use the special tools to remove the second shaft lock nut
Caution: When install the second shaft lock nut, the tightening
torque is : 250-270N·m
22.Remove the thrust plate
23.Use the magnetic rod to remove the steel ball.
24.Remove the 5th-Gear driven gear assembly
Caution: When install the 5th-Gear driven gear assembly, it should
use the plug gage to test the 5th-Gear driven gear assembly axial
clearance, ensure the axial clearance is within 0.170-0.284mm
25.Remove the 5th-Gear driven gear needle bearing
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27. Use the pliers to remove the split pin on the reverse shaft lock
nut.
28. Use the special tools to remove the reverse lock nut
Caution: when install the reverse lock nut, the tightening torque
is within 20-60N·m
29. Remove the thrust plate
30. Remove the 5th/reverse -Gear synchronizer assembly
a. Use the special tools to remove the 5th/reverse -Gear synchronizer
assembly
26. Remove the synchronizer gear ring
Caution: When install the synchronizer gear, it should use the
plug gage to test the synchronizer gear ring axial clearance, en-
sure the axial clearance is within 1.25-1.65mm
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31. Remove the reverse gear
32. Remove 2 needle bearings of reverse gear
33. Remove the reverse driven gear
34. Remove the needle bearing of reverse driven gear
b. Remove the sleeve and 5th/reverse -Gear synchronizer assembly
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35. Remove the reverse drive gear
36. Remove the intermediate shaft spacing ring
37. Remove 8 countersunk screws
Caution: when install the countersunk screw, the tightening torque
is within 15-22N·m
38. Remove the support axial lock plate
39. Remove the air duct grease baffle
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Disassembly of clutch housing assembly /bearing
housing assembly
40. Use the special tools to remove the reverse shaft
Use the magnetic rod to take out 2 interlocking pins
Remove the first bearing block assembly
a. Use the special tools to install 6 M8 bolts.
Caution: When install 6 M8 bolts, the tightening torque is 10-
13N·m
Clutch housing assembly / Bearing housing assembly
bush
oil seal
Used component which can not be used any more.
throwout bearing
assembly
washer 8
¦ non-standard spring
first bearing
first shaft assembly
needle bearing
second shaft assembly
¦circles for shaft
¦adjusting shim
leather cup
separation rocker arm assembly
separation rocker arm ball support
clutch cylinder assembly
front space ring of intermediate shaft
intermediate shaft assembly
aluminum waher
Specified torque
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b. Remove the first bearing blocks assembly ; take out the adjusting
shim
Caution: It should select the adjusting shim when install the
adjusting shim
43. Remove the bearing snap ring
44 Remove the intermediate shaft assembly
45. Remove the first shaft assembly
46. Remove the needle bearing
Mark
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47. Remove the 3rd/4th-Gear shift fork
Remove the second shaft assembly
a. Use the rubber hammer to knock the second shaft
b. Remove the needle bearing bushing of reverse driven gear
c. Remove the double inner-race ball bearing assembly
d. Remove the second shaft assembly
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Secondary shaft assembly
49. Disassembly of second shaft assembly
a. Remove the second shaft rear retainer
Caution: It should select the circlip for shaft when install the
circlip for shaft.
b. Remove the 3rd/4th-Gear synchronizer assembly
c. Remove the 3rd/4th-Gear synchronizer gear ring
Caution: When install the 3rd/4th-Gear synchronizer gear ring, it
should use the plug gage to measure the end surface clearance of
gear ring to ensure it is within 1.25-1.65mm
¦circlips for shaft
3rd/4th-Gear syn-
chronizer assembly
1st/2nd-Gear synchronizer assembly
synchronizer gear ring
3rd-Gear driven gear assembly
needle bearing
second shaft
2nd-Gear driven gear assembly
2nd-Gear synchronizer gear ring
needle bearing
sleeve
1st-Gear synchronizer gear ring
1st-Gear driven gear assembly
double inner-race
N
m: specified torque
Used component which can not be used any more.
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d. Remove the 3rd-Gear driven gear assembly
Caution: When install the 3rd-Gear driven gear assembly, it should
use the plug gage to measure the 3rd-Gear driven gear assembly
axial clearance to ensure it is within 0.17-0.284mm
e. Remove the 3rd-Gear driven gear needle bearing
f. Use the special tools to press the second shaft to remove the inner
race of double inner-race ball bearing.
Remove the 1st-Gear driven gear
Caution: When install the 1st-Gear driven gear, it should use the
plug gage to measure the 1st-Gear driven gear axial clearance to
ensure it is within 0.17-0.284mm.
h. Remove the 1st-Gear driven gear needle bearing
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Transmission-23
i. Remove the sleeve
j. Remove the 1st-Gear synchronizer gear ring
k. Remove the 1st/2nd-Gear synchronizer assembly
l. Remove the 2nd-Gear synchronizer gear ring , 2nd-Gear driven gear
and second shaft
Caution: When install the 2nd-Gear driven gear, it should use the
plug gage to measure the 2nd-Gear driven gear axial clearance to
ensure it is within 0.17-0.284mm
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2. Operation of 4WD
The operating auxiliary steering column can be shifted to 4WD status.
For position of auxiliary steering column and corresponding operating
condition refer to table.
