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ZF Automatic Transmissions Service Manual

1. e o 9 o 2 E o 5 E 6 3 P la ec WZH HI HET lii F sc FH GL EE 005 d i Qnin Um 1 8 Lj L Wh w Kee BI uU UA iis of H s WHA E D j NOLLISOd 10 Issue 1 August 1994 ZF Automatic Transmissions Service Manual POSITION H EVESSE Ch CET x db SI ananunua 4 n TER n u w w 11 Issue 1 August 1994 3 9 2 9 o 9 o 2 E o E 9 E 6 3 lt LL N n Seen s WET 1 z FH zum GO a ke H Wen E EXT E 12 Gi ELE DD LL BEA HI Ch 10 r Z d e 5 T e L Issue 1 August 1994 5 e o o E 9 2 E o 9 E 2 6 5 lt LL N aru EIL Y PER REP
2. 1 Jaguar Number Description Notes To be issued III TORQUE TIGHTENINGSPECIFICATIONS Fixing Tightening Torque Nm be issued Description Uses Notes To be issued Description Data Transmission fluid Capacity 8 0 Liters Transmission fluid type Fill Esso 20 Top up Esso 20 2E or 3 Transmission weight includingtorque converter 74 75 kg Transmission Ratios 1st 12 48 1 2nd 11 481 3rd Reverse 1 00 1 Torque Converter Stallspeed 2100 RPM 150RPM Transmission unit pressures Drive Idle stationary 630 710kPa Drive Reverse Reverse FullThrottle stall Idle stationary FullThrottle stall 780 950 kPa 1070 1150 1620 1780 kPa Issue 1 August 1994 ZF Automatic Transmissions Service Manual IV Service Data continued Item Description Data Transmission fluid Capacity 95 Liters Transmission fluid type Fill Esso 2D TOP UP Esso2D 2E or Transmission weight includingtorque converter 79 65 kg Transmission Ratios 161 2 48 1 Torque converter Federal Specification Ratio Reverse Final drive 3 58 1 Nominal size diameter 280mm Torque 322 Nm 2000 RPM Stall speed UK Specification 2000 RPM 150RPM 1900 RPM 150 RPM 2 12 1 Stall Gear train end float Elect
3. ZF Automatic Transmissions Service Manual 2 IPAE 2 9 LI it w H EERW a a 2 8 E 3 o S ELI di RA 57 Issue 1 August 1994 ZF Automatic Transmissions Service Manual POSITION D DRIVE 4th GEAR LQC lt UP Issue 1 August 1994 58 ZF Automatic Transmissions Service Manual POSITION T 1st GEAR KXEXERCETFISTXEEETENREKIWAITEFIZZEWENYETETENVEFEEFENEZEENFEWEIRTFYTYYEXEVEYTYXGETEGXNENXETEEXXI rr ee AAA Hr E bet p na LE K Fetz X 444 637 59 Issue 1 August 1994 ZF Automatic Transmissions Service Manual 2 3 FAULT DIAGNOSIS The following tables are intended as a guide to diagnosis of possiblefaults in the ZF 4 HP 24 E transmission When the fault involves a leak it is recommended that it is located by the use of a crack detection fluid eg Met L Check which is available in spray form and permits the leakto be located after a short test drive 2 3 1 Initial Checks Note Before attempting fault diagnosis ensure that the following settings are checked Transmission oil level a Ensurethat the transmission is at normal operating temperature e g by conducting 20 mile roadtest If starting from cold checkfor presen
4. 28 Issue 1 August 1994 ez Wz Hj bz 8 gt WH HH TH truc hmi 2 122 eg tes rnm CER EE m E E M E H gt e R r lessen T SS CH 3 e o o c 9 7 2 E o c 5 m G E D gt 3 lt LL N Lei miu E t l 8 TES NR EH 4 a dea El es Sc 2 TINS PUZ Issue 1 August 1994 3 c 9 e o E 9 o 2 E o E 9 E m 6 3 lt XL W lei 8 WH CT m 30 Issue 1 August 1994 5 e o o E 9 o 2 E o 9 E 9 6 LL N U eiert om UTE
5. e 9 o o 2 E o 9 E Ceci 6 5 Wa Li __ __ _ ___ rw L ee eee mam TD h ice m amina 8 s pe i gz Li X L R 21 AWW 0 emn 177 i TERR DA iM LEE LL f xxx X A d ZE ZE d e a CES an 22 Issue 1 August 1994 G 2 2 o gt x 22 o Hd 42 S Q CS E o N 69 CER i 6z Wem C L Tun e se GE LIC GE mem k wa H HL BASSE 07 Qe d r 1 August 1994 23 5 gt CH o o E 9 o 2 E o 5 6 3 SEELEN 13 Miho sz gH 22 EE a 24 Issue 1 August 1994 T 5 e o o o 2 E o 9 E 2 6 LL N Vi am 9 MALO K u FILLOYHL Lued HV39 P NOILISOd d d d D verdee Issue 1 Augus
6. 73 Automatic Transmissions service Manual Published by Product Development amp Publications JaguarCars Limited Part of set JJM 1004 12 50 ZF Automatic Transmissions Service Manual CONTENTS Section Title SRO Page afta aya Sha ii Ta tata eere Service Tools amp Equipment iii Hzc ire tinus Torque Tightening iii Service MaternalS gol lae ev eee DIRE a iii IV t donis are ux sus udi aw ncs DIS ED d vts ili 4 HP 22 Transmission General Description 1 Id Torqueconverter 1 TA E Four speed Epicyclic Gear n 2 VAS Operation Of Gear Train Clutches 3 Td vei aes Transmission Output Shaft Extension HOUSING 4 1 115 deve tuis Transmission Control Unit eene E REENEN ok orna eos Gs s nen 4 Gearshift Selection ace reu eee Ad S m oe tha ee 8 Jae caq ah eae Thrott
7. Ln ui ag er 1 46 5 e sc wel n FR SANI d ol yz Uus i 7 be Vi E EE Rs UN X Fe ES 19 EL 1 L xp s issue 1 August 1994 13 5 c e o c 9 7 2 E o D E E 6 3 lt nni Fee 3 rure cm ae aum mr a m 62 I Ke xxu 1 S Rn h sz cmn Lm E 5 8l Tr eer bee Hae L O T UE M D d B Ka NAME ELT m Ww 8 s LEE IILI FTLLOYHL 113 ISL JAYA 5 4 arm X HD 14 Issue 1 August 1994 lt e o o o 2 E o 5 E 2 6 5 lt LL N xx 5 5 rou ini rm 92 WE LITE LI EE La um 0 7 vi ETEA Doro 184 ELR SL TINA WA I WAWJ aE kw p sama f d MATT LAG Tn NAY
8. Governor pressureto converter clutch hysteresis valve Converter clutch lock up Line pressureto converter pressure valve D4 selected Converter clutch damper Aids quality of converter clutch application Clutch valves amp Dampers Aids quality of clutch application relevantto modulator amp line pressures Governor Varies pressure in accordance with road speed Issue 1 August 1994 ZF Automatic Transmissions Service Manual 1 1 6 Gearshift Selection Gearshift selection is by movementofthe shift lever which through aselector cable causes repositioning ofthe manual selector valve to direct oil pressure to the required shift valve The automatic shift points are determined by acceler ator position and road speed throttle movement moves onthe throttle valve directing oil pressure to the shift valves and modulator valve road speed modulates hydraulic pressure through acentrifugal governor driven by the transmission output shaft Operation of the hydraulic control system is shown diagrammatically in the circuit dia grams on the following pages 1 Engine 8 Pumpregulator valve 2 Torque converter 9 Damper 3 Pump 10 Governor valve 4 Clutch amp gears 11 Shift valve 5 Governor 12 Kickdown cable amp throttle cam 6 Shift 13 Throttle modulator valves 7 Solenoid valve 14 Transmission housing B Fig 1 Schematic Diagram of Hydraulic Control 1 1 7 Thro
9. MV2 wire earthed remains in 2nd gear MV2 faulty Shift valve 2 3 seized Speed sensor faulty Renew harness Renew valve block Renew valve block Rectify or renew No upshift 2nd to 3rd B Clutch faulty Renew transmission Issue 1 August 1994 ZF Automatic Transmissions Service Manual 2 3 6 Fault Finding Chart continued Problem Possible Cause Action No upshift 3rd to 4th or lownshift 4th to 3rd Shift valve 3 4 seized MV1 wire earthed MV 1 faulty Speed sensor faulty Renew valve block Renew harness Renew valve block Rectify or renew Vo upshift 3rdto 4th 2ownshift 4th to 3rd too hard Manual gearshift Dto 3rd too F Clutch faulty Damper faulty Damper E faulty Drain orifice partially blocked Renew transmission Renew valve block Drain orifice partially blocked Renew valve block Renew valve block Renew valve block Manual gearshift 3rd to 2nd too ard Vo 1st gear 2nd gear start only No 1stor 2nd gear 3rd gear start only Damper C1 faulty Renew valve block Speed sensor faulty MV1 faulty MV1 wire earthed Shift valve 1 2 seized 1st Gear Inhibit circuit operated or Performance Mode switch faulty Transmission Limp Home mode Speed sensor faulty MV1 or MV2 faulty Shift valves 1 2 and 2 3 seized Check or renew speed sensor Renew valve block Re
10. Transmission in Limp Home mode Engine out of tune Torque converter freewheel seized Engine out of tune Renew torque converter Referto EDM rectify renew Kick down switch Check Check tune Renew torque converter Check engine tune Position P 7 Park Will not move out of Park not engage Park not hold Gearshift interlock failure iCheck cable adjustment mechanism sticking Check cable adjustment Parking pawl mechanism damaged Referto EDM rectify renew fuse check circuits renew relay and solenoid Check central check Park switch check Brake switch Adjust to correct setting Renew park pawl components connecting bar pawl pin torsion spring pawl guide piece and guide sheet Adjust to correct setting Replace park components 61 Issue 1 August 1994 ZF Automatic Transmissions Service Manual 2 3 6 Fault Finding Chart continued Problem Starter motor does not operate Possible Cause Rotary switch adjustment Adjust switch Rotary switch wiring fault Rotary switch faulty or renew Position P or N not selected Select P or N osition R Reverse Reverse gear inoperative MV2 faulty Renew valve block Wire to MV2 earthed Renew harness Clean replace filter and
