SECTION : 5A1 ZF 4 HP 16 AUTOMATIC TRANSAXLE CAUTION : sconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS INTRODUCTION .......scesscseeseessesees SATS ZF 4HP 16 Automatic Transaxle 5A1-3 Transaxle Components SAI—4 SPECIFICATIONS .. » BAIS General Specifications 5A1-5 Transaxle Gear Ratio 5AI-5 Fluid Capacity 5A1-5 Fastener Tightening Specifications 5AI-5 Shift Speed Chart 5AI-7 Line Pressure 5A1-8 SPECIAL TOOLS . . SAT ‘Special Tools Table 5A1-9 SCHEMATIC AND ROUTING DIAGRAMS ... 5A1-11 Transaxle Control Module (1 of 2) 5At-11 Transaxle Contro| Module (2 of 2) BAI-12 Shift Mode Diagram SAI-13 Power Flow Diagram SA1-17 COMPONENT LOCATOR ........cse00s0008 SAI-33 Transaxle Identification Information 5A1-33 Torque Converter 5A1-34 Transaxle Housing 5A1-35 il Pump 5A1-36 Rear Cover & Oil Pan Cover 5A1-37 Parking Lever 5A1-38 Input Shaft & Shift Gear . 5A1-39 Valve Body 5A1-41 Gear Shift Control 5A1-42 DIAGNOSTIC INFORMATION AND PROCEDURES DIAGNOSIS . ~ SAI-A3, Basic Knowiedge Required 5A1-43 Functional Check Procedure A143 Line Pressure Check Procedure 5A1-43 Clutch Plate Diagnosis. . 5A1-A5 Cooler Flushing and Flow Test A145 ‘Transaxle Fluid Level Service Procedure .... 51-45 Electrical/Garage Shift Test SA1-47 Road Test Procedure 5A1-47 Torque Converter Lock-Up Clutch(TCC) Diagnosis a 5A1-48 TCM Initialization Procedure 5A1-50 Shift Speed Chart 5AI-51 Intemal Wiring Harness Check A151 Transaxle Wiring Hamess Connector 5A1-54 ‘Symptom Diagnosis 5A1-56 DIAGNOSTIC TROUBLE CODE DIAGNOSIS 5A1-50 Diagnostic Trouble Code (DTC) Identification SA1-60. DTC P0562 ~ System Voltage Low 5A1-68 DTC P0563 ~ System Voltage High SAI-71 DTC P0601 — Internal Control Module Memory Checksum Error SAI-74 DTC P0603 — Internal Control Module Keep Alive Memory(KAM) Error . 5A1-76 DTC P0604 — Internal Controi Module Random ‘Access Memory(RAM) Error 5A1-78 DTC P0606 - Transaxle Control Module Processor Fault 5A1-80 DTC P0703 - Brake Switch Circuit Malfunction 5A1-83 DTC P0705 - Transmission Range Sensor Circuit Maifunction(PRNDL Input) SA1-86 DTC PO710 — Transmission Fiuid Temperature Sensor Circuit Malfunction . DTC PO715 — Input Speed Sensor(ISS) Circuit Malfunction DTC PO716 ~ Input Speed Sensor(ISS) Circuit RangelPerformance DTC P0717 — Input Speed Sensor(ISS) Circuit 5A1-89 5A1-92 5A1-95 No Signal 5A1-98 DTC PO720 ~ Output Speed Sensor(0SS) Circuit Matfunction - SAT101 OTC PO721 — Output Speed Sensor108S) Circuit Range/Performance 5A1~1045A1 ~ 2 ZF 4 HP 16 AUTOMATIC TRANSAXLE DTC P0722 - Output Speed Sensor(OSS) Circuit No Signal 5A1~107 DTC P0725 ~ Engine Speed Input Circuit Malfunction 5A1-110 DTC P0726 - Engine Speed Input Circuit Range’Performance 5AI-112, DTC P1868 — EDS 6 Output Shorted To DTC P0727 ~ Engine Speed Input Circuit No Signal BAI-114 DTC P0731 ~ Gear 4 Incorrect Ratio 5A1-116 DTC P0732 ~ Gear 2 Incorrect Ratio. 5AI-118 DTC P0733 ~ Gear 3 Incorrect Ratio. 5A1~120 DTC P0734 ~ Gear 4 Incorrect Ratio. BAI~122 DTC P0781 ~ 1-2 Shift Malfunction BAIW~124 DTC P0782 ~ 2-3 Shift Malfunction 5AI~126 DTC P0783 ~ 3-4 Shift Malfunction 5A1~128 DTC P1604 ~ Data Check of Internal & Extended Ram Failed . 5A1-130 DTC P1606 - Failure Of Extemel Watchdog 5A1~132 DTC P1871 — CAN Transmit Nessage Failure 5AIW-134 DTC P1672 ~ CAN Bus Off Failure 5AI~136 DTC P1675 ~ CAN Receive ECM Massage Failure 5A1-138 DTC P1830 EDS 3 Output Shorted To Ground 5A1~140 DTC P1840 ~ EDS 3 Output Shorted To Power 5AIW~142 DTC P1841 — EDS 3 Output Open -. SMI144 DTC P1850 ~ Solenoid 1 Output Shorted To Ground 5A1~146 DTC P1851 ~ Solenoid 1 Ouput Shorted To Power 5A1-148 DTC P1852 Solenoid 1 Output Open... 5A1~150 DTC P1853 - Solenoid 2 Ouput Shorted To Ground 5AI~152 DTC P1854 Solenoid 2 Output Shorted To Power 5AI-154 DTC P1855 — Solencid 2 Output Open .... SA1~156 DTC P1861 — EDS 4 Output Shorted To Ground 5AI-158 DTC P1862 - EDS 4 Output Shorted To Power ceeeeee SMI160 DTC P1863 EDS 4 Output Open 5A1—162 DTC P1864 — EDS 5 Output Shorted To Ground cee SAI64 DTC P1865 — EDS 5 Output Shorted To Power 5A1166 DTC P1866 EDS 5 Output Open ........ SA1~168 DTC P1867 - EDS 6 Output Shorted To Ground 5A1-170 Power 5A1-172 DTC P1869 - EDS 6 Output Open . SAI-174 DTC P1871 - EDS Valve Power Supply Circuit Shorted to Power - SAI-176 DTC P1874 — Solenoid Valve Power surety Circuit Shorted to Power . SAI-178 DTC P1881 - 2-1 Shift Malfunction 5A1~180 DTC P1883 - 3-2 Shift Malfunction 5AI~182 DTC P1884 — 4-3 Shift Malfunction 5At~184 DTC P1885 - 3-1 Shift Malfunction 5A1~186 DTC P1886 4-2 Shift Malfunction ....... 5A1-188 MAINTENANCE AND REPAIR .......+.0++ 5A1-190 ON-VEHICLE SERVICE 5A1-190 Transaxle Fluid Level Checking Procedure . 5A1-190 Changing the Fluid 5AI-194 Fluid Level Set After Service 5A1~192 Repairing Fluid Leaks se SAI~192 Case Porosity Repair - oe SAI“193 Shift Control Lever Assembly . - 5A1~193 Shift Control Cable 5A1~195 Shift Control Cable Adjustment 5A1-196 Transaxle Control Module(TCM) 5At-197 Park/Neutral Start Switch 5A1~198 ll Cooler PipesiHoses 5A1-199 Drive Axle Oil Seal 5A1-201 ll Pan, Oil Pan Gasket 5A1-201 Control Valve Body Assembly 5A1~203 Left Transaxle Mounting Bracket .......... 51-205 Transaxle Assembly . - 5A1-206 UNIT REPAIR - SA-212 Torque Converter 5A1-212 Transaxle Holding Fixture Assembly 5A1-212 Valve Body 5AI-212 Rear Cover 5A1-213 Clutch BE . SA1-214 Clutch BIE Measurement Procedure 5A1-217 Planetary Gear Set .... - 5A1-220 Brake CID 5A1-221 Differential 5A1-224 Side Shaft 5A1-224 Brake F, Slotted Nut 5A1-225 Torque Converter Housing 5A1-227 Shift Mechanism .. se. SAI=-228 Parking Lock System .. - 5A1-229 Bearing Piate(With Spur Gear) Assembly. 5A1-220 ll Pump Assembly 5A1-229 Differential/Side Shaft Outer Race, Bearing Shim 5A1-230ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1~3 Important Measurement/Adjustment ....... 51-230 Mechanical Components » SA1-232 Electronical Components - SAT-236 GENERAL DESCRIPTION AND SYSTEM TCM Inputs That Affect the 4HP 16 OPERATION ..... cee « SA1-232 Transaxle BA1-241 ZF 4HP 16 AUTOMATIC TRANSAXLE ‘The ZF 4 HP 16 is a four-speed automatic transaxle de- signed for cars with front-wheel drive and a transversely mounted engine The transaxle has a hydrodynamic torque converter with a controlled slip lock-up clutch. ‘A planetary gear train establishes the mechanical gear ra- tios. The integral constant ratio can be adapted to the en- gine’s power output and the vehicle's weight. The elec- tronic-hydraulic control makes controlled power shifts and various shift programs possible. In selector lever position *P’, the output is locked mechanically ‘The special feature of this transaxle is that it operates with- out freewheels. Shifting between individual gears takes place by means of overlapping clutch engagement and re- lease. The advantage of overlap shifting is as follows: ~The transaxle can be of more compact design and is lighter on account of the absence of free- ‘wheels and the lower number of shift elements. = Lower drag losses, i.e. higher efficiency — Lower peak torques acting on the components and driveline. However, overiap shifting necessitates high-performance hardware and software, and precision engine signals.5A1 ~ 4 ZF 4 HP 16 AUTOMATIC TRANSAXLE TRANSAXLE COMPONENTSZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 5: GENERAL SPECIFICATIONS Definition Transaxle Type 4-speed with four-wheel