4HP20
4HP20
4HP20
4 HP- 20
subject to alterations
Copyright 1998 all rights reserved and published by
ZF Getriebe GmbH, Saarbrcken, Department MKTD
No part of this manual may be reproduced or transmitted in any form or
by any means, electronic or mechanical, including photocopying and recording,
for any purpose without the express written permission of
ZF Getriebe GmbH, Saarbrcken
Printed in Germany
Table of contents
1.
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
Preliminary information
Page
ii
General information
Picture of the transmission
Power flow diagram
Specifications
1.3.1 Screw torque specifications
1.3.1.1 Converter bell housing
(PSA/RSA)
1.3.1.2 Converter bell housing
(MB)
1.3.1.3 Converter bell housing
(FIAT)
1.3.1.1 Transmission cover
(PSA/RSA)
Adjustments
1.4.0 Measuring the clutch packs (procedure)
1.4.1 Adjusting the preload for the side shaft and differential
1.4.1.1 Determining side shaft installation space
1.4.1.2 Determining side shaft installation height
1.4.1.3 Determining the side shaft shim
1.4.1.4 Determining differential installation space
1.4.1.5 Determining differential installation height
1.4.1.6 Determining the differential shim
1.4.2 Adjusting the preload for the bearing plate
1.4.3 Adjusting brakes C and D
1.4.3.1 Adjusting clearance of brake D (adjustment disc)
1.4.3.2 Adjusting clearance of clutch C (snap ring)
1.4.4 Adjusting clearance of cylinder C (snap ring)
1.4.5 Adjusting clutches B and E
1.4.5.1 Determining snap ring play
1.4.5.2 Measuring installation space, clutch B
1.4.5.3 Measuring installation space, clutch E
1.4.5.4 Measuring clutch pack B
1.4.5.5 Determining adjustment disc B
1.4.5.6 Measuring clutch pack E
1.4.5.7 Determining adjustment disc E
1.4.6 Installing position switch
1.4.7 Adjusting clearance of brake F
1.4.7.1 Measuring installation space F
1.4.7.2 Measuring clutch pack F
1.4.7.3 Determining adjustment disc F
1.4.8 Assembly cover for adjusting axial play (preparation)
1.4.9 Adjusting axial play, input shaft
Tightening torques
Transmission test (test bench)
Special tools
Function tests
1.8.1 Position switch
1.8.1.1 PSA/RSA
1.8.1.2 MB/FIAT
1.1/1
1.1/1
1.2/1
1.3/1
1.3/1
1.3/1
1.3/1
1.3/1
1.3/1
1.4/1
1.4/1
1.4/3
1.4/3
1.4/5
1.4/7
1.4/8
1.4/10
1.4/12
1.4/13
1.4/18
1.4/18
1.4/19
1.4/21
1.4/22
1.4/23
1.4/24
1.4/25
1.4/26
1.4/26
1.4/27
1.4/27
1.4/28
1.4/29
1.4/29
1.4/30
1.4/30
1.4/31
1.4/32
1.5/1
1.6/1
1.7/1
1.8/1
1.8/1
1.8/1
1.8/1
CD
2.
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
3.
