Automatic transmission 4hp16 DIY repair

Automatic transmission ZF4HP16 Designed for use with front wheel drive vehicles. This modification of gearboxes appeared on the conveyor in 2002. The automatic transmission was manufactured by ZF specialists and is used on French cars, and under license on cars from manufacturers such as Chevrolet, Daewoo and Suzuki.

One of the features of this gearbox is its miniature size. This allows you to easily place it in a small engine compartment. It is possible to use a four-speed gearbox ZF4HP16 with vehicles in which the power unit is located transversely.

This transmission model was developed for use with small cars. The maximum possible engine volume is 2 liters. The gearbox has a fairly simple design, which has a positive effect on its reliability indicators. In fact, this unkillable automatic transmission can be used for many decades. It is only necessary to regularly change the oil in the transmission and monitor the condition of the lubricant during operation.

Of the problems of this modification of the gearbox, one can note the failure of the solenoids, which is caused by the use of low-quality oil or the lack of an oil change during the operation of the car. In rare cases, electrical problems may appear, which is caused by improper operation of the car. In rare cases, there are problems with the valve body, which leads to the need for a major overhaul of the gearbox. It should be noted that the cost of spare parts is not too high, so the overhaul budget automatic transmission ZF4HP16 does not differ in significant cost.

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The AGREGATKA company is a federal network of technical centers whose main specialization is the repair and maintenance of automatic transmissions of all types, including dual-clutch robotic transmissions, CVT transmissions and classic hydromechanical automatic transmissions

The AGREGATKA company is a federal network of technical centers whose main specialization is the repair and maintenance of automatic transmissions of all types, including dual-clutch robotic transmissions, CVT transmissions and classic hydromechanical automatic transmissions

4-speed automatic transmission for front-wheel drive ZF 4HP16 came out in the early 2000s when the design of the predecessor had already been worked out - ZF4HP20 and is its reduced constructive copy.

Most of the hardware parts are proportionally reduced, they are indistinguishable on the catalog diagram, but not interchangeable (except for the filter, oil seals, solenoids, friction clutches and some other unified consumables).

ZF automatic transmission 4HP16 designed for lower torque (up to 240 Nm) and is produced mainly by Koreans under license from ZF for front-wheel drive cars Daewoo, Chevrolet (Lacetti), Grand Vitara from Suzuki, etc. with an engine from 1.6 to 2 liters. It is a competitor to the Aisin family U240, which suffered from the back cover.

Quite rare in automatic transmission repair. Partly due to the fact that it is simple, reliable and “indestructible” in German, like most 4-speed automatic transmissions from this manufacturer, partly due to the fact that it is still young and rarely found on the market among Korean cars of this displacement.

Oil change is carried out by partial change or displacement method, with the engine running and the ATF oil cooler disconnected.

Checking the oil level is carried out at the overflow hole, dirty oil after 40 tkm indicates the need to change the oil. With careful driving, an oil change is made after 60 tkm. Oil - synthetic type Dexron III (or LT 71141) is used in the same way and yellow and red. When replacing, it is not recommended to mix oils of different colors. With a complete overhaul, you can replace the oil of one color (yellow) with another (red).

It is unpretentious to oil, but requires a correctly set level and relatively clean oil.

Pick up repair kits - key on the left

A typical oil change order is a disposable felt filter - 172010. Which are recommended to be changed after the second oil change, and for older cars - at each oil change, which saves solenoids and a very expensive hydraulic plate.

- Repair kit for gaskets and seals (Overol Kit) - No. 172002. For bulkheads, ATOK is preferred, followed by Overol Precision in popularity.

- Clutch kit - No. 172003. They don't change as often compared to the "C" clutch pack. (below)

- A complete set of gaskets for oil seals and clutches with steel discs (Masterkit) - No. 172007. Ordered for a complete overhaul, adding a filter and a pump bushing (172034) to it.

In the clutch package "C" one-way clutches are on fire - No. 172104. Together with them, the reciprocal steel disk 172144 burns. These three problematic friction discs were replaced by designers in subsequent modifications. The selection is made according to the vin of the car.

Often the piston C - 172962 is also changed here.

Replace consumables in the age torque converter - 172001.