11. ZF Automatic Transmissions Service Manual 2 1 15 Main harness connectors 12 way amp 8 way Pin Size Function mm 12 way connector 1A Switch common 2A Code X output 1 6 3A Code Y output Code Z output N C N C 7 12 Oil temperature signal 344 704 Oil temperature ground Road speed screen Road speed sensor Fig 1 Main Harness Connector 12 way 12A 0 5 Road speed sensor Pin Size Function mm 1B 10 Solenoids output 2B 10 1 solenoid 3 3B 10 MV2 solenoid 4B 10 MV WK solenoid 5B 05 Pressure regulator 8 eB 0 5 Start inhibit output 7B 05 Start inhibit ground 8B 0 5 Reverse lights output 444 705 2 Main Harness Connector 8 way Issue 1 August 1994 50 ZF Automatic Transmissions Service Manual 2 2 HYDRAULIC CIRCUIT DIAGRAMS Component Engagement Selector Gear Solenoid Clutches Free wheel Converter Position Valves Clutch W A B F G H J K 1 2 3 P R R N a D 1 C D 2 D 3 x x D 4 3 1 3 2 3 3 2 1 2 2 E Key To Hydraulic Diagrams commencing on page 52 1 Oil pump 19 Pressurevalve 2 2 Sump 20
12. Renew valve block Renew gear unit 1stto 2nd to 3rd and 3rd to 4th changes too long Full load and kick down changes too long Full load and kick down changes too hard Valve block bolt torque incorrect Damper faulty faulty wire earthed Modulation valve seized Pressure regulator valves 1 and 2 seized Valve block bolt torque incorrect Modulation pressuretoo low Clutch plates faulty Valve block bolt torque incorrect Modulation pressuretoo low Clutch plates faulty Reset to correct torque Renew valve block Renew valve block Renew harness Renew valve block Renew valve block Reset to correct torque Renew valve block Renewtransmission Reset to correct torque Renew valve block Renew transmission No engine braking Manual gearchange 3rd to 2nd inoperative Clutch C1 or Clutch E faulty Speed sensor faulty MV2 faulty 65 Renew transmission Check TCM Diagnostics renew Speed sensor Renew valve block issue 1 August 1994 ZF Automatic Transmissions Service Manual 2 3 6 Fault Finding Chart continued Problem Possible Cause Action onverter clutch gt lutch engagement speed ncorrect Control circuit fault Speed sensor faulty Check TCM Diagnostics rectify fault Check TCM Diagnostics renew Speed sensor ingagementtoo hard Valve
13. of 1 1 4th Gear Clutches A B C and F are engaged Freewheels 3 4 and 5 are over run Epicyclic gear set 1 rotates as a solid block The hollow shaft with the sun wheel of epicyclic gear set 2 is locked Above a predetermined road speed lock up clutch 6locks torque converter 7 solidto prevent slip m J44 694 Fig 1 HF H 1 4 r Gy Fia 2 JLL 69 6 7 p 2 2 d ILL T T T a 7 5 4 3 1445697 Issue 1 August 1994 ZF Automatic Transmissions Service Manual Reverse Gear Clutches B D and are engaged As the front planet gear carrier of epicyclic gear set 1 is locked the direction of output shaft rotation is reversed Epicyclic gear 2 also rotates as a solid block J44 698 Fig 1 1 1 4 Transmission Output Shaft Exlension Housing This housing contains the output shaft and speed governor andthe parking lock mechanism The governor comprises two spring loaded valves a spindle and a weight the governor is influenced by centrifugal and hydraulic forces and supplies a varying hydraulic pressure The parking lock pawl operates on a toothed wheel attachedto the output shaft speed governor the mechanism is operated from the selector position by actuator rod 1 1 5 The hydrauliccontrol unit comprising a series of valve blocks housing the manual selector valve contr
14. Q O O O OO immediate selection of a lower ratio is also available by kick down pressingthe accelerator down beyondthe normal full throttle position for example when overtaking 111 Torque Converter Thetorque converter servestwo mainfunctions it acts as afluid coupling between engine andtransmission geartrain and it provides multiplication of engine torque when required The torque converter consists of an impeller a turbine and a stator which is mounted on a one way clutch The converter cover is fixedto the impeller to seal the three elements within a common housing forming a closed circuit through which oilflows when the transmission is in operation The impeller istherefore connected to the engine and rotates at engine speed when the engine is operating Torque multiplication is at its greatest when the vehicle is driven away from standstill The stator bears against the housing through its one way clutch and deflects the oil so that the flow is accelerated As road speed builds up the impeller and turbine wheels turn at almost the same speed so that the stator ceasesto accelerate the oil flow and in stead is disengaged from the housing and turns freely inthe flow of oil At this stage the torque converter acts as a fluid coupling 1 Issue 1 August 1994 ZF Automatic Transmissions Service Manual The torque converter acts in all four forward gears and in reverse The converter lock up clutch closes in 4th gear a point
15. Safefy Inhibit Reverse is selected when the vehicle is travelling forwards at more than 5 mile h solenoid valve MV2 will be energised to prevent engagement of reverse gear 2 1 11 Gearshift Interlock A brake pedal gearshift interlock is incorporated in the gear selector mechanism The gear selector lever may only be moved from the P Park position if the ignition key switch is in position and the foot brake is applied The ignition key cannot be removed from the ignition switch unless the shift lever is inthe P Park position Once the ignition key has been removed the shift lever is locked inthe park position 2 1 12 Starter Inhibit Switch The starter inhibit switch prevents the starter motor from being operated when the shift lever is not in position P Park or position N Neutral The switch is located inthe gear selector housing 47 issue 1 August 1994 ZF Automatic Transmissions Service Manual JLL 699 C1 Clutch valve Manual selector valve 2 3 shift valve piston Aclutch damper Cclutch damper valve 1 2 shift valve Bclutch damper B clutch damper valve 1 2 shift valve piston Cclutch damper D clutch valve and piston 2 3 shift valve Pressure regulating valve Converterpressurevalve Note Numericalannotations are not used in this application Fig 1 Manual Valve Block 43 Issue 1 August 1994 ZF Automatic Transmissions Service Manual One way valve lubri
16. TES DEED 61 NENNEN NA a Electical wu aden RENE RR S ND NE E ERU RE 61 20 0 Fault FINDING uu IG EN e EP ES 61 E Service Operations 68 Issue 1 August 1994 ZF Automatic Transmissions Service Manual FOREWORD This manual provides information relevant to the servicing of ZF Automatic Transmission Units 4 HP 22 and 4 HP 24 E irrespective of the vehicle range to which the unit is fitted The manual should be used in conjunction with the rel evant Vehicle Service Manual VSM and Electrical Diagnostic Manual EDM Itassumes that the transmission has been removedfrom the vehicle in accordance with the Vehicle Service Manual and is in aclean condition and all service tools and materials are available The manual is divided intotwo sections covering ZF 4 HP 22 and ZF 4 24 E and each section is divided into sub sections covering Service information Q General Description Hydraulic Circuit Diagrams Q Fault Diagnosis Q Service Repair Operations An index can befound atthe rear of the manual Note For information relating to in vehicle operations referto the Vehicle Service Manual Issue 1 August 1994 ii ZF Automatic Transmissions Service Manual