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
II
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
2.7.1 Dismantling clutch B/E
2.7.2 Dismantling brake C/D
Dismantling the cover, bearing plate, side shaft and differential
2.8.1 Dismantling the cover
2.8.2 Dismantling the bearing plate
2.8.3 Dismantling the side shaft
2.8.4 Dismantling the differential
2.1/1
2.1/1
2.2/1
2.3/1
2.4/1
2.5/1
2.6/1
2.7/1
2.7/1
2.7/4
2.8/1
2.8/1
2.8/1
2.8/3
2.8/3
Assembly
Completing the differential and side shaft
3.1.1 Completing the differential
3.1.2 Completing the side shaft
Installing the parking lock mechanism and bearing shells in the housing
3.2.1 Installing the parking lock mechanism in the housing
3.2.2 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
3.4.1 Installation of brake D/C
3.4.1.1 Completing brake D
3.4.1.2 Completing brake C
3.4.2 Installation of planetary drive
3.4.3 Completing clutch B and E
3.4.3.1 Inserting clutch pack E
3.4.3.2 Inserting clutch pack B
Completing and installing the transmission cover
Installing brake F
Installing the side shaft, differential, parking lock and position switch
3.7.1 Installing the side shaft and differential
3.7.2 Installing the parking lock and position switch
Installing the converter bell housing, control unit, inductive transmitter
and oil pan
3.8.1 Completing and installing the converter bell housing
3.8.2 Installing the control unit, inductive transmitter and oil pan
Installing ancillaries (oil cooler, converter, speedometer shaft
connection, transport protection cap)
3.9.1 Installing the oil cooler
3.9.2 Installing the breather cover, oil dipstick and oil drain plug
3.9.3 Installing the converter
3.9.4 Installing the speedometer shaft with connection
3.9.5 Function test for the position switch
3.9.6 Installing the protective transport caps
3.1/1
3.1/1
3.1/1
3.1/2
3.2/1
3.2/1
3.2/3
3.3/1
CD
3.4/1
3.4/2
3.4/2
3.4/3
3.4/5
3.4/6
3.4/8
3.4/8
3.5/1
3.6/1
3.7/1
3.7/1
3.7/2
3.8/1
3.8/1
3.8/8
3.9/1
3.9/2
3.9/3
3.9/3
3.9/3
3.9/3
3.9/4
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.
The following requirements should be met before the repair work is started:
The required special tools should be available.
(The complete set of special tools is listed in Chapter 1.7)
A suitable transmission testing rig should be available.
The required testing values can be found in the Service Bulletins.
CD
III
Note:
This manual treats the automatic control unit as a complete unit, which should not be disassembled without special knowledge; it should be exchanged as a complete unit.
A separate repair manual is planned for the automatic control unit.
Important:
The transmission is filled with long-life oil.
The oil does not have to be changed until it has been in use for ten years.
The transmission must only be delivered with the oil type and oil amount specified in the corresponding parts list documentation (see Part List).
Technical Documentation
Bach
Reus
IV
CD
Schultz
1.
1.1
General information
Picture of the transmission
CD
1.1/1
1st GEAR
Input
2nd GEAR
Output
Output
Input
3rd GEAR
Output
Output
Input
Output
Output
4th GEAR
Input
Reverse
GEAR
Output
Output
Input
Output
Output
CD
1.2/1
1.3 Specifications
1.3.1 Screw torque specifications
1.3.1.1Converter bell housing (PSA)
First pre-tighten the screws in the following order:
19 14 9 8 3 4
Then, in numerical order, tighten the
screws all the way (see diagram).
1 2 3 ... 23
Important!
The numbers correspond to the actual
sequence for final tightening.
(Assessment, Specification 1019 700 137)
(See Chapter 1.5 for tightening torque)
1.3.1.2 Converter bell housing (MB)
First pre-tighten the screws in the following order:
21 20 11 8 3 4
Then, in numerical order, tighten the
screws all the way (see diagram).
1 2 3 ... 24
Important!
The numbers correspond to the actual
sequence for final tightening
(Assessment, Specification 1019 700 138 )
(See Chapter 1.5 for tightening torque)
1.3.1.3 Converter bell housing (FIAT)
First pre-tighten the screws in the following order.
19 20 11 8 3 6
Then, in numerical order, tighten the
screws all the way (see diagram).
1 2 3 ... 24
Important!
The numbers correspond to the actual
sequence for final tightening
(Assessment, Specification 1019 700 088)
(See Chapter 1.5 for tightening torque)
99/04/01 4 HP 20 ZF Getriebe GmbH Saarbrcken
CD
1.3/1
1.3/2
CD
1.4
Making adjustments
1.4.0 Measuring the clutch packs
(procedure)
Place the two intermediate pieces
5p01 050 329/5p01 060 329 on the
marked position on measuring fixture
5p01 000 330.
