Официальное руководство по ремонту АКПП ZF 4HP20
Официальное руководство по ремонту АКПП ZF 4HP20
Официальное руководство по ремонту АКПП ZF 4HP20
4 HP- 20
Printed in Germany
Table of contents
Page
Preliminary information ii
3. Assembly 3.1/1
3.1 Completing the differential and side shaft 3.1/1
3.1.1 Completing the differential 3.1/1
3.1.2 Completing the side shaft 3.1/2
3.2 Installing the parking lock mechanism and bearing shells in the housing 3.2/1
3.2.1 Installing the parking lock mechanism in the housing 3.2/1
3.2.2 Installing the bearing shells in the housing 3.2/3
3.3 Completing and installing the bearing plate 3.3/1
3.4 Installing brake C/D, planetary drive and clutch B/E
in the transmission housing 3.4/1
3.4.1 Installation of brake D/C 3.4/2
3.4.1.1 Completing brake D 3.4/2
3.4.1.2 Completing brake C 3.4/3
3.4.2 Installation of planetary drive 3.4/5
3.4.3 Completing clutch B and E 3.4/6
3.4.3.1 Inserting clutch pack E 3.4/8
3.4.3.2 Inserting clutch pack B 3.4/8
3.5 Completing and installing the transmission cover 3.5/1
3.6 Installing brake F 3.6/1
3.7 Installing the side shaft, differential, parking lock and position switch 3.7/1
3.7.1 Installing the side shaft and differential 3.7/1
3.7.2 Installing the parking lock and position switch 3.7/2
3.8 Installing the converter bell housing, control unit, inductive transmitter
and oil pan 3.8/1
3.8.1 Completing and installing the converter bell housing 3.8/1
3.8.2 Installing the control unit, inductive transmitter and oil pan 3.8/8
3.9 Installing ancillaries (oil cooler, converter, speedometer shaft
connection, transport protection cap) 3.9/1
3.9.1 Installing the oil cooler 3.9/2
3.9.2 Installing the breather cover, oil dipstick and oil drain plug 3.9/3
3.9.3 Installing the converter 3.9/3
3.9.4 Installing the speedometer shaft with connection 3.9/3
3.9.5 Function test for the position switch 3.9/3
3.9.6 Installing the protective transport caps 3.9/4
This manual covers the procedure for repairing the complete transmission.
The repairing of this transmission is only allowed to persons with specific training from ZF
Getriebe GmbH.
The photographs were kept general in nature so that they can be used with various applications;
they are not binding in every case.
The Service Bulletins regulations and specifications must be followed when making repairs.
Depending on the type of damage that has occured, the repair work can be limited to that which is
necessary to repair the damage.
• Seals (such as O-rings, shaft seals, gaskets, and filters) must always renewed.
• All O-rings, rectangular-section rings, and other sealing rings must always be lubricated
with petroleum jelly before installation.
• All bearings must always be oiled lightly when installed.
• For transmissions that have covered a large number of kilometers (> 80,000 km), all lined
clutch discs and steel clutch discs must be replaced.
• After clutches/ brakes have been damaged, the converter, oil tubes, and oil cooler, must be
cleaned thoroughly with a suitable cleaning agent.
• If brakes C or D has been damaged, or if a considerable distance has been covered (>
80,000 km), pistons C and D must be replaced.
The following requirements should be met before the repair work is started:
This manual treats the automatic control unit as a complete unit, which should not be dis-
assembled without special knowledge; it should be exchanged as a complete unit.
Important:
The oil does not have to be changed until it has been in use for ten years.
The transmission must only be delivered with the oil type and oil amount specified in the corre-
sponding parts list documentation (see Part List).
Technical After Sales Service Technical Documentation After Sales Service School
1st GEAR
Input
2nd GEAR
Output Output
Input
Input
Input
Reverse
Output Output
GEAR
Input
Output Output
Important!
The numbers correspond to the actual
sequence for final tightening.
(Assessment, Specification 1019 700 137)
Important!
The numbers correspond to the actual
sequence for final tightening
(Assessment, Specification 1019 700 138 )
Important!
The numbers correspond to the actual
sequence for final tightening
(Assessment, Specification 1019 700 088)
Important!