17. Torque converter pressure valve 3 Torque converter 21 Lubrication valve 4 cooler 22 Lubrication valve 5 Clutch damper 23 Lock up control valve 6 Clutch valve and damper 24 Modulation pressure valve 7 Clutch C damper 25 Main pressure valve 8 Clutch C valve 26 Gearchange valve 9 Clutch valve and damper 27 Solenoid valves MV1 MV2 MV3 10 Clutch D valve and damper 28 Pressure regulator 11 Clutch damper 29 ECM inputs and outputs 12 Clutch F valve and damper 30 Enginetorque 13 Reverse locking valve 31 Throttle valve 14 Shift valve 1 2 32 Engine speed RPM 15 Shiftvalve 2 3 33 Transmission speed RPM 16 Shiftvalve3 4 34 Transmission rotary switch 17 Safety valve 35 filter 18 Pressure valve 1 A Clutch D Clutch D G Torque converter freewheel B Clutch B E Clutch H C Clutch freewheel C Clutch F Clutch J D Clutch freewheel c Clutch K E Clutch freewheel L Exhaust Reduced pressure zxz Throttle mom Modulation pressure C3 33 Sump Main pressure Lubrication pressure Converter pressure Throttle pressure 51 Issue 1 August 1994 5 gt o o c 9 2 E o c E 9 Ce G E D 3 lt LL N n AAA H Xr 1 52 Issue 1 August 1994 ZF Automatic Tra
18. block Renew converter Check TCM Issue 1 August 1994 ZF Automatic Transmissions Service Manual 2 4 SERVICE OPERATIONS 2 4 1 ZF 4 HP 22 Transmission SROs to be added when available 2 4 2 4 HP 24 E Transmission SROs to be added when available Issue 1 August 1994 68 Index D drive Ist idle 13 D drive Ist kickdown 15 Fault diagnosis D drive 2nd full throttle 17 ZF 4HP 22 D drive 2nd idle 16 Electrical checks 33 D drive 2nd kickdown 18 Enginetune 33 D drive 3rd full throttle 20 Fault finding chart 34 D 7 drive 3rd kickdown 21 Initial checks 33 D drive 3rd partthrottle 19 Roadtest 33 D drive 4th full throttle lock up 24 Stall test 33 D drive 4th partthrottle 22 ZF 4HP 24 E D drive 4th part throttle lock up 23 Electricaltests 61 neutral 12 Engine tune 60 P park 10 Fault finding chart 61 R reverse 11 Initial checks 60 Key 9 Roadtest 61 ZF 4HP 24 E Stall test 60 7 1st 59 2 D drive 1st 55 Foreword ii D drive 2nd 56 D drive 3rd 57 G D drive 4th lock up 58 N neutral 54 General description P park 52 ZF 4HP 22 R 7 reverse 53 Epicyclic gear train 2 Key 51 Gear train clutches operation 3 Gearshift interlock 8 S Gearshift selection 8 Output shaft extension housing 4 Service data
19. is operated by electrical solenoid located adjacentto the selector an override latch is incorpo rated into the mechanism enable the gearshift interlock to be manually overridden inthe event of electrical failure or when towing Issue 1 August 1994 8 ZF Automatic Transmissions Service Manual 21 b 4 Og s 4 F JLL 699 C1 Clutch valve 2 3 shift valve piston C clutch damper valve B clutch damper 1 2 shift valve piston D clutch valve and piston Pressure regulating valve Manual selector valve A clutch damper 1 2 shift valve B clutch damper valve C clutch damper 2 3 shift valve Converter pressure valve o mm COD gt SST st Note Numerical annotations are not usedin this application Fig 1 Manual Valve Block 5 Issue 1 August 1994 ZF Automatic Transmissions Service Manual 4 ni IWWWWWW 1 15 16 144 70 A One way valve lubrication 3 4 shift valve B 2nd gear inhibit valve 1st gear inhibitvalve C Fclutch damper H Fclutch valve D Fclutchinhibit valve reverse E clutch damper E 3 4 shift valve piston J C1 clutch damper Note Numerical annotations are not used in this application Fig 1 Rear Valve Block Issue 1 August 1994 ZF Automatic Transmissions Service Manual 12 A Modulator valve B Throttle valve Kick down valve C Reverse inhibit valve
20. 1 3 6 Problem Fault Finding Chart continued oss of oil through breather Possible Cause Oil level too high Incorrect oil Breather blocked No breather cap O ring breather damaged Securing clip faulty Action Check level Remove transmission ensuring that it is drained including torque converter oil cooler and pipes Change breather check for foul condition of foam insulation pad Fit cap or renew breather Remove tail housing and replace O ring Renew clip Jil leak at intermediate plate eakage between gearbox and 2xtension housing Noises Jigh pitched squeaking noise dependant on engine RPM in all years when oil is warm and accompanied by intermittent drive after a long journey digh pitched noise in all oositions especially if oil is cold Sucking noise from pump Very noisy in lock up Blanking plug loose Tighten plugs Renew sealing washers Fastening screws loose Gasket faulty Dirty filter Low oil level Filter not sealing Leaking valve block Filter damaged Torsion damper faulty Tighten screws to specified torque Renew gasket If there is no debris in the sump renew the filter and oil If debris is present renew the transmission Top up as necessary Check renew O ring Service renew valve block Check filter Renew torque converter Torsional vibrations from engine when in lock up Engine RPM isto
21. 45 Transmission Control Module TCM 46 Z6 4 Transmission Rotary een 47 2A ra wie 16 610 1017 210 1 47 PerformanceMode Switch 47 21 9 Kick down Mechanism nnns 47 2 1 10 Reverse Safety Inhibit 47 apa su aq Gearshift Interlock aera ras s eer et Y 47 2 1 12 isis BI Starter Inhibit Switch eee uer e E ET ce 47 2 113 2 d adea t TE us 48 24 14 eoi ue Rotary Switch Harness 49 2 415 es een ai ace Main Harness Connectors 12way and 8 way si ae e 50 2 2 Eessen See Hydraulic Circuit Diagrams y 51 Fault 60 E Initial Checks re ee ee deeg 60 2 3 2 diea s Engine vaa a FRIAR EE EE 60 CUBE NEM TEM 60 Z3 eed tarn
22. Note Numerical annotations are not used in this application Fig 1 Throttle Valve Block 7 Issue 1 August 1994 1 2 HYDRAULIC CIRCUIT DIAGRAMS ZF Automatic Transmissions Service Manual Key To Hydraulic Circuit Diagrams commencing on page 10 n c amp gt 0uoomso0wNF Governor Torque Converter Sump Pump Pressure Regulating Valve Clutch B Valve And Damper Clutch D Valve And Damper Reverse Gear Inhibit Manual Valve Oil Cooler Converter And Reversing Valve Converter Clutch Damper One way Valve Modulator Valve 1st Gear Inhibit Clutch A Clutch B Clutch C Clutch Clutch D Clutch Clutch _v Exhaust Throttle Orifice L Branch V Main Pressure Converter Pressure VII Throttle Pressure 16 17 18 19 20 21 22 23 24 25 26 27 28 29 1 2 Shift Valve Clutch C Valve Clutch Damper Clutch Valve 2 3 Shift Valve 2nd Gear Inhibit Throttle Valve Converter Clutch Lock up Control Valve Converter Clutch Hysteresis Valve 3 4 Shift Valve Clutch F Valve And Damper Clutch Damper Clutch Damper Clutch F Inhibit Valve Reverse VII Governor Pressure IX Locking Pressure X Modulation Pressure mamm Pump Pressure Lubrication Pressure issue 1 August 1994 T 5
23. OQDPODI 9 ISL NOILISOd Issue 1 August 1994 15 3 c a e o o 9 2 E o E 52 Ce E m 3 lt nt Sc ALT 3 WS CG EEN d po ES KN 9 WWW WT 16 Issue 1 August 1994 3 c e 9 o 9 o 2 E o m E 5 lt LL N cro MM 7 ww x F 4 N owe 8 b H CO Ll ko LL Issue 1 August 1994 17 9 9 pre ec D D D H 2 Cem r 8 sz ER 12 z 3 dd e WWW ei CET Esq oz za 0 1 4 1 7 RP SEES I L3 al 134 2 KO 1 z AW HHI 1 4 E om d M PF 3 3 3 3 9 CG NMOGIODI PUZ NOLLISOd 3 c e o o 9 o 2 E o Ce 6 m 3 lt 18 Issue 1 August 1994 L e Un Ui Sc NE KE 3 e o o 9 7 2 E o 5 E 9 m E D 3 lt LL N al al MW 1 4 as zi WWW d Se
24. ace cable Replace cable Service renew valve block Noisy and no drive after a long ourney Oil filter on valve block faulty If there is no burnt lining inthe sump renew the filter and oil If debris is present renew the transmission Very noisy and no drive Drive plate is worn or broken Renew the drive plate Jil leaks dripping from the bell Seal ring in pump housing Renew seal ousing damaged Defective pump O ring Renew C ring eakage betweentransmission and oil sump eakage between intermediate and main housing especially at pump pressure 3oint leak at output eakage from cooler pipes eakage between main housing and tail housing Pump housing porous Converter leaking from welded seam Bolts incorrectly torqued Sump gasket damaged Bell housing bolts loose Gasket damaged Output oil seal damaged Loose connections Pipes damaged Cooler leaks Loose bolts Gasket damaged Renew pump housing Renew converter Tighten bolts to specified torque Renew sump gasket Tighten bolts to specified torque Renew gasket Renew seal Tighten connections Renew pipes Renew cooler Tighten bolts Renew gasket Dil leak from kick down cable at Transmission end O ring connection damaged Renew O ring or complete cable 37 Issue 1 August 1994 ZF Automatic Transmissions Service Manual