98009
98011
CD
1.4/1
98017
1.4/2
CD
98018
97577
CD
1.4/3
=
=
BSW =
=
0.215 + 82.492
82.707 mm
0.55 + 34.497
35.047 mm
1.4/4
CD
1.4.1.2
98120
98121
Important!
Strictly cleanliness !
(See Chapter 1.5 for tightening torques)
98123
CD
1.4/5
98124
= 132.287 mm
= 30.013 mm
M1
M2
= 14.33 mm
= 14.27 mm
MS
= (14.33 + 14.27)/2
= 14.3 mm
HS
1.4/6
CD
1.4.1.3
Zero dimension NS is equal to installation space BS minus side shaft height HS.
Disc thickness SS is equal to zero dimension
NS plus preload dimension VS in accordance with specification 0000 700 907.
The parts list shows preload dimension VS as
0.07 to 0.12 mm. The test value is permissible
when it is between 0.055 and 0.135 mm.
Calculation:
NS = BS - HS
SS = VS + NS
= 118.014 mm
= 116.574 mm
VS
= 0.07 to 0.12 mm
NS
= 118.014 - 116.574
= 1.44 mm
SS
Chosen:
SS = 1.54 mm
CD
1.4/7
1.4.1.4
Determining differential
installation space
1.4/8
CD
0.285 + 24.996
25.281 mm
0.67 + 119.998
120.668 mm
CD
1.4/9
1.4.1.5
98125
98126
98123
1.4/10
CD
Calculation:
HD = KS + MD - KG
Example: (for 1.4.1.5)
KD
KG
= 151.242 mm
= 30.013 mm
M3
M4
= 23.35 mm
= 23.51 mm
MD
= (23.35 + 23.51)/2
= 23.43mm
HS
CD
1.4/11
1.4.1.6
= 146.209 mm
= 144.659 mm
VD
ND
= 146.209 -144.659
= 1.55 mm
SD
Selected:
SD = 1.78 mm
1.4/12
CD
97583
Insert the side shaft. Install the bolt, support bolt, and parking lock pawl with leg
spring.
Attach the spring.
Engage the parking lock.
Remove the slotted nut with securing ring.
97585
97587
CD
1.4/13
97588
97589
Now turn the knurled screw in the opposite direction until resistance can be
detected, and give it a half further rotation.
Turn the output gear further by turning
the side shaft until the indicator on the
dial gauge settles down and then read the
dial gauge dimension M
Note !
Turn until the indicator movements no
longer become smaller.
1.4/14
CD
97590
Calculation:
N=D-M
Shim thickness S is equal to zero dimension N minus adjusting dimension V, preload dimension V acc. to specification
0000 700 907, from the parts list is 0.03
to 0.085 mm.
The test value is permissible if it is between 0.03 and 0.1 mm
Remove measuring fixture.
Calculation:
S = N -V
= 0.22 mm
= 6.3 mm
= 0.03 to 0.085 mm
= 6.3 - 0.22 mm
= 6.08 mm
S
S
Selected:
S = 6.025 mm
CD
1.4/15
1.4/16
CD
98114
CD
1.4/17
WD
MD
= 17.02mm
= 13.43 mm
ED
=
=
=
=
PD
17.02 + 1.48
18.5 mm
18.5 - 13.43
5.07 mm
1.4/18
CD
98115
CD
1.4/19
WC
MC
= 6.95 mm
= 6.41 mm
EC
=
=
=
=
PC
6.95 + 1.48
8.43 mm
8.43 - 6.41
2.02 mm
1.4/20
CD
98102
= 1.48 mm
M1
M2
M3
= 1.93 mm
= 1.88 mm
= 1.83 mm
= 1.88 + 1.48
= 3.36 mm
= 3.2 mm
CD
1.4/21
Note !
Adjusting ring E
for variant A 5p89 004 182
for variant B 5p89 004 374
97615
Note !
Adjusting ring B
for variant A 5p89 004 181
for variant B 5p89 005 403
97616
Put the complete set on measuring fixture 5p01 002 984 and connect the fixture to the compressed-air system.
Note !
Maximum air pressure: 5 bar.
