Great Wall Hover. Service Manual — part 3
Clutch-6
Clutch
4. Disassembly procedure:
a. Clutch cover assembly, clutch disc assembly
b. Profile spring, throwout bearing assembly
c. Dustproof cover, separation rocker arm assembly
d. Separation rocker arm ball support
Warning: When maintaining the clutch assembly, it is now
allowed to use the sand mill or dry brush and compressed air for
cleaning, lest there is powder (use wet cloth). The clutch disc
has the “asbestos fiber”, if there is powder scrap during
maintaining, the asbestos fiber in the powder scrap will floats in
the air, when human inhales the air containing the asbestos
fiber, it will cause great damage to human health.
Removal of clutch assembly
1.Remove the transmission
Remarks: Do not dry the transmission oil.
2.Remove the clutch cover and clutch disc
a. Make the alignment mark on the clutch cover and flywheel
b. Remove the fixed bolt gradually, until release the tension of spring
c. Remove the fixed bolt, pull out the clutch cover and clutch disc.
3. Remove the bearing and separation fork form the transmission
a. Remove the clip and pull out the bearing .
b. Remove the separation rocker arm assembly and leather cup.
clutch disc assembly
clutch cover assembly
bolt, spring and
washer assembly
release bearing
assembly
profile spring
separation rocker arm assembly
separation rocker arm ball support
leather cup
N
m: specified torque
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Clutch-7
Checking the clutch components
1. Whether there is breakage of the clutch disc
The maximum of the rivet head: 0.3mm
If there is problem, the clutch disc needs to be replaced.
3. Measure the radial run-out tolerance of the flywheel
Use the dial gauge to measure the radial run-out tolerance of the
flywheel.
Maximum radial run-out tolerance: 0.2mm
If the radial run-out tolerance exceeds the maximum value, the flywheel
needs to be replaced.
4.Check the guide bearing
Rotate the bearing with hand along the direction of the axis.
If the bearing cannot be rotated or there is great resistance, the guide
bearing needs to be replaced.
The bearing is lubricated eternally, so there is no need for
cleaning and lubrication.
2. Check the radial run-out tolerance of the clutch disc
Use dial gauge to check the radial run-out tolerance of the clutch disc.
The maximum radial run-out tolerance: 0.8mm
If the radial run-out tolerance exceeds the maximum value, the clutch
disc needs to be replaced.
5. If necessary, replace the guide bearing.
Use the special tools to remove the guide bearing.
special tools
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Clutch-8
b. Use special tools to install the guide bearing
Remarks: Install the guide bearing into the flywheel, make
sure that the bearing can rotate well.
6. Check to see whether there is wearing of the diaphragm spring
Use caliper to check the wearing depth and width of the diaphragm
spring
Limit value: maximum depth 0.6mm
Maximum width 5.0mm
7. Check the throwout bearing
Rotate the bearing with hand along the axis direction.
If the bearing can not rotate or the resistance is too large, it is necessary
to replace the throwout bearing.
Remarks: The bearing is permanent lubricated, so cleaning
and lubricating is unnecessary.
special tools
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Clutch-9
2.Installtion of clutch cover
a. Align the matching mark of clutch shell with that of flywheel .
b. Tighten the bolt evenly. Exert force along the edge of the clutch
cover repeatedly until binding tightly. Tighten the bolt.
Tightening force: 19N
m
Remarks: First tighten the upper most bolt of the 3 bolts
near the
location pin.
3. Check the end surface runout of diaphragm spring clutch finger.
Use the special tools to check the alignment of diaphragm spring.
Maximum displacement: 0.5mm
If the displacement is greater than the specified value, use the special
tools to adjust the face runout amount of the diaphragm spring clutch
finger.
4. Coat the following components with the molybdenum disulfide
lithium base grease (NLGI NO.2) or multi-purpose grease :
contacting point of separation rocker arm assembly and bearing
bush
contacting point of separation rocker arm assembly and subcylinder
push bar
separation rocker arm assembly supporting point
gear box 1
st
axle spline
5. Install the leather cup, separation rocker arm assembly, clutch
cover assembly and throwout bearing in the transmission.
