oil level JAGUAR XJ 1994 2.G ZF Automatic Transmission Manual

ZF Automatic Transmissions Service Manual
1.3 FAULT DIAGNOSIS
The followina tables are intended as a auide to diaanosis of Dossible faults in the ZF 4 HP 22 transmission. When the
fault involvesa leak, it is recommendedthat it is located by the use of a crack detection fluid, eg Met-L-Check, which
is available in spray form and permits the leak to be located after a short test drive.
1.3.1 Initial Checks
Note: Before attempting diagnosis, ensure that the following settings are checked:
Transmission oil level.
. Ensure that the transmission is at normal operating temperature, eg by conducting a road test. If starting from cold,
. Check that the vehicle is on level ground.
. Firmly apply the parking and footbrakes and run the engine at idle speed.
. To ensure that the system is primed, slowly move the selector lever through all the gear positions.
. With the engine still running, engage ‘P‘ Park, withdraw the dipstick and wipe with a lint free cloth.
. Replace the dipstick slowly and withdraw it noting the level.
. Top up as required and recheck the level.
check
for presence of oil on dipstick at idle
in Park before start of road test.
1.3.2 Engine Tune
Selector cable adjustment.
Check gear selection in all selector positions.
If in doubt, select ’N’, disconnect the cable at the gearbox selector lever, check that the gearbox lever is in ’N’ position
. Adjust as necessary, see Vehicle Service Manual.
(third
detent from the rear) and refit the selector cable ball pin to the lever.
Kickdown switch adjustment, see Vehicle Service Manual.
1.3.3 Stall Test
. Ensure the transmission is at normal running temperature.
. Fully apply the parking brake.
. Fully depress the footbrake.
= Select position ‘D‘- Drive.
. Fully depress the accelerator(’kick-down’ detent fully depressed).
. Note the tachometer reading.
Start
the engine.
. 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 in any
half-hour.
1.3.4 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.
CAUTION: When renewing the transmission, ALWAYS flush out the oil cooler and feed and return pipes.
1.3.5 Electrical Checks
If any electrical component fault issuspected, referto the Electrical Diagnostic Manual (EDM) to verify the failure mode
before a repair or replacement is attempted.
Issue 1 August 1994 33

ZF Automatic Transmissions Service Manual
Problem Possible Cause
1.3.6 Fault Finding Chart
Action
Converter
Stall speed too low
Stall speed too
high and keeps
rising
Acceleration below specification
Top speed below specification
Position 'P'- Park
Will not move out of Park
Does not engage Park
Does not hold
Starter motor does not operate
Position 'R- Reverse
No reverse gear or severely
delayed engagement
High pitched squeaking noise 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.
Engine out of tune.
Torque converter freewheel seized.
Engine out of tune.
Gearshift interlock failure
Parking pawl mechanism sticking
Check cable adjustment
Parking pawl mechanism damaged
Check cable adjustment
Starter
inhibit switch faulty.
Faulty selector lever.
Position
'P' or 'N' not selected.
Check cable adjustment
Dirty oil filter.
Jammed governor.
Jammed reverse inhibit valve.
Low oil level.
'B' clutch destroyed (also no 3rd
gear
in Drive).
'D' clutch destroyed.
'E' clutch destroyed (no engine
braking
in 2nd & 3rd gears.
Reverse gear safety valve faulty. Renew
torque converter
Check engine tune.
Check oil level, check mechanical
failure, renew transmission as
necessary.
Renew torque converter.
Check engine tune.
Renew torque converter.
Check engine tune.
Rectify. Renew fuse, check circuits,
renew relay and solenoid.
Renew park pawl components:
connecting bar, pawl
pin, tension
spring, guide piece
& 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.
Renew oil filter.
Replace governor.
Replace valve block.
Check oil.
Service
/ renew transmission.
Service
/ renew transmission.
Service
/ renew transmission.
Service
/ renew valve block.
Issue 1 August 1994 34