1.4/22
97617
CD
1.4.5.1
97618
97619
M1
M2
M3
= 0.27 mm
= 0.23 mm
= 0.25 mm
CD
1.4/23
1.4.5.2
97620
= 2.36 mm
= 2.40 mm
= 2.38 mm
= 11.99 mm
MB
EB = 11.99 + 2.38
= 14.37 mm
1.4/24
CD
1.4.5.3
Calculation:
ME = (M7 + M8 + M9) / 3
EE = RE + ME - S
=
=
=
=
2.6 mm
2.55 mm
2.54 mm
20,98 mm
ME
CD
1.4/25
1.4.5.4
98116
= 11.44 mm
= 14.38 mm
PB
= 14.38 - 11.44
= 2.94 mm
LB = 2.1 mm
1.4/26
CD
1.4.5.6
98117
1.4.5.7
= 16.78 mm
= 23.29 mm
PE
= 23.29 - 16.78
= 6.51 mm
LE = 4.8 mm
CD
1.4/27
97641
97642
1.4/28
CD
97655
M1
M2
= 18.6 mm
= 18.8 mm
BF
= (18.6 + 18.8) / 2
= 18.7 mm
CD
1.4/29
1.4.7.2
98118
1.4.7.3
= 14.2 mm
= 18.7 mm
PF
= 18.7 - 14.2
= 4.5 mm
EF = 3.3 mm
1.4/30
CD
97632
97633
Note!
The selected shim should allow axial
play.
97634
Important!
See tightening torque specifications in
Chapter 1.3
CD
1.4/31
97659
97660
=
=
=
=
0.51 mm
0.49 mm
(0.51 + 0.49)/2
0.5 mm
S
D
= 0.18 to 0.42 mm
= 0.5 -(0.18 to 0.42)
= 0.08 to 0.32 mm
= 0.2 mm (selected)
CD
97633
Note!
See Completing and installing transmission cover (Chapter 3.5)
CD
1.4/33
1 Machine screw
(pretightening, conv.
bell housing)
(final tightening,
Part ListItem-No.
22.120
22.130
)
Page
Hexagonal
SAF = 13 mm
1.3/1
3.8/5
22.120
22.130
22.132
2 Machine screw
(final tightening, conv.
bell housing)
22.134
3 Machine screw
(pretightening, trans. cover)
01.060
01.164
(final tightening,
Wrench size
No.
Tightening
torque [Nm]
15 2
26 2.6
TORX - TX 40
or
Hexagonal
SAF = 13 mm
1.3/1
3.8/5
TORX - TX 40
1.3/2
1.4/31
3.5/2
26 2.6
15 2
23 2.3
4 Machine screw
(differential)
09.120
5 Machine screw
(guide plate)
06.160
6 Machine screw
(bearing plate)
14.020
7 Slotted nut
(bearing plate)
Hexagonal
SAF = 19 mm
3.1/1
TORX - TX 27
3.2/2
145 14.5
10 1
TORX - E10
1.4/14
3.3/2
35 3.5
1.4/13
3.3/2
250 25
8 Machine screw
(transmission cover)
01.064
3.5/2
9 Countersunk screw
(transmission cover)
01.060
TORX - TX 40
23 2.3
TORX - TX 40
3.5/2
23 2.3
10 Machine screw
(adjusting plate, switch )
01.180
11 Machine screw
(oil baffle plate)
01.016
12 Hexagon screw
(switch)
01.210
13 Machine screw
(oil baffle plate)
22.230
TORX - TX 27 H
1.4/28
10 1
TORX - TX 27
3.7/1
8 0.8
Hexagonal
SAF = 10 mm
3.7/2
TORX - TX 27
3.8/2
10 1
8 0.8
CD
1.5/1
No. Designation
Part ListItem-No.
14 Machine screw
10.020
(converter bell housing/pump)
Wrench size
No.