If you start this replacement, then the seals 178070 flow and the pump starts to break - 172500. with the stuffing box, then the pump sleeve also changes - No. 172034 -EM.

If you start a timely replacement, then the vibrations break the rest of the nodes, then you have to change the set of bushings 5 ​​pcs. — 172030 .

The remaining oil seals for “decorative” repairs are 172076 and 172077.

Of the first diseases, minor problems with the electrician were noticed, which cannot withstand the hot summer in the city and aggressive driving with oil overheating.

– Solenoid-electrovalve (2 pcs) No. 172421A

Problems with dirty solenoids lead to insufficient oil pressure, which primarily affects the oil seals, bushings and torque converter pump.

– Electroregulator solenoid EDS black (3 pcs. +1 pc.) No. 172431

- Gear shift selector / sensor - 172410A).

And both Sensor-sensor output 172436 and input speed - 172438.

In second place in terms of combustion are packages D and E.

– Piston Rubber coated, D CLT (193.5 mm x 142 mm x 11 mm) # 172961

– Back cover 172759, oil seals

Diseases of age-related/dead machine guns (usually after 200 tkm) - similar to the problems of the “big brother” - 4HP20.

The ZF 4HP16 repair manual is related to the older brother (4HP20) and can be found here .

On which cars this family of automatic transmissions was installed:

The ZF 4HP16 4-speed automatic transmission has been produced since about 2000 and is installed on models from many manufacturers, primarily Daewoo Lacetti and its numerous clones. The transmission is aggregated with engines up to 2.4 liters and 240 Nm of torque.

The 4HP family also includes automatic transmissions: 4HP14, 4HP18, 4HP20, 4HP22 and 4HP24.

On the example of a 2005 Chevrolet Lacetti with a 1.8 liter engine:

Similar transmissions from other manufacturers:

A simple and reliable box quietly walks up to 150 - 200 thousand km without repairs

When driving through traffic jams in the heat, failures occur in the electrical part of the automatic transmission

If you do not change the consumables of the torque converter, leaks from the seals are possible

Other problems are related to normal wear and tear and apply to any machine.

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Next, we go to court. Don't push your luck, we have over 30 successful internet projects and already won a dozen lawsuits.

The zf4hp 16 automatic transmission is a 4-speed high-tech unit from the German company ZF. This box was released in 2000 according to the already developed design of the zf4hp 20 automatic transmission. In practice, this is the same unit, but in a reduced size. The 16th series has exactly the same shape of all structural parts and their location as the 20th, but in a reduced form. Therefore, the repair of the zf 4hp16 automatic transmission is in many ways similar to that carried out for the zf4hp20 automatic transmission series.

The automatic gearbox zf4hp 16 is designed for a smaller amount of torque - about 240 Nm. It is successfully used to complete small-capacity front-wheel drive French cars, and the box, produced under license, is used in Chevrolet, Daewoo, Suzuki cars.

Features of operation and breakdowns of automatic transmission

German boxes zf4hp 16 are distinguished by their reliability and long maintenance-free period. The long-term and fault-tolerant operation of the automatic transmission is facilitated by both the high reliability of its components and components, and timely routine maintenance, which includes replacing the automatic transmission oil zf 4hp16 and the corresponding filter. In addition, it may be necessary to adjust the operation of the electrical systems of the box, since the “electrician can be naughty” due to the constant operation of the box in the heat of the summer or when the oil overheats, provoked by prolonged aggressive driving at high engine speeds.

One of the main problems that arise during the operation of this box is the failure of its solenoids, which occurs due to the use of low-quality gear oil or if the oil was not changed at all on the zf 4hp16 automatic transmission. Also quite characteristic breakdowns for automatic transmissions of this series are the wear of oil seals and bushings, problems with the operation of the OEM gear sensor.

Somewhere around 200 thousand kilometers in the box, there may be problems with the valve body, which is often clogged with friction wear products, and also due to poor-quality oil cleaning. This happens if the automatic transmission filter is not replaced on the 4hp16 or the scheduled oil change dates and the corresponding filter elements are not observed.

In order to exclude complex repair of the 4hp16 automatic transmission valve body and possible failure of the oil pump, it is better to contact the Vegas-ATM service center at the first uncharacteristic symptoms of the gearbox operation - extraneous noises, jerks and bumps when picking up speed.