The numbers correspond to the actual
sequence for final tightening
(Assessment, Specification 1019 700 218)
98009
98011
98012
98017
Note!
In each case, the X index in MX stands
for the brake/ clutch clutch packs that are
98018
put in (B, C, D, E, F).
Calculation:
BSG = GSG + HSG
98104
Calculation:
BSW = GSW + HSW
97577
Calculation:
BS = BSG + BSW + KP
HSG = 82.492 mm
HSW = 34.497 mm
KP = 0.26 mm
GSG = 0.215 mm
GSW = 0.55 mm
Important!
Strictly cleanliness !
98120
(See Chapter 1.5 for tightening torques)
98123
Calculation:
98124
HS = KS + MS - KG
KS = 132.287 mm
KG = 30.013 mm
M1 = 14.33 mm
M2 = 14.27 mm
MS = (14.33 + 14.27)/2
= 14.3 mm
Calculation:
NS = BS - HS
SS = VS + NS
BS = 118.014 mm
HS = 116.574 mm
VS = 0.07 to 0.12 mm
NS = 118.014 - 116.574
= 1.44 mm
Chosen:
➮ SS = 1.54 mm
Calculation:
BDG = GDG + HDG
Important!
Use plug gauge 5p89 004 768 for MB
application.
Calculation:
BDW = GDW + HDW
Calculation:
BD = BDG + BDW + KP
HDG = 24.996 mm
HDW = 119.998 mm
KP = 0.26 mm
GDG = 0.285 mm
GDW = 0.67 mm
Important!
Strictly cleanliness !
Bush 5p01 050 331 is to be fixed with
4 screws (M6x12) into measuring plate
98125
5p01 040 331 for MB application.
(See Chapter 1.5 for tightening torques)
98123
Calculation:
98127
HD = KS + MD - KG
KD = 151.242 mm
KG = 30.013 mm
M3 = 23.35 mm
M4 = 23.51 mm
MD = (23.35 + 23.51)/2
= 23.43mm
Calculation:
ND = BD - HD
SD = VD + ND
BD = 146.209 mm
HD = 144.659 mm
ND = 146.209 -144.659
= 1.55 mm
Selected:
➮ SD = 1.78 mm
97583
97585
97587
97588
97589
Note !
Turn until the indicator movements no
97590
longer become smaller.
1.4/14 CD 4 HP 20 © ZF Getriebe GmbH Saarbrücken 99/04/01
Zero dimension N is equal to the thick-
ness of disc D minus dimension M.
Calculation:
N=D-M
Calculation:
S = N -V
M = 0.22 mm
D = 6.3 mm
V = 0.03 to 0.085 mm
N = 6.3 - 0.22 mm
= 6.08 mm
Selected:
➮ S = 6.025 mm
Note !
See
Dismantling the bearing plate (Chapter 2.8.2)/
Completing the bearing plate (Chapter 3.3)
➮ MD
98114
Calculation:
ED = WD + F + SD
PD = ED - MD
WD = 17.02mm
MD = 13.43 mm
ED = 17.02 + 1.48
= 18.5 mm
PD = 18.5 - 13.43
= 5.07 mm
➮ MC
98115
Calculation:
EC = WC + F
PC = EC - MC
WC = 6.95 mm
MC = 6.41 mm
EC = 6.95 + 1.48
= 8.43 mm
PC = 8.43 - 6.41
= 2.02 mm
Calculation:
P=M+D
D = 1.48 mm
M1 = 1.93 mm
M2 = 1.88 mm
M3 = 1.83 mm
P = 1.88 + 1.48
= 3.36 mm
➮S = 3.2 mm
(Here variant B)
Note !
Adjusting ring E
for variant A 5p89 004 182
for variant B 5p89 004 374
97615
Specification 1019 700 126
(Here variant B)
Note !
Adjusting ring B
for variant A 5p89 004 181
for variant B 5p89 005 403
97616
Specification 1019 700 127
Note !
97617
Maximum air pressure: 5 bar.