1.3.6 Fault Finding Chart (continued)
Problem Possible Cause
slipping or shaking from start in
'everse gear
Strong jerk, or distant double
erk, when engaging positions
P
-R', or 'N-R' (below 1500RPM
tngine speed)
'B','E or 'D' clutch defective
Damper
'6' defective (will give the
same symptoms when changing
from 2nd to 3rd gears
Action
Service 1 renew transmission.
Service
1 renew valve block
qeverse lamp does not illuminate Starter inhibit switch faulty.
bulbs, fuses and cables
'unctioning correctly) Faulty selector lever.
io drive or severe delay. Renew
switch.
Renew lever.
Slipping or shaking during initial Position
'R' not
selected.
'orward movement
Strong jerk 'N
-D' (below 1500
3PM engine speed) Select
'R'.
Sear change functions
faulty (in c'
Zhange 1st to 2nd 12nd to 1st Governor dirty.
Shift valve 1-2 sticking.
Zhange 1st to
2nd
Renew governor.
Renew valve block.
Zhange 2nd to 3rd
13rd to 2nd
Governor dirty.
Shift valve 3
-4 sticking.
:hange 2nd to 3rd
Zhange 3rd to
4th I 4th to 3rd Renew
governor.
Renew valve block.
Sudden shifts
Jehicle starts in 2nd gear Governor sleeve sticking.
Shift valve 1
-2 sticking.
Governor sleeve sticking.
Shift valves 1
-2 and 2-3 sticking.
Jehicle starts in 3rd gear Renew
governor.
Renew valve block.
Renew governor.
Service
I renew valve block.
Searbox changes 1st to 3rd
Uo shifts Dirty
oil filter.
Oil level incorrect.
'A' clutch defective.
'D' clutch one
-way clutch faulty.
'A' clutch damaged
'A' clutch faulty.
'A' clutch damper faulty.
Id or warm state)
If there is no debris in sump, renew the
oil filter and oil;
if debris is present in
the sump, renew the transmission.
Check oil level.
Service
I renew transmission.
Service
1 renew transmission.
Service
I renew transmision
Service
1 renew transmission.
Service
/ renew valve block.
Brake
'Cl' and 1 or 'C' faulty I Service / renew transmission
Governor dirty.
I Renew governor.
Shift valve 2-3 sticking.
'B' clutch faultv
Renew valve block.
Service
I renew transmission
Dampers sticking
I Service I renew valve block
Shift valve 2
-3 sticking I Service 1 renew valve block
Governor sticking.
Dampers sticking. Change
governor.
Service
I renew valve block
Issue 1 August 1994 35

1.3.6 Fault Finding Chart (continued)
Problem
.oss of oil through breather
3il leak at intermediate plate
-eakage between gearbox and
2xtension housing
Uoises
iigh pitched squeaking noise,
jependant on engine RPM, in all
jears, when oil is warm and
accompanied by intermittent
hive after a long journey
iigh pitched noise in all
Dositions, especially if oil is cold.
Sucking noise from pump.
dery noisy in 'lock-up'
rorsional vibrations from engine
Nhen in 'lock-up'
-oud noisewhen converter
:lutch engages
Engine vibrations when
:onverter clutch engaged
Possible Cause
Oil level too high.
Incorrect oil.
Breather blocked.
No breather cap.
'0' ring breather damaged.
Securing clip faulty.
Blanking plug loose
Fastening screws loose.
Gasket faulty.
Dirty filter
Low oil level.
Filter not sealing.
Leaking valve block.
Filter damaged.
Torsion damper faulty
Engine
RPM is too low, 'lock-up'
shift point incorrect
Torsion damper defective
Change point too low
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
'0'
ring.
Renew clip.
Tighten plugs. Renew sealing washers.
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
I renew 0-ring.
Service
/ renew valve block.
Check filter.
Renew torque converter
Service
I renew valve block
Renew converter
Check valve block ~~
Issue 1 August 1994 38

ZF Automatic Transmissions Service Manual
0
2.3 FAULT DIAGNOSIS
The following tables are intended as a guide to diagnosis of possible faults 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 leak to be located after a short test drive.
2.3.1 Initial Checks
&@: Before attempting fault diagnosis, ensure that the following settings are checked:
Transmission oil level
. Ensure that the transmission is at normal operating temperature, e.g. by conducting a 20 mile road test. If starting
. Check that the vehicle is on level ground.
. Firmly apply the parking and footbrakes and run the engine at idle speed.
. To ensure that the system is primed, slowly move the selector lever through all the gear positions.
. With the engine still running, engage 'P' Park, withdraw the dipstick and wipe with a lint free cloth.
. Replace the dipstick slowly and withdraw it noting the level.
. Top up as required and recheck the level.
from
cold: check for presence of
oil on dipstick at idle in 'P' Park before setting off.
Note: The oil level can only be accuratelychecked when at normal temperature-approximately 20 miles at moderate
speeds.
2.3.2 Engine Tune
Selector cable adjustment
. Check gear selection in all selector positions.
. If in doubt, select 'N', disconnect the cable at the gearbox selector lever, checkthat the gearbox lever is in 'N' position
. Adjust as necessary at the selector lever inside the vehicle.
(third detent from the rear) and refit the selector cable ball pin to the lever.
2.3.3 Stall Test
. Ensure the transmission is at normal running temperature.
. Fully apply the parking brake.
. Start the engine.
= Fully depress the footbrake.
. Select position 'D'- Drive.
. Fully depress the accelerator('kick-down' switch fully depressed).
. 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 between
tests to allow the transmission fluid to cool down. Do not carry out more than 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.
60 Issue 1 August 1994

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
61 Issue 1 August 1994

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
Issue 1 August 1994 63

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
. _.~ -

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