lock JAGUAR XJ 1994 2.G ZF Automatic Transmission Manual

ZF Automatic Transmissions Service Manual
2.1.6 Transmission Rotary Switch
This switch is located on a square extension of the transmission selector shaft and is linked to the shift lever via the
selector cable. The switch comprises a selector bar which moves across a series of copper segments located on the
switch 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 in the form of a three
-digit code which takes up three of the seven bands of the
quadrant; the remaining four bands are used for reverse, ground and start inhibit.
2.1.7 Decoder Module
The decoder module, located on the right hand side of the J-gate assembly, is used to translate the three-digit codes
from the rotary transmission switch into single-line functions to feed the illumination module and to provide the fol-
lowing information:
. Cruise control, ie when cruise control can or cannot be engaged.
. Indication when the vehicle is not in 'P' Park.
. 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:
. 'Normal Mode' -for everyday use,
. '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. I. 9 'Kick-down' Mechanism
'Kick-down' is activated by the final travel of the accelerator pedal which contacts a floor-mounted switch located be- hind the 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 Safefy Inhibit
If 'R' 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 hterlock
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 II and the foot brake is applied.
The ignition key cannot be removed from the ignition switch unless the shift lever is in
the 'P - Park position. Once
the ignition key has been removed, the shift lever is locked in the 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 in the gear selector housing.
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ZF Automatic Transmissions Service Manual
1
1
33
2
A. C1 Clutch valve
B. 2-3 shift valve piston C. C clutch damper valve D. B clutch damper E. 1-2 shift valve piston F. D clutch valve and piston
G. Pressure regulating valve
H. Manual (selector) valve I. A clutch damper J. 1-2 shift valve K. B clutch damper valve L. C clutch damper
M. 2-3 shift valve N. Converter pressure valve
!!Me: Numerical annotations are not used in this application.
Fig. 1 Manual Valve Block
&
JLL-699
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ZF Automatic Transmissions Service Manual
2 1.
I
Jh
A. One way valve (lubrication) B. 2nd gear inhibit valve C. F clutch damper D. F clutch inhibit valve (reverse) E. 3-4 shift valve piston
F. 3-4 shift valve G. 1st gear inhibit valve H. F clutch valve
I. E clutch damper
J. C1 clutch damper
IWQ: Numerical annotations are not used in this application.
Fig.
1 Rear Valve Block
70
44 Issue 1 August 1994

ZF Automatic Transmissions Service Manual
3
C
? a
12 L?-'
A. Modulator valve B. Kick-down valve C. Reverse inhibit valve
Note: Numerical annotations are not used in this application.
s
JbI-701
Fig. 1 Throttle Valve Block
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ZF Automatic Transmissions Service Manual
2.2 HYDRAULIC CIRCUIT DIAGRAMS
Component Engagement
Key
To Hydraulic Diagrams (commencing on page 52)
1. 2.
3. 4.
5. 6.
7.
8. 9. 10. 11. 12. 13.
14. 15. 16.
17.
18.
Oil pump Sump
Torque converter
Olil cooler
Clutch 'A' damper
Clutch 'B' valve and damper
Clutch 'Cl' damper
Clutch 'Cl' valve
Clutch 'C' valve and damper
Clutch
'D' valve and damper
Clutch 'E' damper
Clutch
'F' valve and damper
Reverse locking valve
Shift valve
1 - 2
Shift valve 2 - 3
Shift valve 3 - 4
Safety valve
Pressure valve
1
A Clutch 'A' D Clutch 'D B Clutch 'B' E Clutch 'E'
C Clutch 'C' F Clutch 'F'
C1 Clutch 'C"
19.
20.
21.
22.
23. 24.
25.
26.
27.
28.
29.
30.
31.
32.
33. 34.
35.
G
H J K
Pressure valve 2
Torque converter pressure valve
Lubrication valve
Lubrication valve
Lock
-up control valve
Modulation pressure valve
Main pressure valve
Gear change valve
Solenoid valves
MVllMV2l MV3
Pressure regulator
ECM
- inputs and outputs
Engine torque
Throttle valve Engine speed
(RPM) Transmission speed (RPM) Transmission rotary switch
Oil filter
Torque converter freewheel
(C) Clutch freewheel (D) Clutch freewheel (E) Clutch freewheel
Exhaust - Reduced pressure
=X= Th rott le - Modulation pressure
4= Orifice 2- Sump
- Main pressure - Lubrication pressure
- Converter pressure
Throttle pressure
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ZF Automatic Transmissions Service Manual
Problem Possible Cause
2.3.4 Road Test
. 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.
