ZF 4HP20 gearbox, repair e-manual

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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