1994 JAGUAR XJ ESP

ZF Automatic Transmissions Service Manual
FORE WORD
This manual provides information relevant to the servicing of ZF Automatic Transmission Units 4 HP 22 and 4 HP 24 E (irrespective of the vehicle range to which the unit is fitted). The manual should be used in conjunction with the rel- evant Vehicle Service Manual (VSM) and Electrical Diagnostic Manual (EDM).
It assumes that the transmission has been removed from the vehicle, in accordance with the Vehicle Service Manual,
and is
in a clean condition and all service tools and materials are available.
The manual is divided into two sections covering the ZF
4 HP 22 and ZF 4 HP 24 E and each section is divided into sub- sections covering:
0 Service Information
0 General Description
0 Hydraulic Circuit Diagrams
0 Fault Diagnosis
o Service Repair Operations.
An index can be found at the rear of the manual.
Ne@: For information relating to in-vehicle operations, refer to the Vehicle Service Manual.
ii Issue 1 August 1994

ZF Automatic Transmissions Service Manual
Problem Possible Cause
1.3.6 Fault Finding Chart (continued)
Action
>hange points at incorrect
;peeds
3eneral
Kick-down' cable sticking
Voisy and no drive after a long
ourney
dery noisy and no drive
3il leaks
3il dripping from the bell
iousing
-eakage between transmission
and oil sump
-eakage between intermediate
date and main housing
:especially at pump pressure
Doint)
3il leak at output
-eakage from cooler pipes
-eakage between main housing
jnd tail housing
3il leak from 'kick-down' cable at
:ransmission end 'Lock
-up'
safety valve sticking.
'Kick
-down' cable setting incorrect.
No 4th gear.
Governor pressure incorrect.
Nipple in throttle cam is worn.
Too much friction in sleeve of
'kick
-down' cable.
Throttle pressure piston sticking.
Oil filter on valve block faulty
Drive plate is worn or broken
Seal ring in pump housing
damaged.
Defective pump 0
-ring.
Pump housing porous.
Converter leaking from welded
seam.
Bolts incorrectly
torqued.
Sump gasket damaged.
Bell housing bolts loose.
Gasket damaged.
Output oil seal damaged
Loose connections.
Pipes damaged.
Cooler leaks.
Loose bolts.
Gasket damaged.
'0' ring connection damaged Service
/ renew valve
block / governor.
Adjust setting.
Check cable adjustment, service
/
renew valve block / governor.
Service
1 renew valve block I governor.
Replace cable.
Replace cable
Service
/ renew valve block.
If there is no burnt lining in the sump,
renew the filter and oil. If debris is
present, renew the transmission.
Renew the drive plate
Renew seal.
Renew
@ring.
Renew pump housing.
Renew converter.
Tighten bolts to specified torque.
Renew sump gasket.
Tighten bolts to specified torque.
Renew gasket.
Renew seal
Tighten connections.
Renew pipes.
Renew cooler.
Tighten bolts.
Renew gasket.
Renew
'0' ring or complete cable
issue 1 August 1994 37

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
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