torque JAGUAR XFR 2010 1.G Workshop Manual

1 Blades 2 Stator held – fluid flow redirected 3 Stator rotates freely 4 Roller 5 Converter at coupling speed 6 Fluid flow from turbine 7 Converter multiplying 8 Fluid flow from impeller 9 Drive from engine 10 Impeller 11 Stator 12 Turbine 13 Output to transmission Fluid emitted from the impeller acts on the turbine. If the turbine is rotating at a slower speed than the fluid from the impeller,
the fluid will be deflected by the turbine blades in the path 'A'. The fluid is directed at and deflected by the stator blades from
path 'B' to path 'C'. This ensures that the fluid is directed back to the pump in the optimum direction. In this condition the
sprag clutch is engaged and the force of the fluid on the stator blades assists the engine in rotating the impeller.

As the rotational speed of the engine and therefore the turbine increases, the direction of the fluid leaving the turbine changes
to path 'D'. The fluid is now directed from the turbine to the opposite side of the stator blades, rotating the stator in the
opposite direction. To prevent the stator from resisting the smooth flow of the fluid from the turbine, the sprag clutch releases,
allowing the stator to rotate freely on its shaft.

When the stator becomes inactive, the torque converter no longer multiplies the engine torque. When the torque converter
reaches this operational condition it ceases to multiply the engine torque and acts solely as a fluid coupling, with the impeller
and the turbine rotating at approximately the same speed.

The stator uses a sprag type, one way, freewheel clutch. When the stator is rotated in a clockwise direction the sprags twist
and are wedged between the inner and outer races. In this condition the sprags transfer the rotation of the outer race to the
inner race which rotates at the same speed. www.JagDocs.com

1 Sprags 2 Inner race 3 Outer race 4 Sprag and cage assembly 5 Sprag outer race 6 Sprag inner race 7 Retaining ring The free wheel clutch can perform three functions; hold the stator stationary, drive the stator and free wheel allowing the
stator to rotate without a drive output. The free wheel clutch used in the ZF 6HP28 transmission is of the sprag type and
comprises an inner and outer race and a sprag and cage assembly. The inner and outer races are pressed into their related
components with which they rotate. The sprag and cage assembly is located between the inner and outer races.

The sprags are located in a cage which is a spring which holds the sprags in the 'wedge' direction and maintains them in
contact with the inner and outer races.

Referring to the illustration, the sprags are designed so that the dimension 'B' is larger than the distance between the inner
and outer race bearing surfaces. When the outer race rotates in a clockwise direction, the sprags twist and the edges across
the dimension 'B' wedge between the races, providing a positive drive through each sprag to the inner race. The dimension 'A'
is smaller than the distance between the inner and outer race bearing surfaces. When the outer race rotates in an
anti-clockwise direction, the dimension 'A' is too small to allow the sprags to wedge between the races, allowing the outer
race to rotate freely.

On the illustration shown, when the outer race is rotated in a clockwise direction, the sprags twist and are 'wedged' between
the inner and outer races. The sprags then transfer the rotation of the outer race to the inner race, which rotates at the same
speed.

Lock-Up Clutch Mechanism

The TCC (torque converter clutch) is hydraulically controlled by an EPRS, which is controlled by the TCM. This allows the torque converter to have three states of operation as follows:
• Fully engaged
• Controlled slip variable engagement
• Fully disengaged.

The TCC is controlled by two hydraulic spool valves located in the valve block. These valves are actuated by pilot pressure supplied via a solenoid valve which is also located in the valve block. The solenoid valve is operated by PWM (pulse width One Way Free Wheel Clutch – Typical

Item Description A Unlocked condition B Locked condition 1 Clutch plate 2 Clutch piston 3 Torque converter body 4 Turbine 5 Impeller 6 Stator 7 Piston chamber 8 Turbine chamber The lock-up clutch is a hydro-mechanical device which eliminates torque converter slip, improving fuel consumption. The
engagement and disengagement is controlled by the TCM to allow a certain amount of controlled 'slip'. This allows a small difference in the rotational speeds of the impeller and the turbine which results in improved shift quality. The lock-up clutch
comprises a piston and a clutch friction plate.

