JAGUAR XJ 1994 2.G ZF Automatic Transmission Manual

ZF Automatic Transmissions Service Manual
0
3il in bell housing
2.3.6 Fault Finding Chart (continued)
Oil pump seal leaking.
Oil pump 0
-ring leaking.
Pump housing leaking.
Converter seam leaking.
Problem Possible Cause Action
:onverter clutch
-eakage between gearbox and
sump
Leakage between intermediate
date and gearbox
Leakage at harness plug
:onnector
Leakage at drive flange
:Iutch engagement speed
ncorrect
Loose fastening screws.
Sump gasket faulty.
Bell housing to gearbox screws loose
Connector 'O'ring faulty
Rear oil seal faulty
ingagement
too hard
Jo clutch engagement
Ionverter clutch engaging at
dle (engine will not idle in
'D')
Control circuit fault.
Speed sensor faulty.
Valve body problem.
Converter unit faulty
Control circuit fault
MV3 faulty.
Converter clutch valve seized.
Converter faulty. Pressure reducing valve
1 seized.
Incorrect oil level.
Oil filter not sealing.
Control circuit fault.
MV3 faulty.
MV3 wire earthed.
Converter clutch valve
sticking.
Check TCM Diagnostics / rectify
fault.
Check TCM Diagnostics
1 renew
speed sensor.
Renew valve body
Renew converter unit
Check TCM Diagnostics
1 rectify
fault.
Renew valve block.
Renew valve block.
Renew converter.
Renew valve block.
Check oil level.
Check 0
-ring etc.
Check TCM Diagnostics
/ rectify
fault.
Renew valve block.
Renew harness.
Renew valve block.
Renew oil pump seal.
Renew 0
-ring.
Renew oil pump.
Renew converter.
Torque tighten.
Renew gasket.
Torque tighten
Renew
'0' ring
Renew oil seal
Issue 1 August 1994 66
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ZF Automatic Transmissions Service Manual
2.3.6 Fault Finding Chart (continued)
a
0
0
a
Problem
Leakage at breather
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
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
Possible Cause
Oil level too high.
Incorrect oil specification.
Breather cover missing.
Breather cover
'0' ring faulty.
Breather cover loose.
Pipe lock nuts loose.
Pipe line faulty.
Oil cooler leaking.
Intermediate plate plug leaking
Fastening screws loose. Gasket
faultv.
Oil filter dirty
Drive plate to converter connection
damaged.
Pump drive damaged.
Oil level too low.
Valve block leaking.
Torsion damper defective
Change point too low
Action
Rectify.
Change
oil and flush system.
Replace breather cover.
Renew
'0' ring.
Renew lockwasher.
Torque tighten.
Renew relevant pipes.
Renew oil cooler.
Torque tighten plug.
Renew sealing washer.
Torque tighten
Renew gasket.
Clean
/ replace filter. If clutch debris
found, renew transmission, flush
cooling system
Renew drive plate and converter as
necessary.
Renew transmission.
Rectify.
Renew valve block.
Renew converter
Check TCM
Issue 1 August 1994 67

ZF Automatic Transmissions Service Manual
2.4 SERVICE 0 PERATIO NS
2.4.1 ZF 4 HP 22 Transmission
[SROs to be added when available]
2.4.2
[SROs to be added when available]
Zf 4 HP 24 E Transmission
68 Issue 1 August 1994

E
Fau;t diagnosis
ZF 4HP 22
Electrical checks,
33
Engine tune, 33
Fault finding chart, 34
Initial checks, 33
Road test, 33
Stall test, 33
Electrical tests, 61
Engine tune, 60
Fault finding chart, 61
Initial checks, 60
Road test, 61
Stall test, 60
ZF 4HP 24 E
Foreword, ii
G
General description
ZF4HP22
Epicyclic gear train, 2
Gear train clutches operation, 3
Gearshift interlock, 8
Gearshift selection, 8
Output shaft extension housing, 4
Starter inhibit switch, 8
Throttle valve mechanism, 8
Torque converter, 1
Transmission control unit, 4
Control layout schematic illustration, 46
Decoder module, 47
Epicyclic gear train, 40
Gear train clutches operation, 41
Gearshift interlock, 47
Harness connections, 48
Kick-down mechanism, 47
Main harness connector
ZF
4HP 24 E
12-way, 50
Sway, 50
Performance mode switch, 47
Reverse safety inhibit, 47
Rotary switch connector pins, 49
Rotary switch harness, 49
Starter inhibit switch, 47
TCM connector pins, 48
Torque converter, 39
Transmission control module, 46
Transmission control unit, 42
Transmission rotary switch, 47
H
Hydraulic circuit diagrams
‘1 ’ - 1 st, full throttle, 32
‘1’ - 21-14 idling, 31
‘1 ’ - 3rd, idling, 30
‘2’ - 2nd, full throttle, 29
‘2’ - 3rd, idling, 28
‘3’ - 3rd, full throttle, 26
‘3’ - 3rd, kickdown, 27
‘3’ - 3rd, part throttle, 25
ID’- drive, Ist, full throttle, 14
ZF 4HP 22
‘D’ - drive, lst, idle, 13
‘D’ - drive, lst, kickdown, 15
‘D’ -drive, 2nd, full throttle, 17
‘D’ - drive, 2nd, idle, 16
‘D’ - drive, 2nd, kickdown, 18
‘D’ -drive, 3rd, full throttle, 20
‘D’ - drive, 3rd, kickdown, 21
‘D’ -drive, 3rd, part throttle, 19
‘D’ -drive, 4th, full throttle lock-up, 24
‘D’ -drive, 4th, part throttle, 22
‘D’ - drive, 4th, part throttle lock-up, 23
‘N’ - neutral, 12
‘P’ - park, 10
‘R‘ - reverse, 11
Key, 9
‘1’ - Ist, 59
‘D’ - drive, 1 st, 55
‘D’ - drive, 2nd, 56
‘D’ - drive, 3rd, 57
‘D’ - drive, 4th, lock-up, 58
‘N’ - neutral, 54
‘P’ - park, 52
‘R‘ - reverse, 53
Key, 51
ZF 4HP 24 E
S
Service data, iii
Service materials, iii
Service operations
ZF 4HP 22, Not yet available, 68
ZF 4HP 24 E, Not yet available, 68
Service tools & equipment, iii
T
Torque tightening specifications, iii