Service Manual2005 ZF 4 HP 16 AUTOMATIC TRANSAXLE

SECTION 5A

ZF 4 HP 16 AUTOMATIC TRANSAXLE

Caution : Disconnect 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.

INTRODUCTION

ZF 4HP 16 Automatic Transaxle

The ZF 4 HP 16 is a four-speed automatic transaxle designed 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 ratios. The integral constant ratio can be adapted to the engine's power output and the vehicle's weight. The electronic-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 without freewheels. Shifting between individual gears takes place by means of overlapping clutch engagement and release.

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 freewheels and the lower number of shift elements

- Lower drag losses, i.e. higher efficiency

- Lower peak torques acting on the components and driveline.

However, overlap shifting necessitates high-performance hardware and software, and precision engine signals.

Transaxle Components

SPECIFICATIONS

General Specifications

.	Definition
Transaxle Type	4-speed with four-wheel drive and transverse engine
Input Torque	240 N•m (177 lb-ft)
Transaxle Weight	76kg (168 lb)
Torque Converter Capacity	9.72kg (21.4 lb)
Transaxle Fluid Type (manufacture company)	ESSO LT 71141 or TOTAL ATF H50235
Transaxle Fluid Capacity	7.3±0.2 qt (6.9±0.2L)

Transaxle Gear Ratio

Gear	Ratio
First	2.719
Second	1.487
Third	1.000
Fourth	0.717
Reverse	2.529
Final	3.945:1 (2.0 DOHC)

Fluid Capacity

.	Litres	Quarts
Bottom Pan Removal	4	4.2
Complete Overhaul	6.9±0.2	7.3±0.2
Torque Converter Removal	2	2.1
(Measurements are approximate)

Fastener Tightening Specifications

Application	N•m	Lb-Ft	Lb-In
Bearing Plate Bolts	23.5	17.5	-
Slotted Nut	220	162	-
Rear Cover Attachment Bolts	23.5	17.5	-
Baffle Plate Attachment Bolts	10	-	89
Park/Neutral Position Switch	10	-	89
Fluid Pump Connecting Bolts	10	-	89
Fluid Filter Housing Cover Attachment Bolts	10	-	89
Input Speed sensor Attachment Bolts	8	-	71
Output Speed Sensor Attachment Bolts	8	-	71
Valve Body Bolts	8	-	71
Valve Body Upper & Lower Fixing Bolts	6	-	53
Fluid Pan Connecting Bolts	6	-	53
Fluid Pan Drain Plug	45	33	-
Fluid Level Plug	45	33	-
Line Pleasure Plugs	20	15	-
Valve Housing 1 Cover Attachment Bolts	6	-	53
Solenoid Valve Attachment Bolts	6	-	53
Pressure Control Regulator(EDS) Attachment Bolts	6	-	53
Oil Cooler Inlet Pipe Bolts	35	26	-
Oil Cooler Outlet Pipe Bolts	35	26	-
Shift Control Cable Adjuster Pinch Nut	8	-	71
Shift Control Cable Attachment Nut	8	-	71
Upper Transaxle-to-Engine Bolts	75	55	-
Selector Lever(On Transaxle Case)	15	11	-
TCM Mounting Nuts	23	17	-
Torque Converter Attachment Bolts	45	33	-
Shift Control Assembly Mounting Bolt	8	-	71
Lower Engine-to-Transaxle Bolts(a)	75	55	-
Lower Engine-to-Transaxle Bolt(b)	21	15	-
Lower Engine-to-Transaxle Bolts(c)	31	23	-
Front Engine Mounting Bracket Bolts(a) and Nut	90	66	-
Front Engine Mounting Bracket Bolt(b) and Nut	80	59	-
Front Engine Mounting Bracket Bolt(c)	65	48	-
Rear Transaxle Mounting Bracket Bolts	65	48	-

