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:

DESCRIPTION:

ZF Transmission 4 HP – 20 Repair Manual – PDF DOWNLOAD

Preliminary information:

This manual covers the procedure for repairing the complete transmission.

• The repairing of this transmission is only allowed to persons with specific training from ZF
  Getriebe GmbH.
• The entire disassembly and assembly procedure is described in chronological order.
• The photographs were kept general in nature so that they can be used with various applications;
  they are not binding in every case.
• We use Service Bulletins and training to announce important information and application-specific
  changes that must be taken into consideration in maintenance work. If this repair manual is given
  to a third party, there will be no modification service.

The Service Bulletins regulations and specifications must be followed when making repairs.Depending on the type of damage that has occured, the repair work can be limited to that which is
necessary to repair the damage.
In this case you must observe the following:

• Seals (such as O-rings, shaft seals, gaskets, and filters) must always renewed.
• All O-rings, rectangular-section rings, and other sealing rings must always be lubricated with
petroleum jelly before installation.
• All bearings must always be oiled lightly when installed.
• For transmissions that have covered a large number of kilometers (> 80,000 km), all lined clutch
discs and steel clutch discs must be replaced.
• After clutches/ brakes have been damaged, the converter, oil tubes, and oil cooler, must be
cleaned thoroughly with a suitable cleaning agent.
• If brakes C or D has been damaged, or if a considerable distance has been covered (>
80,000 km), pistons C and D must be replaced.

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

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