SECTION : 5A1

ZF 4 HP 16 AUTOMATIC TRANSAXLE
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A13 Transaxle Fluid Level Service Procedure . . . . 5A145
ZF 4HP 16 Automatic Transaxle . . . . . . . . . . . . 5A13 Electrical/Garage Shift Test . . . . . . . . . . . . . . . 5A147
Transaxle Components . . . . . . . . . . . . . . . . . . . . 5A14 Road Test Procedure . . . . . . . . . . . . . . . . . . . . . 5A147
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 5A15 Torque Converter LockUp Clutch(TCC)
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A148
General Specifications . . . . . . . . . . . . . . . . . . . . 5A15
TCM Initialization Procedure . . . . . . . . . . . . . . 5A150
Transaxle Gear Ratio . . . . . . . . . . . . . . . . . . . . . . 5A15
Shift Speed Chart . . . . . . . . . . . . . . . . . . . . . . . . 5A151
Fluid Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A15
Internal Wiring Harness Check . . . . . . . . . . . . 5A151
Fastener Tightening Specifications . . . . . . . . . . 5A15
Transaxle Wiring Harness Connector . . . . . . . 5A154
Shift Speed Chart . . . . . . . . . . . . . . . . . . . . . . . . . 5A17
Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . 5A156
Line Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A18
DIAGNOSTIC TROUBLE CODE DIAGNOSIS 5A160
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5A19
Diagnostic Trouble Code (DTC) Identification 5A160
Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 5A19
DTC P0562 System Voltage Low . . . . . . . . . 5A168
SCHEMATIC AND ROUTING DIAGRAMS . . . 5A111 DTC P0563 System Voltage High . . . . . . . . 5A171
Transaxle Control Module (1 of 2) . . . . . . . . . . 5A111 DTC P0601 Internal Control Module Memory
Transaxle Control Module (2 of 2) . . . . . . . . . . 5A112 Checksum Error . . . . . . . . . . . . . . . . . . . . . . . 5A174
Shift Mode Diagram . . . . . . . . . . . . . . . . . . . . . . 5A113 DTC P0603 Internal Control Module Keep
Alive Memory(KAM) Error . . . . . . . . . . . . . . . 5A176
Power Flow Diagram . . . . . . . . . . . . . . . . . . . . . 5A117
DTC P0604 Internal Control Module Random
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . 5A133 Access Memory(RAM) Error . . . . . . . . . . . . . 5A178
Transaxle Identification Information . . . . . . . . 5A133 DTC P0606 Transaxle Control Module
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . 5A134 Processor Fault . . . . . . . . . . . . . . . . . . . . . . . . 5A180
Transaxle Housing . . . . . . . . . . . . . . . . . . . . . . . 5A135 DTC P0703 Brake Switch Circuit
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A136 Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A183
DTC P0705 Transmission Range Sensor
Rear Cover & Oil Pan Cover . . . . . . . . . . . . . . 5A137
Circuit Malfunction(PRNDL Input) . . . . . . . . 5A186
Parking Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A138
DTC P0710 Transmission Fluid Temperature
Input Shaft & Shift Gear . . . . . . . . . . . . . . . . . . 5A139 Sensor Circuit Malfunction . . . . . . . . . . . . . . 5A189
Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A141 DTC P0715 Input Speed Sensor(ISS) Circuit
Gear Shift Control . . . . . . . . . . . . . . . . . . . . . . . 5A142 Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A192
DIAGNOSTIC INFORMATION AND PROCEDURES DTC P0716 Input Speed Sensor(ISS) Circuit
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A143 Range/Performance . . . . . . . . . . . . . . . . . . . . 5A195
Basic Knowledge Required . . . . . . . . . . . . . . . . 5A143 DTC P0717 Input Speed Sensor(ISS) Circuit
No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A198
Functional Check Procedure . . . . . . . . . . . . . . 5A143
DTC P0720 Output Speed Sensor(OSS)
Line Pressure Check Procedure . . . . . . . . . . . 5A143 Circuit Malfunction . . . . . . . . . . . . . . . . . . . . 5A1101
Clutch Plate Diagnosis . . . . . . . . . . . . . . . . . . . 5A145 DTC P0721 Output Speed Sensor(OSS)
Cooler Flushing and Flow Test . . . . . . . . . . . . . 5A145 Circuit Range/Performance . . . . . . . . . . . . . 5A1104
5A1 2IZF 4 HP 16 AUTOMATIC TRANSAXLE

DTC P0722 Output Speed Sensor(OSS) DTC P1868 EDS 6 Output Shorted To
Circuit No Signal . . . . . . . . . . . . . . . . . . . . . . 5A1107 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1172
DTC P0725 Engine Speed Input Circuit DTC P1869 EDS 6 Output Open . . . . . . . . 5A1174
Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1110 DTC P1871 EDS Valve Power Supply
DTC P0726 Engine Speed Input Circuit Circuit Shorted to Power . . . . . . . . . . . . . . . 5A1176
Range/Performance . . . . . . . . . . . . . . . . . . . 5A1112 DTC P1874 Solenoid Valve Power Supply
DTC P0727 Engine Speed Input Circuit No Circuit Shorted to Power . . . . . . . . . . . . . . . 5A1178
Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1114 DTC P1881 21 Shift Malfunction . . . . . . . 5A1180
DTC P0731 Gear 1 Incorrect Ratio . . . . . . 5A1116 DTC P1883 32 Shift Malfunction . . . . . . . 5A1182
DTC P0732 Gear 2 Incorrect Ratio . . . . . . 5A1118 DTC P1884 43 Shift Malfunction . . . . . . . 5A1184
DTC P0733 Gear 3 Incorrect Ratio . . . . . . 5A1120 DTC P1885 31 Shift Malfunction . . . . . . . 5A1186
DTC P0734 Gear 4 Incorrect Ratio . . . . . . 5A1122 DTC P1886 42 Shift Malfunction . . . . . . . 5A1188
DTC P0781 12 Shift Malfunction . . . . . . . 5A1124 MAINTENANCE AND REPAIR . . . . . . . . . . . . 5A1190
DTC P0782 23 Shift Malfunction . . . . . . . 5A1126 ONVEHICLE SERVICE . . . . . . . . . . . . . . . . . . 5A1190
DTC P0783 34 Shift Malfunction . . . . . . . 5A1128 Transaxle Fluid Level Checking Procedure . 5A1190
DTC P1604 Data Check of Internal & Changing the Fluid . . . . . . . . . . . . . . . . . . . . . . 5A1191
Extended Ram Failed . . . . . . . . . . . . . . . . . . 5A1130 Fluid Level Set After Service . . . . . . . . . . . . . 5A1192
DTC P1606 Failure Of External Watchdog 5A1132 Repairing Fluid Leaks . . . . . . . . . . . . . . . . . . . 5A1192
DTC P1671 CAN Transmit Message Case Porosity Repair . . . . . . . . . . . . . . . . . . . . 5A1193
Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1134 Shift Control Lever Assembly . . . . . . . . . . . . . 5A1193
DTC P1672 CAN Bus Off Failure . . . . . . . . 5A1136 Shift Control Cable . . . . . . . . . . . . . . . . . . . . . . 5A1195
DTC P1673 CAN Receive ECM Message Shift Control Cable Adjustment . . . . . . . . . . . 5A1196
Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1138 Transaxle Control Module(TCM) . . . . . . . . . . 5A1197
DTC P1839 EDS 3 Output Shorted To Park/Neutral Start Switch . . . . . . . . . . . . . . . . 5A1198
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1140 Oil Cooler Pipes/Hoses . . . . . . . . . . . . . . . . . . 5A1199
DTC P1840 EDS 3 Output Shorted To Drive Axle Oil Seal . . . . . . . . . . . . . . . . . . . . . . 5A1201
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1142 Oil Pan, Oil Pan Gasket . . . . . . . . . . . . . . . . . 5A1201
DTC P1841 EDS 3 Output Open . . . . . . . . 5A1144 Control Valve Body Assembly . . . . . . . . . . . . 5A1203
DTC P1850 Solenoid 1 Output Shorted To Left Transaxle Mounting Bracket . . . . . . . . . . 5A1205
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1146
Transaxle Assembly . . . . . . . . . . . . . . . . . . . . . 5A1206
DTC P1851 Solenoid 1 Output Shorted To UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1212
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1148
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . 5A1212
DTC P1852 Solenoid 1 Output Open . . . . 5A1150
Transaxle Holding Fixture Assembly . . . . . . . 5A1212
DTC P1853 Solenoid 2 Output Shorted To
Valve Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1212
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1152
Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1213
DTC P1854 Solenoid 2 Output Shorted To
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1154 Clutch B/E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1214
Clutch B/E Measurement Procedure . . . . . . 5A1217
DTC P1855 Solenoid 2 Output Open . . . . 5A1156
Planetary Gear Set . . . . . . . . . . . . . . . . . . . . . 5A1220
DTC P1861 EDS 4 Output Shorted To
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1158 Brake C/D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1221
DTC P1862 EDS 4 Output Shorted To Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1224
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1160 Side Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1224
DTC P1863 EDS 4 Output Open . . . . . . . . 5A1162 Brake F, Slotted Nut . . . . . . . . . . . . . . . . . . . . . 5A1225
DTC P1864 EDS 5 Output Shorted To Torque Converter Housing . . . . . . . . . . . . . . . 5A1227
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1164 Shift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . 5A1228
DTC P1865 EDS 5 Output Shorted To Parking Lock System . . . . . . . . . . . . . . . . . . . . 5A1229
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1166 Bearing Plate(With Spur Gear) Assembly . . 5A1229
DTC P1866 EDS 5 Output Open . . . . . . . . 5A1168 Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . 5A1229
DTC P1867 EDS 6 Output Shorted To Differential/Side Shaft Outer Race, Bearing
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1170 Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1230