1.4/22 CD 4 HP 20 © ZF Getriebe GmbH Saarbrücken 99/04/01
1.4.5.1 Determining snap ring play
97618
S = (M1 + M2 + M3) / 3
97619
M1 = 0.27 mm
M2 = 0.23 mm
M3 = 0.25 mm
Calculation:
MB = (M4 + M5 + M6) / 3
EB = RB + MB
M4 = 2.36 mm
M5 = 2.40 mm
M6 = 2.38 mm
RB = 11.99 mm
➮ EB = 11.99 + 2.38
= 14.37 mm
Calculation:
ME = (M7 + M8 + M9) / 3
EE = RE + ME - S
M7 = 2.6 mm
M8 = 2.55 mm
M9 = 2.54 mm
RE = 20,98 mm
➮ MB
98116
Calculation:
PB = EB - MB ➮ LB
MB = 11.44 mm
EB = 14.38 mm
PB = 14.38 - 11.44
= 2.94 mm
➮ LB = 2.1 mm
➮ ME
98117
Calculation:
PE = EE - ME ➮ LE
ME = 16.78 mm
EE = 23.29 mm
PE = 23.29 - 16.78
= 6.51 mm
➮ LE = 4.8 mm
97641
(Torx TX-27H)
97642
Calculation:
BF = (M1 + M2) / 2
97655
M1 = 18.6 mm
M2 = 18.8 mm
BF = (18.6 + 18.8) / 2
= 18.7 mm
➮ MF
98118
Calculation:
PF = BF - MF ➮ EF
MF = 14.2 mm
BF = 18.7 mm
PF = 18.7 - 14.2
= 4.5 mm
➮ EF = 3.3 mm
97632
Note!
The selected shim should allow axial
97633
play.
Important!
See tightening torque specifications in
97634
Chapter 1.3
99/04/01 4 HP 20 © ZF Getriebe GmbH Saarbrücken CD 1.4/31
1.4.9 Adjusting axial play, input shaft
97659
97660
M1 = 0.51 mm
M2 = 0.49 mm
M = (0.51 + 0.49)/2
= 0.5 mm
S = 0.18 to 0.42 mm
D = 0.5 -(0.18 to 0.42)
= 0.08 to 0.32 mm
➮D = 0.2 mm (selected)
Note!
See Completing and installing transmis-
97633
sion cover (Chapter 3.5)
Proper oil level; observe the vehicle manufacturer’s specifications and Part List.
Danger of loss due to splashing, formation of foam, strong increases in temperature at high
road speeds. Loss of oil via breather; among other things, burned clutches and shifting
problems can result.
Correct adjustment of selector linkage or control cable; observe the vehicle manufacturer’s
specifications.
1
5p01 000 329 Identical
-Force measuring unit
5 HP 24
98008
2
5p01 000 330 Identical
-Measuring fixture, clutch play
5 HP 24
(Measuring plate:
- short neck >20 mm
- long neck <20 mm
clutch pack thickness)
98034
3
5p01 000 331
-Height-measuring fixture,
differential and side shaft
98128
4
Identical 5p01 001 458
-Adjusting device, preload
4 HP 18 Q
5 HP 24
97301
5
5p01 002 379
-Fixture, axial play, input shaft
98129
6
5p01 002 925
-Measuring fixture, snap ring play,
cylinder C
98103
7
5p01 002 984
-Measuring fixture, installation
space and snap ring play, clutches
B/E
98130
8
5p89 004 177
-Plug gauge installation space,
converter bell housing, side shaft
98107
9
5p89 004 178
-Plug gauge, installation space,
transmission housing, side shaft
98106
10
5p89 004 181
-Adjusting ring, clutch B,
variant A (~ 17 mm)
98131
11
5p89 004 182
-Adjusting ring, clutch E,
variant A (~ 24 mm)
98132
12
5p89 004 372
-Adjusting ring, clutch E,
variant B (~ 21 mm)
98133
13
5p89 005 403
-Adjusting ring, clutch B,
variant B (~ 12 mm)
98134
14
5x46 030 167 Identical
-Assembly bracket for pressing
down cup spring B 4 HP 14 Q
4 HP 18 Q
(equivalent to part 3 of device 4 HP 22
5x46 000 167) 5 HP 18
5 HP 24
98305
15
5x46 000 306 Identical
-Plug gauge, pump (moves easily)
4 HP 18 Q
98135
16
Identical 5x46 000 763
-Work bench fixing device
5 HP 18
5 HP 24
5 HP 30
91199
17
5x46 001 036
-Assembly bracket for pressing
down the cup spring E
98137
18