Range	Park/ Neutral	Reverse	D				3			2		1
Gear	N	R	1st	2nd	3rd	4th	1st	2nd	3rd	1st	2nd	1st
Solenoid Valve 1	ON	ON/ OFF	ON/ OFF	ON/ OFF	ON/ OFF	ON/ OFF	ON/ OFF	ON/ OFF	ON/ OFF	ON/ OFF	ON/ OFF	ON/ OFF
Solenoid Valve 2	ON	ON	ON	OFF	OFF	OFF	ON	OFF	OFF	ON	OFF	ON
Line Pressure Control Solenoid Valve 3 (EDS 3)	OFF	OFF	OFF	ON	ON/ OFF	ON/ OFF	OFF	ON	ON/ OFF	OFF	ON	OFF
Line Pressure Control Solenoid Valve 4 (EDS 4)	ON	OFF	ON	ON	ON	OFF	ON	ON	ON	ON	ON	ON
Line Pressure Control Solenoid Valve 5 (EDS 5)	OFF	OFF	ON	ON	OFF	OFF	ON	ON	OFF	ON	ON	ON
Line Pressure Control Solenoid Valve 6 (EDS 6)	ON	OFF	ON	ON	ON	OFF	ON	ON	ON	ON	ON	ON
Brake B	A	A	A	.	A	.	A	.	A	A	.	A
Brake C	.	.	.	.	.	H	.	.	.	.	.	.
Brake D	.	H	.	.	.	.	.	.	.	.	.	.
Clutch E	.	.	.	A	A	A	.	A	A	.	A	.
Brake F	.	.	H	H	.	.	H	H	.	H	H	H
Lock-up Clutch	.	.	.	.	.	A	.	.	.	.	.	.
A = Applied H = Holding ON = The solenoid is energized. OFF = The solenoid is de-energized. = Manual Second-Third gear is only available above approximately 100 km/h (62 mph). * = Manual First-Second gear is only available above approximately 60 km/h (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 mph (4.8km/h))				Second-Third gear (±4.0 mph (6.4km/h))				Third-Fourth gear (±5.0 mph (8km/h))
MODEL	10% TPS	25% TPS	50% TPS	100% TPS	10% TPS	25% TPS	50% TPS	100% TPS	10% TPS	25% TPS	50% TPS	100% TPS
2.0 DOHC mph (km/h)	11 (18)	12 (20)	17 (28)	34 (54)	19 (31)	24 (38)	34 (54)	70 (112)	39 (63)	41 (66)	53 (85)	103 (165)

Down Shift Speed

MODEL	Down Shift (±4.0 mph (6.4km/h))			Lock Up Clutch Applied (Fourth)		Lock Up Clutch Released (Fourth)
MODEL	Fourth-Third (Coast)	Third-Second (Coast)	Second-First (Coast)	10%	25%	10%	25%
2.0 DOHC mph (km/h)	29 (46)	15 (24)	7 (11)	48 (78)	48 (78)	39 (62)	40 (65)

Line Pressure

Gear Range	Solenoid	Line Pressure	B Port	E Port
Park / Neutral	ON	LOW	90~124.7 psi (6.2~8.6 bar)	.
Park / Neutral	OFF	HIGH	221.9~252.3 psi (15.3~17.4 bar)	.
Reverse	ON	LOW	89.9~124.7 psi (6.2~8.6 bar)	.
Reverse	OFF	HIGH	221.9~252.3 psi (15.3~17.4 bar)	.
Drive	ON	LOW	.	90~124.7 psi (6.2~8.6 bar)
Drive	OFF	HIGH	.	137.7~162.4 psi (9.5~11.2 bar)
3	ON	LOW	90~124.7 psi (6.2~8.6 bar)	90~124.7 psi (6.2~8.6 bar)
3	OFF	HIGH	221.9~252.3 psi (15.3~17.4 bar)	137.7~162.4 psi (9.5~11.2 bar)
2	ON	LOW	.	90~124.7 psi (6.2~8.6 bar)
2	OFF	HIGH	.	137.7~162.4 psi (9.5~11.2 bar)
1	ON	LOW	90~124.7 psi (6.2~8.6 bar)	.
1	OFF	HIGH	221.9~252.3 psi (15.3~17.4 bar)	.

SPECIAL TOOLS

Special Tools Table

	Scan Tool
	DW110-060 Engine Support Fixture
	DW260-020 Transaxle Holding Fixture
	DW260-010 Transaxle Support Fixture
	DW260-030 Axle Seal Installer
	DW260-050 Park/Neutral Position Switch Installer
	DW260-060 Brake F Split Stop Ring Remover/Installer
	DW260-070 Transaxle Fluid Plug Remover/Installer
	DW240-010 Universal Pressure Gauge Set
	DW260-150 Clutch E Stop Ring Remove/Installer
	DW260-140 Clutch B Stop Ring Remover/Installer
	DW260-160 Brake C/D Snap Ring Remover/Installer
	DW260-080 Clutch B/E Shim Setting Gauge
	DW260-120 Clutch B Adjust Ring
	DW260-130 Clutch E Adjust Ring
	DW260-100 Clutch B/E Disc Thickness Measuring Fixture
	DW260-090 Clutch B/E (Snap Ring Play, Installation Space) Measuring Fixture
	DW260-110 Brake F Disc Clearance Measuring Bar

SCHEMATIC AND ROUTING DIAGRAMS

Transaxle Control Module (1 of 2)

Transaxle Control Module (2 of 2)

Shift Mode Diagram

Economic Mode (2.0 DOHC)

Lock-up Clutch Applied (Economic Mode ; Third Gear, Fourth Gear) (2.0 DOHC)

Power Mode (2.0 DOHC)

Hold Mode (2.0 DOHC)

Power Flow Diagram

Park/Neutral

Park/Neutral

In Park or Neutral with the engine running there is no drive to the planetary gear set. Line pressure (from the oil pump) is supplied 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, depending on the turbine torque. Line pressure increase linearly by time. But it has a limit point. When pressure reaches 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 solenoid valves (EDS) are supplied. This makes it possible to use smaller solenoid valves.

