ZF Tech Guide repair manual (4HP, 5HP) [106s].pdf

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Technical Service Information
BMW, AUDI, PORSCHE
Technicians Guide
INDEX
ZF 4HP-18FLE AND ZF 4HP-18 FLA DIAGNOSTIC INFORMATION
ZF 4HP-22/24 SERIES DIAGNOSTIC INFORMATION
MODEL “E-7” VALVE BODY WITH 5 SOLENOIDS
MODEL “E-9” VALVE BODY WITH 4 SOLENOIDS
ZF 5HP-18 DIAGNOSTIC INFORMATION
ZF 5HP-19FL DIAGNOSTIC INFORMATION
ZF 5HP-24 DIAGNOSTIC INFORMATION
ZF 5HP-30 DIAGNOSTIC INFORMATION
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
огром�½ый архив докуме�½тации по автомобилям
Volkswagen, Skoda, Seat, Audi
AUTOMATIC TRANSMISSION SERVICE GROUP
INDEX
INTRODUCTION
BMW, AUDI, PORSCHE
Published
September, 2003
This booklet contains information that has not normally been available in most OEM repair manuals and can be
used by the technician to diagnose electrical concerns, identify the location and direction of the valves, springs,
retainers and bore plugs in the valve body. This information has been prepared from actual valve bodies and in
some cases may vary from one model to another, but is invalueable when the need arises to diagnose and repair
electrical and valve body concerns.
This Manual covers the following models:
ZF-4HP-18FLE/FLA Transaxle, found in Audi and Porsche.
ZF-4HP-22/24 Series, Model "E7", "5 Solenoid" Valve Body found in various vehicles.
ZF-4HP-22/24 Series, Model "E9", "4 Solenoid" Valve Body found in various vehicles.
ZF-5HP-18 Series, found in various BMW models.
ZF-5HP-19FL Transaxle, found in various BMW models.
ZF-5HP-24 Series, found in various BMW models.
ZF-5HP-30 Series, found in various BMW models and Rolls Royce.
No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or
by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,
without
written
permission of Automatic Transmission Service Group. This includes all text illustrations,
tables and charts.
The information and part numbers contained in this booklet have
been carefully compiled from industry sources known for their
reliability, but ATSG does not guarantee its accuracy.
Copyright © ATSG 2003
DALE ENGLAND
FIELD SERVICE CONSULTANT
JIM DIAL
TECHNICAL CONSULTANT
WAYNE COLONNA
TECHNICAL SUPERVISOR
ED KRUSE
TECHNICAL CONSULTANT
PETER LUBAN
TECHNICAL CONSULTANT
GREGORY LIPNICK
TECHNICAL CONSULTANT
JON GLATSTEIN
TECHNICAL CONSULTANT
DAVID CHALKER
TECHNICAL CONSULTANT
JERRY GOTT
TECHNICAL CONSULTANT
STANTON ANDERSON
TECHNICAL CONSULTANT
GERALD CAMPBELL
TECHNICAL CONSULTANT
ROLAND ALVAREZ
TECHNICAL CONSULTANT
MIKE SOUZA
TECHNICAL CONSULTANT
AUTOMATIC TRANSMISSION SERVICE GROUP
9200 S. DADELAND BLVD. SUITE 720
MIAMI, FLORIDA 33156
(305) 670-4161
1
TECH N ICIA N S DIAGNOS TIC GUIDE
BMW, AUDI, PORSCHE
INDEX
We wish to thank the following for supplying the actual
valve bodies that have made these illustrations possible.
LORY
TRANSMISSION
PARTS
2414 SW 8TH STREET
MIAMI, FLORIDA 33135
Toll Free (800) 966-4621
Phone (305) 642-4621
Fax
(305) 541-1444
ERIKSSON INDUSTRIES
WENTWORTH ENGINEERING, INC.