5x46 001 046
-Assembly bracket for pressing
down cup spring, brake C/D
98163
19
5x46 001 089
-Slotted nut insert, bearing plate
98138
20
5x46 001 134
-Assembly drift, shaft seal, selec-
tor shaft
98142
21
5x46 001 396
-Assembly bracket, transmission,
complete
98139
22
5x46 001 418
-Assembly sleeve, retaining ring,
input shaft
98143
23
5x46 001 443
-Assembly fixture, piston D
98144
24
5x46 001 453
-Assembly drift, shaft seal, pump
98140
25
5x46 001 454
-Adjusting tool, position switch
98141
26
5x46 001 775
-Assembly fixture (lifting) for
input shaft with clutches B and E
98145
27
5x46 002 123
-Adjusting device, preload, bear-
ing plate
Consisting of:
98146
28
5x46 001 937
-Dismantling tool for pistons B
and E (compressed air)
98147
29
5x46 001 955
-Core insert for ROLLEX extrac-
tor (side shaft)
98171
30
5x46 001 956
-Core insert for ROLLEX extrac-
tor (differential)
98168
31
5x46 001 957
-Core insert for ROLLEX extrac-
tor (output spur gear)
98170
32
5x46 001 999
-Core insert for ROLLEX extrac-
tor (side shaft)
98172
33
5x46 002 033
-Drift dowl pin
(selector shaft)
98148
34
Identical 5x56 000 090
-Extracting handles for converter
3 HP 22 (2 items)
4 HP 14 Q
4 HP 18 Q
4 HP 22
5 HP 18
5 HP 24
5 HP 30
76046
35
Identical 5x46 021 007
Kukko extractor 21/7
4 HP 14 Q
4 HP 18 Q or
98149
36
Identical 5x46 022 002
Kukko extractor 22-2
4 HP 14 Q (basic tool)
4 HP 18 Q
98150
37
5x46 503 491 Identical
Rollex extractor Size IA
(basic tool) 4 HP 18 Q
98151
38
5x46 010 011 Identical
Rollex extractor 1000/1
(basic tool) 3 HP 22
4 HP 14 Q
4 HP 18 Q
98152
39
5x46 013 011
Rollex extractor 13000/1
(spur gear, bearing plate)
98153
40
Identical 5x46 485 001
Rollex extractor 48500
4 HP 14 Q (side shaft)
4 HP 18 Q
98154
41
5x46 302 206
Rollex extractor 30-32206/1
(side shaft)
98164
42
5x46 032 010
Rollex extractor 32010X/1
(differential)
98155
43
5x95 000 415
-Extractor handles, sealing sleeve
98156
44
PSA only 5p89 004 681
-Plug gauge, installation space,
transmission housing, differential
98108
45
PSA only 5p89 004 682
-Plug gauge, installation space,
converter bell housing, differen-
tial
98109
46
PSA only 5x46 001 051
-Fixture for dismantling/ assembly,
cup spring, brake F
98157
47
5x46 001 450 PSA only
-Drift, shaft seal, transmission
housing, differential
98158
48
5x46 001 451 PSA only
-Drift, shaft seal, converter bell
housing, differential
98159
49
MB only 5p89 004 767
-Plug gauge, installation space,
converter bell housing differential
98110
50
MB only 5p89 004 768
-Plug gauge, installation space,
transmission housing, differential
98111
51
MB only 5x46 001 308
-Fixture for disassembly/ assem-
bly, cup spring, brake F
98160
52
5x46 001 625 MB only
-Drift, shaft seal, transmission
housing, differential
98161
53
5x46 001 627 MB only
-Drift, shaft seal, converter bell
housing, differential
98162
54
5x46 002 000 MB only
-Core insert for ROLLEX extrac-
tor (differential)
98169
1.8.1.2 MB/FIAT
12
97501
(Wrench size = 17 mm
Wrench size = 13 mm)
97503
97504
97505
97506
(Torx TX-27)
97507
97508
97509
97510
(Wrench size = 19 mm
Wrench size = 13 mm)
97511
97512
97516
97517
97518
98101
97519
97520
97521
97522
97523
Important!