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 ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 3

Important Measurement/Adjustment . . . . . . . 5A1230 Mechanical Components . . . . . . . . . . . . . . . . . 5A1232

Electronical Components . . . . . . . . . . . . . . . . 5A1236
GENERAL DESCRIPTION AND SYSTEM TCM Inputs That Affect the 4HP 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1232 Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A1241

INTRODUCTION
The special feature of this transaxle is that it operates with-
ZF 4HP 16 AUTOMATIC TRANSAXLE out freewheels. Shifting between individual gears takes
The ZF 4 HP 16 is a fourspeed automatic transaxle de- place by means of overlapping clutch engagement and re-
signed for cars with frontwheel drive and a transversely lease.
mounted engine. The advantage of overlap shifting is as follows:
The transaxle has a hydrodynamic torque converter with The transaxle can be of more compact design
a controlled slip lockup clutch. and is lighter on account of the absence of free-
A planetary gear train establishes the mechanical gear ra- wheels and the lower number of shift elements
tios. The integral constant ratio can be adapted to the en- Lower drag losses, i.e. higher efficiency
gines power output and the vehicles weight. The elec- Lower peak torques acting on the components
tronichydraulic control makes controlled power shifts and and driveline.
various shift programs possible. In selector lever position However, overlap shifting necessitates highperformance
P, the output is locked mechanically. hardware and software, and precision engine signals.

DAEWOO V121 BL4

5A1 4IZF 4 HP 16 AUTOMATIC TRANSAXLE

TRANSAXLE COMPONENTS

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SPECIFICATIONS
GENERAL SPECIFICATIONS
Definition
Transaxle Type 4speed with fourwheel drive and transverse engine
Input Torque 240 NSm (177 lbft)
Transaxle Weight 76kg (168 lb)
Torque Converter Capacity 9.72kg (21.4 lb)
Transaxle Fluid Type (manufacture company) ESSO LT 71141 or TOTAL ATF H50235
Transaxle Fluid Capacity 7.3qt (6.9L)

TRANSAXLE GEAR RATIO

Gear Ratio
First 2.719
Second 1.487
Third 1.000
Fourth 0.717
Reverse 2.529
Final 3.945:1

FLUID CAPACITY
Litres Quarts
Bottom Pan Removal 4 4.2
Complete Overhaul 6.9 7.3
Torque Converter Removal 2 2.1
(Measurements are approximate)

FASTENER TIGHTENING SPECIFICATIONS

Application NSm LbFt LbIn
Bearing Plate Bolts 23.5 17.5
Slotted Nut 220 162
Rear Cover Attachment Bolts 23.5 17.5
Baffle Plate Attachment Bolts 10 89
Park/Neutral Position Switch 10 89
Fluid Pump Connecting Bolts 10 89
Fluid Filter Housing Cover Attachment Bolts 10 89
Input Speed sensor Attachment Bolts 8 71
Output Speed Sensor Attachment Bolts 8 71
Valve Body Bolts 8 71
Valve Body Upper & Lower Fixing Bolts 6 53
Fluid Pan Connecting Bolts 6 53
Fluid Pan Drain Plug 45 33

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Application NSm LbFt LbIn

Fluid Level Plug 45 33
Line Pleasure Plugs 20 15
Valve Housing 1 Cover Attachment Bolts 6 53
Solenoid Valve Attachment Bolts 6 53
Pressure Control Regulator(EDS) Attachment Bolts 6 53
Oil Cooler Inlet Pipe Bolts 35 26
Oil Cooler Outlet Pipe Bolts 35 26
Shift Control Cable Adjuster Pinch Nut 8 71
Shift Control Cable Attachment Nut 8 71
Upper TransaxletoEngine Bolts 75 55
Selector Lever(On Transaxle Case) 15 11
Torque Converter Attachment Bolts 45 33
Shift Control Assembly Mounting Bolt, Nut 8 71
Lower EnginetoTransaxle Bolts(a) 75 55
Lower EnginetoTransaxle Bolt(b) 21 15
Lower EnginetoTransaxle Bolts(c) 31 23
Rear Transaxle Mounting Bracket Bolts 62 45
Damping Block Connection Bolt and Nut 68 50
Left Transaxle Mount Bracket Cage Bolt(a) 110 81
Left Transaxle Mount Bracket Cage Bolt(b) 65 48
Left Transaxle Mount Bracket Cage Nut(c) 65 48
Left Transaxle Mounting Bolts 48 35

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 ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 7

Range Park/ Rever D 3 2 1

Neutr se
al
Gear N R 1st 2nd 3rd 4th 1st 2nd 3rd 1st 2nd 1st
Solenoid Valve ON ON/ ON/ ON/ ON/ ON/ ON/ ON/ ON/ ON/ ON/ ON/
1 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
Solenoid Valve ON ON ON OFF OFF OFF ON OFF OFF ON OFF ON
2
Line Pressure OFF OFF OFF ON ON/ ON/ OFF ON ON/ OFF ON OFF
Control Sole- OFF OFF OFF
noid Valve 3
(EDS 3)
Line Pressure ON OFF ON ON ON OFF ON ON ON ON ON ON
Control Sole-
noid Valve 4
(EDS 4)
Line Pressure OFF OFF ON ON OFF OFF ON ON OFF ON ON ON
Control Sole-
noid Valve 5
(EDS 5)
Line Pressure ON OFF ON ON ON OFF ON ON ON ON ON ON
Control Sole-
noid Valve 6
(EDS 6)
Brake B A A A A A A A A
Brake C H
Brake D H
Clutch E A A A A A A
Brake F H H H H H H H
Lockup A
Clutch
A = Applied
H = Holding
ON = The solenoid is energized.
OFF = The solenoid is deenergized.
** = Manual SecondThird gear is only available above approximately 100 km/h (62 mph).
*** = Manual FirstSecond gear is only available above approximately 60 km/h (37 mph).
Note : Manual FirstThird gear is also possible at high vehicle speed as a safety feature.

