1994 JAGUAR XJ automatic transmission fluid

ZF Automatic Transmissions Service Manual
Illustration I JaguarNumber 1 Description Notes
1 To
be issued I I I I
Fixing
11.
Tghtening Torque
(Nm)
TORQUE TIGHTENING SPECIFICATIONS
Description UseS Notes
1 To be issued
Item Description Data
1 I To be issued
Torque Converter: 3rd
1 ,oo: 1
4th 0,73: 1
Reverse 2,09: 1
Stall
speed 2100 RPM i 150 RPM
1 Transmission fluid: I Capacity I8,O Liters I
Transmission unit pressures:
Transmission
fluid type: Fill
I Esso 2D
I Esso 2D, 2E or 3 TOP-UP
Drive: Idle (stationary) 630-710 kPa
Drive: Full Throttle (stall) 780 - 950 kPa
1 Transmission weight: (including torque converter) I74,75 kg I
Transmission Ratios: IIst I 2,48 1 I
I2nd 11,481 I
Reverse: Idle (stationary) I 1070 - 1150 kPa
Reverse: Full
Throttle (stall) 1 1620 - 1780 kPa ~ ~~~
Issue 1 August 1994

ZF Automatic Transmissions Service Manual
Item Description I
IC! Service Data (continued)
Data
Tra ns m i ssi on f I u i d :
Transmission fluid type: Capacity
9,5 Liters
Fill Esso 2D
TOP
-UP Esso 2D,2E or 3
Torque converter:
Transmission
weight: (including torque converter)
Transmission Ratios:
I 1st
I2nd
79,65 kg
2,48: 1
I1,48:1
4th
Reverse
Final drive
I3rd
0,73: 1
2,09: 1
3,58: 1
I1,OO:l
Nominal size (diameter)
Torque Stall speed
UK Specification
Federal Specification
280mm
322 Nm @ 2000 RPM
2000 RPM (+ 150 RPM)
1900 RPM (+ 150 RPM)
Ratio I I Gear train end-float I0,2mm to 0,4mm
Electrical data
Solenoid valves;
I MV1, MV2 and MV3 I28 - 60 ohms (33,5 ohms @ 200
Pressure regulator solenoid valve
Output shaft sensor 15-7 ohms
I300 ohms (+ 10%)
I Sensor air gap I0,5mm to 1,Omm I
iv Issue 1 August 1994

ZF Automatic Transmissions Service Manual
1.1 ZF 4 HP 22 TRANSMISSION, GENERAL DESCRIPTION
The ZF Automatic Transmission covered in this section comprises a hydrodynamic torque converter, four speed gear
train and a hydraulic transmission control unit.
1. Torque converter
2. Throttle cable 3. 4-speed gear train 4. Output flange 5. Transmission control unit
Fig.
P \R
HP 22 ZF
6. Oil outlet (drain plug)
7. Selector cable attachment 8. Selector lever positions (see text) 9. Dipstick / oil filler tube 10. Oil cooler connection
.ansmission -
The transmission provides six gearshift positions:
0 Position 'P': Park - in this position the driven wheels are mechanically locked at the transmission.
0 Position 'R': Reverse - reverse gear selected.
0 Position 'N': Neutral - engine disconnected from driveline and wheels.
0 Position 'D': Drive - all four speed ranges are selected automatically with lock-up available in top gear only.
0 Position '3': automatic selection of the lowest three speed ranges only.
0 Position '2': automatic selection of the lowest two speed ranges only, transmission is prevented from shifting
up to the third and top speed ranges.
Immediate selection of a lower ratio is also available by 'kick-down' (pressing the accelerator down beyond the normal
full throttle position) for example when overtaking.
1.1.1 Torque Converter
The torque converter serves two main functions: it acts as a fluid coupling between engine and transmission geartrain
and it provides multiplication of engine torque when required.
The torque converter consists of an impeller, a turbine and a stator which is mounted on a one
-way clutch. The
converter cover is fixed to the impeller to seal the three elements within a common housing forming a closed circuit
through which oil flows when the transmission is in operation. The impeller is therefore connected to the engine and
rotates at engine speed when the engine is operating.
Torque multiplication is at its greatest when the vehicle is driven away from standstill. The stator bears against the
housing through its one
-way clutch and deflects the oil so that the flow is accelerated. As road speed builds up, the
impeller and turbine wheels turn at almost the same speed, so that the stator ceases to accelerate the oil flow and in- stead is disengaged from the housing and turns freely in the flow of oil. At this stage, the torque converter acts as a
fluid coupling.
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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.
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ZF Automatic Transmissions Service Manual
2.1
electronic-hydraulic transmission control unit.
ZF 4 HP 24 E TRANSMISSION, GENERAL DESCRIPTION
The ZF Transmission covered in this section comprises a hydrodynamic torque converter, four speed gear train and
1
/ /
7 6
, 5 4
J4L- 688
1. Torque converter 5. Oil outlet (drain plug)
2. 4-speed gear train 6. Rotary switch positions (see text)
3. Output flange 7. Dipstick/ oil filler tube 4. Transmission control unit 8. Oil cooler connection
Fig. 1 ZF 4 HP 24 E Transmission
The automatic transmission provides six gearshift positions:
0 Position 'P': Park - in this position the driven wheels are mechanically locked at the transmission.
0 Position 'R': Reverse - reverse gear selected.
0 Position 'N': Neutral -engine disconnected from drive-line and wheels.
0 Position 'D': Drive - all four speed ranges are selected automatically with lock-up available in top gear only.
0 Position '3': automatic selection of the lowest three speed ranges only.
0 Position '2': automatic selection of the lowest two speed ranges only, transmission is prevented from shifting
up to the third and top speed ranges.
Immediate selection of a lower ratio is also available by 'kick
-down' (pressing the accelerator down beyond the normal
full throttle position) for example when overtaking.
2.1.1 Torque Converter
The torque converter serves two main functions: it acts as a fluid coupling between engine and transmission geartrain
and it provides multiplication of engine torque when required.
The torque converter consists of an impeller, a turbine and a stator which is mounted on a one
-way clutch. The
converter cover is fixed to the impeller to seal the three elements within a common housing forming a closed circuit
through which oil flows when the transmission is in operation. The impeller is therefore connected to the engine and
rotates at engine speed when the engine is operating.
Torque multiplication is
at its greatest when the vehicle is driven away from standstill. The stator bears against the
housing through its one-way clutch and deflects the oil so that the flow is accelerated. As road speed builds up, the
impeller and turbine wheels turn at almost the same speed, so that the stator ceases to accelerate the oil flow and in- stead is disengaged from the housing and turns freely in the flow of oil. At this stage, the torque converter acts as a
fluid coupling.
Issue 1 August 1994 39

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