1994 JAGUAR XJ service

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
Issue 1 August 1994 64

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.
issue 1 August 1994 65

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

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