Action
CAUTION:
When renewing the transmission, ALWAYS flush out the oil cooler and feed and return pipes.
2.3.5 Electrical Checks
. Check 'Kick-down'.
If any electrical component fault is suspected, refer to Electrical Diagnostic Manual (EDM) to verify the failure mode
before a repair or replacement is attempted.
2.3.6 Fault Finding Chart
Stall speed too low
Stall speed too high and keeps
,ising
hceleration below specification
Top speed below specification
'osition 'P - Park
Nil1 not move out of Park
Ioes not engage Park
Ioes not hold Stator
freewheel faulty allowing stator to
revolve
Engine out of tune
Transmission slip
Engine out of tune
Torque converter freewheel faulty
allowing stator to revolve.
'Kick
-down' switch defective.
Transmission
in 'Limp Home' mode
Engine out of tune
Torque converter freewheel seized
Engine out of tune
Gearshift interlock failure
Check cable adjustment
Parking pawl mechanism sticking
Check cable adjustment
Parking pawl mechanism damaged Renew
torque converter
Check engine tune
Check oil level, check mechanical
failure, renew transmission as
necessary
Check engine tune
Renew torque converter.
Refer to EDM, rectify
I renew
'Kick
-down'switch.
Check.
Check
engine tune
Renew torque converter
Check engine tune
Refer to EDM, rectify
- renew fuse,
check circuits, renew relay and
solenoid.
Check central
'P, 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 pawl components
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ZF Automatic Transmissions Service Manual
a
2.3.6 Fault Finding Chart (continued)
Problem
Starter motor does not operate
'osition 'R' - Reverse
3everse gear inoperative
Slipping and juddering
Harsh
engagement'p-R' chan
'N-R' change (below 1500RPF
engine speed)
Reverse lamp does not
illuminate (bulbs, fuses and
cables functioning correctly)
Possible Cause
Rotary switch adjustment.
Rotary switch wiring fault.
Rotary switch faulty.
Position
'P or 'N' not selected.
vIV2 faulty.
rNire to MV2 earthed.
3il filter dirty.
Damper
'6' faulty.
Clutch
'6' faulty (also no 3rd gear).
Clutch 'D' faulty.
Clutch
'E' faulty (also no engine braking
in 2nd and 3rd gears).
Pressure regulator valve 1 binding
Rotary switch wiring fault.
Rotary switch faulty.
Reverse gear inhibit valve activated.
Main pressure control valve seized (also
no forward drive in 'D' Drive).
'B'Clutch, 'D'Clutch or 'E' Clutch faulty.
Pressure regulator valve 1 binding
'F'Clutch drum sealing rings faulty
causing
loss of 'E' Clutch pressure.
Damper
'6' faulty (also no 2nd to 3rd
shift).
Pressure regulator valve 1 binding
Modulation pressure too high.
Rotary switch faulty.
Rotary switch setting incorrect.
Rotary switch faulty.
Rotary switch wiring fault.
Action
4djust switch.
qectify.
3ectify or renew.
Select 'F" or 'N'.
Renew valve block.
Renew harness.
Clean
/ replace filter and flush out
the
oil cooler and pipes.
Renew valve block.
Renew transmission.
Renew transmission.
Renew transmission.
Renew valve block.
Rectify.
Rectify or renew.
Renew valve block.
Renew valve block.
Renew transmission.
Renew valve block.
Renew transmission.
Renew valve block.
Renew valve block.
Check TCM Fault Codes.
Rectify or renew.
Adjust setting.
Renew.
Rectify.
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ZF Automatic Transmissions Service Manual
Problem Possible Cause
2.3.6 Fault Finding Chart (continued)
e Action
Starter will not operate Rotary
switch faulty or incorrect setting. Rectify
or renew.
3rive not transmitted (neutral
:ondition)
Vehicle moves
Slipping and juddering at start Rotary
switch wiring fault. Rectify 'A'Clutch seized Renew
transmission
Checksecurity System
Harsh engagement
'N'-'D'(under 1500RPM engine
speed)
No 1st to 2nd upshift or 2nd to
1st downshift
No upshift 1st to 2nd
No upshift 2nd to 3rd or
downshift 3rd to 2nd
No upshift 2nd to 3rd
3il filter dirty.