In the unlocked condition, the oil pressure supplied to the piston chamber and the turbine chamber is equal. Pressurized fluid
flows through a drilling in the turbine shaft and through the piston chamber to the turbine chamber. In this condition the clutch
plate is held away from the torque converter body and torque converter slip is permitted.

In the locked condition, the TCC spool valves are actuated by the EPRS. The fluid flow in the unlocked condition is reversed and the piston chamber is vented. Pressurized fluid is directed into the turbine chamber and is applied to the clutch piston.
The piston moves with the pressure and pushes the clutch plate against the torque converter body. As the pressure increases,
the friction between the clutch plate and the body increases, finally resulting in full lock-up of the clutch plate with the body.
In this condition there is direct mechanical drive from the engine crankshaft to the transmission planetary gear train.

FLUID PUMP

The fluid pump is an integral part of the transmission. The fluid pump is used to supply hydraulic pressure for the operation of
the control valves and clutches, to pass the fluid through the transmission cooler and to lubricate the gears and shafts.
The ZF 6HP28 fluid pump is a crescent type pump and is located between the intermediate plate and the torque converter. The
pump has a delivery rate of 16 cm3
per revolution.

1 Securing ring 2 Shaft oil seal 3 O-ring seal 4 Pump housing 5 Ring gear 6 Crescent spacer 7 Roller bearing 8 Impeller 9 Centering pin 10 Spring washer 11 Outlet port (high pressure) 12 Inlet port (low pressure) The pump comprises a housing, a crescent spacer, an impeller and a ring gear. The housing has inlet and outlet ports to direct
flow and is located in the intermediate plate by a centering pin. The pump action is achieved by the impeller, ring gear and
crescent spacer.

The crescent spacer is fixed in its position by a pin and is located between the ring gear and the impeller. The impeller is
driven by drive from the torque converter hub which is located on a needle roller bearing in the pump housing. The impeller
teeth mesh with those of the ring gear. When the impeller is rotated, the motion is transferred to the ring gear which rotates
in the same direction.

The rotational motion of the ring gear and the impeller collects fluid from the intake port in the spaces between the teeth.
When the teeth reach the crescent spacer, the oil is trapped in the spaces between the teeth and is carried with the rotation
of the gears. The spacer tapers near the outlet port. This reduces the space between the gear teeth causing a build up of fluid
pressure as the oil reaches the outlet port. When the teeth pass the end of the spacer the pressurized fluid is released into
the outlet port.

The fluid emerging from the outlet port is passed through the fluid pressure control valve. At high operating speeds the
pressure control valve maintains the output pressure to the gearbox at a predetermined maximum level. Excess fluid is
relieved from the pressure control valve and is directed, via the main pressure valve in the valve block, back to the pump inlet
port. This provides a pressurized feed to the pump inlet which prevents cavitation and reduces pump noise.

transmission functions. The Mechatronic valve block comprises the following components:
TCM

Pressure regulator solenoids
Shift control solenoid
Damper
Hydraulic spool valves
Selector valve
Temperature sensor
Turbine speed sensor
Output shaft speed sensor.
Sensors

Speed Sensors

The turbine speed sensor and the output shaft speed sensor are Hall effect type sensors located in the Mechatronic valve block
and are not serviceable items. The TCM monitors the signals from each sensor to determine the input (turbine) speed and the output shaft speed.

The turbine speed is monitored by the TCM to calculate the slip of the torque converter clutch and internal clutch slip. This signal allows the TCM to accurately control the slip timing during shifts and adjust clutch application or release pressure for overlap shift control.

The output shaft speed is monitored by the TCM and compared to engine speed signals received on the CAN bus from the ECM. Using a comparison of the two signals the TCM calculates the transmission slip ratio for plausibility and maintains adaptive pressure control.
Temperature Sensor

The temperature sensor is also located in the Mechatronic valve block. The TCM uses the temperature sensor signals to determine the temperature of the transmission fluid. These signals are used by the TCM to control the transmission operation to promote faster warm-up in cold conditions or to assist with fluid cooling by controlling the transmission operation when high
fluid temperatures are experienced. If the sensor fails, the TCM will use a default value and a fault code will be stored in the TCM.
Damper

There is one damper located in the valve housing. The damper is used to regulate and dampen the regulated pressure supplied
via EPRS. The damper is load dependent through modulation of the damper against return spring pressure.