25. alve block Sudden shifts Dampers sticking Service renew valve block Jehicle starts in 2nd gear Governor sleeve sticking Renew governor Shift valve 1 2 sticking Renew valve block Vehicle starts in 3rd gear Governor sleeve sticking Renew governor Shift valves 1 2 and 2 3 sticking Service renew valve block 3earbox changes 1stto 3rd Shift valve 2 3 sticking Service renew valve block No shifts Governor sticking Change governor Dampers sticking Service renew valve block 35 Issue 1 August 1994 ZF Automatic Transmissions Service Manual 1 3 6 Fault Finding Chart continued Problem Possible Cause Action No changes at light throttle setting Dirty governor Shift valves sticking Renew governor Service renew valve block Change points incorrect at full throttle setting Kick down cable setting incorrect Adjust setting No changes at kick down 1st to 2nd 2nd to 1st Kick down cable setting incorrect Adjust setting No changes at kick down 2nd 3rd to 2nd Kick down cable setting incorrect Adjust setting Poor changes Harsh changes at low throttle Throttle valve kickdown cable setting incorrect Defective damper Modulation pressure too high Clutch plates damaged Kick down cable setting incorrect Adjust setting Service renew valve block Service renew valve block Adjust setting Service ren
26. am switch input 33 Position code Z input 5 Solenoid valve MV1 output 34 37 not used 6 Pressure control valve PCV output 38 Vehicle speed sensor minus input 7 Digital ground input 39 40 not used 8 13 not used 41 Kick down switch input 14 15 Diagnostic L line 43 not used 16 Transmission malfunction indicator lamp 44 Oil temperature sensor ground output 7 18 not used 45 not used 19 Solenoid valves plus input Oil temperature sensor input 20 Vehicle speed sensor screen Throttle position input 2 Enginetorque signal T T input not used not used Sport mode indicator output Solenoid valve MV2 output Position code X input 2 2 not used Diagnostics K line mana not used Issue 1 August 1994 48 ZF Automatic Transmissions Service Manual 2 1 14 Rotary Switch Harness 286 1857 Fig 1 Transmission Connector 9 Pin Color Size Function mm 0 5 Speed sensor B OG 0 5 Pressure regulator solenoid valve D YG 05 1 sensor input F RIN 0 5 Speed sensor H J K YB 1 0 Solenoid valve 1 MV1 BG 0 5 Oil temperature sensor ground Solenoid valve 2 MV2 Lock up solenoid MVK Solenoid supply YP 1 0 Color Code N Brown Y Yellow B Black O Orange W White S Slate K Pink L Light G Green P Purple R Red U Blue Indigo 49 Issue 1 August 1994
27. body problem Converter unit faulty Renew valve body Renew converter unit clutch engagement Control circuit fault MV3 faulty Converter clutch valve seized Converter faulty Pressure reducing valve 1 seized clutch engaging at dle engine will not idle in D Incorrect oil level Oil filter not sealing Control circuit fault faulty MV3 wire earthed Converter clutch valve sticking Check TCM Diagnostics rectify fault Renew valve block Renew valve block Renew converter Renew valve block Check oil level Check 0 etc Check TCM Diagnostics rectify fault Renew valve block Renew harness Renew valve block in bell housing Oil pump seal leaking Oil pump O ring leaking Pump housing leaking Converter seam leaking Renew oil pump seal Renew 0 Renew oil pump Renew converter eakage between gearbox and sump Loose fastening screws Sump gasket faulty Torque tighten Renew gasket Leakage between intermediate slate and gearbox Bell housing to gearbox screws loose Torque tighten Leakage at harness plug Connector O ring faulty Renew OT Leakage at drive flange Rear oil seal faulty Renew oil seal 66 issue 1 August 1994 2 3 6 ZF Automatic Transmissions Service Manual Fault Finding Chart contin
28. cation 2nd gear inhibit valve Fclutch damper Fclutch inhibit valve reverse 3 4 shift valve piston 3 4 shift valve 1stgear inhibit valve F clutch valve E clutch damper C1 clutch damper moOo9 c rgo n Note Numerical annotations are not used in this application Fig 1 Rear Valve Block issue 1 August 1994 44 70 ZF Automatic Transmissions Service Manual A Modulator valve B Kick down valve C Reverseinhibit valve Note Numerical annotations are not used in this application itol Fig 1 Throttle Valve Block 45 Issue 1 August 1994 ZF Automatic Transmissions Service Manual 1 8 7 p 10 11 I i 1 6 15 13 14 E d 444 718 1 Selector 9 Transmission control module TCM 2 Mode switch 10 Reverse lamps 3 Rotary switch 11 Start inhibiter 4 Transmissioncontrol unit 12 Engine speed 5 Output shaft speed sensor 13 Ignition retard 6 Kick down switch 14 Engine load 7 Battery 15 Engine control module ECM 8 Transmission relay 16 Engine speed sensor Fig 1 Control Layout Schematic 2 1 5 TransmissionControl Module TCM The Transmission Control Module TCM is an electronic control unit located in the front passengerfootwell behind the underscuttle pad It is electrically connectedto the transmission and other componentsthrough cable harness and multiple pin plug The TCM continuously monitors the gear selected viathe r
29. ce of oil on dipstick at idle in Park before setting off a Check that the vehicle is on level ground a Firmly apply the parking and footbrakes and runthe engine at idle speed a ensure that the system is primed slowly the selector lever through all the gear positions a With the engine still running engage H Park withdraw the dipstick and wipe with a lint free cloth a Replace the dipstick slowly and withdraw it noting the level up as required and recheck the level Note Theoillevelcanonly beaccuratelychecked when at normaltemperature approximately 20 milesat moderate speeds 2 3 2 Engine Tune Selector cable adjustment a Check gear selection in all selector positions a If indoubt select N disconnect the cable atthe gearbox selector lever checkthat the gearbox leveris in N position third detent from the rear and refitthe selector cable ball pinto the lever a Adjust as necessary the selector lever inside the vehicle 2 3 3 Stall Test a Ensurethe transmission is at normal runningtemperature Fully apply the parking brake a Startthe engine Fully depress the footbrake Select position D Drive a Fully depress the accelerator kick down switch fully depressed a Note the tachometer reading Compare the tachometer reading to the specification CAUTION Thistest mustnotlast morethan 5seconds Always allowthe engineto idlefor at least 2 minutes between teststo allowthe transmi
30. d A QC E Freewheel 15 over runs 44 2 d Clutches C1 and C lock the sun gear to the housing Y 5 e Ic 4 Fig 2 144 695 3rd Gear Clutches and E are engaged AB j E Freewheels 14 and 15 are over run Epicyclic gear sets 9 and 10 rotate solid block at aratio A of 1 1 54 944 69 Fig 3 4th Gear Clutches A B C and F are engaged 6 7 Freewheels 14715 and 16 are over run AB C F 1 2 Epicyclic gear set 9 rotates as a solid block 2 22 7 4 The hollow shaft with the sun wheel of epicyclic gear set 10 I is locked T a Above a predetermined road speed lock up clutch 2 locks torque converter 3 solid to prevent slip 5 4 3 Fig 4 J44 697 41 Issue 1 August 1994 ZF Automatic Transmissions Service Manual Reverse Gear Clutches and are engaged As the front planet gear carrier of epicyclic gear 9 is locked the direction of output shafgt rotation is reversed gear set 10 also rotates as a solid block omg J44 698 Fig 1 2 1 4 Transmission Control Unit Theelectronic hydraulic control unit comprising a series of valve blocks housing acable operated manual valve con trol pistons and pressure valves is attached to the underside of the transmission housing the unit controls the oper ation of the gear train clutches and directs oil p