Page
TORX - TX 27
3.8/3
10 1
15 Machine screw
10.010/150 TORX - TX 27
(converter bell housing/pump)
3.8/3
16 Hexagon screw
(oil tank)
22.270
Hexagonal
SAF = 10 mm
3.8/4
17 Hexagon screw
(oil filter)
22.180
Hexagonal
SAF = 10 mm
3.8/4
18 Hexagon screw
22.130
(converter bell housing/retaining strap)
Hexagonal
SAF = 13 mm
3.8/5
19 Machine screw
(converter bell housing)
22.132
TORX - TX 40
3.8/5
20 Hexagon screw
(converter bell housing)
22.134
22.120
21 Union screw
(oil tube)
01.290
22 Machine screw
(oil tube)
01.286
10 1
10 1
10 1
26 2.6
26 2.6
3.8/5
SAF = 13 mm
26 2.6
Hexagonal
SAF = 13 mm
3.8/5
Hexagonal
SAF = 13 mm
3.8/6
Internal hexagon
SAF = 5 mm
3.8/6
24 Machine screw
(inductive transmitter)
01.130
TORX - TX 27
3.8/7
25 Machine screw
(control unit)
27.300
26 Machine screw
(inductive transmitter)
27.230
27 Hexagon screw
(oil pan)
03.050
1.5/2
Tightening
torque [Nm]
25 2.5
23 2.3
20 2
8 0.8
TORX - TX 27
3.8/8
8 0.8
TORX - TX 27
3.8/8
8 0.8
3.8/8
SAF = 10 mm
CD
6 0.6
3.8/8
20 2
No. Designation
Part ListItem-No.
22.150
30 Union screw
(heat exchanger)
01.340
22.100
22.200
33 Hexagon screw
(speedometer connection)
09.392
Wrench size
No.
Page
Internal hexagon
SAF = 5 mm
3.8/8
Internal hexagon
SAF = 8 mm
3.9/2
Internal hexagon
SAF = 8 mm
3.9/2
Internal hexagon
SAF = 6 mm
3.9/2
Tightening
torque [Nm]
12 1.2
35 3.5
20 2
30 3
3.9/3
SAF = 11 mm
7 0.7
3.9/3
SAF = 13 mm
20 2
3.9/3
SAF = 17 mm
36 Screw (M6x12)
(height measuring device)
Internal hexagon
SAF = 5 mm
1.4/5
1.4/10
10 1
37 Screw (M6x16)
(height measuring device)
Internal hexagon
SAF = 5 mm
1.4/5
1.4/10
10 1
38 Screw (M10x30)
(height measuring device)
Internal hexagon
SAF = 8 mm
1.4/5
1.4/10
35 3,5
CD
20 2
1.5/3
CD
1.6/1
OBJECT
Order-No. / Application
Remarks
Identical
5 HP 24
98008
Identical
5 HP 24
(Measuring plate:
- short neck >20 mm
- long neck <20 mm
clutch pack thickness)
98034
98128
CD
1.7/1
Remarks
Identical
Order-No. / Application
OBJECT
4 HP 18 Q
5 HP 24
97301
98129
98103
1.7/2
CD
OBJECT
Order-No. / Application
Remarks
98130
98107
98106
CD
1.7/3
Remarks
Order-No. / Application
OBJECT
10
98131
11
98132
12
98133
1.7/4
CD
OBJECT
13
Order-No. / Application
Remarks
98134
14
Identical
4 HP 14 Q
4 HP 18 Q
4 HP 22
5 HP 18
5 HP 24
98305
15
Identical
4 HP 18 Q
98135
CD
1.7/5
Remarks
Identical
Order-No. / Application
OBJECT
16
5 HP 18
5 HP 24
5 HP 30
91199
17
98137
18
98163
1.7/6
CD
OBJECT
19
Order-No. / Application
Remarks
98138
20
98142
21
98139
CD
1.7/7
Remarks
Order-No. / Application
OBJECT
22
98143
23
98144
24
98140
1.7/8
CD
OBJECT
25
Order-No. / Application
Remarks
98141
26
98145
27
98146
CD
1.7/9
Remarks
Order-No. / Application
OBJECT
28
98147
29
98171
30
98168
1.7/10
CD
OBJECT
31
Order-No. / Application
Remarks
98170
32
98172
33
98148
CD
1.7/11
Order-No. / Application
Remarks
Identical
3 HP 22
4 HP 14 Q
4 HP 18 Q
4 HP 22
5 HP 18
5 HP 24
5 HP 30
OBJECT
34
76046
Identical
4 HP 14 Q
4 HP 18 Q