SHIFT SPEED CHART

Up Shift Speed
MODEL FirstSecond gear (3.0 SecondThird gear (4.0 ThirdFourth gear (5.0
mph (4.8km/h)) mph (6.4km/h)) mph (8km/h))
10% 25% 50% 100% 10% 25% 50% 100% 10% 25% 50% 100%
TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS
1.8 DOHC 9 11 18 32 18 23 34 62 25 34 47 98
mph (km/h) (15) (18) (29) (52) (29) (37) (55) (99) (45) (55) (76) (157)

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5A1 8IZF 4 HP 16 AUTOMATIC TRANSAXLE

Down Shift Speed

MODEL Down Shift (4.0 mph (6.4km/h)) Lock Up Clutch Applied Lock Up Clutch
(Fourth) Released
(Fourth)
FourthTh ThirdSec SecondFi 10% 25% 10% 25%
ird ond rst
(Coast) (Coast) (Coast)
1.8 DOHC 25 (41) 13 (21) 7 (11) 48 (77) 48 (77) 42 (68) 42 (68)
mph (km/h)

LINE PRESSURE
Gear Range Solenoid Line Pressure B Port E Port
Park / Neutral ON LOW 90~124.7 psi
(6.2~8.6 bar)
OFF HIGH 221.9~252.3 psi
(15.3~17.4 bar)
Reverse ON LOW 89.9~124.7 psi
(6.2~8.6 bar)
OFF HIGH 221.9~252.3 psi
(15.3~17.4 bar)
Drive ON LOW 90~124.7 psi
(6.2~8.6 bar)
OFF HIGH 137.7~162.4 psi
(9.5~11.2 bar)
3 ON LOW 90~124.7 psi 90~124.7 psi
(6.2~8.6 bar) (6.2~8.6 bar)
OFF HIGH 221.9~252.3 psi 137.7~162.4 psi
(15.3~17.4 bar) (9.5~11.2 bar)
2 ON LOW 90~124.7 psi
(6.2~8.6 bar)
OFF HIGH 137.7~162.4 psi
(9.5~11.2 bar)
1 ON LOW 90~124.7 psi
(6.2~8.6 bar)
OFF HIGH 221.9~252.3 psi
(15.3~17.4 bar)

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 ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 9

SPECIAL TOOLS
SPECIAL TOOLS TABLE

DW260030
Scan Tool Axle Seal Installer

DW260050
DW110060 Park/Neutral Position
Engine Support Fixture Switch Installer

DW260020 DW260060
Transaxle Holding Brake F Split Stop Ring
Fixture Remover/Installer

DW260010 DW260070
Transaxle Support Transaxle Fluid Plug
Fixture Remover/Installer

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5A1 10IZF 4 HP 16 AUTOMATIC TRANSAXLE

DW240010 DW260120
Universal Pressure Clutch B
Gauge Set Adjust Ring

DW260150 DW260130
Clutch E Stop Ring Clutch E
Remove/Installer Adjust Ring

DW260100
DW260140
Clutch B/E
Clutch B Stop Ring
Disc Thickness
Remover/Installer
Measuring Fixture

DW260090
DW260160 Clutch B/E (Snap Ring
Brake C/D Snap Ring Play, Installation
Remover/Installer Space) Measuring
Fixture

DW260080 DW260110
Clutch B/E Shim Brake F Disc Clearance
Setting Gauge Measuring Bar

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SCHEMATIC AND ROUTING DIAGRAMS

TRANSAXLE CONTROL MODULE (1 OF 2)

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5A1 12IZF 4 HP 16 AUTOMATIC TRANSAXLE

TRANSAXLE CONTROL MODULE (2 OF 2)

Switch

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SHIFT MODE DIAGRAM

Economic Mode (1.8 DOHC)

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5A1 14IZF 4 HP 16 AUTOMATIC TRANSAXLE

Lockup Clutch Applied (Economic Mode ; Fourth Gear)

(1.8 DOHC)

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Power Mode (1.8 DOHC)

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5A1 16IZF 4 HP 16 AUTOMATIC TRANSAXLE

Hold Mode (1.8 DOHC)

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POWER FLOW DIAGRAM

Park/Neutral

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5A1 18IZF 4 HP 16 AUTOMATIC TRANSAXLE

The TCM monitors numerous inputs to determine the ap-

Park/Neutral propriate solenoid state combination and transaxle gear
In Park or Neutral with the engine running there is no drive for the vehicle operating conditions.
to the planetary gear set. Line pressure (from the oil pump)
is supplied to the valve body. Only clutch B is supplied and In Park and Neutral solenoid valve 1 is ON. So line pres-
the torque converter is released. sure flows to the safety valve and the line pressure control
valve via the solenoid valve.
Control
Line Pressure Control Valve Clutch B Engaged
The line pressure control valve sets the general pressure In Park and Neutral solenoid valves 1 and 2 are both ON.
level in the valve body. When gearshifts are not taking Pressure control solenoids (EDS) 4 and 6 are also turned
place, the line pressure varies between two levels, de- ON.
pending on the turbine torque. Line pressure increase lin-
early by time. But it has a limit point. When pressure reach- When EDS 6 is ON, the fluid supplied from the reduction
es that point, excess oil pressure drains back into the oil valve flows to the safety valve, clutch valve B and holding
sump. valve B. The oil that is supplied to the inlet port of the clutch
valve presses on the valve spool. Line pressure then flows
Reduction Valve to the holding valve and check ball, engaging clutch B.
The reduction valve reduces the line pressure with which
the downstream solenoid valves and pressure control so- Lockup Clutch (TCC)
lenoid valves (EDS) are supplied. This makes it possible
Solenoid 2 is turned ON and the line pressure control
to use smaller solenoid valves.
valves spool will be depressed. Fluid will now flow through
The line pressure comes from the oil pump and flows to the the torque converter pressure valve.
reduction valve. The inlet port to the reduction valve will be
blocked and line pressure will be maintained at the ap- As a result, the oil pressure behind the converter lockup
propriate level. clutch piston and in the turbine zone is equal. The direction
of flow is through the turbine shaft and through the space
Solenoid Valve 1, 2 behind the piston, to the turbine chamber.
Solenoid Valve 1 controls the line pressure (high and low)
to the clutch valves. Solenoid Valve 1 is either ON or OFF. Lubrication/Cooling.
When the solenoid is turned ON the line pressure will be
low [87~116psi (6~8bar)].When the solenoid is turned The lubricating valve ensures that the converter is sup-
OFF the line pressure will be high [232~261psi plied with cooling oil first if the pump rate is low. The lubri-
(16~18bar)]. cating pressure valve in addition guarantees that the nec-
essary amount of cooling and lubricating oil is available via
Solenoid 2 controls the fluid flow to clutch valve E or the the bypass duct.
TCC clutch valve. When solenoid 2 is ON fluid is directed
to the TCC pressure valve and if the solenoid is switched The fluid, which is supplied from the torque converter,
OFF fluid will flow to the inlet at clutch valve E. flows to the cooler via the lubrication valve.

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Reverse

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In Reverse, solenoid 1 is switched ON and EDS 4 is

Reverse switched OFF. This will cause the fluid supplied to the re-
In Reverse, transaxle drive is via the input shaft and clutch duction valve to flow to clutch valve D via the EDS 4.
B. The elements of this transaxle function are as follows: The spool of clutch valve D will be depressed allowing fluid
S Clutch B is engaged and drives the reverse sun to pass to holding valve D.
gear in a clockwise direction.
S The D band is engaged and holds the planetary Lockup Clutch (TCC)
gear carrier (front & rear) stationary causing the Solenoid 2 is turned ON and the line pressure control valve
differential pinion to rotate clockwise. spool will be depressed. Fluid will now flow through the
S The differential rotates in a counterclockwise direc- torque converter pressure valve.
tion. As a result, the oil pressure behind the converter lockup
S The output shaft is driven in a counterclockwise or clutch piston and in the turbine zone is equal. The direction
reverse direction. of flow is through the turbine shaft and through the space
behind the piston, to the turbine chamber.
Control
Clutch B Engaged Lubrication/Cooling
The lubricating valve ensures that the converter is sup-
The line pressure, which is supplied by the oil pump, is di-
plied with cooling oil first if the pump rate is low. The lubri-
rected to clutch B via the manual valve. The position of the
cating pressure valve in addition guarantees that the nec-
check ball will change allowing direct pressure to clutch B.
essary amount of cooling and lubricating oil is available via
Brake D Engaged the bypass duct.
The line pressure, which engaged clutch B, is also sup- The fluid, which is supplied from the torque converter,
plied to clutch valve D. flows to the cooler via the lubrication valve.