The damper comprises a piston, a housing bore and a spring. The piston is subject to the pressure applied by the spring. The
bore has a connecting port to the function to which it applies. Fluid pressure applied to the applicable component (i.e. a
clutch) is also subjected to the full area of the piston, which moves against the opposing force applied by the spring. The
movement of the piston creates an action similar to a shock absorber, momentarily delaying the build up of pressure in the
circuit. This results in a more gradual application of clutches improving shift quality.

Spool Valves

The valve block spool valves control various functions of the transmission. The spool valves are of conventional design and are
operated by fluid pressure.

Each spool valve is located in its spool bore and held in a default (unpressurized) position by a spring. The spool bore has a
number of ports which allow fluid to flow to other valves and clutches to enable transmission operation. Each spool has a
piston which is waisted to allow fluid to be diverted into the applicable ports when the valve is operated.

When fluid pressure moves a spool, one or more ports in the spool bore are covered or uncovered. Fluid is prevented from
flowing or is allowed to flow around the applicable waisted area of the spool and into another uncovered port. The fluid is
either passed through galleries to actuate another spool, operate a clutch or is returned to the fluid pan.

1 Cylinder 2 Baffle plate 3 Ring gear 4 Sun gear 5 Planetary gear spider 6 Torque converter input shaft Torque Converter Input Shaft



Item Description 1 Planetary gear spider 2 Planetary gears (short) 3 Ring gear 4 Output shaft 5 Planetary gear carrier 6 Sunwheel 7 Double planetary gears (long) 8 Sunwheel

solenoid valve in the valve housing directs hydraulic pressure to the lock cylinder, which moves the piston within the cylinder
and releases the park lock pawl at the rear of the transmission by means of a connecting rod. The solenoid on the lock cylinder
is energized and locks the cylinder piston in the unlocked position. Additional locking of the piston is achieved with ball
catches within the lock cylinder.

When park is selected, the solenoid on the lock cylinder is de-energized, the ball catches are released and the piston is free to
move in the lock cylinder. The solenoid in the valve housing is also de-energized. The spring loaded parking disc pulls the
cylinder piston in the park direction which allows the park disc to move on its mounting. This movement is transferred via the
connecting rod to parking pawl, which is engaged in the park lock gear.

If an electrical failure occurs, the park lock can be manually released by means of an emergency park release lever located in
the floor console. The lever is connected to the parking disc by a cable and allows the park lock to be released manually. For
additional information, refer to 307-05B Automatic Transmission/Transaxle External Controls.

TRANSMISSION CONTROL MODULE

The TCM is an integral part of the Mechatronic valve block which is located at the bottom of the transmission, within the fluid pan. The TCM is the main controlling component of the transmission.
The TCM processes signals from the transmission speed and temperature sensors, ECM and other vehicle systems. From the received signal inputs and pre-programmed data, the module calculates the correct gear, torque converter clutch setting and
optimum pressure settings for gear shift and lock-up clutch control.