35
or
5x46 021 007
Kukko extractor 21/8
98149
Identical
4 HP 14 Q
4 HP 18 Q
36
98150
1.7/12
CD
OBJECT
37
Order-No. / Application
Remarks
Identical
Identical
4 HP 18 Q
98151
38
3 HP 22
4 HP 14 Q
4 HP 18 Q
98152
39
98153
CD
1.7/13
Remarks
Identical
4 HP 14 Q
4 HP 18 Q
Order-No. / Application
OBJECT
40
98154
41
98164
42
98155
1.7/14
CD
OBJECT
43
Order-No. / Application
Remarks
98156
CD
1.7/15
Remarks
PSA only
Order-No. / Application
OBJECT
44
98108
PSA only
45
98109
PSA only
46
98157
1.7/16
CD
OBJECT
47
Order-No. / Application
Remarks
PSA only
PSA only
98158
48
98159
CD
1.7/17
Remarks
MB only
Order-No. / Application
OBJECT
49
98110
MB only
50
98111
MB only
51
98160
1.7/18
CD
OBJECT
52
Order-No. / Application
Remarks
MB only
MB only
MB only
98161
53
98162
54
98169
CD
1.7/19
1.8.1.2 MB/FIAT
Using a multimeter, make a resistance
test on the switch according to the function table.
Code table
12
CD
1.8/1
2. Disassembly
2.1 Removing converter, control unit
Clamp the transmission into retaining
bracket 5x46 001 396 and fasten onto the
assembly trolley, possibly in work bench
fixing device 5x46 000 763.
Turn the transmission with oil pan
upwards.
Unscrew two oil drain plugs and let the
oil drain.
(Wrench size = Internal hexagon, 8 mm
Wrench size = Internal hexagon, 6 mm)
97501
97503
97504
CD
2.1/1
97505
97506
97507
2.1/2
CD
Loosen the fastening screw for the inductive transmitter under the control unit.
Then lever the cable out of the retaining
clip and pull out the inductive transmitter.
97508
97509
CD
2.1/3
97510
97511
97512
CD
2.2/1
2.2/2
CD
97516
CD
2.2/3
97517
97518
98101
CD
2.3/1
97519
97520
Release piston D (by applying compressed air to the feed bore) and remove
it.
Turn transmission by 180.
97521
CD
2.4/1
97522
97523
Release the slotted nut lock, mount fixture 5x46 001 051 and remove the brake
F split stop ring.
Remove the fixture and take off the cup
spring.
Important!
Other applications may require a different assembly fixture.
2.4/2
CD
97524
97525
97526
Important!
Take note of the oil cooler seals.
97527
CD
2.4/3
97528
97529
97530
2.4/4
CD
97531
Important!
Since the bearing seat is tight, press the
bearing plate upwards from underneath
to remove it.
CD
2.4/5
97532
97533
97534
Note!
The two centering bushes, the position
switch adjusting plate and the breather
normally remain installed.
CD
2.5/1
97535
97536
97537
CD
2.6/1
97538
97539
Important!
To prevent possible running noises later,
keep the bearing shells together with the
correct taper roller bearing.
2.6/2
CD
97540
97541
CD
2.6/3
97542
97543
97544
CD
2.7/1
97545
97546
97548
2.7/2
CD
97549
97550
97551
CD
2.7/3
97552
98166
Note !
If the fitting keys are not loose, leave
them on the disc carrier.
2.7/4
CD
98167
Important!
There may be a ball installed in the dowel
pin bore under the oil feeding bush.
Danger of loss!
97555
97556
CD
2.8/1
97557
97559
97558
2.8/2
CD
97560
97561
Important!