Main pressure control valve seized.
Low oil level.
'A'Clutch faulty.
'D'Clutch one-way clutch slips. ~
'A'Clutch faulty
Low oil level.
'A'Clutch faulty.
'A'Clutch damper faulty (5).
Throttle pot. volts high.
Rotary switch faulty
/ out of adjustment.
MVI wire earthed(remains in 2nd gear).
MVI faulty.
Control circuit fault.
Shift valve
1-2 seized.
Pressure reducing valve
1 seized.
Speed sensor or connectors faulty.
Clutches
'Cl' and 'C' faulty
MV2 wire earthed (remains in 2nd gear).
MV2 faulty.
Shift valve 2
-3 seized.
Speed sensor faulty.
'B'Clutch faulty Clean
/ replace
filter.
Renew valve block.
Check oil level.
Renew transmission.
Renew transmission.
Renew transmission.
Check oil level.
Renew transmission.
Renew valve block.
Check throttle 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
Renew harness.
Renew valve block.
Renew valve block.
Rectify or renew.
Renew transmission
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ZF Automatic Transmissions Service Manual
0
2.3.6 Fault Finding Chart (continued)
Problem
Uo upshift 3rd to 4th or
lownshift 4th to 3rd
Vo upshift 3rd to 4th
lownshift 4th to 3rd too hard
Manual gearshift D to 3rd too
lard
Manual gearshift 3rd to 2nd too
9ard
Vo 1st gear; 2nd gear start only.
No 1st or 2nd gear; 3rd gear
start only
No 2nd gear; transmission shifts
1st to 3rd gear
Light throttle gear change
speeds incorrect
Up to 'kick
-down' detent, gear
change speeds not to
specification
Possible Cause
Shift valve 3-4 seized.
MVl wire earthed.
MV1 faulty.
Speed sensor faulty.
'F'Clutch faulty
3rain orifice 'F' partially blocked.
Damper
'E' faulty.
Damper
'E' faulty.
Drain orifice
'F' partially blocked.
Damper
'Cl' faulty
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.
Speed sensor faulty.
Shift valve 2
-3 seized.
Shift valves sticking.
Speed sensor faulty.
Throttle pot. volts incorrect.
Transmission Control Module
(TCM).
'Kick-down' switch out of adjustment
3enew valve block.
3enew harness.
Renew valve block.
Rectify or renew.
Renew transmission
Renew valve block.
Renew valve block.
Renew valve block.
Renew valve block.
Renew valve block
Check or renew speed sensor.
Renew valve block.
Renew harness.
Renew valve block.
Operate 'Performance Mode' switch
to correct function or renew switch.
Check Diagnostics
1 JDS.
Renew speed sensor.
Renew valve block.
Renew valve block.
Check or
recheck Diagnostics,
renew speed sensor.
Renew valve block.
Renew valve block.
Check or renew speed sensor.
Check voltage
- JDS.
Check TCM Diagnostics.
Readjust 'kick
-down' switch
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ZF Automatic Transmissions Service Manual
No engine braking
Manual gearchange 3rd to 2nd
inoperative Clutch 'Cl' or
Clutch 'E' faulty
Speed sensor faulty.
MV2 faulty.
a
Renew transmission
Check TCM Diagnostics
1 renew
speed sensor.
Renew valve block.
a
0
Problem
Vo 'kick-down' change
Light throttle speeds only
Light throttle gear change too
hard
1st to
2nd, 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 ~
Possible Cause
'Kick-down'
switch out of adjustment 1
full throttle stop adjustment.
'Kick
-down' switch faulty.
'Kick
-down' switch connector or wiring
Fa u Ity.
TCM faulty
Valve block bolt torque incorrect.
Modulation pressure too high.
Damper faulty.
Clutch plates faulty.
Valve block bolt torque incorrect.
Damper faulty.
PRSV faulty.
PRSV wire earthed.
Modulation valve seized.
Pressure regulator valves
1 and 2 seized.
mve block bolt torque incorrect.
Modulation pressure too low.
Clutch plates faulty.
Valve block bolt torque incorrect.
Modulation pressure too low.
Clutch plates faulty.
Action
Adjust as per Engine Set Up
procedure on JDS.
Renew 'kick
-down' switch.
Rectify.
Check TCM
Reset to correct torque.
Renew valve block.
Renew valve block.
Renew gear unit.
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.
Renew transmission.
Reset to correct torque.
Renew valve block.
Renew transmission.
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