31. d accelerator position engine power is then transmitted by purely mechanical means A low loss oil pump inthe front of the transmission housing supplies the converter the automatic gear shift and the lubrication circuit oil is drawn from a sump inthe bottom ofthe gear train housing through a filter The pump drive gear is keyedto the converter impeller hub and therefore turns when the engine is running thereby pressurizing the oil 2 1 2 Four speed Epicyclic Gear Train The torque converter drives a mechanical epicyclic geartrain providing four forward ratios and reverse Individual ra tios are obtained by coupling together the various parts of the gear train by means of solenoid operated hydraulically actuated multi disc clutches and brakes built in freewheels permit gear shifts without any interruption of the power flow For information on the operation of the solenoids clutches brakes and freewheels refer to the table below and the schematic diagrams shown overleaf A parking lock pawl is provided the rear ofthe gear train operating on atoothed wheel attached to the output shaft the parking lock is operated from the selector position P by actuator rod An electro magnetic sensor detects output shaft revolutions by means of atoothed disc attachedtothe shaft one rev olution ofthe shaft is equal to 36 pulses The electrical signal from the sensor is passed via a screened cable to the TCM Selecte
32. d ratios Solenoid Resulting clutch operation D4 MV2 A Clutch drives annulus clockwise 31 D Clutch OWC holds F carrier against shaft clockwise 21 E Clutch amp OWC drives output shaft clockwise Do MV1 MV2 A Clutch drives annulus clockwise 32 C1 Clutch holds sungear against anti clockwise 2 C Clutch amp OWC holds sungear against anti clockwise 12 Ds MV1 MV3 A Clutch drives annulus clockwise 33 B Clutch drives sungear clockwise 23 C Clutch 8 holds sungear against anti clockwise Du MV2 A Clutch drives annulus clockwise B Clutch drives sungear clockwise C Clutch amp OWC holds sungear against anti clockwise R B Clutch drives sungear clockwise D Clutch holds carrier against clockwise E Clutch amp OWC drives output shaft anti clockwise Park MV2 E Clutch amp OWC applied hydraulics Neutral OWC one way clutch Issue 1 August 1994 40 ZF Automatic Transmissions Service Manual 2 1 3 Operation Of Gear Train Clutches Operation of the gear train clutches to provide the five gear ratios is as follows 1st Gear Clutches A and are engaged The front planet gear carrier of gear set 9 is locked against A D 2 E the housing of through freewheel 10 when the engine is pulling but is over run when the engine is coasting T ff Epicyclic gearset 10 rotates as a solid blockwith the second planet set 2 I T 454 6 9 Fig 1 2nd Gear Clutches A C1 C and are engage
33. depending on road speed and accelerator position engine power isthen transmitted by purely mechanical means A low lossoil pump inthe front ofthe transmission housing supplies the converter the automatic gear shift and the lubrication circuit oil is drawn from a sump inthe bottom ofthe geartrain housingthrough a filter The pump drive gear is keyedto the converter impeller hub and therefore turns when the engine is running thereby pressurizing the oil 1 1 2 Four speed Epicyclic Gear Train The torque converter drives a mechanical epicyclic gear train providing four forward ratios and reverse Individual ra tios are obtained by coupling togetherthevarious parts of the geartrain by means of hydraulically actuated multi disc clutches and brakes built infreewheels permit gear shifts without any interruption of the powerflow Operation of the clutches and gear sets is described in sub section 1 1 3 Each epicyclic or planetary gear set comprises a central sungear an annulus and a planetary carrier which supports four small planet gears or pinions Two gear sets are used inthistransmission A compound gear set comprising front annulus and planet carrier rear annulus and planet carrier and acommon sungear transmits the drive inall gears ex REVERSE a single planetary carrier annulus and sungear transmits the fourth gear drive The table belowshows the resulting clutch operation in the selected gear ratios Selected ratios Resulti
34. ding Chart continued Possible Cause Action Starter will not operate Vehicle moves 2rive not transmitted neutral zondition Rotary switch faulty or incorrect setting Rotary switch wiring fault A Clutch seized filter dirty Main pressure control valve seized Low oil level A Clutch faulty D Clutch one way clutch slips Rectify or renew Rectify CheckSecurity System Renew transmission Clean replace filter Renew valve block Check oil level Renew transmission Renewtransmission Slipping and juddering at start AClutch faulty Low oil level Renew transmission Check oil level Harsh engagement N D under 1500RPM engine speed No 1stto 2nd upshift or 2nd to 1st downshift AClutch faulty A Clutch damper faulty 5 Throttle pot volts high Rotary switch faulty out of adjustment No upshift 1stto 2nd MV1 wire earthed remains in 2nd gear MV1 faulty Control circuit fault Shift valve 1 2 seized Pressure reducing valve 1 seized Speed sensor or connectors faulty Clutches C1 and faulty Renew transmission Renew valve block Checkthrottle pot volts Rectify or renew Renew harness Renew valve block Check TCM Diagnostics rectify Renew valve block Renew valve block Check connections rectify or renew Renew transmission No upshift 2nd to 3rd or downshift 3rd to 2nd
35. election of a lower ratio is also available by kick down pressingthe accelerator down beyondthe normal full throttle position for example when overtaking 2 1 1 Torque Converter Thetorque converter servestwo mainfunctions it acts as afluid coupling between engine andtransmission geartrain and it provides multiplication of engine torque when required The torque converter consists of an impeller a turbine and a stator which is mounted on a one way clutch The converter cover is fixed to the impeller to seal three elements within a common housing forming a closed circuit through which oil flows when the transmission is in operation The impeller istherefore connected to the engine and rotates at engine speed when the engine is operating Torque multiplication is at its greatest when the vehicle is driven away from standstill The stator bears against the housing through its one way clutch and deflects the oil so that the flow is accelerated As road speed builds up the impeller and turbine wheels turn at almost the same speed so that stator ceasesto acceleratethe oil flow and in stead is disengaged from the housing and turns freely inthe flow of oil At this stage the torque converter acts as a fluid coupling 39 Issue 1 August 1994 ZF Automatic Transmissions Service Manual The torque converter acts in all four forward gears and in reverse The converter lock up clutch closes in 4th gear at a point depending on road speed an
36. ene 8 h Dh H DI s SET Mz e 1 1 12 D rei m A 1 nna k L gt sss SC bic t lt JILLOYHL 1 JAYA NOLLISOd Issue 1 August 1994 S c 3 9 K gt im L I o 2 E E S gt 6 5 U N ez WE H eee nt om Cox 52 zi P ERU ATLLOYHL TINA HV39 PAE JAHA NOILISOd bz e ron CELA ELp et 29 ISSUE AUEUSI 3 c a e o o 9 o 2 E o c E 2 E m 3 lt LL N 69 per n 2 Issue 1 August 1994 G4 4 T Lj L ET E ES i d C 21 E E zi WWW 47 am SE 2 FAS Mu 6 25 4 In 91 WA s WHT E Hv39 PJE JAYA NOILISOd E m a
37. evel ground Firmly apply the parking and footbrakes and runthe engine at idle speed To ensure that the system is primed slowly movethe selector lever through allthe gear positions a With the engine still running engage Park withdraw the dipstick and wipe with a lint free cloth a Replace the dipstick slowly and withdraw it noting the level a up as required and recheck the level 1 3 2 Engine Tune Selector cable adjustment Check gear selection in all selector positions Ifindoubt select disconnectthe cable atthe gearbox selector lever checkthatthe gearbox lever in N position third detent from the rear and refit the selector cable ball pinto the lever Adjust as necessary see Vehicle Service Manual s Kick down switch adjustment see Vehicle Service Manual 1 3 3 Stall Test a Ensurethe transmission is at normal runningtemperature a Fully apply the parking brake Startthe engine Fully depress the footbrake s Select position D Drive Fully depress the accelerator kick down detent fully depressed a Note the tachometer reading Compare the tachometer reading to the specification CAUTION This test must not last more than 5 seconds Always allow the engine to idle for at least 2 minutes be tween tests to allow the transmission fluid to cool down Do not carry out more than three tests any half hour 1 3 4 Road Test Fully check all shift speeds and note Compare