Other applications may require a differ-
97524
ent assembly fixture.
2.4/2 CD 4 HP 20 © ZF Getriebe GmbH Saarbrücken 99/04/01
Move selector lever to the “N” position.
Remove the position switch screws and
take off the position switch.
97525
Important!
97526
Take note of the oil cooler seals.
97527
97528
97529
97530
Important!
Since the bearing seat is tight, press the
bearing plate upwards from underneath
97531
to remove it.
97532
97533
Note!
The two centering bushes, the position
switch adjusting plate and the breather
97534
normally remain installed.
99/04/01 4 HP 20 © ZF Getriebe GmbH Saarbrücken CD 2.5/1
2.6 Dismantling the converter bell
housing
Take off the oil filter by loosening the
retaining screw.
Pull off the O-ring.
Unscrew the oil tank.
97535
97536
97537
97538
97539
Important!
To prevent possible running noises later,
keep the bearing shells together with the
97540
correct taper roller bearing.
2.6/2 CD 4 HP 20 © ZF Getriebe GmbH Saarbrücken 99/04/01
Unscrew the screw plug from the con-
verter bell housing.
97541
97542
97543
97544
97545
97546
97548
97549
97550
97551
97552
98166
Note !
If the fitting keys are not loose, leave
98167
them on the disc carrier.
2.7/4 CD 4 HP 20 © ZF Getriebe GmbH Saarbrücken 99/04/01
2.8 Dismantling the cover, bearing
plate, side shaft and differential
2.8.1 Dismantling the cover
Important!
There may be a ball installed in the dowel
pin bore under the oil feeding bush.
Danger of loss!
97555
97556
97557
97559
97558
97560
Important!
Core piece 5x46 002 000 is additionally
97561
used for other applications.
09.120
09.090
09.110
09.070 *
09.100
09.030
09.010
09.080
09.020
Important!
If the speedometer worm is made of plas-
tic, it must be put on the differential body
97562
before the bearing inner ring.
99/04/01 4 HP 20 © ZF Getriebe GmbH Saarbrücken CD 3.1/1
3.1.2 Completing the side shaft
97563
01.010/110
01.440
09.030
01.460
09.090 06.150
06.160
01.010/130
06.040
/120 /130
/110
/140
/160
06.080
06.010
06.060
97567
97568
98165
97570
Important!
Avoid build-up of filings !!!
97582
Making adjustments, Chapter 1.4.1
/110
14.010 /120
/130
/150
/140
/170
14.020
06.100
06.110 06.130
06.120
97564
Important !
Making adjusments, Chapter 1.4.2 when
97565
bearing components are replaced
97566
97591
73.010 73.070
73.060 /110
73.020
/120
/210
/200 *
73.040 /190 *
/180 *
/170 *
/220
/110
/120
/130 32.070
/140
32.050 32.060
/150
/160
/170
32.010
/160 /190
/200
/210
02.010
/150
/140 /220
/230
/130
/180 /120
/250 /240
/110
02.030
/260 /320
02.040 /270
02.060
02.040 /310
/300
02.070
/110
02.080
02.090
02.100
/360
/350
/120
/130
/340
/330
/140
/160
/170
/180 /150
97592
Important !
Making adjustments, Chapter 1.4.3.1
98167
Important !
Newer transmissions have two lined
clutch discs and one steel clutch disc
here instead.
The lined discs must be installed in such
a way that the lining faces the steel disc.
This is called the brake disc version.
97599
Making adjustments, Chapter 1.4.3.2
Important !
If the fitting keys 73.040/120 did not
remain on the disc carrier, drive them
98166
into the center of the disc carrier.
Important !
Insert the fitting keys into the appropriate
97604
grooves.
99/04/01 4 HP 20 © ZF Getriebe GmbH Saarbrücken CD 3.4/3
Carefully press piston C 73.060/120 into
cylinder C 73.060/110.
Important !
97605
Do not damage the sealing lips.
