ZF Transmission 4 HP-20 Repair Manual – PDF DOWNLOAD

Description

ZF Transmission 4 HP-20 Repair Manual – PDF DOWNLOAD

FILE DETAILS:

ZF Transmission 4 HP-20 Repair Manual – PDF DOWNLOAD

Language : English
Pages : 140
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

ZF Transmission 4 HP-20 Repair Manual – PDF DOWNLOAD

Selection of language 0
Repair manual 4 HP-20 1
Preliminary information 5
Table of contents 3
1 General information 7
1 1 Picture of the transmission 7
1 2 Power flow diagram 9
1 3 Specifications 11
1 3 1 Screw torque specifications 11
1 3 1 1 Converter bell housing (PSA) 11
1 3 1 2 Converter bell housing (MB) 11
1 3 1 3 Converter bell housing (FIAT) 11
1 3 1 4 Transmission cover (PSA/RSA) 12
1 4 Making adjustments 13
1 4 0 Measuring the clutch packs (procedure) 13
1 4 1 Adjusting the preload for the side shaft and differential 15
1 4 1 1 Determining side shaft installation space 15
1 4 1 2 Determining side shaft installation height 17
1 4 1 3 Determining the side shaft shim 19
1 4 1 4 Determining differential installation space 20
1 4 1 5 Determining the differential installation height 22
1 4 1 6 Determining the differential shim 24
1 4 2 Adjusting the preload for the bearing plate 25
1 4 3 Adjusting brakes C and D 29
1 4 3 1 Adjusting clearance of brake D (adjustment disc) 29
1 4 3 2 Adjusting clearance of clutch C (snap ring) 31
1 4 4 Adjusting clearance of cylinder C (snap ring) 33
1 4 5 Adjusting clutches B and E 34
1 4 5 1 Determining snap ring play 35
1 4 5 2 Measuring installation space, clutch B 36
1 4 5 3 Measuring installation space, clutch E 37
1 4 5 4 Measuring clutch pack B 38
1 4 5 5 Determining adjustment disc B 38
1 4 5 6 Measuring clutch pack E 39
1 4 5 7 Determining adjustment disc E 39
1 4 6 Installing position switch 40
1 4 7 Adjusting clearance of brake F 41
1 4 7 1 Measuring installation space F 41
1 4 7 2 Measuring clutch pack F 42
1 4 7 3 Determining adjustment disc F 42
1 4 8 Assembly cover for adjusting axial play (preparation) 43
1 4 9 Adjusting axial play, input shaft 44
1 5 Tightening torques 47
1 6 Transmission test (test bench) 51
1 7 Special tools 53
1 8 Function tests 73
1 8 1 Position switch 73
1 8 1 1 Typ PSA/RSA 73
1 8 1 2 Typ MB/FIAT 73
2 Disassembly 75
2 1 Removing converter, control unit 75
2 2 Removing clutch B/E 79
2 3 Removing and dismantling planetary gear set I + II 83
2 4 Taking out brake C and D 85
2 5 Removing shifting mechanism and ancillaries 91
2 6 Dismantling the converter bell housing 93
2 7 Dismantling clutch B/E, and brake C/D 97
2 7 1 Dismantling clutch B/E 97
2 7 2 Dismantling brake C/D 100
2 8 Dismantling the cover, bearing plate, side shaft and differential 101
2 8 1 Dismantling the cover 101
2 8 2 Dismantling the bearing plate 101
2 8 3 Dismantling the side shaft 103
2 8 4 Dismantling the differential 103
3 Assembly 105
3 1 Completing the differential and side shaft 105
3 1 1 Completing the differential 105
3 1 2 Completing the side shaft 106
3 2 Installing the parking lock mechanism and bearing shells in the housing 107
3 2 1 Installing the parking lock mechanism in the housing 107
3 2 2 Installing the bearing shells in the housing 109
3 3 Completing and installing the bearing plate 111
3 3 1 Completing the bearing plate 111
3 3 2 Installing the bearing plate 112
3 4 Installing brake C/D, planetary drive and clutch B/E in the transmission housing 115
3 4 1 Installation of brake D/C 116
3 4 1 1 Completing brake D 116
3 4 1 2 Completing brake C 117
3 4 2 Installation of planetary drive 119
3 4 3 Complete clutch B and E 120
3 4 3 1 Inserting clutch pack E 122
3 4 3 2 Inserting clutch pack B 122
3 5 Completing and installing the transmission cover 123
3 6 Installing brake F 125
3 7 Installing the side shaft, differential, parking lock and position switch 127
3 7 1 Installing the side shaft and differential 127
3 7 2 Installing the parking lock and position switch 128
3 8 Installing the converter bell housing, control unit, inductive transmitter and oil pan into 129
3 8 1 Completing and installing the converter bell housing 130
3 8 2 Installing the control unit, inclusive transmitter and oil pan 135
3 9 Installing ancillaries (oil cooler, converter, speedometer shaft connection, protective transport caps) 137
3 9 1 Installing the oil cooler 138
3 9 2 Installing the breather cover, oil dipstick and oil drain plug 138
3 9 3 Installing the converter 139
3 9 4 Installing speedometer shaft with connection 139
3 9 5 Function test for the position switch 139
3 9 6 Installing the protective transport caps 140

S.V 08/24