Core piece 5x46 002 000 is additionally
used for other applications.
CD
2.8/3
3. Assembly
3.1 Completing the differential and side shaft
09.120
09.110
09.090
09.070 *
09.100
09.010
09.030
09.080
09.020
97562
Important!
If the speedometer worm is made of plastic, it must be put on the differential body
before the bearing inner ring.
CD
3.1/1
97563
3.1/2
CD
3.2 Installing the parking lock mechanism and bearing shells in the housing
3.2.1 Installing the parking lock mechanism in the housing
01.010/110
01.440
09.030
01.460
09.090
06.160
06.150
01.010/130
06.040
/120
/130
/110
/140
/160
06.080
06.010
06.060
97567
CD
3.2/1
97568
98165
97570
3.2/2
CD
Important!
Avoid build-up of filings !!!
97582
CD
3.2/3
/110
/120
14.010
/130
/150
/140
/170
14.020
06.100
06.110
06.130
06.120
97564
CD
3.3/1
Important !
Making adjusments, Chapter 1.4.2 when
bearing components are replaced
97565
97566
97591
3.3/2
CD
Note!
To do this, install side shaft, bolt 06.100,
support bolt 06.130, parking lock pawl
06.110, and leg spring 06.120. Install
spring, set parking lock and tighten the
slotted nut with slotted nut wrench
5x46 001 089. Afterwards, take these
parts back off.
CD
3.3/3
3.4 Installing brake C/D, planetary drive and clutch B/E in the transmission housing
73.070
73.010
/110
73.060
73.020
/120
/210
/200
73.040
/180
/170
/190
/220
/110
/120
/130
32.070
/140
32.050
32.060
/150
/160
/170
32.010
/190
/160
/200
/210
02.010
/150
/220
/140
/230
/130
/120
/180
/250
/240
/110
02.030
02.040
/320
/260
/270
02.060
02.040
/300
02.070
/310
/110
02.080
02.090
02.100
/350
/120
/360
/130
/340
/330
/140
/160
/170
/180
/150
CD
3.4/1
97592
Important !
Making adjustments, Chapter 1.4.3.1
Be sure to leave the adjustment disc off
when making adjustments!
97593
98167
3.4/2
CD
Important !
Newer transmissions have two lined
clutch discs and one steel clutch disc
here instead.
The lined discs must be installed in such
a way that the lining faces the steel disc.
This is called the brake disc version.
97599
98166
Important !
If the fitting keys 73.040/120 did not
remain on the disc carrier, drive them
into the center of the disc carrier.
97604
Important !
Insert the fitting keys into the appropriate
grooves.
CD
3.4/3
Important !
Do not damage the sealing lips.
97605
Important !
The brake C feed must be aligned with
the feed bore in the transmission housing.
97606
Important !
Making adjustments, Chapter 1.4.4
97608
CD
3.4/4
97609
97640
97515
CD
3.4/5
97611
97612
97613
3.4/6
CD
97614
Important !
Making adjustments, Chapter 1.4.5
97627
97628
CD
3.4/7
97629
97630
97631
3.4/8
CD
01.020/110
01.020
/110
01.060
01.064
/120
/130
01.070
/140
/160
01.080
01.090
01.100
Important !
For transmissions with a removable oilfeed bush, the cover must be installed as
described in Chap. 1.4.8 in order to be
able to perform the Adjustment of axial
play for the input shaft.
Note !
When the bore for the dowel pin in the
cover is too deep (> 10 mm) a ball with a
diameter of 3.5 mm must also be put in,
otherwise the dowel pin might fall out.
99/04/01 4 HP 20 ZF Getriebe GmbH Saarbrcken
CD
3.5/1
3.5/2
CD
77.010
77.020
77.030
77.040
77.050
77.060
77.070
77.080
77.090
77.100
Important !
Making adjustments, Chapter 1.4.7
Turn the transmission by 180.
Put O-rings 77.020 and 77.030 on piston
77.010 and carefully press the piston into
the bearing plate.