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Drive Range First Gear

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Clutch F Engaged
Drive Range First Gear EDS 5 will be switched ON. The line pressure, which
In Drive 1, transaxle drive is via the input shaft to clutch B. passed through the reduction valve, will flow to the holding
The elements of this transaxle function are as follows: valve and the clutch valve inlet. As a result the valve spool
is depressed.
S Clutch B is engaged to drive the rear sun gear.
S The rear sun gear drives the front planetary gear Lockup Clutch (TCC)
carrier clockwise. Solenoid 2 is turned ON and the line pressure control valve
S The rear planetary gear carrier drives the front ring spool will be depressed. Fluid will now flow through the
gear and front planetary gear carrier clockwise. torque converter pressure valve.
As a result, the oil pressure behind the converter lockup
Control clutch piston and in the turbine zone is equal. The direction
of flow is through the turbine shaft and through the space
Clutch B Engaged behind the piston, to the turbine chamber.
In Park and Neutral solenoid valves 1 and 2 are both ON. Lubrication/Cooling
Pressure control solenoids (EDS) 4 and 6 are also turned The lubricating valve ensures that the converter is sup
ON. plied with cooling oil first if the pump rate is low. The lubri-
When EDS 6 is ON, the fluid supplied from the reduction cating pressure valve in addition guarantees that the nec-
valve flows to the safety valve, clutch valve B and holding essary amount of cooling and lubricating oil is available via
valve B. The oil that is supplied to the inlet port of the clutch the bypass duct.
valve presses on the valve spool. Line pressure then flows The fluid, which is supplied from the torque converter,
to the holding valve and check ball, engaging clutch B. flows to the cooler via the lubrication valve.

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Drive Range Second Gear

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Clutch F Engaged
Drive Range Second Gear EDS 5 will be switched ON. The line pressure, which
passed through the reduction valve, will flow to the holding
In Drive 2, the transaxle drive is via the input shaft and
valve and the clutch valve inlet. As a result the valve spool
clutch E. The elements of this transaxle function are as fol-
is depressed.
lows:
Lockup Clutch
S Clutch E is applied to drive the front ring gear. Solenoid valve 2 is turned ON and the line pressure control
S The front ring gear drives the front planetary gear valve spool will be depressed. Fluid will now flow through
carrier. the torque converter pressure valve.
S The front planetary gear carrier drives the differen-
tial pinion gear clockwise. As a result, the oil pressure behind the converter lockup
S Brake F is applied holding the front sun gear sta- clutch piston and in the turbine zone is equal. The direction
tionary. of flow is through the turbine shaft and through the space
behind the piston, to the turbine chamber.
Lubrication/Cooling
Control
The lubricating valve ensures that the converter is sup-
plied with cooling oil first if the pump rate is low. The lubri-
Clutch E Engaged cating pressure valve in addition guarantees that the nec-
Solenoid 2 will be switched OFF. Line pressure, which is essary amount of cooling and lubricating oil is available via
supplied by the reduction valve, flows to the inlet port of the bypass duct.
clutch valve E. Fluid will then pass through the clutch valve The fluid, which is supplied from the torque converter,
and clutch E will engage. flows to the cooler via the lubrication valve.

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Drive Range Third Gear

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Pressure control solenoids (EDS) 4 and 6 are also turned

Drive Range Third Gear ON.
In Drive 3, transaxle drive is via the input shaft to clutches When EDS 6 is ON, the fluid supplied from the reduction
B and E. The elements of this transaxle function are as fol- valve flows to the safety valve, clutch valve B and holding
lows: valve B. The oil that is supplied to the inlet port of the clutch
valve presses on the valve spool. Line pressure then flows
S Clutches B and E are engaged to drive the rear sun to the holding valve and check ball, engaging clutch B.
gear and rear planetary gear carrier clockwise.
S The clockwise rotation of the rear sun gear and rear Lockup Clutch (TCC)
planetary gear carrier will cause the front planetary Solenoid valve 2 is turned ON and the line pressure control
gear to rotate in the same direction. valve spool will be depressed. Fluid will now flow through
the torque converter pressure valve.
Control As a result, the oil pressure behind the converter lockup
clutch piston and in the turbine zone is equal. The direction
Clutch B Engaged of flow is through the turbine shaft and through the space
In Park and Neutral solenoid valves 1 and 2 are both ON. behind the piston, to the turbine chamber.

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Drive Range Fourth Gear

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Drive Range Fourth Gear

Clutch C Engaged
In Drive 4, transaxle drive is via the input shaft and
clutches E and C. The elements of this transaxle function EDS 4 will be switched OFF causing the fluid level to be
are as follows: high. Line pressure will be directed to the safety valve,
clutch valve D and holding valve D. Clutch valve C and
S Clutch E is engaged to drive the rear planetary gear
holding valve C will engage as pressure flows through the
carrier.
safety valve.
S The rear planetary gear carrier drives the rear ring
gear.
S The rear ring gear carrier drives the differential Lockup Clutch
gear.
Solenoid valve 2 is turned ON and the line pressure control
Control valve spool will be depressed. Fluid will now flow through
the torque converter pressure valve.
Clutch E Engaged
Solenoid 2 will be switched OFF. Line pressure, which is As a result, the oil pressure behind the converter lockup
supplied by the reduction valve, flows to the inlet port of clutch piston and in the turbine zone is equal. The direction
clutch valve E. Fluid will then pass through the clutch valve of flow is through the turbine shaft and through the space
and clutch E will engage. behind the piston, to the turbine chamber.

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Drive Range Fourth Gear ; Emergency/Substitute Mode

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Control
Drive Range Fourth Gear ;
Clutch E Engaged
Emergency/Substitute Mode
Solenoid 2 will be switched OFF. Line pressure, which is
In Drive 4, transaxle drive is via the input shaft and supplied by the reduction valve, flows to the inlet port of
clutches E and C. The elements of this transaxle function clutch valve E. Fluid will then pass through the clutch valve
are as follows: and clutch E will engage.

S Clutch E is engaged to drive the rear planetary gear Clutch C Engaged

carrier. EDS 4 will be switched OFF causing the fluid level to be
S The rear planetary gear carrier drives the rear ring high. Line pressure will be directed to the safety valve,
gear. clutch valve D and holding valve D. Clutch valve C and
S The rear ring gear carrier drives the differential holding valve C will engage as pressure flows through the
gear. safety valve.

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Drive Range Third Gear ; Emergency/Substitute Mode

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Control
Drive Range Third Gear ; Clutch B Engaged
Emergency/Substitute Mode In Park and Neutral solenoid valves 1 and 2 are both ON.
Pressure control solenoids (EDS) 4 and 6 are also turned
In Drive 3, transaxle drive is via the input shaft to clutches
ON.
B and E. The elements of this transaxle function are as fol-
lows: When EDS 6 is ON, the fluid supplied from the reduction
valve flows to the safety valve, clutch valve B and holding
S Clutches B and E are engaged to drive the rear sun valve B. The oil that is supplied to the inlet port of the clutch
gear and rear planetary gear carrier clockwise. valve presses on the valve spool. Line pressure then flows
S The clockwise rotation of the rear sun gear and rear to the holding valve and check ball, engaging clutch B.
planetary gear carrier will cause the front planetary
gear to rotate in the same direction.