Automatic transmission repair zf 4hp16

Vegas-ATM is ready to provide fast and high-quality repairs at reasonable prices to its customers. Our highly qualified mechanics, who have over 10 years of experience with automatic transmissions, are able to quickly find the cause of the failure of the transmission and effectively eliminate it. Diagnostics of automatic transmission 4hp16 and its repair is carried out using modern equipment and tools. Only original parts are used as components, and only the highest quality consumables are used.

An automatic transmission is an expensive unit. There is no point in delaying the repair if it starts to work incorrectly. In a car service, such repairs are an expensive pleasure. You have to pay for the work of specialists and for parts. Having studied the market and the price range of services in this segment, motorists come to the conclusion that do-it-yourself automatic transmission repair is not such a pointless undertaking. The prices of service station masters cannot be called modest, and professionalism does not always correspond to the price. And, after some thought, motorists may decide to troubleshoot on their own.

Wherever you decide to repair the gearbox, the whole process goes as follows:

• diagnostics,
• dismantling the box
• box disassembly,
• spare parts kit,
• assembly (installation),
• car installation,
• diagnostics after repair.

To fix the problem yourself, you will need some car mechanic skills, tools, a certain amount of time to work, patience and perseverance.

All automatic transmissions are arranged in the same way, but There are two types of transmission control - hydraulic and electronic. Their repair has some differences.

It is important to notice problems in the transmission at an early stage. Then, with proper diagnosis, complex repairs can be avoided. Quiet and smooth operation of the automatic transmission is considered normal. There are a lot of signs that something is wrong with the box. Most often, these are extraneous sounds when shifting gears or during transmission robots. It can be a crunch, clicks. An unpleasant smell also indicates problems. It can appear during long or short-term operation of the box. Worse, if the gear shifting slows down, or one of them does not work at all. Then immediate intervention is required.

Do not be lazy to look under the car, it should be clean there. Spots of red color will indicate an oil leak from the gearbox. Checking the oil level regularly is a must. Normally, it should be translucent, reddish in color. No smells of burnt or cloudy shades! If they appear, it's time to change the oil.

Automatic transmission malfunctions often occur due to improper use. The transmission becomes unusable due to insufficient oil level or its overheating. For this reason, gears wear out, the machine can jerk when switching gears. As a result, any part of the automatic transmission may fail. Shocks during movement indicate oil overheating and problems in the valve body.

Aggressive driving with hard accelerations and decelerations will cause details to be erased. Does not add durability to the box and driving in traffic jams, slipping. All this leads to overheating of the box and badly affects its general condition.

All faults are divided into two subgroups. They may occur in

• electronic control system,
• mechanical and hydraulic parts of the gearbox.

In the event of a malfunction, the automatic transmission goes into emergency mode, that is, it becomes in third gear and does not switch. The corresponding icon appears on the board.

If problems arose with the electronics, then it will not be possible to fix them by repairing the automatic transmission. Therefore, it is important to understand the nature of the faults.

In diagnostics, the main thing is to collect the necessary information and interpret it correctly. Therefore, it is better to turn to specialists. Determine what the problem is in the service station, and repair it yourself. Without proper experience and equipment, you will spend a lot of time diagnosing. There are mechanical and computer diagnostics.

The general scheme for carrying out diagnostic procedures:

• check the oil
• check the operation of the engine at idle, the connection points of the electrical wiring and cables,
• determine the error codes for the operation of control units (CU) of the gearbox and engine,
• check the box on the car without movement,
• check the automatic transmission in motion,
• check the pressure inside the control system.

If the cause of the malfunctions is problems with the electronics, then most likely you will not need to dismantle and disassemble the automatic transmission. Diagnostics of malfunctions in this system is carried out by the control unit. It monitors the sensor signals, the gear ratio of the gearbox and the resistance of the output circuits. Malfunctions of such parts and assemblies may occur:

• input sensors,
• electronic control unit,
• executive devices of the control system,
• violation of the integrity of electrical wiring connections.

The transmission computer receives signals from various sensors.If any parameters are out of the norm, it writes the code of this problem (DTC) into memory. You can decipher such numbers using a special scanner.

