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
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