146 B ELM STREET
OLD SAYBROOK, CT 06475
Toll Free (800) 388-4418
DIVISION OF
INDEPENDENT TRANSMISSION SERVICE
AND MARIO ARISTIDES
5846 SW 68TH STREET
SOUTH MIAMI, FLORIDA 33143
Phone (305) 666-3544
Phone (305) 666-4208
Fax
(305) 666-8238
Copyright © 2001 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
3
TECH N ICIA N S DIAGNOS TIC GUIDE
BMW, AUDI, PORSCHE
INDEX
ZF-4HP-18FLE AND ZF-4HP-18FLA
DIAGNOSTIC INFORMATION
The ZF-4HP-18FLE is mounted longitudinal in the front of the vehicle, and was produced in 2 Wheel Drive
models (FLE) and All Wheel Drive (FLA) models, as shown in Figure 1. This unit is totally electronic
controlled and is totally different than any 4-HP-18 unit that you are currently familiar with.
ZF-4HP-18FLE And ZF-4HP-18FLA Is Found In The Following Vehicles;
Audi - - - 100 Quatro, A6 .................................................................................................. 1991-1997
Audi - - - A8 ...................................................................................................................... 1994-1996
Porsche - - - 944 ............................................................................................................... 1991-1994
There has been very little pertinent information published on these units. The information in this bulletin has
been prepared from an actual transaxle and valve body, and has been formulated to provide you with the
preliminary information needed to diagnose and repair electrical and valve body concerns.
Refer to Figure 1 for illustrations of both the 4-HP-18FLE (2WD) and 4-HP-18FLA (AWD) models.
Refer to Figure 2 for internal component resistance charts and connector pin identification.
Refer to Figure 3 for complete wiring schematic with computer terminal identification and transaxle
terminal identification, which makes it easier for electrical diagnosis.
Refer to Figure 4 for the solenoid application chart and component application chart.
Refer to Figure 5 for illustration of the complete valve body assembly.
Refer to Figure 6 for exploded view of oil filter and oil filter transfer plate.
Refer to Figure 7 for exploded view of the manual valve body.
Refer to Figure 8 for exploded view of the solenoid body, and notice that it provides you with the factory
setting for the adjustment on the pressure regulator valve for EDS-1 solenoid. The Legend for Figure 8
which identifies the solenoid body components and solenoids is found on Page 13.
Refer to Figure 9 for exploded view of the valve body assembly components.
Refer to Figure 10 for exploded detail view of the "Rear Side" of the main valve body. The Legend for Figure
10 which identifies the main valve body components is found on Page 16.
Continued on Page 5
SPECIAL NOTE:
All nomenclatures in this booklet are ATSG interpretations, not Audi's nor ZF.
Copyright © 2001 ATSG
4
AUTOMATIC TRANSMISSION SERVICE GROUP
TECH N ICIA N S DIAGNOS TIC GUIDE
BMW, AUDI, PORSCHE
Continued from Page 4.
Refer to Figure 11 for exploded detail view of the "Front Side" of the main valve body.
INDEX
Refer to Figure 12 for valve body spring specifications. The spring dimensions listed in Figure 12 were
"Observations" from only one valve body, and may vary from one model to another.
Refer to Figure 13 for Solenoid Body screen and retainer locations, and to Figure 14 for the Manual Valve
Body retainer locations.
Refer to Figure 15 for the Main Valve Body "Top Side" retainer locations, check valve and checkball
locations, and the locations of the small flat disc orifices.
Refer to Figure 16 for the Main Valve Body "Bottom Side" check valve location, and the location of the small
flat disc orifices.
Refer to Figure 17 for location of the small flat disc orifices in the channel plate.
Refer to Figure 18 for the two pressure tap locations on the back of case.
Refer to Page 22 for explanation of Safety Mode Valve operation.
Refer to Page 23 for complete color hydraulic schematic.
SPECIAL NOTE:
All nomenclatures in this booklet are ATSG interpretations, not Audi's nor ZF.
Copyright © 2001 ATSG
AUTOMATIC TRANSMISSION SERVICE GROUP
5

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