drive and transverse engine Input Torque 240 Nem (177 I-A) Transaxle Weight 7ekg (168 Ib) Torque Converter Capacity 9:72kg (21.4 1b) Transaxle Fluid Type (manufacture company) ESSO LT 71141 or TOTAL ATF H50235 Transaxle Fluid Capacity 73at (6.9L) TRANSAXLE GEAR RATIO Gear Ratio First 2719 ‘Second 1487 Third 7.000 Fourth Ori? Reverse 2.529 Final 30454 FLUID CAPACITY Litres: Quarts Bottom Pan Removal 4 42 Complete Overhaul 69 73 Torque Converter Removal 2 24 (Measurements are approximate) FASTENER TIGHTENING SPECIFICATIONS ‘Application Nem Ub-Ft Lb-In Bearing Plate Bolts 235 175 = Slotted Nut 220 162 = Rear Cover Attachment Bolts 235 75 = Baffle Plate Attachment Bolts 10 = 89 ParkiNeuiral Postion Switch 10 = EJ Fluid Pump Connecting Bolts 10 = 89 Fluid Filer Housing Cover Attachment Bolts 70 = 9 Input Speed sensor Attachment Bolts 8 = i ‘Output Speed Sensor Attachment Bolts a = 71 Vaive Body Bots 8 = 71 Valve Body Upper & Lower Fixing Bol é = 53 Fluid Pan Connecting Bolts 6 = 58 Fluid Pan Drain Plug & Ey =5A1 ~ 6 ZF 4 HP 16 AUTOMATIC TRANSAXLE Application Nem Lb-Ft Ubon Fluid Level Plug 5 33 = Line Pleasure Plugs 20 5 = Valve Housing 1 Cover Attachment Bolts 6 = 3 ‘Solenoid Valve Attachment Bolts 6 = Eg Pressure Control Regulator(EDS) Attachment Bolts 6 = 3 Oil Cooler Inlet Pipe Bolts 35 26 = Oil Cooler Outlet Pipe Balts 35 268 = Shift Control Cable Adjuster Pinch Nut 8 = 7A ‘Shift Control Cable Attachment Nut 8 = 7A Upper Transaxie-to—Engine Bolts 75 3 = Selector Lever(On Transaxle Case) 15 11 = Torque Converter Attachment Bolts Eg 33 = Shift Control Assembly Mounting Bolt, Nut 8 = 7A Lower Engineto-Transexle Bolts(a) 75 5 = Lower Engineto—Transaxie Bolt(b) 24 © = Lower Engineto—Transaxle Bolts(c) 3 23 = Rear Transaxle Mounting Bracket Bolts 2 5 = Damping Block Connection Bolt and Nut cy 50 = afl Transaxle Mount Bracket Cage Bolt(a) 110 a = Loft Transaxle Mount Bracket Cage Bolt(b) 5 8 = Left Transaxle Mount Bracket Cage Nut(c) 55 48 [ Taft Transaxle Mounting Bolts Ey EF =~ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1~7 Range Park/ D 3 2 1 Neutr | se al Gear N R| 4st | 2nd | ard] 4th | 1st | 2nd] 3rd | 1st | and | tet Solencid Valve] ON | ON | ON’ | ON’ | ON | ON | ON | ONT] ON’ | ON | ONT] ON 1 OFF | OFF | OFF | OFF | OFF | OFF | OFF | OFF | OFF | OFF | OFF Solenoid Valve| ON | ON | ON | OFF | OFF | OFF | ON | OFF | OFF] ON | OFF | ON 2 Line Pressure| OFF | OFF | OFF | ON | ON | ON’ | OFF | ON | ON’ | OFF | ON | OFF Control Sole- OFF | OFF OFF noid Valve 3 (EDS 3) Line Pressure] ON | OFF | ON | ON | ON | OFF | ON | ON | ON | ON | ON | ON Control Sole noid Valve 4 (EDS 4) Line Pressure| OFF | OFF | ON | ON | OFF | OFF | ON | ON | OFF | ON | ON | ON Control Sole- noid Valve 5 {EDS 5) Line Pressure] ON | OFF | ON | ON | ON | OFF | ON | ON | ON | ON | ON | ON Control Sole- noid Valve 6 (EDS 6) Brake B 3 aA | A a 3 aA aA Brake C H Brake D H Clutch E A | ALA aA | A a Brake F H [A H | A H | oH] A H = Holding ON = The solenoid is energized. OFF = The solenoid is de—energized. lanual Second-Third gear Is only available above approximately 100 kmih (62 mph). "= Manual First-Second gear is only available above approximately 60 krvh (37 mph). Note : Manual First-Third gear is also possible at high vehicle speed as a safety feature. SHIFT SPEED CHART Up Shift Speed MODEL First-Second gear(=3.0 | Second—Third gear (#40 | Third-Fourth gear (25.0 mph (4.8kmv/h) mph (6.4km/h)) mph (8km/h)) 10% | 25% | 50% | 100%| 10% | 25% | 50% | 100%| 10% | 25% | 50% | 100% tes | Tes | Tes | Tes | tps | TPs | TPs | Tes | TPS | TPs | TPS | TPS 7.8 DOHC o | 7 | i | 32 | te | 23 | 34 | 62 | 25 | 3a | a7 | 98 mph ¢kminy | (15) | (18) | (29) | (52) | (29) | 7) | 5) | (99) | (45) | 5) | (76) | (157)5A1 ~ 8 ZF 4 HP 16 AUTOMATIC TRANSAXLE Down Shift Speed MODEL Down Shift (4.0 mph (6.4km/h)) | Lock Up Clutch Applied Lock Up Clutch (Fourth) Released (Fourth) Fourth-Th | Third-Sec | Second-Fi] 10% 25% 10% 25% ird ond rst (Coast) | (Coast) (Coast) 1.8 DOHC 25 (41) 13 (21) 7M) 48 (77) 48 (77) 42 (68) 42 (68) mph (krv/h) LINE PRESSURE Gear Range Solenoid Line Pressure B Port E Port Park / Neutral ‘ON Low (90-124,7 psi (6.2-8.6 bar) OFF HIGH 221.9-282.3 psi (15.3~17.4 bar) Reverse ‘ON Low 89.9~124,7 psi (6.2-8.6 bar) OFF HIGH 221.9~252.3 psi (18.3~17.4 bar) Drive ‘ON Low ‘90-124,7 psi (6.2~8.6 bar) OFF HIGH 137.7=162.4 psi (9.5-11.2 bar) 3 ‘ON tow 90~124,7 psi ‘90~124,7 psi (6.2-8.6 bar) (6.2-8.6 bar) OFF HIGH 221.9~252.3 psi 137.7~162.4 psi (18.3~17.4 bar) (9.5-11.2 bar) 2 ‘ON Low ‘90-124,7 psi (6.2~8.6 bar) OFF HIGH 137.7=162.4 psi (9.5-11.2 bar) 1 ‘ON Low 90-124.7 psi (6.2-8.6 bar) OFF HIGH 221.9~252.3 psi (18.3~17.4 bar)ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1~9 SPECIAL TOOLS SPECIAL TOOLS TABLE cr] p Dw260-030 Scan Tool 1) Axle Seal Installer pp Dw260-050 Dw 10-060 e 2 ParkiNeutral Position Engine Support Fiture reNeutral Post Dw260-020 DW260-060 Transaxle Holding Brake F Split Stop Ring Fixture Remover/installer Dw260-010 Dw260-070 Transaxle Support ci) Transaxle Fluid Plug Fixture Remover/installer5A1 ~ 10 ZF 4 HP 16 AUTOMATIC TRANSAXLE Dw240-010 Dw260-120 Universal Pressure Clutch B Gauge Set Adjust Ring DWw260-150 Dw260-130 Clutch € Stop Ring Cluteh & Remove/installer Adjust Ring Dw260-100 Dw260- 140 Clutch B/E Clutch B Stop Ring Remover/installor Disc Thickness Measuring Fixture Dw260-090 (/ w290-160 clutch BE (Snap Rng Brake OD Snap Rng Py, nation Remover/installer Space) Measuring We Fixture Dw260-080 Dw260-110 Clutch B/E Shim Brake F Disc Clearance Setting Gauge Measuring BarZF 4 HP 16 AUTOMATIC TRANSAXLE 5A‘ ~ 11 SCHEMATIC AND ROUTING DIAGRAMS TRANSAXLE CONTROL MODULE (1 OF 2) Hot at All Times Hot nun and Start TT Tenino I ~The | aS eno [fue | Fuse ge aoc | I tock Baw L t lore) JORNELK(H/5) 48 ¥o202 4Ycan can cat £ “— 1K GAN! revere ARN [OKO dh bee ae —— Spero Pe Kis I 1s[0K or | Eom wp-140) | ty Buc La 4 pte a Loos S2085A1 ~ 12 ZF 4 HP 16 AUTOMATIC TRANSAXLE TRANSAXLE CONTROL MODULE (2 OF 2) Hot in Ran and Start Tengine [ IFuse | 58) a 7 Ycz0s ; Bu pax || om g tT | scienoa " ean | so] ceo Fe roa SF2 [Fuse J _JBlosk ay caer uP | aS Fis [Fuse | Lg Bleek a 76201 JORN bk pL 18,0206 lpn RED Lr Jann OK RED. atu lRED (Retin Rin ana Sit Hotat Al Times WPF Enaine IFuse | 1505 ens |Fuso EE aoa | | IB Solenoid Solenoid Lr ‘Such 50% IcrNr crn LT GN 7 cI Sotenoa * | 6 FransadeZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 13 SHIFT MODE DIAGRAM Economic Mode (1.8 DOHC) TPS (26) 32 23 24 1-2 Ko. too _| eo ‘3500. 4900. 4500. 5000. 5500. 6000. 6500. 7000. ‘1000. 1500. 2000. 2500. 3000. 500, °O Transmission Output Speed [1/min] 10. 20. 30. 40. 50. 60. 70. 80. 90.100. 110. 120. 190. 140. 150. 160. 170. 180.190. 3 Vehicle Speed [km/h]Lock-up Clutch Applied (Economic Mode ; Fourth Gear) (1.8 DOHC) TPS (%) 5A1 ~ 14 ZF 4 HP 16 AUTOMATIC TRANSAXLE Transmission Output Speed [1/min] Vehicle Speed [km/h] «| wrokropen SH | 4th gear control—-open 1000. 1500. 2000. 2500. 3000. 3500. 4000. 4500. 5000. 5500. 6000. 6500. 7000. 500, 10. 20. 30. 40, 50. 60. 70. 80. 90.100. 110. 120. 190. 140. 150, 160. 170. 180. 190. O ko. 0ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 15 Power Mode (1.8 DOHC) TPS (4) 7o4 2 Q 100. 1000. 1500. 2000. 2500. 3000. 3500. 4000. 4500. 5000. 5500. 6000. 6500. 7000. 500, 0 Transmission Output Speed [1/min] 10. 20. 30. 40, 50. 