38. ew transmission Soft changes at full throttle and Kick down Harsh changes at full throttle and kick down Defective damper Modulation pressure too low Clutch plates damaged Incorrect modulation pressure Defective damper Kick down cable setting incorrect Service renew valve block Adjust setting Kick down cable setting incorrect Service renew valve block Service renew transmission Service renew valve block 1 Adjust setting Manual change 3rd to 2nd faulty Locking valve 2 sticking Governor faulty Service renew valve block governor Service renew valve block governor No engine braking Brake or damaged Service renew transmission Issue 1 August 1994 36 1 3 6 Problem points at incorrect speeds ZF Automatic Transmissions Service Manual Fault Finding Chart continued Possible Cause Lock up safety valve sticking Kick down cable setting incorrect No 4th gear Governor pressure incorrect 3eneral Action Service renew valve block governor Adjust setting Check cable adjustment service renew valve block governor Service renew valve block governor Kick down cable sticking Nipple in throttle cam is worn Too much friction in sleeve of kick down cable Throttle pressure piston sticking Repl
39. flush out the oil cooler and pipes filter dirty Renew valve block Damper faulty Renew transmission Clutch B faulty also no 3rd gear Clutch D faulty Renew transmission Clutch faulty also no engine braking Renewtransmission in 2nd and 3rd gears Pressure regulator valve 1 binding Renew valve block Rotary switch wiring fault Rotary switch faulty Rectify Reverse gear inhibit valve activated Rectify or renew Main pressurecontrol valve seized also Renew valve block noforward drive in D Drive Renew valve block Renew transmission Slipping and juddering B Clutch D Clutch or Clutch faulty Pressure regulator valve 1 binding Renew valve block F Clutch drum sealing rings faulty causing loss of E Clutch pressure Renew transmission Renew valve block Harshengagement P R change Damper B faulty also no 2nd to 3rd N R change below 1500 shift engine speed Pressure regulator valve 1 binding Renew valve block Modulation pressuretoo high Check TCM Fault Codes Rotary switch faulty Rectify or renew Reverse lamp does not Rotary switch setting incorrect Adjust setting illuminate bulbs fuses and cables functioning correctly Rotary switch faulty Renew Rotary switch wiring fault Rectify Issue 1 August 1994 62 2 3 6 Problem ZF Automatic Transmissions Service Manual Fault Fin
40. iii Starter inhibit switch 8 Throttle valve mechanism 8 Service materials iii Torque converter 1 Service operations ZF 4HP 22 Not yet available 68 Control layout schematic illustration 46 88 Decoder module 47 Servicetools amp equipment iii Epicyclic gear train 40 Gear train clutches operation 41 T Gearshift interlock 47 Harness connections 48 zn ZEIEN Torque tightening specifications iii Main harness connector 12 way 50 8 50 Performance mode switch 47 Reverse safety inhibit 47 Rotary switch connector pins 49 Rotary switch harness 49 Starter inhibit switch 47 connector pins 48 Torque converter 39 Transmission control module 46 Transmission control unit 42 Transmission rotary switch 47 H Hydraulic circuit diagrams ZF 4HP 22 1 1st full throttle 32 1 2nd idling 31 1 3rd idling 30 2 2nd full throttle 29 2 3rd idling 28 8 3rd full throttle 26 3 ard kickdown 27 3 3 partthrottle 25 D drive Ist full throttle 14 69 Issue 1 August 1994
41. le Valve Mechanism kick down 8 TAG Slater aem 8 ES Ez ease Grea are Beatie Gearshift interlok dea Dime rer OP 8 pa inte ea Hydraulic Circuit Diagrams cece ccc eee ene hh hh hn 9 Fault Diagnosis sis cung du p E eed A ae 33 E EE Initial ee 33 1 3 2 Engine EF MEUSE a ERE 33 Stall Meet uds eor EO REB RE E Sic eth a Sakata a re a sepe 33 TEC MI MULT Er 33 1 35 velis Electrical Checks eere Ada a eR Eb Pre NER MEME TA qe 33 1 36 sce aces Fault Finding Chart i vices e CK HEN CE EAR Ve 34 dua ede oy PT ZF 4 24 E Transmission General Description 39 ana Torqueconverter 39 Four speed Epicyclic Gear 40 2113 Operation Of Gear Train Clutches 2 41 2 1 4 Transmission Control Unit samisi an SES SEN RR Rae RR RR eae ae 42 2
42. lock erk when engaging positions same symptoms when changing or N R below 1500RPM 2nd to 3rd gears tngine speed ieverse lamp does not illuminate Starter inhibit switch faulty Renew switch bulbs fuses and cables unctioning correctly Faulty selector lever Renew lever Position R not selected Select No drive or severe delay Dirty oil filter Ifthere is no debris in sump renewthe oil filter and oil if debris is present in the sump renew the transmission Check oil level Oil level incorrect Service renew transmission A clutch defective Service renew transmission D clutch one way clutch faulty Slipping or shaking during initial A clutch damaged Service renew transmision orward movement Strong jerk N D below 1500 clutch faulty Service renew transmission engine speed A clutch damper faulty Service renew valve block Sear change functions faulty ine Id or warm state Zhange 1stto 2nd 2nd to 1st Governor dirty Renew governor Shift valve 1 2 sticking Renew valve block Zhange 1stto 2nd Brake C1 and or C faulty Service renew transmission Zhange 2nd to 3rd 3rd to 2nd Governor dirty Renew governor Shift valve 2 3 sticking Renew valve block Change 2ndto 3rd B clutch faulty Service renew transmission Zhange 3rd to 4th 4th to 3rd Governor dirty Renew governor Shift valve 3 4 sticking Renew v
43. new harness Renew valve block Operate Performance Mode switch to correct function or renew switch Check Diagnostics JDS Renew speed sensor Renew valve block Renew valve block No 2nd gear transmission shifts 1stto 3rd gear Speed sensor faulty Shift valve 2 3 seized Check or recheck Diagnostics renew speed sensor Renew valve block Light throttle gear change speeds incorrect Shift valves sticking Speed sensor faulty Throttle pot volts incorrect Transmission Control Module TCM Renew valve block Check or renew speed sensor Check voltage JDS Check TCM Diagnostics Upto kick down detent gear change speeds not to specification Kick down switch out of adjustment Readjust kick down switch Issue 1 August 1994 64 ZF Automatic Transmissions Service Manual Problem Possible Cause n No kick down change LLL ss Lightthrottle speeds only Lightthrottle gear changetoo hard Kick down switch out of adjustment fullthrottle stop adjustment Kick down switch faulty Kick down switch connector or wiring Faulty TCM faulty Action Adjust as per Engine Set Up procedure on JDS Renew kick down switch Rectify Check TCM Valve block bolt torque incorrect Modulation pressuretoo high Damper faulty Clutch plates faulty Reset to correct torque Renew valve block
44. ng clutch operation D4 34 21 A Clutch drives annulus clockwise E Clutch 8 OWC drives output shaft clockwise Ds 32 22 A Clutch drives annulus clockwise C1 Clutch holds sungear against anti clockwise C Clutch amp OWC holds sungear against anti clockwise Ds 33 23 A Clutch drives annulus clockwise B Clutch drives sungear clockwise C Clutch amp OWC holds sungear against anti clockwise D A Clutch drives annulus clockwise B Clutch drives sungear clockwise C Clutch amp OWC holds sungear against anti clockwise R B Clutch drives sungear clockwise D Clutch holds carrier against clockwise E Clutch amp OWC drives output shaft anti clockwise Park Neutral E Clutch amp OWC applied hydraulics OWC one way clutch Issue 1 August 1994 2 ZF Automatic Transmissions Service Manual 11 3 Operation Of Gear Train Clutches 1st Gear Clutches A and E are engaged The front planet gear carrier of gear set 1 is locked against the housingofthroughfreewheel 2 when the engine is pul ling but is over run when the engine is coasting Epicyclic gear set 2 rotates as a solid block with the second planet set 2nd Gear Clutches and are engaged Freewheel 4 over runs Clutches C1 and lock the sun gear to the housing 3rd Gear Clutches A B C are engaged Freewheels 4 and 5 are over run Epicyclic gear sets 1 and 2 rotate as a solid blockat ratio
45. nsmissions Service Manual POSITION R REVERSE lil tra P SE Geen 53 Issue 1 August 1994 ZF Automatic Transmissions Service Manual LORS e POSITION N NEUTRAL KSE sore iin i I 111 SE 1 L issue 1 August 1994 54 ZF Automatic Transmissions Service Manual POSITION D DRIVE 1st GEAR xc X II 344 633 H 1 E eg 23 H ERN wanmi M KS I n ICC TERA CORTE CIRCE MOL SCH 32 33 34 30 31 55 Issue 1 August 1994 ZF Automatic Transmissions Service Manual A POSITION D DRIVE 2nd GEAX por CES EN 553 CL EI SSW e Kei EI RA d ais MeH pasian 525 i