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COMPONENT LOCATOR
TRANSAXLE IDENTIFICATION INFORMATION

1. Part Number 3. Model Code

2. Serial Number 4. Manufactured Nation and Company

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TORQUE CONVERTER

1. Torque Converter Housing 10. Screw

2. Torque Converter 11. Pressure Plug
3. Torque Converter Gasket 12. Pressure Plug
4. Steel Gasket 13. Oil Drain Plug
5. Oil Baffle Plate 14. Oil Level Plug
6. Bolt 15. Screw
7. Magnet 16. Bolt
8. Oil Filter 17. Bolt
9. Oring

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TRANSAXLE HOUSING

1. Transaxle Housing 10. Output Speed Sensor

2. Bushing 11. Washer
3. Shaft Seal 12. Bolt
4. Axle Shaft Seal 13. Shim
5. Sealing Sleeve 14. Shim
6. Breather Pipe 15. Park/Neutral Position Switch
7. Sleeve Protector 16. Bolt
8. Type Plate 17. Sealing sleeve
9. Cable Terminal

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OIL PUMP

1. Oil Pump 5. Dowel Pin

2. Oil Pump Seal 6. Bolt
3. Washer 7. Bolt
4. Oring

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REAR COVER & OIL PAN COVER

1. Rear Cover 7. Bolt

2. Piston Ring 8. Oil Pan
3. Oring 9. Oil Pan Gasket
4. Needle Bearing 10. Oil Pan Bracket
5. Shim 11. Bolt
6. Screw Plug

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PARKING LEVER

1. Selector Shaft 6. Leg Spring

2. Stop Bushing 7. Pawl
3. Detent Disc 8. Pin
4. Clamping Sleeve 9. Support Bolt
5. Connecting Bar

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INPUT SHAFT & SHIFT GEAR

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1. Inner Disc Carrier F 40. Rear Planetary Gear Set

2. Clutch Plate F 41. Snap Ring
3. Line Clutch Disc F 42. Rear Sun Gear
4. Clutch Outer Disc F 43. Needle Bearing
5. Spring Disc 44. Snap Ring
6. Stop Ring 45. Piston B
7. Cup Spring 46. Clutch Plate B
8. Oring 47. Clutch Outer Disc B
9. Oring 48. Line Clutch Disc B
10. Piston D 49. Spring Disc
11. Slotted Nut 50. Piston Ring
12. Roller Bearing 51. Inner Disc Carrier E
13. Adjust Ring 52. Needle Bearing
14. Bearing Plate 53. Snap Ring
15. Roller Bearing 54. Clutch Plate Disc E
16. Spur Gear 55. Line Clutch Disc E
17. Piston D 56. Clutch Outer Disc E
18. Spring Disc 57. Spring Disc
19. Snap Ring 58. Retainer Ring
20. Clutch Plate D 59. Oring
21. Cup Spring 60. Oil Dam
22. Line Clutch Disc D 61. Cup Spring
23. Spring Disc 62. Oring
24. Disc Carrier C/D 63. Piston E
25. Pitting Key 64. Oring
26. Line Clutch Disc C 65. Input Shaft
27. Clutch Outer Disc C 66. Oring
28. Cup Spring 67. Oring
29. Line Clutch Disc C 68. Piston
30. Snap Ring 69. Oil Dam
31. Piston C 70. Oring
32. Cylinder C 71. Cup Spring
33. Snap Ring 72. Stop Ring
34. Front Ring Gear 73. Shim
35. Oil Tray 74. Needle Bearing
36. Front Planetary Gear 75. Oring
37. Front Sun Gear 76. Piston Ring
38. Snap Ring 77. Rear Cover
39. Needle Bearing

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VALVE BODY

1. Control Valve Body 9. Solenoid Valve

2. Valve Body Wiring Harness 10. Cap Screw
3. Oring 11. Fixing Plate
4. Plug 12. Fixing Plate
5. Cable Terminal 13. Cap Screw
6. Retaining Clip 14. Solenoid Valve
7. Input Speed Sensor 15. Solenoid Valve
8. Cap Screw

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GEAR SHIFT CONTROL

1. Selector Control Lever 7. Positioning Spring

2. Gear Shift Knob 8. Solenoid
3. Cover 9. Base Plate
4. Step Gate Slider 10. T/A Lever
5. BTSI Button 11. Select Cable
6. Spring 12. Cable Fastener

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DIAGNOSTIC INFORMATION AND

PROCEDURES DIAGNOSIS
S Check all electrical connections for tightness.
BASIC KNOWLEDGE REQUIRED S Use onboard diagnostic tool or a scan tool to see
You must be familiar with some basic electronics to use if any transaxle trouble codes have been set. Refer
this section of the Service Manual. They will help you to to the appropriate Diagnostic Trouble Code (DTC)
follow diagnostic procedures. information and repair the vehicle as directed. After
repairing the vehicle, perform the road test and
Notice : Lack of the basic knowledge of this transaxle
verify that the code has not set again.
when performing diagnostic procedures could result in in-
S Perform the Electrical/Garage Shift Tests.
correct diagnostic performance or damage to transaxle
S Perform the Road Test Procedure in this section.
components.
S Inspect the oil and check for metal or other contam-
Do not, under any circumstances, attempt to diagnose a inants in the oil pan.
transaxle problem without this basic knowledge.
Notice : If a wire is probed with a sharp instrument and not LINE PRESSURE CHECK
properly sealed afterward, the wire will corrode and an PROCEDURE
open circuit will result.
Diagnostic test probes are now available that allow you to The 4HP 16 A/T uses a trochoid type oil pump to produce
probe individual wires without leaving the wire open to the hydraulic pressure, and a pressure control solenoid (sole-
environment. These probe devices are inexpensive and noid 1) to control that pressure at the pressure regulator
easy to install, and they permanently seal the wire from valve, after it leaves the pump. The transaxle pressure
corrosion. control solenoid is controlled by an electrical signal that
ranges from 0 to 12 volts corresponds to minimum line
Special Tools pressure (approx. 89.9 to 124.7 psi (6.2 to 8.6 bar)) and
You should be able to use a Digital Volt Meter (DVM), a cir- 0 volt corresponds to a maximum line pressure (approx.
cuit tester, jumper wires or leads and a line pressure gauge 221.9 to 252.4 psi (15.3 to 17.4 bar)) in all range.
set. Line pressures are calculated for two sets of gear ranges
The functional check procedure is designed to verify the DriveParkNeutral and Reverse. This allow the trans-
correct operation of electronic components in the trans- axle line pressure to be appropriate for different pressure
axle. needs in different gear ranges:
This will eliminate the unnecessary removal of transaxle
Gear Solenoid RPM Pressure
components.
Range 1
FUNCTIONAL CHECK PROCEDURE Drive, Off 2,500 221.9~252.4psi
Reverse (15.3~17.4 bar)
Begin with the Functional Check Procedure which pro-
vides a general outline of how to diagnose automatic On 2,500 17.4~269.8psi
transaxle. The following functional check procedure will in- (1.2~18.6 bar)
dicate the proper path of diagnosing the transaxle by de- Neutral, Off 2,500 221.9~252.4psi
scribing the basic checks and then referencing the loca- Park (15.3~17.4 bar)
tions of the specific checks.
On 2,500 89.9~269.8 psi
S Check the fluid level according to the Fluid Level (6.2~18.6 bar)
Service Procedure.
S Check the transaxle for fluid leaks. Before performing a line pressure check, verify that the
S Check if the transaxle fluid is not burnt by color and pressure control solenoid is receiving the correct electrical
smell. signal from the TCM:
S Ensure that the transaxle is not in Limp Home 1. Install a scan tool.
Mode(LHM). 2. Start the engine and set parking brake.
S Check the battery terminals and the ground con- 3. Check for a stored pressure control solenoid diag-
nections for corrosion or looseness. nostic trouble code, and other diagnostic trouble
S Check that the cooler flow is not restricted. codes.

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4. Repair vehicle, if necessary. 6. Start engine and allow it to warm up at idle.

Inspect: 7. Access the Solenoid 1 Control Mode on the scan-
S Fluid level. ner.
S Manual linkage. 8. Switching solenoid 1 ON/OFF, accelerating the en-
Install or Connect: gine to 2,500rpm, and then read the line pressure
S Scan tool (scanner) at the each gear.
S Oil pressure gauge at line pressure port (clutch B or 9. Compare data to the DriveParkNeutral line pres-
E ports on transaxle case) sure chart below.
Notice : Total test running time should not exceed 2 min-
utes, or transaxle damage could occur.
CAUTION : Brake must be applied at all times to pre-
vent unexpected vehicle motion.
If pressure readings differ greatly from the line pressure
chart, refer to the Diagnosis Charts contained in this sec-
tion.
Notice : Clutch damage may occur.
The scanner is only able to control the pressure control so-
lenoid in Park and Neutral with the vehicle stopped.
This protects the clutches from extremely high or low pres-
sures in Drive or Reverse rang.
5. Put gear selector in Park and set the parking brake.
Gear Range Solenoid Line B Port E Port
Pressure
Park / Neutral ON LOW 90~124.7 psi (6.2~8.6 bar)
OFF HIGH 221.9~252.3 ps
i (15.3~17.4 bar)
Reverse ON LOW 90~124.7 psi (6.2~8.6 bar)
OFF HIGH 221.9~252.3 psi
(15.3~17.4 bar)
Drive ON LOW 90~124.7 psi (6.2~8.6 bar)
OFF HIGH 137.7~162.4 psi
(9.5~11.2 bar)
3 ON LOW 90~124.7 psi (6.2~8.6 bar) 90~124.7 psi (6.2~8.6 bar)
OFF HIGH 221.9~252.3 psi 137.7~162.4 psi
(15.3~17.4 bar) (9.5~11.2 bar)
2 ON LOW 90~124.7 psi (6.2~8.6 bar)
OFF HIGH 137.7~162.4 psi
(9.5~11.2 bar)
1 ON LOW 90~124.7 psi (6.2~8.6 bar)
OFF HIGH 221.9~252.3 psi
(15.3~17.4 bar)