60. 70, 80, 90.100. 110, 120. 190. 140. 150. 160. 170. 180. 190, 0. Vehicle Speed [km/h]5A1 ~ 16 ZF 4 HP 16 AUTOMATIC TRANSAXLE Hold Mode (1.8 DOHC) nl Io It 14 0” "500, 1000. 1500. 2000. 2500. 3000. 3500. 4000, 4500. 5000. 5500. 6000. 6500. 7000. Transmission Output Speed [1/min] 6. 10. 20. 30. 40. 80. 60. 70. 80. 90.100. 110. 120. 130. 140. 150. 160. 170. 180. 190. Vehicle Speed [km/h]ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 17 POWER FLOW DIAGRAM Park/Neutral —oh —5A1 ~ 18 ZF 4 HP 16 AUTOMATIC TRANSAXLE Park/Neutral In Park or Neutral with the engine running there is no drive to the planetary gear set. Line pressure (from the cil pump) is supplies to the valve body. Only clutch B is supplied and the torque converter is released, Control Line Pressure Control Valve ‘The line pressure control valve sets the general pressure level in the valve body. When gearshifts are not taking place, the line pressure varies between two levels, de- ending on the turbine torque. Line pressure increase lin- early by time, But it has a limit point, When pressure reach- 2s that point, excess oil pressure drains back into the oil sump. Reduction Valve ‘The reduction valve reduces the line pressure with which the downstream solenoid valves and pressure control so- lenoid valves (EDS) ere supplied. This makes it possible to use smaller solenoid valves. ‘The line pressure comes from the oll pump and flows to the reduction valve. The inlet port to the reduction valve will be blocked and line pressure will be maintained at the ap- propriate level Solenoid Valve 1, 2 Solenoid Valve 4 controls the line pressure (high and low) to the clutch valves. Solenoid Valve 1 is either ON or OFF. ‘When the solenoid is turned ON the line pressure will be low [87~116psi (6~8dar).When the solenoid is turned OFF the line pressure will be high [232~261psi (16~18ban)) Solenoid 2 controls the fui flow to clutch valve E or the TCC clutch valve. When solenoid 2 is ON fluid is directed tothe TCC pressure valve and ifthe solenoid is switched OFF fluid will flow to the inlet at clutch valve E. ‘The TCM monitors numerous inputs to determine the ap- propriate solenoid state combination and transaxle gear for the vehicle operating conditions, In Park and Neutral solenoid valve 1 is ON. So line pres- sure flows to the safety valve and the line pressure control valve via the solenoid valve. Clutch B Engaged In Park and Neutral solenoid valves 1 and 2 are both ON. Pressure control solenoids (EDS) 4 and 6 are also turned ON. When EDS 6 is ON, the fluid supplied from the reduction valve flows to the safety valve, clutch valve B and holding valve B. The oil that is supplied to the inlet port ofthe clutch valve presses on the valve spool. Line pressure then flows to the holding valve and check ball, engaging clutch B. Lock-up Clutch (TCC) Solenoid 2 is tumed ON and the line pressure control valves spoo! will be depressed. Fluid will now flow through the torque converter pressure valve. ‘As a result, the oil pressure behind the converter lock-up clutch piston and in the turbine zone is equal. The direction Of flow is through the turbine shaft and through the space behind the piston, to the turbine chamber. Lubrication/Cooling. ‘The lubricating valve ensures thet the converter is sup- plied with cooling oil firs if the pump rate is low. The lubri- cating pressure vaive in addition guarantees that the nec- ‘essary amount of cooling and lubricating oll is available via the bypass duct. ‘The fluid, which is supplied from the torque converter, flows to the cooler via the lubrication valve.ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 19 Reverse5A ~ 20 ZF 4 HP 16 AUTOMATIC TRANSAXLE Reverse In Reverse, transaxle drive is via the input shaft and clutch B, The elements of this transaxle function are as follows: + Clutch B is engaged and drives the reverse sun gear in a clock—wise direction. + The D band is engaged and holds the planetary gear carrier (front & rear) stationary causing the differential pinion to rotate clockwise. + The differential rotates in a counterclockwise direc tion ‘+ The output shaft is driven in a counterclockwise or reverse direction. Control Clutch B Engaged ‘The line pressure, which is supplied by the oil pump, is di- rected to clutch B via the manual valve. The position of the ccheck ball will change allowing direct pressure to clutch B. Brake D Engaged The line pressure, which engaged clutch B, is also sup- plied to clutch valve D. In Reverse, solenoid 1 is switched ON and EDS 4 is switched OFF. This will cause the fluid supplied to the re- duction valve to flow to clutch valve D via the EDS 4. ‘The spool of clutch valve D will be depressed allowing fluid to pass to holding valve D. Lock-up Clutch (TCC) Solenoid 2 is turned ON and the line pressure control valve spool will be depressed, Fluid will now flow through the torque converter pressure valve, ‘As a result, the oil pressure behind the converter lock-up clutch piston and in the turbine zone is equal. The direction Of flow is through the turbine shaft and through the space behind the piston, to the turbine chamber. Lubrication/Cooling ‘The lubricating vaive ensures that the converter is sup- plied with cooling oil first if the pump rate is low. The lubri- cating pressure vaive in addition guarantees that the nec- ‘essary amount of cooling and lubricating oll is available via the bypass duct. The fluid, which is supplied from the torque converter, flows to the cooler Via the lubrication valve.ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 21 Drive Range - First Gear5A1 ~ 22 ZF 4 HP 16 AUTOMATIC TRANSAXLE Drive Range - First Gear In Drive 1, transaxle drive is via the input shaff to clutch B. ‘The elements of this transaxle function are as follows: + Clutch B is engaged to drive the rear sun gear. + The rear sun gear drives the front planetary gear cartier clockwise. + The rear planetary gear carrier drives the front ring gear and front planetary gear carrier clockwise. Control Clutch B Engaged In Park and Neutral solenoid valves 1 and 2 are both ON. Pressure control solenoids (EDS) 4 and 6 are also turned ON. When EDS 6 is ON, the fluid supplied from the reduction valve flows to the safety valve, clutch valve B and holding valve B. The oil that is supplied to the inlet port ofthe clutch valve presses on the valve spool. Line pressure then flows to the holding valve and check ball, engaging clutch B. Clutch F Engaged EDS 5 will be switched ON. The line pressure, which assed through the reduction valve, will low to the holding valve and the clutch valve inlet. As a result the valve spool is depressed, Lock-up Clutch (TCC) Solenoid 2 is tumed ON and the line pressure control valve spool will be depressed. Fluid will now flow through the torque converter pressure valve. As a result, the oll pressure behind the converter lock-up clutch piston and in the turbine zone is equal. The direction of flow is through the turbine shaft and through the space behind the piston, to the turbine chamber. Lubrication/Cooling ‘The lubricating valve ensures that the converter is sup— plied with cooling oil firs if the pump rate is low. The lubri- cating pressure valve in addition guarantees that the nec- essary amount of cooling and lubricating oll is available via the bypass duct. The fluid, which is supplied from the torque converter, flows to the cooler via the lubrication valve.ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 23 Drive Range - Second Gear5A ~ 24 ZF 4 HP 16 AUTOMATIC TRANSAXLE Drive Range - Second Gear In Drive 2, the transaxle drive is via the input shaft and clutch €. The elements of this transaxle function are as fol lows: + Clutch E is applied to drive the front ring gear ‘+ The front ring gear drives the front planetary gear cartier, + The front planetary gear carrier drives the differen- tial pinion gear clockwise. * Brake F is applied holding the front sun gear sta- tionary. Control Clutch E Engaged Solencid 2 will be switched OFF. Line pressure, which is supplied by the reduction valve, flows to the inlet port of clutch valve E. Fluid will then pass through the clutch vaive and clutch E will engage. Clutch F Engaged EDS 5 will be switched ON. The line pressure, which assed through the reduction valve, will low to the holding valve and the clutch valve inlet. As a result the valve spool is depressed, Lock-up Clutch Solenoid vaive 2 is turned ON and the line pressure control valve spool will be depressed. Fluid will now flow through. the torque converter pressure valve. As a result, the oll pressure behind the converter lock-up clutch piston and in the turbine zone is equal. The direction of flow is through the turbine shaft and through the space behind the piston, to the turbine chamber. Lubrication/Cooling ‘The lubricating valve ensures that the converter is sup- plied with cooling oil firs if the pump rate is low. The lubri- cating pressure valve in addition guarantees that the nec- essary amount of cooling and lubricating oll is available via the bypass duct. The fluid, which is supplied from the torque converter, flows to the cooler via the lubrication valve.ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 25 Drive Range - Third Gear en xt Seen Ne5A1 ~ 26 ZF 4 HP 16 AUTOMATIC TRANSAXLE Drive Range - Third Gear In Drive 3, transaxle drive is via the input shaft to clutches B and E. The elements of this transaxle function are as fol lows: + Clutches B and E are engaged to drive the rear sun, geer and rear planetary gear carrier clockwise. + The clockwise rotation of the rear sun gear and rear planetary gear carrier will cause the front planetary gear to rotate in the same direction Control Clutch B Engaged In Park and Neutral solenoid valves 1 and 2 are both ON. Pressure control solenoids (EDS) 4 and 6 are also turned ON. When EDS 6 is ON, the fluid supplied from the reduction valve flows to the safety valve, clutch valve B and holding valve B. The oil that is supplied to the inlet port of the clutch valve presses on the valve spool. Line pressure then flows to the holding valve and check ball, engaging clutch B. Lock-up Clutch (TCC) Solenoid vaive 2 is turned ON and the line pressure control valve spool will be depressed, Fluid will now flow through the torque converter pressure valve, ‘As a result, the oil pressure behind the converter lock-up clutch piston and in the turbine zone is equal. The direction Of flow is through the turbine shaft and through the space behind the piston, to the turbine chamber.ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A‘ ~ 27 Drive Range - Fourth Gear5A ~ 28 ZF 4 HP 16 AUTOMATIC TRANSAXLE Drive Range - Fourth Gear In Drive 4, transaxle drive is via the input shaft and clutches € and C. The elements ofthis transaxle function are as follows: + Clutch E is engaged to drive the rear planetary gear cartier. + The rear planetary gear cartier drives the rear ring geer. +The rear ring gear carrier drives the differential geer. Control Clutch E Engaged Solenoid 2 will be switched OFF. Line pressure, which is supplied by the reduction valve, flows to the inlet port of clutch valve E. Fluid will then pass through the clutch vaive and clutch E will engage. Clutch C Engaged EDS 4 will be switched OFF causing the fiuid level to be high. Line pressure will be directed to the safety valve, lute valve D and holding valve D. Clutch valve C and holding valve C will engage as pressure flows through the safety valve. Lock-up Clutch Solenoid vaive 2 is turned ON and the line pressure control valve spool will be depressed. Fluid will now flow through. the torque converter pressure valve. As a result, the oll pressure behind the converter lock-up clutch piston and in the turbine zone is equal. The direction Of flow is through the turbine shaft and through the space behind the piston, to the turbine chamber.ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A‘ ~ 29 Drive Range - Fourth Gear ; Emergency/Substitute Mode5A1 ~ 30 ZF 4 HP 16 AUTOMATIC TRANSAXLE Drive Range - Fourth Gear ; Emergency/Substitute Mode In Drive 4, transaxle drive is via the input shaft and clutches E and C. The elements of this transaxle function are as follows: Clutch E is engaged to drive the rear planetary gear cartier. ‘The rear planetary gear carrier drives the rear ring geer. ‘The rear ring gear cartier drives the differential gear. Control Clutch E Engaged Solenoid 2 will be switched OFF. Line pressure, which is supplied by the reduction valve, flows to the inlet port of clutch valve E. Fluid will then pass through the clutch valve and clutch will engage. Clutch C Engaged EDS 4 will be switched OFF causing the fluid level to be high. Line pressure will be directed to the safety valve, clutch valve D and holding valve D. Clutch valve C and holding valve C will engage as pressure flows through the safety valve.ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 31 Drive Range - Third Gear ; Emergency/Substitute Mode5A1 ~ 32 ZF 4 HP 16 AUTOMATIC TRANSAXLE Drive Range - Third Gear ; Emergency/Substitute Mode ln Drive 3, transaxle dive is via the input shaft to clutches B and E. The elements of ths transaxle function are as fol lows: Clutches B and E are engaged to drive the rear sun gear and rear planetary gear carrier clockwise. ‘The clockwise rotetion of the rear sun gear and rear planetary gear carrier will cause the front planetary gear to rotate in the same direction, Control Clutch B Engaged In Park and Neutral solenoid valves 1 and 2 are both ON. Pressure control solenoids (EDS) 4 and 6 are also turned ON. When EDS 6 is ON, the fluid supplied from the reduction valve flows to the safety valve, clutch valve B and holding valve B. The oil that is supplied to the inlet port ofthe clutch valve presses on the valve spool. Line pressure then flows. to the holding valve and check ball, engaging clutch B.ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 33 COMPONENT LOCATOR TRANSAXLE IDENTIFICATION INFORMATION 4. Part Number 3. Model Code 2. Serial Number 4. Manufactured Nation and Company5A ~ 34 ZF 4 HP 16 AUTOMATIC TRANSAXLE TORQUE CONVERTER Senegrens Torque Converter Housing ‘Torque Converter ‘Torque Converter Gasket Steel Gasket Oil Baffle Plate Bolt Magnet Oi Filter O-ring 10. 11 12, 13, 14, 15. 16. 17. Screw Pressure Plug Pressure Plug Oil Drain Plug Oil Level Plug Screw Bolt BoltZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 35 TRANSAXLE HOUSING Senegrens Transaxle Housing Bushing Shaft Seal Axle Shaft Seal Sealing Sleeve Breather Pipe Sleeve Protector ‘Type Plate Cable Terminal 10. 11 12, 13, 14, 15. 16. 