Great Wall Hover. Manual — part 39

f. Make the installation of oil bottom shell is proper for transfer case and the tighten the safety valve according to the

specification and sequence (Refer to Figure 8.61). do not distort it.

16.Torque converter and support sleeve assembly

Install the hydraulic torque converter and housing assembly, the procedure is shown as follows:

a. Install the hydraulic torque converter housing on the main case.

Caution:

All hardware should be installed correctly and comply with the specification.

b. Use the Loctite243 or equivalent to fix the torque converter housing; install and tighten it to standard specification.

c. Install the torque converter; ensure the pump gear sealing is installed correctly.

17. Rear wheel drive mode of output ring flange assembly

Assemble the output shaft assembly, the procedure is shown as follows:

a. Place the paw of transmission operating rod on the parking position and lock the output shaft.

b. Wash the output shaft upper line; use the loctite243 or equivalent.

c. Install and tighten the ring flange, O-ring and nut.

Caution: In the heavy steel slide plate, place the ring flange on the upper nut; avoid the damage of bearing.

d. Tighten the nut on the output shaft

T o r q u e t y p e

s p e c i f ic a t io n

N .m

F t / lb

t r a n s m i s s io n a s s e m b ly

t o r q u e c o n v e r te r h o u s i n g to

h o u s in g

M 1 2 × 3 2

4 , 8 o r 9

5 4 -6 8

4 0 -5 0

r e a r e n d h o u s i n g to h o u s in g

- C h a ir m a n

M 1 2 × 3 2

4

5 4 -6 8

4 0 -5 0

C o n n e c to r h o u s in g to h o u s in g

- 4 W D

M 8 × 2 5

1 0

3 5 -4 0

2 6 -3 0

r e a r e n d h o u s i n g to h o u s in g

- 2 W D

M 8 × 2 5

1 0 3 5 -4 0

2 6 -3 0

r e a r s e r v o c o v e r to h o u s in g

M 8 × 2 5

6 3 0 -3 5

2 2 -2 6

O i l p a n to h o u s in g

M 6 × 1 6

9 4 - 6

3 - 4 .5

O i l c o o le r p i p e c o n n e c t io n

2 4 0 -4 5

2 9 .5 - 3 3

V a lv e t o h o u s in g

M 6 × 2 6

7 8 - 1 3

6 - 9 .5

V a lv e t o h o u s in g

M 6 × 4 5

5 8 - 1 3

6 - 9 .5

B r a k e b a r s p r i n g

M 8 × 1 6

1 2 0 -2 2

1 5 -1 6

c e n t r a l s u p p o r t to h o u s i n g

M 1 0 × 3 4

2 2 0 -2 7

1 5 -2 0

C a m d i s c to h o u s in g

M 8 × 1 6

2 1 6 -2 2

1 2 -1 6

G e a r - p o s i tio n s e n s o r to

h o u s in g

1 0 -2 4 × 1 3

2 4 - 6

3 - 4 .5

O u tp u t s h a f t lo c k n u t

M 2 4 × 1 .5

1 1 0 0 -1 1 0

7 4 -8 1 .5

o i l f i lli n g p lu g

M 2 0

1 3 0 -3 5

2 2 -2 6

P u m p h o u s i n g a s s e m b ly

P u m p to p u m p c o v e r

M 8 × 5 5

5 2 4 -2 7

1 8 -2 0

P u m p c o v e r to h o u s in g

M 8 × 4 0

6 2 4 -3 4

1 8 -2 5

P u m p c o v e r to h o u s in g

M 8 × 5 8

2 2 4 -3 4

1 8 -2 5

P u m p c o v e r d i s c to p u m p

c o v e r

M 6 × 1 6

5 1 3 -1 6

9 .5 -1 2

P u m p c o v e r d i s c to c r e s c e n t

M 6 × 5 4

1 1 3 -1 6

9 .5 -1 2

V a lv e a s s e m b ly

U p p e r v a lv e to lo w e r v a lv e

M 6 × 3 0

2 4 o r 2 5

1 1 -1 6

8 - 1 2

L i n e s o c k e t

M 6

1 4 - 7

3 - 5

s o le n o id v a lv e ( o n /o f f t y p e

a n d V P S , in c lu d i n g S 7 )

M 6 × 1 6

7 8 - 1 2

6 - 9

Table 8.1 Torque specification

thickness Component No. thickness Component No.

Adjustment of front and rear brake belt

1. Setting procedure of brake belt

The setting procedure of brake belt is shown as follows:

a. For the calculating method of front servo mechanism thrust lever refer to Figure 8.62, dimension; standard A.

.Allow the air pressure is in 650/700kPa in the operating area of front servo mechanism (external of B1), (refer to

Figure 8.63).

. The forward dimension of thrust lever minus 3mm.

Dimension requirement for selection of shim:

Caution:

The small shim requires that the shim size is 1mm always; the available thickness is listed in Table 8.2.

.

Release air.

b. Proper shim to end of thrust lever pole.

Check the shim for damage, worn or corrosion; replace it if necessary.

The shim is installed on the support surface between the transmission and pole flange, refer to Figure 8.62.

Install the shim by hand, and not the hammer or pressure.

Press the shim by hand until has the click the noise. The noise means the shim is clamped by the housing correctly.

c. Recheck the stroke of thrust lever 3mm

0.25mm.

2. Setting procedure of rear brake belt

The setting procedure of rear brake belt is shown as follows:

a. The setting of distance A is form the back surface of servo piston to inner surface of transmission, use the vernier caliper. Refer

to Figure 8.64.

A allows the air pressure of 650/700kPa is in the front servo mechanism operating area (external of B2), (refer to Figure

8.63).

Deduct 3.75mm from the movement of piston and use the 2.5 mm shim to divide the rest distance.

Caution:

The small shim requires that the shim size is 1mm always; the available thickness is listed in Table 8.2.

. Release air.

b. Select the proper shim for end of thrust lever pole.

Check the shim for damage, worn or corrosion; replace it if necessary.

The shim is installed on the support surface between the transmission and pole flange, refer to Figure 8.64.

Install the shim by hand, and not the hammer or pressure.

Press the shim by hand until has the click the noise. The noise means the shim is clamped by the housing correctly.

c. Recheck the stroke of piston for 3.75mm

0.625mm.

Table 8.2 Effective thickness of shim

Figure 8.62 Setting of brake belt

Figure 8.63 External port position of B1 and B2

Figure 8.64 Setting of rear brake belt

O il filling procedure

According to the procedure described in 7.2.

Specification and special tools

T ype and specification

hydraulic torque converter

maximum torque multiplier factor

179K

stalled speed (80 to 100 ℃ rpm)

(179K torque converter )

Specification

2.00: 1

2090

G ear ratio

First gear

Second gear

Third gear

Fourth gear

Reverse gear

2.393:1

1.450:1

1.000:1

0.677:1

2.093:1

Lubricant

type

dry system

alternative of maintenance

Castrol T Q95

9.0 L (approximation)

4.5L (approximation)

Axial movement of gear assembly

0.50-0.65 mm

Fixed pinion axle movement

0.10-0.50 mm

Table 9.1－ Type specification

Pressing factor of clutch

0588-000001

C1

structure (friction disk )

steel

5

5 (2)

C2

structure (friction disk )

steel

5

4 (2)

C3

structure (friction disk )

steel

4

4 (2)

C4

structure (friction disk )

steel

3

4 (1)

Table 9.2 Shifting point of clutch assembly details