3. Caution for operation:
a. Do not use 4WD in good surface, otherwise the tyre and components
of drive system will be damaged easily and increase the consumption
of fuel, and cause the noise of drive system.
b. Please run in 1st-Gear under “4L” gear position when run in very
low speed in field.
Operating instruction of transmission SC5M4D-C
1.The schematic diagram of transmission operating gear position
is on the handle of steering column.
During the process after vehicle is started and in traveling, it must
step the clutch pedal to bottom before the shifting. If need shift from
5
th
-Gear to reverse-Gear, it should move the shifting bar to the neutral
position of 3rd/4th-Gear. Shift to R-Gear after stop the vehicle stably,
otherwise, it can not shift.
During the traveling process. It should always pay attention to the
shifting to make the vehicle matches to the speed of engine. The
correct shifting can improve the economical efficiency and prolong
the service life of engine. Do not shift from high-Gear to low-Gear on
the condition that the pointer of tachometer may enter into red area,
otherwise, the engine will be damaged.
Warning: Do not shift to reverse-Gear when the vehicle moves
forwardly, otherwise the transmission will be damaged.
hand hall of main steering column
hand ball of auxiliary steering column
Auxiliary steering
column position
drive Operating
condition
2H
2WD
Use this gear position when run in the general railway and high speed highway.
4H
High speed 4WD
Use this gear position when run in the deep snowland, sand ground or uneven road
in normal speed.
N
Neutral gear
When use the gear position during using of winch, it could not drive the vehicle.
4L Low
speed
4WD
Use this gear-position when run in uneven road such as mud land or climbing or
downward (especially when need increase the power).
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Transmission-25
2.Replacement of oil-seal of transfer case
The replacement of transfer case oil seal is shown as figure. Disconnect
the drive shaft from the transfer case, use the flat head screwer to
remove the oil seal
Caution: Do not damage the housing hole during the disassembly.
Then use the special tools to knock the transfer case oil seal into
the transfer case. It should pay attention to the installation dire
tion of oil seal. The oil seal is flush with the port of transfer case.
Shown as figure. Coat the lip of oil seal with the specified general
synthetic gear oil.
3. Disassembly and check of transmission
The preoperation before the removal and after installation of
transmission is : When remove and install the manipulator cover
assembly, drain and fill with the specified transmission and transfer
case lubrication oil. When remove and install the front and rear drive
shaft, separate each plug-in part of transmission from the vehicle.
Inspection of manipulator cover assembly:
The bolt dimension is different for different installation position. Do not
confuse it during the installation. It should install the fixing bolt A firstly.
The tightening torque of bolt A and B bolt is 15
22N
m.
installation position of fastening blot
bolt
bolt
bolt
Repair of transmission SC5M4D-C
1. Inspection of oil level of transmission and transfer case:
Screw off the oil drainage screw plug of main box and transfer case;
drain all lubrication oil, tighten the oil drain plug to specified torque.
The torque is: 30
35N m. Fill the main box and transfer case with
the transmission oil through the oil filling port. The number is hyperbolic
gear oil SAE80W/90, comply with API GL-4. The oil quantities are
main box : 2.2 L, transfer case : 2.7 L. (for high and low temperature
environment refer to maintenance specification). Tighten the oil filling
screw plug to specified torque. The torque is: 30
35N
m.
front output shaft oil
seal (SC
1802504)
rear output shaft oil seal
(SC
1802323)
transmission
transfer case
oil filling screw plug
oil-drain screw-plug assembly
(JK72
1701070)
oil filling screw plug
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Transmission SC5M4D
C assembly
N
m: specified torque
Used component which can not be used any more.
transmission
separated case
spring cylindrical pin
cylindrical
compression spring
steel ball 6.35
cylindrical compression spring
reverse lamp
switch bracket
wire clip
elastic cylindrical
pin
manipulator cover assembly
washer
test switch bracket
select & shift seating
washer
location spring
cylindrical pin
cylindrical compression spring
bush
wire clip
stud M10
1.25
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Transmission-27
Manipulator cover assembly
Rear housing assembly
nut
reverse lock
assembly
manipulator
cover assembly
ball head
rubber cover
auxiliary steering
column stop plate
bush
ball head base
washer
pin
auxiliary steering
column assembly
handle of transfer case
ball head
hood
ball head
rubber cover
stop plate of
main bar
bush
ball head base
pin
washer
master control lever assembly
handle of
gearlever
N
m: specified torque
Used component which can not be used any more.
odometer driven gear
assembly
odometer seating lock plate
14-19
14-19
oil seal
dustproof seal
guide bushing
rear housing
adjusting shim
24-33
26-36
aluminum gasket
mushroom lock spring
aluminum gasket
24-33
mushroom lock spring
26-36
30-42
N
m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special tools
steel ball 7.938 (3)
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Disassembly of rear housing assembly
1.Remove the M8
18 hexagon bolt and the lock plate
Caution: When install the M8
18 hexagon bolt, the tightening
torque is 14-19N
m
2.Remove the odometer driven gear assembly
Use the special tools to remove the odometer driven gear assembly
3.Remove the rear cover assembly
Caution: When install 6 M10
1.25
30 hexagon bolts, the tightening
torque is 14-19N
m
b.Use the plastic hammer to knock the rear cover slightly and take out
the rear cover
c.Take out the adjusting shim
Caution: It should select the adjusting shim as follows when
install it.
mark
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