17. Output Speed Sensor Washer Bolt Shim Shim Park/Neutral Position Switch Bolt Sealing sleeve5A1 ~ 36 ZF 4 HP 16 AUTOMATIC TRANSAXLE OIL PUMP Oil Pump 5. Dowel Pin Oil Pump Seat 6 Bolt Washer 7. Bolt pepe O-ringZF 4 HP 16 AUTOMATIC TRANSAXLE 5A‘ ~ 37 REAR COVER & OIL PAN COVER PoOkeEa Rear Cover 7. Bolt Piston Ring 8 Oil Pan O-ring 9. Oil Pan Gasket Needle Bearing 10. Oil Pan Bracket Shim 11. Bolt Screw Plug5A1 ~ 38 ZF 4 HP 16 AUTOMATIC TRANSAXLE PARKING LEVER pepe Selector Shaft Stop Bushing Detent Dise Clamping Sleeve Connecting Bar Leg Spring Pawl Pin Support BoltZF 4 HP 16 AUTOMATIC TRANSAXLE 5A‘ ~ 39 INPUT SHAFT & SHIFT GEAR5A1 ~ 40 ZF 4 HP 16 AUTOMATIC TRANSAXLE Inner Dise Carrier F Cluteh Plate F Line Clutch Disc F Clutch Outer Dise F Spring Dise Stop Ring Cup Spring O-ring O-ring Piston D Slotted Nut Roller Bearing Adjust Ring Bearing Plate Roller Bearing Spur Gear Piston D Spring Dise Snap Ring Clutch Pate D Cup Spring Line Clutch Disc D Spring Disc Dise Carrier C/D Pitting Key Line Clutch Disc C Clutch Outer Disc © Cup Spring Line Clutch Dise C |. Snap Ring Piston C Cylinder C |. Snap Ring Front Ring Gear Oll Tray Front Planetary Gear Front Sun Gear Snap Ring Needle Bearing Rear Planetary Gear Set Snap Ring Rear Sun Gear Needle Bearing Snap Ring Piston B Clutch Plate B Clutch Outer Dise 8 Line Clutch Dise B Spring Dise Piston Ring Inner Dise Carrier Needle Bearing Snap Ring Clutch Plate Disc & Line Clutch Disc E Clutch Outer Disc & Spring Dise Retainer Ring O-ring Oil Dam Cup Spring O-ring Piston E O-ting Input Shaft ‘O-ring ‘O-ting Piston Oil Dam O-ring Cup Spring Stop Ring Shim Needle Bearing O-ring Piston Ring Rear CoverZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 41 VALVE BODY og PAS BAwN= Control Valve Body \Valve Body Wiring Harness O-ring Plug Cable Terminal Retaining Clip Input Speed Sensor Cap Screw 10. 11 12, 13, 14, 15, Solenoid Valve Cap Screw Fixing Plate Fixing Plate ‘Cap Screw Solenoid Valve Solenoid Valve5A1 ~ 42 ZF 4 HP 16 AUTOMATIC TRANSAXLE GEAR SHIFT CONTROL Sh ¥ nal — — PoOkeEa Selector Control Lever Gear Shift Knob Cover Step Gale Slider BTSI Button Spring Positioning Spring Solenoid Base Plate TIA Lever Select Cable Cable FastenerZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 43 DIAGNOSTIC INFORMATION AND PROCEDURES DIAGNOSIS BASIC KNOWLEDGE REQUIRED You must be familiar with some basic electronics to use this section of the Service Manual. They will help you to follow diagnostic procedures. Notice : Lack of the basic knowledge of this transaxle ‘when performing diagnostic procedures could result in in- correct diagnostic performance or damage to transaxle components. Do not, under any circumstances, attempt to diagnose @ transaxle problem without this basic knowledge Notice : Ifa wir is probed with a sharp instrument and not properly sealed afterward, the wire will corrode and an open circuit will result, Diagnostic test probes are now available that allow you to probe individual wires without leaving the wire open to the environment. These probe devices are inexpensive and easy to install, and they permanently seal the wire from corrosion, Special Tools You should be able to use @ Digital Volt Meter (DVM), a c= cuit tester, jumper wites or leads and a ine pressure gauge set The functional check procedure is designed to verify the correct operation of electronic components in the trans- axle. This will eliminate the unnecessary removal of transaxle components, FUNCTIONAL CHECK PROCEDURE Begin with the Functional Check Procedure which pro- vides @ general outline of how to diagnose automatic transaxle. The following functional check procedure will in- dicate the proper path of diagnosing the transaxle by de- scribing the basic checks and then referencing the loca- tions of the specific checks. ‘+ Check the fluid level according to the Fluid Level Service Procedure, + Check the transaxle for fluid leaks. + Check if the transaxle fluid is not bumt by color and smell + Ensure that the transaxle is not in Limp Home Mode(LHM). + Check the battery terminals and the ground con- nections for corrasion or looseness. ‘© Check thet the cooler flow is not restricted. + Check all electrical connections for tightness. + Use on-board diagnostic tool or a scan tool to see if any transaxle trouble codes have been set. Refer to the appropriate "Diagnostic Trouble Code (DTC)" information and repair the vehicle as directed. After repairing the vehicle, perform the road test and verify that the code has not set again. Perform the ElectricaliGarage Shift Tests. Perform the Road Test Procedure in this section, Inspect the oil and check for metal or ather contam- inants in the oil pan. LINE PRESSURE CHECK PROCEDURE ‘The 4HP 16 A/T uses a trochoid type oil pump to produce hydraulic pressure, and a pressure control solenoid (sole- noid 1) to contro! that pressure at the pressure regulator valve, after it leaves the pump. The transaxle pressure control solenoid is controlled by an electrical signal that ranges from 0 to 12 volts corresponds to minimum line pressure (approx. 89.9 to 124.7 psi (6.2 to 8.6 bar)) and 0 volt corresponds to a maximum line pressure (approx. 221.9 to 252.4 psi (15.3 to 17.4 bar)) in all range, Line pressures are calculated for two sets of gear ranges = Drive-Park-Neutral and Reverse. This allow the trans- axle line pressure to be appropriate for different pressure needs in different gear ranges: Gear |Solencid] RPM | Pressure Range 1 Drive, on | 2,500 [221.9-252.4psi Reverse (18.3~17.4 bar) On | 2,500 | 17.4-260.8ps1 (1.2~18.6 bar) Neutral, | Of | 2,500 |221.9-252.4psi Park (15.3-17.4 bar) On | 2,500 | 89.9-2608 psi (6.2~18.6 bar) Before performing a line pressure check, verify that the pressure control solenoid is receiving the correct electrical signal from the TCM: 1. Install a scan tool 2. Start the engine and set parking brake. 3. Check for a stored pressure control solenoid diag nostic trouble code, and other diagnostic trouble codes.5A1 ~ 44 ZF 4 HP 16 AUTOMATIC TRANSAXLE Repair vehicle, if necessary. Inspect Fluid level Manual linkage. Install or Connect: Scan tool (scanner) Oil pressure gauge et line pressure port (clutch B or E ports on transaxle case) Dw240-010 Put gear selector in Park and set the parking brake. 6. Start engine and allow it to warm up at idle. 7. ecess the "Solenoid 1 Control Mode” on the scan- ner. 8. Switching solenoid 1 ON/OFF, accelerating the en- gine to 2,500rpm, and then read the line pressure at the each gear. 9. Compare data to the Drive-Park-Neutral line pres- ‘sure chart below. Notice : Total test running time should net exceed 2 min- utes, or transaxle damage could occur. CAUTION : Brake must be applied at all times to pre- vent unexpected vehicle motion. Hf pressure readings differ greatly from the line pressure cchart, refer to the Diagnosis Charts contained in this sec tion. Notice : lutch damage may occur. ‘The scanner is only able to control the pressure control so- lenoid in Park and Neutral with the vehicle stopped. This protects the clutches from extremely high or low pres- ssures in Drive or Reverse rang, Gear Range | Solenoid Line B Port E Port Pressure Park / Neutral ON Low (00-1247 psi (6.2-8.6 bar) OFF HIGH 221,9-252.3 ps i (15.3+17.4 bar) Reverse ON Low (00-1247 psi (6.2-8.6 bar) OFF HIGH 221.9-252.3 psi (15.3~17.4 bar) Dive ON tow 90-124.7 psi (6.2-8.6 bar) OFF HIGH 137.7-162.4 psi (9.5-11.2 