6. Install the transmission
matching mark
Installation of clutch
1.Install the clutch disc on the flywheel
Use the special tools to install the clutch disc on the flywheel.
special tools
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Chapter 4
Specification of transmission. . . . . . . . . . . . . . . . . ...2
Repair of transmission (SC5M2D
C). . . . . . . . . . . . . .4
Disassembly of transmission (SC5M2D
C). . . . . . . . . . . 6
Disassembly of transmission housing assembly/bearing housing assembly. 18
Operating instruction of transmission (SC5M4D
C). . . . . . . .24
Repair of transmission (SC5M4D
C). . . . . . . . . . . . ...25
Disassembly of rear housing assembly . . . . . . . . . . . . . ..28
Disassembly of transfer case assembly. . . . . . . . . . . . . ..30
Rear output shaft assembly . . . . . . . . . . . . . . . . . ...35
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Structure diagram of SC5M2D-C and SC5M4D-C transmission: shown in figure
Structure diagram of SC5M2D-C transmission
Structure diagram of SC5M4D-C transmission
Specification of transmission
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1.
Speed ratio of transmissio
Gear
Ⅰ
Ⅱ
Ⅲ
Ⅳ
Ⅴ R
Speed
ratio
3.967
2.136 1.360 1.000 0.856 3.578
2.
Speed ratio of transfer case SC5M4D-C
Gear synchronizer
H
L
Speed ratio
1.000
1.925
3. Central distance of main shaft
transmission 72 mm
transfer case 222.25 mm
4. Instruction for repair specification of transmission
Inspection item
Repair specification
End clearance of gear of Axle 1 (mm)
0~0.06 Adjusted by axial retainer.
Clearance between bearing block and bearing of Axle 1 (mm)
0~0.1 Adjusted by adjusting shim.
End clearance of gear hub of Gear 3/ 4 synchronizer (mm)
0~0.08 Adjusted by axial retainer.
Clearance of rear end cone bearing of intermediate shaft (mm)
0~0.05 Adjusted by adjusting shim.
End clearance of gear hub of high and low gear (mm)
SC5M4D-C
0~0.08 Adjusted by axial retainer.
Clearance between the rear output shaft rear bearing and back
cover (mm) SC5M4D-C
0~0.1 Adjusted by adjusting shim.
Clearance of rear input shaft bearing (mm) SC5M4D-C
0~0.06 Adjusted by adjusting shim.
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Inspection of SC5M2D-C transmission:
1.Check the oil level of transmission:
Screw off the oil discharge plug of the transmission; discharge all lubri-
cate oil; screw on the oil discharge plug to the specified torque; the
torque is: 30
35N
m. Fill the transmission with the transmission
oil through the oil filling port, oil number is hyperbolic gear oil SAE80W/
90, which meet API GL-4, oil capacity are 2.2L. Tighten the oil-filling
plug to the specified torque of 30
35N
m. (for area with high or
low temperature refer to the maintenance specification)
2. Replacement of oil seal of rear hosing:
The replacement of the oil seal of rear housing is shown in figure.
Disconnect the drive shaft from the rear housing; remove the oil seal
by the flat screwdriver, then use the special tools to knock the rear
housing oil seal in the rear housing. It should pay attention to the
installation of oil seal, shown as figure. Coat the lip of oil seal with the
specified transmission oil.
3. Removal, installation and inspection of transmission
The preoperation before removal and after installation of transmission
is: Remove and install the manipulator cover assembly, drain and fill
the transmission oil accordance with the regulation; after remove and
install the drive shaft. Separate each plug-in part from the vehicle
transmission .
4 Inspection of manipulator cover assembly
Shown as figure, remove the adhesive on the surface before installation,
use the screwdriver( M8
1.25) to clean the adhesive in the screw
hole; coat the installed part of bolt screw with the specified screw
adhesive. Firstly, install two positioning bolts A, then install other
two bolt A and bolt C respectively. The tightening torque of all bolts is
15
22N
m.
oil filling screw plug (SC
1701005)
oil-drain screw-plug assembly (JK72
1701071)
rear housing oil seal
bolt C(SC-1704003)
bolt A(SC-1704004)
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SC5M2D-C transmission assembly
handle of gearlever
dustproof seal cover
oil seal 39.6
52
10
odometer driven gear assembly
odometer seating lock plate
cylindrical compression spring
1.0
5.8
41
bush
select & shift seating
N
m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special tools
manipulator cover assembly
elastic cylindrical pin 6
22
rear housing assembly
spring cylindrical pin
reverse lamp switch bracket
bearing housing assembly
clutch housing assembly
location compression
cylindrical pin
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Disassembly of transmission (SC5M2D-C)
1.Remove the hexagon bolt M8
18 and lock plate.
