EN JAGUAR (Automatic Transmissions Service Manual Published by Product Development & Publications jing Partof set - JM 10.04 12/50g ZF Automatic Transmissions Service Manual CONTENTS Section «Service Tools & Equipment «Service Materials « Service Data = Torque Converter ...-.. a « Four-speed Epicyclic Gear Train + Transmission Control Unit «Starter Inhibit Switch + Gearshift Interlock ; « Hydraulic Circuit Diagrams .....- Fault Diagnosis «Stall Test... «Torque Converter « Gearshift Interlock «Fault. Diagnosis... Title SRO Page Foreword .. Torque Tightening Specifications . F4 MP 22 Transmission - General Description ‘Operation Of Gear Train Clutches . Transmission Output Shaft Extension Housing - Gearshift Selection... Throttle Valve Mechanism (kick-down) « Initial Checks. Engine Tune . Road Test Electrical Checks Fault Finding Chart ..... ZF4 HP 24 € Transmission - General Description . Four-speed Epleyelic Gear hain 40 Operation Of Gear Train Clutches “A Transmission Control Unit Sela or 7 Transmission Control Module (TCM) 4B Transmission Rotary Switch 44 Decoder Module 44 Poriormance Mode Switch «+. -- 44 “Kick-down’ Mechanism Reverse Saiety Inhibit Starter Inlubit Switch... Harness Connections Rotary Switch Harness Main Harness Connectors — 12 way and Bway Hydraulic Circuit Diagrams . Initial Checks "selector Cable Adjusiment Beanee 57 Stall Test 57 Road Test 58 «Electrical Checks 58 Fault Finding Chart 58 Service Operations Tesue 2 June 1986ZF Automatic Transmissions Service Manual B FOREWORD This manual provides information rolovant to the servicing of ZF Automatic Tranemiseion Unite 4 HP 22 and 4 HP 24 E (irrespective of the vehicle range to which the unit is fitted). The msnusl should be used in conjunetion with the r ‘evant Vehicle Service Manual (VSM) and Electrieal Diagnostic Manual (EDM). It assumes that the transmission has been removed from the vehicle, in accordance with the Vehicle Service Manual, and is ina clean condition and all service tools and materials are available. ‘The manual is divided into two sections covering the ZF 4 HP 22 and ZF 4 HP 24 E and each section is divided into sub sections coverin, (© Service Information 9. General Description (9. Hydraulic Circuit Diagrams (© Fault Diagnosis © Service Repair Operations. ‘An index can be found at the rear of the manual. Manual, Note: For information relating to in-vohicle operations, refer to the Vehicle Ser Issue 1 August 1994 ii8 ZF Automatic Transmissions Service Manual L SERVICE TOOLS & EQUIPMENT Mlustration Jaguar Number Description il Notes Tobe issued ir a un TORQUE TIGHTENING SPECIFICATIONS: a Fixing Tightening Torque | nm) [Tobe wsuea ma I, SERVICE MATERIALS Description Uses Notes To be issued ™ SERVICE DATA Transmission fluid: Transmission fluid type: Tom Data for ZF 4 HP 22 Transmission Capacity Fill ‘Top-up ‘Transmission weight: (including torque converter) 8,0 Liters Dexron IID or equivalent Dexron IID or equi 7478KG Transmission Ratios: [ist and ard [ath Reverse 2.08: 7 Torque Converter: Stall speed 2100 RPM + 150 RPM ‘Transmission unit pressures: | Drive: Idie (stationary) __ [630-710 kPa Drive Full Throttle (stall) ___| 780-950 kPa Z Reverse: Idle (stationary) [7070-1150 kPa [Reverse Full Throttle (stall) | 1620-1760 kPa Issue 2 June 1995ZF Automatic Transmissions Service Manual Iv. _ Service Data (continued) - Tem I Data Data for ZF ¢ HP 24 E Transmission i Transmission fluid: Capacity 95 Liters ‘Transmission fluidtype: Fil Dexron IID or equivalent Top-Up Dexron iD or equivalent Transmission weight: (including torque converter) 79,65 kg Transmission Ratios: st — 2481 zi Tae 3rd 7,00:7 (ath 0.731 Reverse fost —_] | Final drive a 58T Torque converter: [Nominal size (diameter) 280mm aaani Torque [322 Nm @ 2000 RPM Stall speed UK Speaifi [2000 RPM (+ 150 PM) Federal Specific 71800 RPM (+ 150 RPM) Ratio 2.12:1 @ Stall Gear train end-float i: 0.2mm to 0.4mm Electrical data 7 = Solenoid valves, MV, V2 and MVS 28~60 dhins (B35 ohms @ 200) | Pressure regulator solenoid valve 5=7 ohms | [Output shaft sensor 300 ohms (= 10%) ‘;5mm to 1.0mm Issue 2 June 1995ZF Automatic Transmi: 1 ZF 4 HP 22 TRANSMISSION, GENERAL DESCRIPTION (ie Transmission covered in this section comprises a