The line pressure comes from the oil 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 appropriate level.

Solenoid Valve 1, 2

Solenoid Valve 1 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 (6~8bar)].When the solenoid is turned OFF the line pressure will be high [232~261psi (16~18bar)].

Solenoid 2 controls the fluid flow to clutch valve E or the TCC clutch valve. When solenoid 2 is ON fluid is directed to the TCC pressure valve and if the solenoid is switched OFF fluid will flow to the inlet at clutch valve E.

The TCM monitors numerous inputs to determine the appropriate solenoid state combination and transaxle gear for the vehicle operating conditions.

In Park and Neutral solenoid valve 1 is ON. So line pressure 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 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 2 is turned ON and the line pressure control valves 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 valve ensures that the converter is supplied with cooling oil first if the pump rate is low. The lubricating pressure valve in addition guarantees that the necessary amount of cooling and lubricating oil is available via the bypass duct.

The fluid, which is supplied from the torque converter, flows to the cooler via the lubrication valve.

Reverse

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 direction.
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 directed to clutch B via the manual valve. The position of the check ball will change allowing direct pressure to clutch B.

Brake D Engaged

The line pressure, which engaged clutch B, is also supplied 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 reduction 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.

Lubrication/Cooling

The fluid, which is supplied from the torque converter, flows to the cooler via the lubrication valve.

Drive Range - First Gear

Drive Range - First Gear

In Drive 1, transaxle drive is via the input shaft 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 carrier 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.

Clutch F Engaged

EDS 5 will be switched ON. The line pressure, which passed through the reduction valve, will flow to the holding valve and the clutch valve inlet. As a result the valve spool is depressed.

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.

Lubrication/Cooling

The lubricating valve ensures that the converter is sup- plied with cooling oil first if the pump rate is low. The lubricating pressure valve in addition guarantees that the necessary amount of cooling and lubricating oil is available via the bypass duct.

The fluid, which is supplied from the torque converter, flows to the cooler via the lubrication valve.

Drive Range - Second Gear

Drive Range - Second Gear

In Drive 2, the transaxle drive is via the input shaft and clutch E. The elements of this transaxle function are as follows:

Clutch E is applied to drive the front ring gear.
The front ring gear drives the front planetary gear carrier.
The front planetary gear carrier drives the differential pinion gear clockwise.
Brake F is applied holding the front sun gear stationary.

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 E will engage.

Clutch F Engaged

EDS 5 will be switched ON. The line pressure, which passed through the reduction valve, will flow to the holding valve and the clutch valve inlet. As a result the valve spool is depressed.

Lock-up Clutch

Solenoid valve 2 is turned ON and the line pressure control valve spool will be depressed. Fluid will now flow through the torque converter pressure valve.

Lubrication/Cooling

The fluid, which is supplied from the torque converter, flows to the cooler via the lubrication valve.

Drive Range - Third Gear

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 follows:

Clutches B and E are engaged to drive the rear sun gear 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.

Lock-up Clutch (TCC)

Solenoid valve 2 is turned ON and the line pressure control valve spool will be depressed. Fluid will now flow through the torque converter pressure valve.

Drive Range - Fourth Gear

Drive Range - Fourth Gear

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 carrier.
The rear planetary gear carrier drives the rear ring gear.
The rear ring gear carrier drives the differential gear.

Control

Clutch E Engaged

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.

Lock-up Clutch

Solenoid valve 2 is turned ON and the line pressure control valve spool will be depressed. Fluid will now flow through the torque converter pressure valve.

Drive Range - Fourth Gear ; Emergency/Substitute Mode

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 carrier.
The rear planetary gear carrier drives the rear ring gear.
The rear ring gear carrier drives the differential gear.

Control

Clutch E Engaged

Clutch C Engaged

Drive Range - Third Gear ; Emergency/Substitute Mode

Drive Range - Third Gear ; Emergency/Substitute Mode

In Drive 3, transaxle drive is via the input shaft to clutches B and E. The elements of this transaxle function are as follows:

Clutches B and E are engaged to drive the rear sun gear 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.