46. o low lock up shift point incorrect Service renew valve block oud noisewhen converter slutch engages Torsion damper defective Renew converter Engine vibrations when zonverter clutch engaged Issue 1 August 1994 Change point too low 38 Check valve block ZF Automatic Transmissions Service Manual 2 1 ZF 4 HP 24 E TRANSMISSION GENERAL DESCRIPTION The ZF Transmission covered inthis section comprises a hydrodynamictorque converter four speed gear train and electronic hydraulic transmission control unit 7 6 J44 688 Torque converter 4 speed gear train Output flange Transmission control unit Oil outlet drain plug Rotary switch positions seetext Dipstick oil filler tube Oil cooler connection Fig 1 ZF 4 HP 24 E Transmission The automatic transmission provides six gearshift positions Position Park inthis position the driven wheels are mechanically locked at the transmission Position H Reverse reverse gear selected Position N Neutral engine disconnected from drive line and wheels Position D Drive all four speed ranges are selected automatically with lock up available in top gear only Position 3 automatic selection of the lowest three speed ranges only Position 2 automatic selection of the lowest two speed ranges only transmission is preventedfrom shifting upto the third and top speed ranges Immediate s
47. ol pistons and pressure valves is attachedto the underside of the transmission housing the unit controls the operation of the gear train clutches and directs oil pressureto the appropriate system components referto illustrations pages 5 to 7 to operate the transmission The valve blocks are connectedto a main gallery plate Transmission Control Unit Line pressure from the hydraulic pump is supplied initially to the pressure regulating valve manual valve governor 3 4 shift valve E clutch and damper throttle valve modulator valve and torque converter pressure and reversing valve The function of each of the valves inthe control unit and the governor valve is summarised in the table below Valve Summary of function Pressure regulating Varies line pressure as required 1 2 shift valve Line pressureto C amp C1 clutch valves and dampers 2 3 shift valve Line pressureto C1 clutch 2nd line pressureto B clutch 3rd 2nd gear inhibit 3 4 shift valve Throttle valve Modulator Converter amp Reversing Line pressureto 2 3 shift valve Line pressureto E clutch 3rd line pressureto F clutch Ath Throttle pressureto modulator and shift valves Modulatedthrottle pressurefed to clutch dampers and valves Line pressureto lock up clutch lubrication oil to cooler Reverse inhibit Line pressureto B amp D clutches F Clutch inhibit Governor pressureto 3 4 shift valve inhibited in reverse Converter clutch hysteresis
48. otary transmission switch the speed of the output shaft by speed sensor on the output shaft and throttle position Kick down switch This information plus input from the EngineControl Module ECM of throttle angle and engine speed and loadin conjunction with a pre programmedcon trol map enables the most suitable gear to be selected The TOM by operating solenoid valves MV1 MV2 and controlsthe gear shift speed and in conjunction with the solenoid operated pressure control valve controlsthe gear shift quality Gear shift quality on upshifts is improved by the TCM momentarily retardingthe ignition to reduce the torque input as the gear changetakes place Information isfedtothe TCM from sensors and if any electronic componentfails the basicshift changes will be performed by the hydro mechanicalsystem ie Park Reverse Neutral D3 or D4 Issue 1 August 1994 46 ZF Automatic Transmissions Service Manual 1 13 Hamess Connections c cp ga SS a 0 ca a n 23 a m A SS Y J86 1169 Fig 1 Transmission Control Module Connections Pin Locations Pin Function Pin Function 1 Power supply input 29 Program switch Traction control input 2 Vehicle speed sensor plus input not used 3 Engine speed input 32 Torque reduction T Noutput 4 Progr
49. relay and solenoid Parking pawl mechanism sticking Check cable adjustment Parking pawl mechanism damaged Check cable adjustment Starter inhibit switch faulty Faulty selector lever Position or N not selected Check cable adjustment Renew park pawl components connecting bar pawl pin tension spring guide piece amp guide sheet Adjust cable as necessary Replace park pawl components Adjust cable as necessary Replace switch Replace lever Select P or N Adjust cable as necessary No reverse gear or severely delayed engagement Dirty oil filter Jammed governor Jammed reverse inhibit valve Low oil level Renew oil filter Replace governor Replace valve block Check oil High pitched squeaking noise Issue 1 August 1994 clutch destroyed also no 3rd gear in Drive D clutch destroyed E clutch destroyed no engine braking in 2nd amp 3rd gears Reverse gear safety valve faulty 34 Service renewtransmission Service renew transmission Service renewtransmission Service renew valve block ZF Automatic Transmissions Service Manual 1 3 6 Fault Finding Chart continued Problem Possible Cause Action slipping or shaking from start B E or D clutch defective Service renew transmission everse gear Strong jerk or distant double Damper B defective will give the Service renew valve b
50. ressure to the appropriate system components referto illustrations pages 43 to 46 to operate the transmission The four valve blocks in which the control valves pistons etc are located are mounted and connected through a main gallery plate Thethree solenoid valves MV1 MV2 and MV3 andthe pressure regulator operating solenoid are located onthe upper surface ofthe plate electrical connections between solenoids andthe transmission and transmission control unit are via cable harnesses referto relevant diagrams and tables for details of the various pin connections Operation of the transmission control unit is through an electronic Transmission Control Module TCM which on re ceipt of electrical signalsfromtransmission and engine management sources activatesthe hydraulic pressure regulat ing and shift valves via solenoid valves located onthe valve block The gearshift selector transmits movement via the selector cable tothe selector lever onthe side ofthe gearbox this rotates the selector shaft which controlsthe manual selector valve The rotary position of the shaft is monitored by the rotary switch Issue 1 August 1994 42 ZF Automatic Transmissions Service Manual 2 1 6 TransmissionRotary Switch This switch is located on a square extension of the transmission selector shaft and is linkedto the shift lever via the selector cable The switch comprises a selector bar which moves across a series of copper segments located on the swi
51. rical data 0 2mm to 0 4mm Solenoid valves 1 MV2 and 28 60 ohms 33 5 ohms 20C Pressure regulator solenoid valve 5 7 ohms Output shaft sensor 300 ohms 1090 Sensor air gap 0 5mm to 1 0mm Issue 1 August 1994 ZF Automatic Transmissions Service Manual 1 1 ZF 4 HP 22 TRANSMISSION GENERAL DESCRIPTION The ZF Automatic Transmission covered inthis section comprises a hydrodynamic torque converter four speed gear train and a hydraulic transmission control unit 1 144 687 1 Torque converter 6 Oil outlet drain plug 2 Throttle cable 7 Selector cable attachment 3 4 speed gear train 8 Selector lever positions seetext 4 Output flange 9 Dipstick oil filler tube 5 Transmission control unit 10 Oil cooler connection Fig ZF 22 ansmission The transmission provides six gearshift positions Position Park in this position the driven wheels are mechanically locked at the transmission Position Reverse reverse gear selected Position Neutral engine disconnected from driveline and wheels Position D Drive all four speed ranges are selected automatically with lock up available in top gear only Position 3 automatic selection of the lowest three speed ranges only Position 2 automatic selection of the lowest two speed ranges only transmission is prevented from shifting upto the third and top speed ranges