Caution: The tightening torque is 14-19N
m when install the
hexagon bolt;
2.Remove the odometer driven gear assembly
Use the special tools to remove the odometer driven gear assembly
3.Remove the rear housing assembly
a. Remove 6 M10
1.25
30 hexagon bolts
Caution: The tightening torque is 14-19N
m when installs 6
M10
1.25
30 hexagon bolts.
b. Use the rubber hammer to knock the rear housing and take out the
rear housing assembly.
4. Remove 2 location pins and bushes.
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Manipulator cover assembly
gearbox assembly (one)
reverse lock assembly
nut M8
bulb
rubber cover
pin 7
40
master control lever assembly
bulb base
bush
stop plate of main rod
bush
bulb jacket
N
m: specified torque
Used component which can not be used any more.
Pregummed component
N
m: specified torque
Used component which can not be used any more.
bush
6
oil guiding plate
location pin
steel ball 7.
938
aluminum gasket
reverse lamp switch
gearbox
selection and shifting
shaft
rubber choke plug
bleed plug assembly
bush
selection and shifting block
elastic cylindrical pin 6
22
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N
m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special tools
aluminum
washer
lower cover plate assembly
bush
gear 5 drive gear ball bearing
circlip for shaft
steel ball
odometer drive gear
circlip for shaft
ball bearing
circlip for shaft
reverse gear 5
shift fork
in 6
22
declutch shift shaft for
first and secondea
gear 3/4 declutch
shift shaft
declutch shift shaft
pin 5
22
gear 1/2 shift-
ing block
gear 3/4 shifting
block
earbox assembly (three)
steel ball 4.762
pin 6
22
gear 1/2 shift fork
adjusting shim
spacing ring
reverse drive gear
reverse shaft
needle bearing
reverse gear
thrust washer
split pin
grease baffle of air duct
support axial lock plate
reverse needle bearing bushing
needle bearing
thrust washer
gear 5 needle
bearing bushing
synchronizer gear ring
reverse gear 5 synchronizer assembly
N
m: specified torque
Used component which can not be used any more.
Pregummed component
Use the special tools
gear 3/4
shift fork
reverse driven gear assembly
needle bearing
gear 5 driven
gear assembly
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5. Remove the reverse lamp switch M12×1.25
Caution: When install the reverse lamp switch M12×1.25, the
tightening torque is 26-36 N·m
6. Remove the gearbox
a.Use the wrench to remove the 5 M8×55 bolts, 1 M8×6 bolt and 2
M8×110 bolts
Caution: When install 5 M8×55 bolts, 1 M8×6 bolt and 2 M8×110
bolts. tightening torque is
b. Remove the gearbox assembly
7. Use the circlip pliers to remove the circlip for shaft
8. Remove the odometer drive gear
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10. Use the circlip pliers to remove the circlip for shaft
13. Use the circlip pliers to remove the circlip for shaft
9. Use the magnetic rod to take out the steel ball
11. Use the circlip pliers to remove the circlip for shaft
Caution: It is necessary to circlip for shaft when install the
circlip for shaft
12. Use the drawing die to remove the axle 2 ball bearing
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14. Use the opener to pry out the riveted place of lock nut of
intermedi ate shaft
15.Remove the self-locking screw plug, spring, steel ball
a. Use the special tools to remove 3 locking screw plugs M10×
1.25×19
Caution: The tightening torque is 14-19N·m when install the
locking screw plug M10×1.25×19.
b. Use the magnetic rod to remove 3 springs
c. Use the magnetic rod to remove 3 steel balls
Caution: When install 12 bolts M8×16, the tightening torque
is 15-20N·m
16. Remove the lower cover plate assembly
a. Use the wrench to remove the 12
bolt M8×16
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b. Remove the lower cover plate assembly
17. Remove the declutch shift shaft assembly
a. Use the punch to remove the reverse gear 5 shift fork elastic
cylindrical pin
b. Use the punch to remove the Gear 1/2 shift fork elastic cylindrical
pin
c. Use the punch to remove the Gear 3/4 shift fork cylinder pin.
d. Remove the reverse gear 5 declutch shift shaft assembly
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