bar) 3 ON tow 90-1247 psi (6.2-8.6 bar) | 90-1247 psi (62-86 bar) ‘OFF HIGH 221.9-252.3 psi 137.7=162.4 pal (15.3-17.4 bar) (5-11.2 bar) z ON Low 90-1247 psi (6.2-8.6 bar) OFF HIGH 137.7162. pal (9.5~11.2 bar) 1 ON Low (00-1247 psi (6.2-8.6 bar) OFF HIGH 221.9-252.3 psi (15.3-17.4 bar)ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 45 CLUTCH PLATE DIAGNOSIS Dry the plate and inspect the plates for the following condi- tions Pitting Flaking Wear Glazing Cracking Charing Chips or metal particles embedded in the lining Replace @ composition plate which shows any of these conditions. Steel Plates ‘Wipe the plates dry and check the plates for heat discolor ation. If the surfaces are smooth, even if colorsmeer is in- dicated, you can reuse the plate. Ifthe plate is discolored ‘with hot spots or ifthe surface is scuffed, replace the plate, Important : Ifthe clutch shows evidence or extreme heat or burning, replace the springs. Causes of Burned Clutch Plates ‘The following conditions can result in a bumed clutch plate: Incorrect usage of clutch plates. Engine coolant in the transaxle flu. A.cracked clutch piston. Damaged or missing seals. Low line pressure. Valve problems. ~The valve body face is not flat = Porosity between channels = The valve bushing clips are improperly installed. ~The check balls are misplaced +The seal rings are worn or damaged Engine Coolant in Transaxle Notice : Antifreeze will deteriorate the O-ring seals and the glue used to bond the clutch material to the pressure plate. Both conditions may cause transaxle damage. Perform the following steps if the transaxle cil cooler has developed a leak, allowing engine coolant to enter the transaxle: 1. Because the coolant will attach to the seal material causing leakage, disassemble the transaxle and replace all rubber type seals. 2. Because the facing material may become sepa- rated from the steel center portion, replace the composition faced clutch plate assemblies. Replace all nylon parts including washers. Replace the torque converter. ‘Thoroughly clean and rebuild the transaxle, using new gaskets and oil fter. 6. Flush the cooler lines after you have properly re~ paired or replaced the transaxle. COOLER FLUSHING AND FLOW TEST Notice : You must flush the cooler whenever you receive a transaxle for service, Cooler flushing is essential for SRTA installation, major overhaul, whenever you replace ‘4 pump or torque converter, or whenever you suspect that the fluid has been contaminated. After filing the transaxle with fluid, start the engine and run for 30 seconds. This will remove any residual moisture from the oil cooler. Disconnect the retum line at the trans- axle and observe the flow with the engine running. ifthe fluid flow is insufficient, check the fluid flow by disconnect ing the feed line at the cooler. Observe the flow with the ‘engine running, ‘+ Ifthe flow from the cooler return line at the trans- axle is insufficient, check the flow rate from the feed Tine to the cooler. BLockage exists in the transaxle or the cooler. ‘+ Ifthe flow from the transaxle feed line to the cooler is insufficient, the transaxle is the cause of the fluid flow problem. ‘+ Ifthe flow the transaxle feed line to the cooler is insufficient, but flow from the cooler retum line to the transaxle is insufficient, inspect the cooler pipes and fittings. Then repeat the cooler flushing proce- dure. Ifthe flow is stil insufficient, replace the cool- er. TRANSAXLE FLUID LEVEL SERVICE PROCEDURE This procedure is to be used when checking a concein with the fluid level in a vehicle. A low fluid level will result in slipping and loss of drive’ reverse or delay on engage- ment of drivel reverse when the vehicle is cold. The vehicle is first checked for transaxle diagnostic mes- ‘sages on the scan tool. Ifthe cil level is low, itis possible to register a vehicle speed signal fault. The vehicle is to be test driven to determine if there is an abnormal delay when selecting drive or reverse, or loss of drive. One symptom of low fluid level is a momentary loss of drive when driving the vehicle around a comer. Also when the transaxle fluid level is low, a loss of drive may oc- ‘cur when the transaxle fluid temperature is low. When adding or changing transaxle fluid use only ESSO LT 71141 automatic transaxle fluid or other approved fluids. The use of incorrect fuid will cause the performance and durability of the transaxle to be severely degraded. Fluid Level Diagnosis Procedure 1, Ifthe vehicle is at operating temperature allow the vehicle to cool down for two hours, but no greater than four hours. Or if the vehicle is at cool status, start the engine and allow the engine to idle for approximately 5 minutes (825~875 rpm), if pos-5A1 ~ 46 ZF 4 HP 16 AUTOMATIC TRANSAXLE sible, drive the vehicle for a few kilometers (ND, N-R, shift until two gear). This will allow the trans- axle to be within the correct temperature range. ‘Transaxle fluid level should be checked at tempera- ture 20 to 45°C (68 to 113°F), CAUTION : Removal of the fluid filler plug when the transaxle fluid is hot may cause injury if fluid drains from the filler hole. 2. Switch off accessories, especially alr conditioner, heater. 3. With the brake pedal pressed, move the gear shift control lever through the gear ranges, pausing @ few seconds in each range. Return the gearshift lever to P(Park). Turn the engine OFF. 4, Park the vehicle on a hoist, inspection pit or similar raised level surface, The vehicle must be level to obtain a correct fluid level measurement. 5. Place a fluid container below the fluid filler plug 6. Clean all dirt from around the fuid filler plug, Remove the fiuid filler plug. Clean the filer plug and check that there is no damage to the "0" ring + If fluid drains through the filer hole the transaxle may have been overfiled. When the fluid stops draining the fluid level is correct. install the fluid filler plug and tighten it to 4SNem(34 Ib) + If fluid does not crain through the filler hole, the transaxle fluid level may be low. Lower the ve- hicle, and start the vehicle in P(Park) with the parking brake and the brake applied. With the ‘engine idling, move the gear shift lever through the gear ranges, pausing a few seconds in each. range and adding the fluid until gear application is felt. Return the gear shift lever to P(Park). Tum the engine OFF and raise the vehicle. Check ifthe fluid level is aligned with the bottom of the filer hole. If not, add @ small quantity of fluid to the correct level. Install the fluid filer plug and tighten it to 45Nem(34 Ib-f). 