52. s M uv3 4 NOLLISOd O ec se HEH 14 ez i z h Issue 1 August 1994 31 T 3 c 6 e 9 o 9 o 2 E o c 8 E 2 m E 5 lt LL N 089 tr WZ Li T E PEN FESTER H iT t le a nan im ELI HI 31LLOSUHL 1104 8V39 151 4 5 4 32 Issue 1 August 1994 ZF Automatic Transmissions Service Manual 1 3 FAULT DIAGNOSIS The following tables are intended as a guide to diaanosis of possible faults inthe ZF 4 HP 22 transmission When the fault involves a leak it is recommended that it is located by the use of a crack detection fluid eg Met L Check which is available in spray form and permits the leakto be located after a short test drive 1 3 1 Initial Checks Note Before attempting diagnosis the following settings are checked Transmission oil level a Ensurethat the transmission is at normal operating temperature eg by conducting a roadtest If starting from cold check for presence of oil on dipstick at idle in Park before start of road test Check that the vehicle is on l
53. ssion fluid to cool down Donotcarry out morethan three tests in any half hour Jaguar Diagnostic Equipment JDE must be interrogated and any faults identified and rectified see JDS Manual In structions Check mode switch and gear selector positions using JDE issue 1 August 1994 60 2 3 4 Road Test ZF Automatic Transmissions Service Manual Fully check all shift speeds and note Compare the results with the specification in addition to general observations of transmission behaviour noises leaks etc and consult the following Fault Finding Chart CAUTION When renewing the transmission ALWAYS flush out the oil cooler and feed and return pipes 2 3 5 Electrical Checks Check Kick down electrical component fault is suspected referto Electrical Diagnostic Manual EDM to verify the failure mode before a repair or replacement is attempted 2 3 6 Fault Finding Chart Problem Possible Cause 1 Action Stall speed too high and keeps rising speed too low revolve Engine out of tune Transmission slip Engine out of tune Stator freewheel faulty allowing stator to Renewtorque converter Check engine tune Check oil level check mechanical failure renew transmission as necessary Check engine tune hceleration below specification Top speed below specification Torque converter freewheel faulty allowing stator to revolve Kick down switch defective
54. t 1994 25 g 3 e 9 o o 2 E o c E Ce 6 3 lt BE i 3 zyel ez Fi CELER TE 17 Gm ms L D f A M K H Uu d EE wa d H H zl DESEE Lr e 20 E ST MAC s ELI L rara EE X N n d Ls 7 A TINA 8V39 E NOLLISOd 26 Issue 1 August 1994 E 2 lt o 2 E S 2 E 5 lt LL N 559 vif a aum Lin ez es sees a S Ez CET D Hi EK W nn E M M X Y SL I NOLLISOd Issue 1 August 1994 27 ZF Automatic Transmissions Service Manual A CE LU LI on bel E SESCH EL AAA Fan RAN 1 i WZA DEA aaa aa 5 5 Bora s WW EET In LE
55. tch quadrant The copper segments are set out in seven bands each band providing an electrical output or com bination of outputs to the TCM The electrical outputs to the TCM are inthe form of athree digit code which takes upthree of the seven bands ofthe quadrant the remaining four bands are usedfor reverse ground and start inhibit 2 1 7 Decoder Module The decoder module located onthe right hand side of the J gate assembly is usedto translate the three digit codes from the rotary transmission switch into single line functions to feed the illumination module andto providethe fol lowing information a Cruise control ie when cruise control can or cannot be engaged a Indication when the vehicle is not in Park a Provide the ECM with a Park Neutral signal 2 1 8 Performance Mode Switch This switch located on the shift lever surround provides two alternative shift patterns a Normal Mode for everyday use a Sport Mode gear changes take place at higher road speeds in order to enhance performance Note Torque converter lock up occurs in fourth gear in each mode 2 1 9 Kick down Mechanism Kick down is activated by the final travel ofthe accelerator pedal which contacts a floor mounted switch located be hindthe pedal Operation of the switch provides a signal to the TCM that a downward change is required The switch is adjustable to ensure that the pedal does not overtravel and stretch the cable 2 1 10 Reverse
56. the results with the specification in additionto general observations of transmission behaviour noises leaks etc and consult the following Fault Finding Chart CAUTION When renewingthe transmission ALWAYS flush out the oil cooler and feed and return pipes 1 3 5 Electrical Checks If any electrical componentfault issuspected referto the Electrical Diagnostic Manual EDM to verify the failure mode before a repair or replacement is attempted 33 Issue 1 August 1994 ZF Automatic Transmissions Service Manual 1 3 6 Fault Finding Chart Problem Converter Possible Cause Action Stall speed too low Stator freewheel faulty allowing stator to revolve Engine out of tune Renew torque converter Check engine tune Stall speed too high and keeps rising Acceleration below specification Transmission slip Engine out of tune Check oil level check mechanical failure renew transmission as necessary Torque converter freewheel faulty allowing stator to revolve Engine out of tune Renew torque converter Check engine tune Top speed below specification Torque converter freewheel seized Engine out of tune Renew torque converter Check engine tune Position P Park Will not move out of Park Does not engage Park Does not hold Starter motor does not operate Position R Reverse Gearshift interlock failure Rectify Renew fuse check circuits renew
57. ttle Valve Mechanism kick down Thethrottlevalveor kick down mechanismcomprises acable connected betweenthrottle body pedal andthe throttle valve cam quadrant located onthe selector valve shaft the cam operates the throttle valve housed within the throttle valve block The travel of the valve is proportional to throttle positions and alters shift speeds and pressures during gearshifts to take account of throttle position The mechanism also provides for immediate selection of a lower ratio eg when overtaking by depressing the accelerator beyondthe normalfull throttle position Kick down is oper ated by movement ofthe throttle cable intothe kick down position causing full movement of the throttle valve and directing oil flow to the shift valves 1 1 8 Starter Inhibit Switch The starter inhibit switch prevents the starter motor from being operated when the shift lever is not in position Park or position N Neutral The switch is located inthe gear selector housing 1 1 9 Gearshift Interlock A brake pedal shift lever interlock is incorporated inthe gearselector mechanism The shift lever may only be moved from the P Park position if the ignition key switch is in position andthe foot brake pedal is applied The ignition key cannot be removed from the ignition switch unless the shift lever is inthe Park position Once the ignition key has been removed the shift lever is locked inthe park position The gearshift interlock
58. ued Problem Possible Cause Leakage at breather Oil level too high Incorrect oil specification Breather cover missing Breather cover O ring faulty Breather cover loose Action Rectify Change oil and flush system Replace breather cover Renew O ring Renew lockwasher Leakage from oil cooler circuit Leakage at intermediate plate Leakage between gearbox and extension housing General Noise and associated interruption of power Loud noise with no drive forward or reverse Pipe lock nuts loose Pipe line faulty Oil cooler leaking Torque tighten Renew relevant pipes Renew oil cooler Intermediate plate plug leaking Torque tighten plug Renew sealing washer Fastening screws loose Gasket faultv Torque tighten Renew gasket Oil filter dirty Clean replace filter If clutch debris found renew transmission flush cooling system Drive plate to converter connection damaged Pump drive damaged Renew drive plate and converter as necessary Renew transmission Groaning or buzzing noise can sound like mechanical damage in all selector positions especially when cold Sucking noise from pump Loud noise on converter clutch engagement Engine vibrations when converter clutch engaged Oil leveltoo low Valve block leaking Torsion damper defective Change point too low Rectify Renew valve

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