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6. Flush the cooler lines after you have properly re-

CLUTCH PLATE DIAGNOSIS paired or replaced the transaxle.
Composition Plates COOLER FLUSHING AND FLOW
Dry the plate and inspect the plates for the following condi- TEST
tions :
Notice : You must flush the cooler whenever you receive
S Pitting a transaxle for service. Cooler flushing is essential for
S Flaking SRTA installation, major overhaul, whenever you replace
S Wear a pump or torque converter, or whenever you suspect that
S Glazing the fluid has been contaminated.
S Cracking
S Charring After filling the transaxle with fluid, start the engine and run
for 30 seconds. This will remove any residual moisture
Chips or metal particles embedded in the lining from the oil cooler. Disconnect the return line at the trans-
Replace a composition plate which shows any of these axle and observe the flow with the engine running. If the
conditions. fluid flow is insufficient, check the fluid flow by disconnect-
ing the feed line at the cooler. Observe the flow with the
Steel Plates engine running.
Wipe the plates dry and check the plates for heat discolor- S If the flow from the cooler return line at the trans-
ation. If the surfaces are smooth, even if colorsmear is in- axle is insufficient, check the flow rate from the feed
dicated, you can reuse the plate. If the plate is discolored line to the cooler. BLockage exists in the transaxle
with hot spots or if the surface is scuffed, replace the plate. or the cooler.
Important : If the clutch shows evidence or extreme heat S If the flow from the transaxle feed line to the cooler
or burning, replace the springs. is insufficient, the transaxle is the cause of the fluid
flow problem.
Causes of Burned Clutch Plates S If the flow the transaxle feed line to the cooler is
The following conditions can result in a burned clutch insufficient, but flow from the cooler return line to
plate: the transaxle is insufficient, inspect the cooler pipes
and fittings. Then repeat the cooler flushing proce-
S Incorrect usage of clutch plates. dure. If the flow is still insufficient, replace the cool-
S Engine coolant in the transaxle fluid. er.
S A cracked clutch piston.
S Damaged or missing seals. TRANSAXLE FLUID LEVEL SERVICE
S Low line pressure.
S Valve problems.
PROCEDURE
This procedure is to be used when checking a concern
The valve body face is not flat
with the fluid level in a vehicle. A low fluid level will result
Porosity between channels
in slipping and loss of drive/ reverse or delay on engage-
The valve bushing clips are improperly installed.
ment of drive/ reverse when the vehicle is cold.
The check balls are misplaced.
The vehicle is first checked for transaxle diagnostic mes-
S The seal rings are worn or damaged
sages on the scan tool. If the oil level is low, it is possible
to register a vehicle speed signal fault.
Engine Coolant in Transaxle
Notice : Antifreeze will deteriorate the Oring seals and The vehicle is to be test driven to determine if there is an
the glue used to bond the clutch material to the pressure abnormal delay when selecting drive or reverse, or loss of
plate. Both conditions may cause transaxle damage. drive. One symptom of low fluid level is a momentary loss
of drive when driving the vehicle around a corner. Also
Perform the following steps if the transaxle oil cooler has when the transaxle fluid level is low, a loss of drive may oc-
developed a leak, allowing engine coolant to enter the cur when the transaxle fluid temperature is low.
transaxle:
When adding or changing transaxle fluid use only ESSO
1. Because the coolant will attach to the seal material LT 71141 automatic transaxle fluid or other approved
causing leakage, disassemble the transaxle and fluids. The use of incorrect fluid will cause the performance
replace all rubber type seals. and durability of the transaxle to be severely degraded.
2. Because the facing material may become sepa-
rated from the steel center portion, replace the Fluid Level Diagnosis Procedure
composition faced clutch plate assemblies. 1. If the vehicle is at operating temperature allow the
3. Replace all nylon parts including washers. vehicle to cool down for two hours, but no greater
4. Replace the torque converter. than four hours. Or if the vehicle is at cool status,
5. Thoroughly clean and rebuild the transaxle, using start the engine and allow the engine to idle for
new gaskets and oil filter. approximately 5 minutes (825~875 rpm), if pos-

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sible, drive the vehicle for a few kilometers (ND, move the gear shift lever through the gear ranges,
NR, shift until two gear). This will allow the trans- pausing a few seconds in each range and adding
axle to be within the correct temperature range. the fluid until gear application is felt. Then add an
Transaxle fluid level should be checked at tempera- additional 0.5 liters of fluid. Return the gear shift
ture 20 to 45C (68 to 113F). lever to P(Park). Turn the engine OFF and raise the
CAUTION : Removal of the fluid filler plug when the vehicle. Install the fluid filler plug and tighten it to
transaxle fluid is hot may cause injury if fluid drains 45NSm (34 lbft).
from the filler hole. 5. Drive the vehicle at 2.2 miles(3.5km) to 2.8
2. Switch off accessories, especially air conditioner, miles(4.5 km) with light throttle so that the engine
heater. does not exceed 2500 rpm. This should result in
3. With the brake pedal pressed, move the gear shift the transaxle temperature being in the range 20 to
control lever through the gear ranges, pausing a 45C (68 to 11F). With the brake applied, move
the shift lever through the gear ranges, pausing a
few seconds in each range. Return the gearshift
lever to P(Park). Turn the engine OFF. few seconds in each range at the engine idling.
4. Park the vehicle on a hoist, inspection pit or similar 6. Return the gear shift lever to P(Park). Turn the en-
raised level surface. The vehicle must be level to gine OFF and raise the vehicle on the hoist, if appli-
obtain a correct fluid level measurement. cable, ensuring the vehicle is level. When the three
minutes passed after the engine stopped, remove
5. Place a fluid container below the fluid filler plug.
6. Clean all dirt from around the fluid filler plug. the filler plug. Check if the fluid level is aligned with
Remove the fluid filler plug. Clean the filler plug and the bottom of the filler hole. If not, add a small
check that there is no damage to the O ring. quantity of fluid to the correct level. Install the fluid
filler plug and tighten it to 45NSm (34 lbft).
S If fluid drains through the filler hole the transaxle 7. Wipe any fluid around the filler plug with a rag or
may have been overfilled. When the fluid stops shop towel.
draining the fluid level is correct. Install the fluid
filler plug and tighten it to 45NSm(34 lbft). Fluid Leak Diagnosis and Repair
S If fluid does not drain through the filler hole, the The cause of most external leaks can generally be Lo-
transaxle fluid level may be low. Lower the ve- cated and repaired with the transaxle in the vehicle.
hicle, and start the vehicle in P(Park) with the
parking brake and the brake applied. With the Methods for Locating Leaks
engine idling, move the gear shift lever through
the gear ranges, pausing a few seconds in each General Method
range and adding the fluid until gear application 1. Verify that the leak is transaxle fluid.
is felt. Return the gear shift lever to P(Park). 2. Thoroughly clean the suspected leak area.
Turn the engine OFF and raise the vehicle. 3. Drive the vehicle for approximately 25 km (15
Check if the fluid level is aligned with the bottom miles) or until the transaxle reaches normal operat-
of the filler hole. If not, add a small quantity of ing temperature (88C, 190F).
fluid to the correct level. Install the fluid filler 4. Park the vehicle over clean paper or cardboard.
plug and tighten it to 45NSm(34 lbft). 5. Turn the engine OFF and look for fluid spots on the
paper.
7. When the fluid level checking procedure is com- 6. Make the necessary repairs to correct the leak.
pleted, wipe any fluid around the filler plug with a
rag or shop towel. Powder Method
1. Thoroughly clean the suspected leak area.
Fluid Level Set After Service 2. Apply an aerosol type powder (foot powder) to the
1. Depending on the service procedure performed, suspected leak area.
add the following amounts of fluid through the filler 3. Drive the vehicle for approximately 25 km (15
plug hole prior to adjusting the fluid level: miles) or until the transaxle reaches normal operat-
Oil pan removal 4 liters (4.23 quarts) ing temperature (88C, 190F).
Converter removal 2 liters ( 2.11 quarts) 4. Turn the engine OFF.
Overhaul 6.9liters (7.3 quarts) 5. Inspect the suspected leak area and trace the leak
Oil drain plug removal 4 liters (4.23 quarts) path through the powder to find the source of the
leak.
2. Follow steps 1 through 4 of the Fluid Level Diagno-
6. Make the necessary repairs.
sis Procedure.
3. Clean all dirt from around the fluid filler plug. Dye and Black Light Method
Remove the fluid filler plug. Clean the filler plug and 1. Add dye to the transaxle though the transaxle fluid
check that there is no damage to the O ring. filler plug. Follow the manufacturers recommenda-
4. Lower the vehicle with the filler plug still removed tion for the amount of dye to be used.
and start the vehicle in P(Park) with the parking 2. Use the black light to find the fluid leak.
brake and the brake applied. With the engine idling, 3. Make the necessary repairs.