7. When the fluid level checking procedure is com- pleted, wipe any fluid around the filler plug with 2 rag or shop towel Fluid Level Set After Service 1. Depending on the service procedure performed, Add the following emounts of fluid through the filler plug hole prior to adjusting the fluid level: Oil pan removal — 4 liters (4.23 quarts) Converter removal ~ 2 liters ( 2.11 quarts) Overhaul — 6 9liters (7.3 quarts) Oil drain plug removal — 4 liters (4.23 quarts) 2. Follow steps 4 through 4 of the Fluid Level Diagno- sis Procedure, 3. Clean all ditt from around the fluid filler plug, Remove the fiuid filler plug. Clean the filer plug and check that there is no damage to the "0" ring 4, Lower the vehicle with the filer plug still removed and start the vehicle in P(Park) with the parking brake and the brake applied. With the engine idling, move the gear shift lever through the geer ranges, pausing a few seconds in each range and adding the fluid until gear application is felt. Then add an additional 0.5 lters of fluid. Return the gear shift lever to P(Park). Tum the engine OFF and raise the vehicle. Install the fluid filler plug and tighten it to 45Nem (34 lb-ft), Drive the vehicle at 2.2 miles(3.5km) to 2.8 miles(4.5 km) with light throttle so that the engine does not exceed 2500 rpm. This should result in the transaxle temperature being in the range 20 to 45°C (68 to 11°F). With the brake applied, move the shift lever through the gear ranges, pausing a few seconds in each range at the engine iding, 6. Return the gear shift lever to P(Park). Turn the en- gine OFF and raise the vehicle on the hoist, if appli- Cable, ensuring the vehicle is level. When the three minutes passed after the engine stopped, remove the filler plug. Check if the fluid level is aligned with the bottom of the filler hole, not, add a small quantity of fluid to the correct level. Install the fluid filler plug and tighten it to 45Nem (34 Ib-ft) 7. Wipe any fluid around the filler plug with @ rag or shop towel Fluid Leak Diagnosis and Repair ‘The cause of most external leaks can generally be Lo- cated and repaired with the transaxle in the vehicle. Methods for Locating Leaks General Method 1. Verify that the leak is transaxle fluid, 2. Thoroughly clean the suspected leak area. 3. Drive the vehicle for approximately 25 km (15 miles) or until the transaxle reaches normal operat- ing temperature (88°C, 190°F) 4, Park the vehicle over clean paper or cardboard, 5. Turn the engine OFF and look for fluid spots on the paper. 6. Make the necessary repairs to correct the leak. Powder Method 1. Thoroughly clean the suspected leak area. 2. Apply an aerosol type powder (foot powder) to the suspected leak area, 3. Drive the vehicle for approximately 25 km (15 miles) or until the transaxle reaches normal operat- ing temperature (88°C, 19°F), 4, Turn the engine OFF. Inspect the suspected leak area and trace the leak path through the powder to find the source of the leak. 6. Make the necessary repairs. Dye and Black Light Method 1. Add dye to the transaxle though the transaxle fluid filler plug. Follow the manufacturer's recommenda- tion for the amount of dye to be used. 2. Use the black light to find the fluid leak. 3. Make the necessary repairs,ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 47 Repairing the Fluid Leak Once the leak point is found the source of the leak must be determined. The following list describes the potential causes for the leak’ + Fasteners are not torqued to specification. + Fastener threads and fastener holes are dirty or corroded, + Gaskets, seals or sleeves are misarranged, dam- aged or wom. + Damaged, warped or scratched seal bore or gasket, surface. + Loose or wom bearing causing excess seal or sleeve wears. Case or component porosity. Fluid level is too high. Plugged vent or damaged vent tube. Water or coolant in flu. Fluid drain back holes plugged. ELECTRICAL/GARAGE SHIFT TEST This preliminary test should be performed before a hoist oF road test to make sure electronic control inputs is con- nected and operating, Ifthe inputs are not checked before operating the transaxle, a simple electrical condition could be misdiagnosed as a major transaxle condition, A scan tool provides valuable information and must be used on the automatic transaxle for accurate diagnosis. 1. Move gear selector to P (Park) and set the parking brake. 2. Connect scan tool to Data Link Connector (DLC) terminal. 3. Start engine. 4, Tum the scan tool ON. 5. Verify that the appropriate signals are present. ‘These signals may include: ENGINE SPEED VEHICLE SPEED THROTTLE POSITION TRANSAXLE GEAR STATE GEAR SHIFT LEVER POSITION TRANSAXLE FLUID TEMPERATURE CLOSED THROTTLE POSITION LEARN OPEN THROTTLE POSITION LEARNT. CLOSED ACCEL. PEDAL POSITION LEARNT OPEN ACCEL. PEDAL POSITION LEARNT AIC COMPRESSOR STATUS MODE SWITCH THROTTLE POSITION VOLTAGE GEAR SHIFT LEVER POSITION VOLTAGE TRANS. FLUID TEMPERATURE VOLTAGE AIC SWITCH MODE SWITCH VOLTAGE BATTERY VOLTAGE 6. Monitor the A/C COMPRESSOR STATUS signal while pushing the AIC switch + The AIC COMPRESSOR STATUS should come ‘ON when the A/C switch Is pressed, and turns OFF when the A/C switch is repushed. 7. Monitor the GEAR SHIFT LEVER POSITION signal land move the gear shift control lever through all the ranges. + Verify that the GEAR SHIFT LEVER POSITION value matches the gear range indicated on the instrument panel or console. * Gear selections should be immediate and not harsh. 8. Move gear shift control lever to neutral and monitor the THROTTLE POSITION signal while increasing and decreasing engine speed with the accelerator pedal, + THROTTLE POSITION should increase with engine speed, ROAD TEST PROCEDURE Perform the road test using a scan tool ‘This test should be performed when traffic and road conditions permit. + Observe all traffic regulations. ‘The TCM calculates upshift points based primarily on two inputs : throttle angle and vehicle speed. When the TCM wants a shift to occur, an electrical signal is sent to the shift solenoids which in turn moves the valves to perform the upshift The shift speed charts reference throttle angle instead of “min throttle" or "wot" to make shift speed measurement more uniform and accurate, A scan tool should be used to monitor throttle angle. Some scan tools have been pro- grammed to record shift point information. Check the introduction manual to see if this test is available, Upshift Procedure With gear selactorin drive(0) 1, Look at the shift speed chart contained in this sec- tion and choose a percent throttle angle of 10 or 25%. 2. Set up the scan tool to monitor throttle angle and vehicle speed. 3. Accelerate to the chosen throttle angle and hold the thvotte steady. 4, As the transaxle upshifts, note the shift speed and commanded gear changes for + Second geer. + Third geer. + Fourth gear. Important : Shift speeds may vary due to slight hydraulic delays responding to electronic controls. A change from the original equipment tire size affects shift speeds. Note when TCC applies. This should occur in fourth gear. Hf the apply is not noticed by an rpm drop, refer to the “Lock-up Clutch Diagnosis" information contained in this section,5A ~ 48 ZF 4 HP 16 AUTOMATIC TRANSAXLE ‘The Lock up clutch should net apply unless the transaxle has reached a minimum operating temperature of 8°C (46°F) TRANS TEMP AND engine coolant temp of 50°C (122°). 