These are the main problems of the automatic transmission itself. They are conditionally divided into three subgroups:

1. Damage to friction groups, bushings and housings, calipers, planetary gear sets, pump and other mechanics.
2. Transformer failure. This includes:
   • wire breaks,
   • mechanical destruction of the blades,
   • overrunning clutch,
   • wear of the main locking clutch,
   • depressurization of the piston seal.
   • Problems with the mechanics of the hydraulic plate.

If the diagnosis was successful and you can’t do without dismantling, then we proceed to this stage of automatic transmission repair.

You will need a special lift, or at least a viewing hole. As well as a transmission jack and a set of keys. It is better to carry out such a procedure in a specially equipped garage or box. It would be useful to invite a few physically strong guys to help move the removed box. Her weight is beyond the power of even a very strong person. Further action plan:

1. disconnect all communication tubes and cables;
2. unscrew the torque converter mounting bolts, as well as the motor flywheel membranes;
3. remove and move the gearbox;
4. assess the extent of the damage and proceed with the repair.

Before removing the gearbox, the oil from it can not be drained. However, then do not forget to substitute the container at the attachment point of the oil supply pipes when you disconnect them - otherwise you will get an ugly puddle under your feet.

All actions must be careful. Sudden movements can damage the splines of the diaphragm input shaft.

Do-it-yourself automatic transmission repair is best done with a company manual and a printed gearbox diagram. First you need to inspect all systems serving the gearbox, mounts and blocks. Then we start repairing. For this:

1. We disassemble the gearbox, wash and dry the parts and check them for defects.
2. We change all gaskets, seals, as well as worn parts.
3. Remove the inhibitor block and pan. We clean the dirt inside. It looks like a metal magnetic chip.
4. Remove the ring wires from the plug and push them inside the plug.
5. Remove the hydraulic unit, loosen the brake band bolts. We wash the hydraulic unit.
6. Clutches, gears and planetaries are checked for wear. We replace if there is such a need. All internal rubber bands must be changed!
7. We open the oil pump. We check all the details, especially the filter. We change what has already served its time. We use the manual so as not to change parts in places.
8. We take out the valves and springs. Flush valves. Their sticking can be the cause of incorrect operation of the automatic transmission. We change the accumulator springs if they are broken.
9. Putting everything back in place. It is important not to confuse anything!
10. Replace rings and friction bolts.
11. We check the gearshift assembly and the large piston and put the oil pump in place.

Assembly is in reverse order.

There are some points that it is desirable to take into account when repairing. Often the problem with the operation of the gearbox is related to the filter. You will not be able to change it without removing the valve body. And when it is removed, the gasket breaks. To replace it, you will need to disassemble the hydraulic unit completely. The same applies to the accumulator spring from first to second gear. A special limiter does not allow to remove it without disassembling the valve body. All valve body gaskets are very similar, do not mix them up. When assembling the valve body, we tighten it with a torque wrench. It is important not to overdo it here.

If all the breakdowns are eliminated, we install the automatic transmission. The moment is responsible, haste is inappropriate here. During this work, the following recommendations should be followed:

• When installing the automatic transmission in its place, the membrane is checked for end runout using an indicator head.If such a defect occurs, then it must be replaced.
• The radiator is flushed until the gasoline is clean. Then a liter of gear oil is poured into the gas turbine engine and placed on the input shaft. It is necessary to achieve a reliable connection and a complete fit. Then you need to dock the engine with the box along the guide centering pins. Carters must adjoin completely.
• Tightening the bolts in the box is the next step. After that, the absence of gaps over the entire plane is checked. After connecting all the highways, the correct connections are checked.
• At the final stage, oil is poured and the operation of the automatic transmission is checked at low engine speeds.

Starting the installation of the box, be sure to check for the presence of centering pins on the engine crankcase flange - there should be two of them. If there is not at least one, it is impossible to mount the automatic transmission.

Repair and diagnostics of automatic transmission with your own hands is not an easy, but feasible task. When choosing a car with an automatic transmission, novice motorists believe that its repair at home is impossible. This is not true. But before you decide to carry out such responsible work at home, you need to weigh all your options. Then you will not expect unpleasant surprises during the repair.