DTC Description Possible Cause Action P061B-02
Internal Control Module Torque Calculation
Performance - general signal
failure
Transmission control
module - positive torque
signal not valid Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P061B-26
Internal Control Module Torque Calculation
Performance - signal rate of
change below threshold
Transmission control
module positive torque
signal not valid Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P062F-04
Internal Control Module
EEPROM Error - System
Internal Failures
EEPROM communication
error Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the top of the DTC Index P0642-21
Sensor Reference Voltage A
Circuit Low - signal
amplitude < minimum
Sensor supply voltage
fault low Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the top of the DTC Index P0643-22
Sensor Reference Voltage A
Circuit High - signal
amplitude > maximum
Sensor supply voltage
fault high Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the top of the DTC Index P0657-13
Actuator Supply Voltage A
Circuit / Open - Circuit Open
Actuator supply (pressure
control valves etc) Open
Circuit Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P0657-1C
Actuator Supply Voltage A
Circuit / Open - Circuit
voltage out of range
Actuator supply (pressure
control valves etc)
voltage plausibility fault Refer to electrical Circuit diagrams and check
Transmission control module connector for signs of
water ingress or damage, check pin 7 for Short to
Power or Ground (should NOT be connected and
harness terminal should have a bung fitted). If no
fault identified, suspect the Transmission control
module. Check and install a new Transmission control
module as required, refer to the new
module/component installation note at the top of the
DTC Index P0658-11
Actuator Supply Voltage A
Circuit Low - Circuit Short to
Ground
Actuator supply (pressure
control valves etc)
voltage Short to Ground Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P0659-12
Actuator Supply Voltage A
Circuit High - Circuit Short to
Battery
Actuator supply (pressure
control valves etc)
voltage Short to Power Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P0667-01 PCM / Engine control module / Transmission control
module Internal Temperature
Sensor A Range/Performance
- General Electrical Failure
General electrical failure Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P0667-04 PCM / Engine control module / Transmission control
module Internal Temperature
Sensor A Range/Performance
- System Internal Failures
Internal Electronic Failure Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P0667-49 PCM / Engine control module / Transmission control
module Internal Temperature
Sensor A Range/Performance
- internal electronic failure
Internal electronic failure Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P0700-02 Transmission Control System
(MIL Request) - General signal failure
General Signal failure Clear DTC, Road test and re-test, Read DTCs and
Investigate as required P0700-22 Transmission Control System
(MIL Request) - signal
amplitude > maximum
Double fault from
monitoring of internal
power supply and
pressure
regulator/solenoid
control software If any of the following DTCs are also present;
P074013, P096712, P273912, P273012, P272112,
P096312, P276312, P097112, suspect the Transmission
control module, check and install a new Transmission
control module as required, refer to the new
module/component installation note at the top of the
DTC Index P0700-75 Transmission Control System
(MIL Request) - Emergency
Position Not Reachable
Emergency Position Not
Reachable Clear DTC, Road test and re-test, Read DTCs and
investigate as required

DTC Description Possible Cause Action P0721-64
Output Shaft Speed Sensor
Circuit Range/Performance -
signal plausibility failure
Signal plausibility failure Clear DTC and test. If code re-detects suspect the
Transmission control module. Install a new
Transmission control module as required, refer to the
new module/component installation note at the top of
the DTC Index P0731-07
Incorrect Gear Ratio-
Mechanical Failures
Gear Ratio Monitoring.
Mechanical Failures Check and correct oil level. Clear DTC. If code
re-detects suspect Transmission (gearbox) internal
fault. Install a new Transmission as required, refer to
the new module/component installation note at the top of the DTC Index P0732-07
Incorrect Gear Ratio-
Mechanical Failures
Gear Ratio Monitoring.
Mechanical Failures Check and correct oil level. Clear DTC. If code
re-detects suspect Transmission (gearbox) internal
fault. Install a new Transmission as required, refer to
the new module/component installation note at the top of the DTC Index P0733-07
Incorrect Gear Ratio-
Mechanical Failures
Gear Ratio Monitoring.
Mechanical Failures Check and correct oil level. Clear DTC. If code
re-detects suspect Transmission (gearbox) internal
fault. Install a new Transmission as required, refer to
the new module/component installation note at the top of the DTC Index P0734-07
Incorrect Gear Ratio-
Mechanical Failures
Gear Ratio Monitoring.
Mechanical Failures Check and correct oil level. Clear DTC. If code
re-detects suspect Transmission (gearbox) internal
fault. Install a new Transmission as required, refer to
the new module/component installation note at the top of the DTC Index P0735-07
Incorrect Gear Ratio-
Mechanical Failures
Gear Ratio Monitoring.
Mechanical Failures Check and correct oil level. Clear DTC. If code
re-detects suspect Transmission (gearbox) internal
fault. Install a new Transmission as required, refer to
the new module/component installation note at the top of the DTC Index P0736-07
Incorrect Gear Ratio-
Mechanical Failures
Gear Ratio Monitoring.
Mechanical Failures Check and correct oil level. Clear DTC. If code
re-detects suspect Transmission (gearbox) internal
fault. Install a new Transmission as required, refer to
the new module/component installation note at the top of the DTC Index P0740-13 Torque Converter Clutch
Solenoid Circuit / Open -
Circuit Open
Pressure control solenoid
2 Circuit Open Circuit Clear DTC and test. If code re-detects suspect the
Transmission control module. Install a new
Transmission control module as required, refer to the
new module/component installation note at the top of
the DTC Index P0741-07 Torque Converter Clutch
Solenoid Circuit
Performance/Stuck Off -
Mechanical Failures
Too high slip at torque
converter clutch.
Mechanical Failures Suspect torque converter lockup clutch. Install a new
torque converter, refer to the new module/component
installation note at the top of the DTC Index. If
transmission fluid is in very poor condition and dirty,
install a new transmission, refer to the new
module/component installation note at the top of the
DTC Index P0745-04 Pressure Control Solenoid A
- System Internal Failures
System Internal Failures Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the top of the DTC Index P0745-48 Pressure Control Solenoid A
- Supervision Software
Failure
Supervision Software
Failure Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the top of the DTC Index P0758-12
Shift Solenoid B Electrical -
Circuit Short to Battery
Circuit Short to Power Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the top of the DTC Index P0758-13
Shift Solenoid B Electrical -
Circuit Open
Solenoid valve 1 or
Pressure control Solenoid
G Circuit Open Circuit Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P0771-71
Shift Solenoid E
Performance/Stuck Off -
actuator stuck
Actuator stuck Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the top of the DTC Index P0775-04 Pressure Control Solenoid B
- System Internal Failures
System Internal Failures Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the top of the DTC Index P0775-48 Pressure Control Solenoid B
- Supervision Software
Failure
Supervision Software
Failure Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the top of the DTC Index