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 ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 47

S The A/C COMPRESSOR STATUS should come

Repairing the Fluid Leak ON when the A/C switch is pressed, and turns
Once the leak point is found the source of the leak must OFF when the A/C switch is repushed.
be determined. The following list describes the potential 7. Monitor the GEAR SHIFT LEVER POSITION signal
causes for the leak: and move the gear shift control lever through all the
S Fasteners are not torqued to specification. ranges.
S Fastener threads and fastener holes are dirty or S Verify that the GEAR SHIFT LEVER POSITION
corroded. value matches the gear range indicated on the
S Gaskets, seals or sleeves are misarranged, dam- instrument panel or console.
aged or worn. S Gear selections should be immediate and not
S Damaged, warped or scratched seal bore or gasket harsh.
surface. 8. Move gear shift control lever to neutral and monitor
S Loose or worn bearing causing excess seal or the THROTTLE POSITION signal while increasing
sleeve wears. and decreasing engine speed with the accelerator
S Case or component porosity. pedal.
S Fluid level is too high.
S Plugged vent or damaged vent tube. S THROTTLE POSITION should increase with
S Water or coolant in fluid. engine speed.
S Fluid drain back holes plugged.
ROAD TEST PROCEDURE
ELECTRICAL/GARAGE SHIFT TEST S Perform the road test using a scan tool.
S This test should be performed when traffic and road
This preliminary test should be performed before a hoist conditions permit.
or road test to make sure electronic control inputs is con- S Observe all traffic regulations.
nected and operating. If the inputs are not checked before
The TCM calculates upshift points based primarily on two
operating the transaxle, a simple electrical condition could
inputs : throttle angle and vehicle speed. When the TCM
be misdiagnosed as a major transaxle condition.
wants a shift to occur, an electrical signal is sent to the shift
A scan tool provides valuable information and must be solenoids which in turn moves the valves to perform the
used on the automatic transaxle for accurate diagnosis. upshift.
1. Move gear selector to P (Park) and set the parking The shift speed charts reference throttle angle instead of
brake. min throttle or wot to make shift speed measurement
2. Connect scan tool to Data Link Connector (DLC) more uniform and accurate. A scan tool should be used to
terminal. monitor throttle angle. Some scan tools have been pro-
3. Start engine. grammed to record shift point information. Check the
4. Turn the scan tool ON. introduction manual to see if this test is available.
5. Verify that the appropriate signals are present.
These signals may include: Upshift Procedure
With gear selector in drive(D)
S ENGINE SPEED
S VEHICLE SPEED 1. Look at the shift speed chart contained in this sec-
S THROTTLE POSITION tion and choose a percent throttle angle of 10 or
S TRANSAXLE GEAR STATE 25%.
S GEAR SHIFT LEVER POSITION 2. Set up the scan tool to monitor throttle angle and
S TRANSAXLE FLUID TEMPERATURE vehicle speed.
S CLOSED THROTTLE POSITION LEARN 3. Accelerate to the chosen throttle angle and hold the
S OPEN THROTTLE POSITION LEARNT throttle steady.
S CLOSED ACCEL. PEDAL POSITION LEARNT 4. As the transaxle upshifts, note the shift speed and
S OPEN ACCEL. PEDAL POSITION LEARNT commanded gear changes for :
S A/C COMPRESSOR STATUS S Second gear.
S MODE SWITCH S Third gear.
S THROTTLE POSITION VOLTAGE S Fourth gear.
S GEAR SHIFT LEVER POSITION VOLTAGE
S TRANS. FLUID TEMPERATURE VOLTAGE Important : Shift speeds may vary due to slight hydraulic
S A/C SWITCH delays responding to electronic controls. A change from
S MODE SWITCH VOLTAGE the original equipment tire size affects shift speeds.
S BATTERY VOLTAGE Note when TCC applies. This should occur in fourth gear.
6. Monitor the A/C COMPRESSOR STATUS signal If the apply is not noticed by an rpm drop, refer to the
while pushing the A/C switch. Lockup Clutch Diagnosis information contained in this
section.

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The Lock up clutch should not apply unless the transaxle

has reached a minimum operating temperature of 8C
Manual Gear Range Selection
(46F) TRANS TEMP AND engine coolant temp of 50C Upshifts in the manual gear ranges are controlled by the
(122F). shift solenoids. Perform the following tests by accelerating
at 25 percent TP sensor increments.
5. Repeat steps 14 using several different throttle
angles. Manual Third (3)
S With vehicle stopped, move the gear selector to
Part Throttle Detent Downshift Manual third(3) and accelerate to observe :
At vehicle steeds of 55 to 65km/h (34 to 40mph) in Fourth 12 shift.
gear, quickly increase throttle angle to greater than 50%. 23 shift.

Verify that : Manual Second (2)

S With vehicle stopped, move the gear selector to
S TCC apply. Manual second(2) and accelerate to observe :
S Transaxle downshift to 3rd gear.
12 shift.
S Solenoid 1 turns ON to OFF.
S Solenoid 2 turns OFF. S Accelerate to 40km/h(25mph) and observe :
23 shift does not occur
Full Throttle Detent Downshift TCC does not apply
At vehicle speeds of 55 to 65km/h (34 to 40mph)in Fourth Manual First (1)
gear, quickly increase throttle angle to its maximum posi- S With vehicle stopped, move gear selector to Manu-
tion (100%) al First(1). Accelerate to 30km/h(19mph) and ob-
Verify that : serve :
No upshifts occur
S TCC release.
S Transaxle downshift to Second gear immediately. Reverse (R)
S Solenoid 1 turns ON to OFF S With vehicle stopped, move gear selector to R(Re-
S Solenoid 2 turns OFF. verse) and observe :
Solenoid 1 is OFF
Manual Downshifts Solenoid 2 is OFF
1. At vehicle speeds of 60km/h (40mph)in Fourth Use a scan tool to see if any transaxle trouble codes have
gear, release accelerator pedal while moving gear been set. Refer to Diagnostic Trouble Codesin this sec-
selector to Manual Third (3). Observe that : tion and repair the vehicle as directed. After repairing the
S Transaxle downshift to Third gear immediately. vehicle, perform the hoist test and verify that the code has
S Engine slows vehicle down. not set again.
If the transaxle is not performing well and no trouble codes
2. Move gear selector back to overdrive(D) and accel-
have been set, there may be an intermittent condition.
erate to 31mph (50km/h). Release the accelerator
Check all electrical connections for damage or a loose fit.
pedal and move the gear selector to Manual
You also have to perform a snapshot test which can help
First(1) and observe that :
catch an intermittent condition that dose not occur long
S Transaxle downshift to second gear immediate- enough to set a code.
ly. You may want to read Electronic Component Diagnosis
S Engine slows vehicle down in this section to become familiar with transaxle conditions
caused by transaxle electrical malfunction.
Notice : A Manual FirstThird Gear Ratio will occur at
high speeds as an upshift safety feature. Do not attempt If no trouble codes have been set and the condition is sus-
to perform this shift. pected to be hydraulic, take the vehicle on a road test.

