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ZF 4HP20 gearbox, repair e-manual

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Publisher: © "Motorist"
ISBN: 977-129-542-355-2
Number of pages: 124
Format: file PDF

About the manual

Transmission type: ZF 4HP20

In the manual you will find

  • Step-by-step guide to repair various components and assemblies
  • Self-care and maintenance instructions
  • Gearbox design and prevention information
  • Information for a trip to the service station, if self-repair is not possible
Publisher: Motorist
Categories: Gearboxes
Only original manuals
Available immediately after payment
Full compliance with the paper edition
100% protection of your payments
Publisher: © "Motorist"
ISBN: 977-129-542-355-2
Number of pages: 124
Format: file PDF

About the manual

Transmission type: ZF 4HP20

In the manual you will find

  • Step-by-step guide to repair various components and assemblies
  • Self-care and maintenance instructions
  • Gearbox design and prevention information
  • Information for a trip to the service station, if self-repair is not possible

Content

General information

  • Picture of the transmission
  • Power flow diagram
  • Specifications
  • Screw torque specifications
  • Converter bell housing (PSA/RSA)
  • Converter bell housing (MB)
  • Converter bell housing (FIAT)
  • Transmission cover (PSA/RSA)
  • Adjustments
  • Measuring the clutch packs (procedure)
  • Adjusting the preload for the side shaft and differential
  • Determining side shaft installation space
  • Determining side shaft installation height
  • Determining the side shaft shim
  • Determining differential installation space
  • Determining differential installation height
  • Determining the differential shim
  • Adjusting the preload for the bearing plate
  • Adjusting brakes C and D
  • Adjusting clearance of brake D (adjustment disc)
  • Adjusting clearance of clutch C (snap ring)
  • Adjusting clearance of cylinder C (snap ring)
  • Adjusting clutches B and E
  • Determining snap ring play
  • Measuring installation space, clutch B
  • Measuring installation space, clutch E
  • Measuring clutch pack B
  • Determining adjustment disc B
  • Measuring clutch pack E
  • Determining adjustment disc E
  • Installing position switch
  • Adjusting clearance of brake F
  • Measuring installation space F
  • Measuring clutch pack F
  • Determining adjustment disc F
  • Assembly cover for adjusting axial play (preparation)
  • Adjusting axial play, input shaft
  • Tightening torques
  • Transmission test (test bench)
  • Special tools
  • Function tests
  • Position switch
  • PSA / RSA
  • MB / FIAT

Disassembly

  • Removing converter, control unit
  • Removing clutch B/E
  • Removing and dismantling planetary gear set I + II
  • Taking out brake C and D
  • Removing shifting mechanism and ancillaries
  • Dismantling the converter bell housing
  • Dismantling clutch B/E and brake C/D
  • Dismantling clutch B/E
  • Dismantling brake C/D
  • Dismantling the cover, bearing plate, side shaft and differential
  • Dismantling the cover
  • Dismantling the bearing plate
  • Dismantling the side shaft
  • Dismantling the differential

Assembly

  • Completing the differential and side shaft
  • Completing the differential
  • Completing the side shaft
  • Installing the parking lock mechanism and bearing shells in the housing
  • Installing the parking lock mechanism in the housing
  • Installing the bearing shells in the housing
  • Completing and installing the bearing plate
  • Installing brake C/D, planetary drive and clutch B/E in the transmission housing
  • Installation of brake D/C
  • Completing brake D
  • Completing brake C
  • Installation of planetary drive
  • Completing clutch B and E
  • Inserting clutch pack E
  • Inserting clutch pack B
  • Completing and installing the transmission cover
  • Installing brake F
  • Installing the side shaft, differential, parking lock and position switch
  • Installing the side shaft and differential
  • Installing the parking lock and position switch
  • Installing the converter bell housing, control unit, inductive transmitter and oil pan
  • Completing and installing the converter bell housing
  • Installing the control unit, inductive transmitter and oil pan
  • Installing ancillaries (oil cooler, converter, speedometer shaft connection, transport protection cap)
  • Installing the oil cooler
  • Installing the breather cover, oil dipstick and oil drain plug
  • Installing the converter
  • Installing the speedometer shaft with connection
  • Function test for the position switch
  • Installing the protective transport caps

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