97615
CD
3.6/1
Important!
A different assembly fixture might be
required for other applications.
97636
97637
3.6/2
CD
3.7 Installing the side shaft, differential, parking lock and position switch
3.7.1 Installing the side shaft and differential
06.100
01.014
06.110
06.120
06.130
01.016
01.200
01.150
01.180
01.210
Screw oil baffle plate 01.014 into the transmission housing with three screws 01.016.
97638
CD
3.7/1
Insert the complete side shaft and complete differential into the transmission
housing.
97639
97640
Important !
Making adjustments, Chapter 1.4.6
97643
CD
3.7/2
3.8 Installing the converter bell housing, control unit, inductive transmitter and oil pan into
the transmission housing
22.220
22.260
22.230
09.080
22.270
09.020
22.240
22.240
22.140
22.110
22.010
22.130
22.180
22.144
10.020
22.120
09.370
22.150
/120
22.200
22.170
22.134
10.010
/140
/150
/114
22.130
22.132
22.100
10.050
/154
/160
01.260
09.350
01.286
01.284
01.280
01.270
01.010/120
01.290
01.020/150
01.260
27.220
01.230
03.060
27.230
03.010
01.140
03.040
01.010/110
03.050
/118
/116
27.210
01.110
03.090
01.130
01.010/120
01.120 *
03.090
27.200
27.280
27.300
CD
3.8/1
Important!
Avoid build-up of cuttings !!!
97644
Fasten two magnets 22.240 at the markings on oil baffle plate 22.220.
Screw oil baffle plate tightly onto the
converter bell housing with three screws
22.230.
97645
97646
3.8/2
CD
97647
Note !
The dowel pin must fit into the bore that
was drilled for this purpose.
97648
Important !
To prevent the pump housing from falling out, insert two screws before turning
it over.
97649
CD
3.8/3
97650
97651
Important !
Two dowel pins 01.010.120 must be
inserted in the transmission housing.
3.8/4
CD
97652
97653
Important !
For tightening specification, see Chapter 1.3
97654
Important !
Check axial play.
Making Adjustments, Chapter 1.4.9
97663
CD
3.8/5
97664
Note!
On older transmissions, the testing connections are closed with two plugs
01.260. Newer transmission do not have
any testing connections at all.
(See Chapter 1.5 for tightening torque)
97665
97666
3.8/6
CD
3.8.2 Installing the control unit, inductive transmitter and oil pan
Put a new O-ring 27.200/116 in the
wiring harness plug.
Press sealing sleeve 01.230 into the brake
C feed.
Insert cable clamp 01.140 on the transmission housing web.
97667
Put the complete control unit with inductive transmitter 01.110 and wiring harness 27.200 on the transmission housing,
tilting it slightly.
Insert inductive transmitter 01.110 into
the transmission housing, and screw it
tight with screw 01.130.
(See Chapter 1.5 for tightening torque)
97668
Important !
With some transmission parts specifications, spacing washer 01.120 is installed
underneath the inductive transmitter
retaining strap.
97669
CD
3.8/7
Important !
The groove for the selector shift valve
must be put properly into the detent disc
lug and the dowel pin must be inserted
correctly into the transmission housing.
97670
97671
97672
3.8/8
CD
3.9 Installing ancillaries (oil cooler, converter, speedometer shaft connection, protective
transport caps)
01.340
01.400
01.320
01.330
01.560
01.550
09.394
09.460
09.392
09.390
90.160
09.380
/110
09.450
22.250
22.030
/120
/130
06.190
CD
3.9/1
97674
97675
3.9/2
CD
97676
Important!
Ensure that the converter fastening screw
is not too long, or the converter will be
damaged and the converter clutch will
not function properly.
3.9.4 Installing speedometer shaft
with connection
Put one new O-ring (for 09.390) on the
speedometer connection.
Insert pinion shaft 09.380 into the speedometer connection, and slide both into
the converter bell housing. Fasten with
screw 09.392.
(See Chapter 1.5 for tightening torque)
97677
CD
3.9/3
3.9/4
CD