TORQUE CONVERTER LOCKUP

Coasting Downshifts
CLUTCH(TCC) DIAGNOSIS
1. With the gear selector in Overdrive(D), accelerate
To properly diagnosis the lockup clutch(TCC) system,
to Fourth gear with TCC applied.
perform all electrical testing first and then the hydraulic
2. Release the accelerator pedal and lightly apply the
testing.
brakes, and observe that :
The TCC is applied by fluid pressure which is controlled by
S TCC release. a solenoid Located inside the valve body. The solenoid is
S Down shifts occur at speeds shown ON the shift energized by completing an electrical circuit through a
speed chart. combination of switches and sensors.

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 ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 49

1. Place foot on brake.

Functional Check Procedure 2. Put gear selector in Drive.
Inspect 3. Depress accelerator to approximately 1200rpm for
1. Install a tachometer or scan tool. no more than six seconds.
2. Operate the vehicle unit proper operating tempera- Notice : If the accelerator is depressed for more than six
ture is reached. seconds, damage to the transaxle may occur.
3. Drive the vehicle at 80 to 88km/h (50 to 55 mph) A torque converter noise will increase under this load.
with light throttle(road load).
4. Maintaining throttle position, lightly touch the brake Important : This noise should not be confused with pump
pedal and check for release of the TCC and a slight whine noise which is usually noticeable in P (Park), N
increase in engine speed(rpm). (Neutral) and all other gear ranges. Pump whine will vary
5. Release the brake slowly accelerate and check for with pressure ranges.
a reapply of the Lock up clutch and a slight de- The torque converter should be replaced under any of the
crease in engine speed(rpm). following conditions:
Torque Converter Evaluation S External leaks in the hub weld area.
S Converter hub is scored or damaged.
Torque Converter Stator S Converter pilot is broken, damaged or fits poorly
The torque converter stator roller clutch can have one of into crankshaft.
two different type malfunctions : S Steel particles are found after flushing the cooler
and cooler lines.
A. Stator assembly freewheels in both directions.
S Pump is damaged or steel particles are found in the
B. Stator assembly remains Locked up at all times. converter.
S Vehicle has TCC shudder and/or no TCC apply.
Condition A Poor Acceleration Low Replace only after all hydraulic and electrical diag-
Speed noses have been made.(Lock up clutch material
The car tends to have poor acceleration from a stand still. may be glazed.)
At speeds above 50 to 55km/h(30 to 35mph), the car may S Converter has an imbalance which cannot be cor
act normal. If poor acceleration is noted, it should first be rected. (Refer To Converter Vibration Test Proce-
determined that the exhaust system is not blocked, and dure.)
the transaxle is in 1st(First) gear when starting out. S Converter is contaminated with engine coolant con-
taining antifreeze.
If the engine freely accelerates to high rpm in N(Neutral),
S Internal failure of stator roller clutch.
it can be assumed that the engine and exhaust system are
S Excess end play.
normal. Checking for poor performance in Drive and Re-
S Heavy clutch debris due to overheating (blue con-
verse will help determine if the stator is freewheeling at all
verter).
times.
S Steel particles or clutch lining material found in fluid
Condition B Poor Acceleration High filter or on magnet when no internal parts in unit are
worn or damaged(indicates that lining material
Speed came from converter).
Engine rpm and car speed limited or restricted at high
speeds. Performance when accelerating from a standstill The torque converter should not be replace if :
is normal. Engine may overheat. Visual examination of the S The oil has an odor, is discolored, and there is no
converter may reveal a blue color from overheating. evidence of metal or clutch facing particles.
If the converter has been removed, the stator roller clutch S The threads in one or more of the converter bolt
can be checked by inserting two fingers into the splined in- holes are damaged.
ner race of the roller clutch and trying to turn freely clock- correct with thread insert.
wise, but not turn or be very difficult to turn counter clock- S Transaxle failure did not display evidence of dam-
wise. age or worn internal parts, steel particles or clutch
plate lining material in unit and inside the fluid filter.
Noise S Vehicle has been exposed to high mileage(only).
Torque converter whine is usually noticed when the ve- The exception may be where the Lock up clutch
hicle is stopped and the transaxle is in Drive or Re- damper plate lining has seen excess wear by ve-
verse. The noise will increase when engine rpm is in- hicles operated in heavy and/or constant traffic,
creased. The noise will stop when the vehicle is moving or such as taxi, delivery or police use.
when the torque converter clutch is applied because both
halves of the converter are turning at the same speed. LockUp Clutch Shudder Diagnosis
Perform a stall test to make sure the noise is actually com- The key to diagnosing lockup clutch(TCC) shudder is to
ing from the converter : note when it happens and under what conditions.

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TCC shudder should only occur during the APPLY and/or S EGR valve valve may let it too much unburnable
RELEASE of the Lock up clutch. exhaust gas and cause engine to run lean.
S MAP sensor like vacuum leak, engine wont get
While TCC Is Applying Or Releasing correct amount of fuel for proper engine operation.
If the shudder occurs while TCC is applying, the problem S Carbon on intake valves restricts proper flow or
can be within the transaxle or torque converter. air/fuel mixture into cylinders.
S Flat cam valves dont open enough to let proper
Something is not allowing the clutch to become fully en-
fuel/air mixture into cylinders.
gaged, not allowing clutch to release, or is trying to release
S Oxygen sensor may command engine too rich or
and apply the clutch at the same time. This could be
too lean for too long.
caused by leaking turbine shaft seals, a restricted release
S Fuel pressure may be too low.
orifice, a distorted clutch or housing surface due to long
S Engine mounts vibration of mounts can be multi-
converter bolts, or defective friction material on the TCC
plied by TCC engagement.
plate.
S Axle joints checks for vibration.
S TPS TCC apply and release depends on the TPS
Shudder Occurs After TCC Has Applied :
in many engines. If TPS is out of specification, TCC
In this case, most of the time there is nothing wrong with may remain applied during initial engine starting.
the transaxle! As mentioned above, once the TCC has S Cylinder balance bad piston rings or poorly seal-
been applied, it is very unlikely that will slip. Engine prob- ing valves can cause low power in a cylinder.
lems may go unnoticed under light throttle and load, but S Fuel contamination causes poor engine perfor-
become noticeable after TCC apply when going up a hill mance.
or accelerating, due to the mechanical coupling between
engine and transaxle. TCM INITIALIZATION PROCEDURE
Important : Once TCC is applied there is no torque con- When one or more operations such as shown below are
verter assistance. Engine or driveline vibrations could be performed, all learned contents which are stored in TCM
unnoticeable before TCC engagement. memory should be erased after the operations.
Inspect the following components to avoid misdiagnosis of S When A/T H/W is replaced in a vehicle,
TCC shudder and possibly disassembling a transaxle and/ S When a used TCU is installed in other vehicle,
or replacing a torque converter unnecessarily : S When a vehicle condition is unstable (engine RPM
S Spark plugs Inspect for cracks, high resistance or flare, TPS toggling and so on; at this kind of unsta-
broken insulator. ble conditions, misadaptation might be done).
S Plug wires Lock in each end, if there is red dust 1. Connect the Scan 100 with a DLC connector in a
(ozone) or black substance (carbon) present, then vehicle.
the wires are bad. Also look for a white discolor- 2. Turn ignition switch ON.
ation of the wire indicating arcing during hard accel- 3. Turn the power on for the Scan 100.
eration. 4. Follow the TCM LEARNED INITIALIZE procedure
S Distributor cap and rotor look for broken or un on the Scan 100 menu.
crimped parts. Notice : Before pushing Yes Button for TCM initialization
S Coil look for black on bottom indication arcing on the Scan 100 screen, make sure that the condition is
while engine is misfiring. as follows:
S Fuel injector filter may be plugged.
S Vacuum leak engine wont get correct amount of Condition :
fuel. May run rich or lean depending on where the 1. Engine idle.
leak is. 2. Select lever set P range.

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