5. Repeat steps 1-4 using several different throttle angles. Part Throttle Detent Downshift At vohicle steeds of 85 to 65km/h (34 to 40mph) in Fourth gear, quickly increase throttle angle to greater than 50%, Verify that + TCC apply. + Transaxle downshift to 3rd gear. + Solenoid 1 turns ON to OFF, + Solenoid 2 turns OFF. Full Throttle Detent Downshift At vehicle speeds of 55 to 6Skm/h (34 to 40mph)in Fourth gear, quickly increase throttle angle to its maximum posi- tion (100%) Verity that + TCC release. + Transaxle downshift to Second gear immediately. + Solenoid 1 turns ON to OFF © Solenoid 2 turns OFF. Manual Downshifts 1. At vehicle speeds of 60km/h (40mph)in Fourth gesr, release accelerator pedal while moving gear selector to Manual Third (3). Observe that + Transaxle downshift to Third gear immediately. + Engine slows vehicle down 2. Move gear selector back to overdrive(D) and accel- erate to 31mph (S0km/h). Release the accelerator pedal and move the gear selector to Manual First(1) and observe that * Transaxle downshift to second gear immediate- yy. * Engine slows vehicle down Notice : A Manuel First—Third Gear Ratio will occur at high speeds as an upshift safety feature, Do not attempt to perform this shift Coasting Downshifts 1. With the gear selector in Overdrive(D), accelerate to Fourth gear with TCC applied 2. Release the accelerator pedal and lightly apply the brakes, and observe that + TCC release. + Down shifts occur at speeds shown ON the shift speed chart. Manual Gear Range Selection Upshifts in the manuel gear ranges are controlled by the shift solenoids. Perform the following tests by accelerating at 25 percent TP sensor increments. Manual Third (3) + With vehicie stopped, move the gear selector to Manual third(3) and accelerate to observe = 1-2 shit. = 2-3 shift. Manual Second (2) + With vehicle stopped, move the gear selector to Manual second(2) and accelerate to observe = 1-2 shit. ‘+ Accelerate to 40kmvh(25mph) and observe 2.3 shift does not occur TCC does not apply Manual First (1) + With vehicle stopped, move gear selector to Manu- al First(1). Accelerate to 30knv/h(19mph) and ob- serve = No upshifts occur Reverse (R) ‘+ With vehicle stopped, move gear selector to R(Re- verse) and observe — Solenoid 1 is OFF — Solenoid 2 is OFF Use a scan tool to see if any transaxle trouble codes have been set. Refer to "Diagnostic Trouble Codes'in this sec- tion and repair the vehicle as directed, After repairing the vehicle, perform the hoist test and verify that the code has not set again. Hf the transaxle is not performing well and no trouble codes have been set, there may be an intermittent condition, Check all electrical connections for damage or a loose fit. You also have to perform a snapshot test which can help catch an intermittent condition that dose not occur long ‘enough to set a code. ‘You may want to read "Electronic Component Diagnosis” in this section to become familiar with transaxle conditions caused by transaxle electrical malfunction. Hf no trouble codes have been set and the condition is sus- ected to be hydraulic, take the vehicle on a road test. TORQUE CONVERTER LOCK-UP CLUTCH(TCC) DIAGNOSIS To properly diagnosis the lock-up clutch(TCC) system, perform all electrical testing first and then the hydraulic testing, ‘The TCC is applied by fluid pressure which is controlled by solenoid Located inside the valve body. The solenoid is energized by completing an electrical circuit through a ‘combination of switches and sensors.ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 ~ 49 Functional Check Procedure Inspect 41. Install a tachometer or scan tool 2. Operate the vehicle unit proper operating tempera. ture Is reached 3. Drive the vehicle at 80 to 88kmv/h (50 to 55 mph) ith light throttle(road load), 4, Maintaining throttle position, lightly touch the brake pedal and check for release of the TCC and a slight increase in engine speed(rpm). 5. Release the brake slowly accelerate and check for a reapply of the Lock up clutch and a slight de- crease in engine speed(rpm), Torque Converter Evaluation Torque Converter Stator “The torque converter stator roller clutch can have one of {wo diferent type malfunctions AA Stator assembly freewheels in both directions 2. Stator assembly remains Locked up at al times Condition A - Poor Acceleration Low Speed “The car tends to have poor acceleration from a stand stil. At speeds above 50 to S5kmih(30 to 35mph), the ear may act normal. if poor acceleration is noted, it should fist be determined that the exhaust system is not blocked, and the transaxle is in 1st(Frst) gear when starting out If the engine freely accelerates to high rpm in N(Neutral), it can be assumed that the engine and exhaust system are normal. Checking for poor performance in "Drive" and "Re- verse” wil help determine i the stators freewheeling at all times. Condition B - Poor Acceleration Speed Engine rpm and car speed limited or restricted at high speeds. Performance when accelerating from a standstill is normal. Engine may overheat. Visual examination of the converter may reveal a blue color from overheating Ifthe converter has been removed, the stator roller clutch can be checked by inserting two fingers into the splined in- ner race of the roller clutch and tying to turn freely clock- wise, but not turn or be very dificult to turn counter clock wise. Noise ‘Torque converter whine is usually noticed when the ve- hicle is stopped and the transaxle is in "Drive" or "Re- verse”. The noise will increase when engine rpm is in- creased. The noise will stop when the vehicle is moving or ‘when the torque converter clutch is applied because both halves of the converter are turning at the same speed. Perform a stall test to make sure the noise is actually com- ing from the converter 4. Place foot on brake. 2. Put gear selector in "Drive™ 3. Depress accelerator to approximately 1200rpm for no more than six seconds. Notice : If the accelerator is depressed for more than six ‘seconds, damage to the transaxle may occur. A torque converter noise will increase under this load, Important : This noise should not be confused with pump whine noise which is usually noticeable in P (Park), N (Neutral) and all other gear ranges. Pump whine will vary with pressure ranges. The torque converter should be replaced under any of the following conditions: + Extemal leaks in the hub weld area, Converter hub is scored or damaged. Converter pilot is broken, damaged or fits poorly into crankshaft + Steel particles are found after flushing the cooler and cooler lines. ‘+ Pump is damaged or steal particles are found in the converter. + Vehicle has TCC shudder and/or no TCC apply. Replace only after all hydraulic and electrical diag- noses have been made.(Lock up clutch material may be glazed.) ‘+ Converter has an imbalance which cannot be cor rected. (Refer To Converter Vibration Test Proce- dure.) ‘+ Converter is contaminated with engine coolant con- taining antifreeze, Internal failure of stator roller clutch, Excess end play, Heavy clutch debris due to overheating (blue con- verter), ‘+ Steel particles or clutch lining material found in fluid, filter or on magnet when no internal parts in unit are worn or damaged( indicates thet lining material ‘came from converter). ‘The torque converter should not be replace if ‘+The oil has an odor, is discolored, and there is no evidence of metal or clutch facing particles. ‘+The threads in one or more of the converter bolt holes are damaged. correct with thread insert + Transaxle failure did not display evidence of dam- age or worn internal parts, steel particles or clutch plate lining material in unit and inside the fluid fiter. + Vehicle has been exposed to high mileage(only). ‘The exception may be where the Lock up clutch. damper plate lining has seen excess wear by ve- hicles operated in heavy andior constant traffic, such as taxi, delivery or police use. Lock-Up Clutch Shudder Diagnosis ‘The key to diagnosing lock-up clutch(TCC) shudder is to note when it happens and under what conditions.