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ZF 4HP20 Automatic Transmission Repair Manual

Alfa RomeoCitroenFiatLanciaMercedes

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.

The Service Bulletins regulations and specifications must be followed when making repairs.

Applications:

  • 1995–2004 Peugeot 406 V6 3.0
  • 1996– Mercedes-Benz Vito
  • 1996– Mercedes-Benz V-Class
  • 1997–2001 Citroën Xantia V6 3.0
  • 1997–2001 Citroën XM V6 3.0
  • 1997–1999 Peugeot 605 V6 3.0
  • 1998–2002 Alfa Romeo 166 V6 2.5, V6 3.0
  • 1998– Lancia Kappa, Phedra V6 3.0
  • 1998– Renault Laguna 3.0
  • 1998–2002 Renault Espace V6 3.0
  • 1999–2000 Renault Safrane V6 3.0 24V
  • 2001–2008 Citroën C5 V6 3.0
  • 2004–2010 Peugeot 407 2.2i
  • 2003–2006 Fiat Ducato 2.8 JTD (244 Baumuster)

CONTENTS

  • Preliminary information
  • 1. General information
    • 1.1 Picture of the transmission
    • 1.2 Power flow diagram
    • 1.3 Specifications
      • 1.3.1 Screw torque specifications
        • 1.3.1.1 Converter bell housing
        • 1.3.1.2 Converter bell housing
        • 1.3.1.3 Converter bell housing
        • 1.3.1.1 Transmission cover
    • 1.4 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
    • 1.5 Tightening torques
    • 1.6 Transmission test (test bench)
    • 1.7 Special tools
    • 1.8 Function tests
      • 1.8.1 Position switch
        • 1.8.1.1 PSA/RSA
        • 1.8.1.2 MB/FIAT
  • 2. Disassembly
    • 2.1 Removing converter, control unit
    • 2.2 Removing clutch B/E
    • 2.3 Removing and dismantling planetary gear set I + II
    • 2.4 Taking out brake C and D
    • 2.5 Removing shifting mechanism and ancillaries
    • 2.6 Dismantling the converter bell housing
    • 2.7 Dismantling clutch B/E and brake C/D
      • 2.7.1 Dismantling clutch B/E
      • 2.7.2 Dismantling brake C/D
    • 2.8 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
  • 3. Assembly
    • 3.1 Completing the differential and side shaf
      • 3.1.1 Completing the differential
      • 3.1.2 Completing the side shaft
    • 3.2 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
    • 3.3 Completing and installing the bearing plate
    • 3.4 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
    • 3.5 Completing and installing the transmission cover
    • 3.6 Installing brake F
    • 3.7 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
    • 3.8 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
    • 3.9 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

Language: English
Format: PDF
Pages: 140

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