hydrodynamic torque converter, four speed goar train and a hydraulic transmission control unit. | 1 Ln, | less Fa oeoc Spear 1, Torque converter 6. Oil drain plug) 2, Throttle valve (kick-down) cable 7. Selector cable attach 3, Main casing 8! Selector lever positions (see text) 4 Output flange 9. Dipstick oil filler tube (part only shown) 5. Oil pan (ump) 10. Oifcooter connection (1 of 2) Fig. 1 ZF 4 HP 22 transmission ‘The transmission provides six gearshift positions: Position ’P’: Park - in this position the driven wheels are mechanically locked at the transmission, Position ‘R’: Reverse ~ reverse gear selected. Position ‘N’; Neutral ~ engine disconnected from drive-line and wheels. Position ‘D’: Drive ~ all four gears are selected automatically with lock-up Position ‘3’: automatic selection of the lowest three gears only. Position '2': automatic selection of the lowest two gears only, transmission is prevented from shifting up to the third and top gears. ° ailable in top gear only, eoo0o Immediate selection of a lower ratio is also available by ‘kick-down’ (pressing the accelerator down beyond the normal {ull throttle position) for example when overtaking. 1.1.1 Torque Converter ‘The torque converter serves two main functions: it acts as a fluid coupling between engine and transmission gear train and it provides multiplication of engine torque when required, The torque converter consists of an impollor, a turbine and a stator which is mounted on a one-way clutch. The converter cover is fixed to the impeller to seal the three elements within a common housing through which oil flows when the transmission is in operation. The impeller is therefore 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 beers 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 ceases to accelerate the oil flow and in- stead is disengaged from the housing and turns freely in the flow of oil. At this stage, the torque converter acts as a fluid coupling, 7 Tesue 2 June 1995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 2 point depending on road speed and accelerator position; engine power is then transmitted by purely mechanical ‘A low-loss oil pump in the front of the transmission housing supplies the converter, the epicyclic gear train, the hy- draulic control system and the lubrication circuit; oil is drawn from a sump in the bottom of the gear train housing through a filter. The pump drive gear is keyed to 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 aear train providina four forward ratios and reverse. Individual ra~ tios are obtained by coupling together the various parts of the gear train by means of hydraulically actuated multi~disc clutches and brakes; built in freewheels permit gear shifts without any interruption of the power flow. 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 three or four small planet gears or pinions, Two gear sets are used in this transmission. A compound gear set compris- ing front annulus and planet carrier, rear annulus and planet carrier and a common sungear transmits the drive in all ‘gears except REVERSE; a single planetary carrier, annulus and sungear transmits the fourth gear drive. The table below shows the resulting clutch operation in the selected gear ratios. ‘Selected ratios Resulting clutch operation Dy 34.21 ‘A Clutch drives annulus clockwise |E Clutch & OWC drives output shaft clockwise D Clutch & OWC holds front carrier against annulus clockwise Dz 32% ‘K Clutah drives annulus clockwise 1 Clutch holds sungear against anti-clockwise € Clutch & OWC holds sungear against anti-clockwise | E Clutch & OWC holds front carrier against annulus clockwise [D3 33,25 ‘A Clutch drives annulus clockwise B Clutch drives sungear clockwise | C Clutch & OWC holds sungear ageinst anti-clockwise | E Clutch & OWC holds front carrier against annulus clockwise | Dr ‘A Clutch drives annulus clockwise B Clutch drives sungear clockwise € Clutch & OWC holds sungear against anti-clockwise |F Clutch holds sungear (4th gear set) R B Clutch drives sungear clockwise D Clutch holds carrier against clockwise E Clutch & OWC drives output shaft anti-clockwise Park, Neutral € Clutch & OWC applied (hydraulics) owe ne way clutch Tssue 2 June 1995 2