DTC Description Possible Cause Action P2722-48 Pressure Control Solenoid E
- Supervision Software
Failure
Pressure Control Solenoid
E supervision control
software failure Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P2725-22
Pressure Control Solenoid E
Electrical - signal amplitude
> maximum
Pressure Control Solenoid
E Electrical signal
amplitude > maximum Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P2725-1A
Pressure Control Solenoid E
Electrical - Circuit Resistance
Below Threshold
Pressure control solenoid
E electrical resistance
below threshold Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P2725-1E
Pressure Control Solenoid E
Electrical - Circuit Resistance
Out Of Range
Pressure control solenoid
E circuit resistance out of
range Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P2727-14
Pressure Control Solenoid E
Control Circuit / Open -
Circuit Short to Ground or
Open
Pressure Control Solenoid
E Control Circuit Short to
Ground or Open Circuit Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P2729-11
Pressure Control Solenoid E
Control Circuit Low - Circuit
Short to Ground
Pressure control solenoid
E Circuit Short to Ground Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the top of the DTC Index P2730-12
Pressure Control Solenoid E
Control Circuit High-Circuit
Short to Battery
Pressure control solenoid
E Circuit Short to Power Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the top of the DTC Index P2731-04
Pressure Control Solenoid
F-System Internal Failures
Pressure Control Solenoid
F no sub type
information Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P2731-48
Pressure Control Solenoid F -
Supervision Software Failure
Pressure Control Solenoid
F supervision software
failure Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P2734-22
Pressure Control Solenoid F
Electrical-signal amplitude >
maximum
Pressure Control Solenoid
F Electrical signal
amplitude > maximum Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P2734-1A
Pressure Control Solenoid F
Electrical-Circuit Resistance
Below Threshold
Pressure control solenoid
F electrical circuit
resistance below
threshold Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P2734-1E
Pressure Control Solenoid F
Electrical-Circuit Resistance
Out Of Range
Pressure control solenoid
F electrical circuit
resistance out of range Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P2736-14
Pressure Control Solenoid F
Control Circuit / Open -
Circuit Short to Ground or
Open
Pressure Control Solenoid
F Control Circuit Short to
Ground or Open Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P2738-11
Pressure Control Solenoid F
Control Circuit Low - Circuit
Short to Ground
Pressure Control Solenoid
F Control Circuit Short to
Ground Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P2739-12
Pressure Control Solenoid F
Control Circuit High - Circuit
Short to Battery
Pressure Control Solenoid
F Control Circuit Short to
Power Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the
top of the DTC Index P2763-12 Torque Converter Clutch
Pressure Control Solenoid
Control Circuit High - Circuit
Short to Battery
Pressure control solenoid
F Circuit Short to Power Suspect the Transmission control module. Install a
new Transmission control module as required, refer to
the new module/component installation note at the top of the DTC Index