Great Wall Hover. Manual — part 30

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.

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

st

-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

1

st

-Gear.

The rear brake belt is adjusted incorrectly or

damaged.

The low speed R-Gear /1

st

-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.

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

m.

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

60

.

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.