Important !
The brake C feed must be aligned with
97606
the feed bore in the transmission housing.
Important !
97608
Making adjustments, Chapter 1.4.4
3.4/4 CD 4 HP 20 © ZF Getriebe GmbH Saarbrücken 99/04/01
3.4.2 Installation of planetary drive
97609
97640
97515
97611
97612
97613
Important !
97614
Making adjustments, Chapter 1.4.5
97627
97628
97629
97630
97631
01.020/110
01.020
/110 01.060
01.064
/120
/130
01.070 /140
/160
01.080
01.090
01.100
Important !
For transmissions with a removable oil-
feed bush, the cover must be installed– as
described in Chap. 1.4.8 – in order to be
able to perform the Adjustment of axial
play for the input shaft.
Note !
When the bore for the dowel pin in the
cover is too deep (> 10 mm) a ball with a
diameter of 3.5 mm must also be put in,
otherwise the dowel pin might fall out.
99/04/01 4 HP 20 © ZF Getriebe GmbH Saarbrücken CD 3.5/1
Important! (when the oil feed bush is
removable)
97662
77.010
77.020
77.030
77.040
77.050
77.060
77.070
77.080
77.090
77.100
Important !
Making adjustments, Chapter 1.4.7
97615
Important!
A different assembly fixture might be
97636
required for other applications.
97637
06.100
06.110 01.014
06.130
06.120
01.016 01.150
01.200 01.180
01.210
97638
97639
97640
Important !
97643
Making adjustments, Chapter 1.4.6
3.7/2 CD 4 HP 20 © ZF Getriebe GmbH Saarbrücken 99/04/01
3.8 Installing the converter bell housing, control unit, inductive transmitter and oil pan into
the transmission housing
22.260 22.220
22.230
09.080
22.270
09.020 22.240
22.240
22.140
22.110
22.010
22.130 22.180
22.144
10.020
22.120
09.370 22.150
/120
22.200
22.170
22.134
10.010
/150
/140
/114 22.130
22.100
22.132
10.050
/154
/160 01.260
01.286
09.350 01.280 01.284
01.270
01.010/120
01.290
01.020/150
01.260
01.230 27.220
03.060
27.230
01.140 03.010
03.040
01.010/110
03.050
/118
/116 01.110
03.090
27.210
01.130
01.010/120
01.120 *
03.090
27.200
27.280 27.300
Important!
97644
Avoid build-up of cuttings !!!
97645
97646
Note !
The dowel pin must fit into the bore that
97647
was drilled for this purpose.
Important !
To prevent the pump housing from fall-
ing out, insert two screws before turning
97648
it over.
97649
97650
97651
Important !
Two dowel pins 01.010.120 must be
97652
inserted in the transmission housing.
3.8/4 CD 4 HP 20 © ZF Getriebe GmbH Saarbrücken 99/04/01
Fasten retaining strap 22.110 onto the
converter bell with two screws 22.130.
Insert one screw with new Usit ring
22.132 in the converter bell at the bore
with screw contact face that has been
milled smooth.
Insert and tighten two screws 22.134 and
four screws 22.130 inside and 14 screws
22.120 in the converter bell.
Important !
97653
For tightening specification, see Chapter 1.3
Important !
Check axial play.
97654
Making Adjustments, Chapter 1.4.9
97663
97664
Note!
On older transmissions, the testing con-
nections are closed with two plugs
01.260. Newer transmission do not have
any testing connections at all.
97665
(See Chapter 1.5 for tightening torque)
97666
97667
Important !
With some transmission parts specifica-
tions, spacing washer 01.120 is installed
underneath the inductive transmitter
97668
retaining strap.
97669
Important !
The groove for the selector shift valve
must be put properly into the detent disc
lug and the dowel pin must be inserted
97670
correctly into the transmission housing.
97671
97672
01.340
01.400
01.320
01.330
01.560
09.460
09.394 01.550
09.392
09.390
90.160
09.380
09.450 /110
22.250
22.030
06.190 /120
/130
97674
97675
Important!
Ensure that the converter fastening screw
is not too long, or the converter will be
damaged and the converter clutch will
97676
not function properly.
97677
97678