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 is manufactured by ZF specialists and is used on French cars, and under license on cars from such manufacturers as Chevrolet, Daewoo and Suzuki.

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

This transmission model has been designed for use with small cars. The maximum possible engine displacement 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.

From 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 oil change during the operation of the car. In rare cases, electrical problems may appear, which is caused by improper operation of the vehicle. In rare cases, there are problems with the valve body, which leads to the need for 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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CVTs, DSG, torque converters, new and remanufactured automatic transmissions, spare parts

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AGGREGATKA is a federal network of technical centers, the main specialization of which is the repair and maintenance of automatic transmissions of all types, including robotic transmissions with double clutch, CVT transmissions and classic hydromechanical automatic transmissions

AGGREGATKA is a federal network of technical centers, the main specialization of which is the repair and maintenance of automatic transmissions of all types, including robotic transmissions with double clutch, 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 - ZF 4HP20 and is its reduced constructive copy.

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

Automatic transmission ZF 4HP16 is designed for lower torque (up to 240 Nm) and is produced mainly by Koreans under a ZF license 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 Aisinovsky U240 family, which was sick with the back cover.

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

The oil is changed by partial change or by displacement, with the engine running and the ATF cooler disconnected.

The oil level is checked at the overflow hole, dirty oil after 40 tkm indicates the need to change the oil. With careful driving, the oil change is carried out after 60 tkm. Synthetic oil like Dexron III (or LT 71141) is used in the same yellow and red colors. When replacing, it is not recommended to mix oils of different colors. With a full bulkhead, one color (yellow) oil can be replaced with another (red) oil.

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

Pick up repair kits - key on the left

Typical Oil Change Order - Disposable Felt Membrane 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 oil seals (Overol Kit) - No. 172002. For bulkheads, ATOK is preferred, followed by Overol Precision in popularity.

- A set of clutches - No. 172003. Not so often changed compared to the "C" clutch package. (below)

- Complete set of gaskets and clutches with steel discs (Masterkit) - No. 172007. Order for complete bulkhead by adding filter and pump bushing (172034).

One-way clutches in clutch pack "C" are lit - No. 172104. Together with them, the counter steel disc 172144 burns. These three problematic friction discs in subsequent modifications, the designers were interchanged. The selection is made by vin auto.

Piston C - 172962 is also often changed here.

Replace consumables in the age converter - 172001.

If you start this replacement, then the oil seals 178070 are leaking and the pump begins to break - 172500. with an oil seal, then the pump bushing is also changed - No. 172034 -EM.

If you start a timely replacement, then the vibrations break the rest of the units, then you have to change a set of 5 bushings. - 172030.

The rest of the seals for the "decorative" repair - 172076 and 172077.

Of the first illnesses, minor problems with the electrics were noticed, which could not withstand the hot summer in the city and aggressive driving with overheating of the oil.

- Solenoid-solenoid valve (2pcs) No. 172421A

Dirty solenoid problems result in insufficient oil pressure, which primarily affects the oil seals, bushings and the converter pump.

- Solenoid-electric regulator EDS black (3 pcs. +1 pcs.) No. 172431

- Gear selector / sensor - 172410A).

And both sensor-sensors output 172436 and input revolutions - 172438.

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

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

- Back cover 172759, oil seals

Diseases of aged / killed machine guns (usually after 200 tkm) - similar to the problems of the "big brother" - 4HP20.

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

On which cars this automatic transmission family was installed:

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

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

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

Similar transmissions from other manufacturers:

A simple and reliable box easily goes 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 oil seals are possible.

Other problems are associated with normal wear and tear and relate to any machine

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The automatic transmission zf4hp 16 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 automatic transmission zf4hp 20. This is practically the same unit, but in a reduced size. The 16th series possesses exactly the same shape and arrangement of all structural parts as the 20th, but in a reduced form. Therefore, the repair of the automatic transmission zf 4hp16 is in many ways similar to that which is carried out for the automatic transmission zf4hp20 series.

The automatic transmission zf4hp 16 is designed for a lower amount of torque - about 240 Nm. It is successfully used for the complete set of small 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 fail-safe robot of the automatic transmission is facilitated by both the high reliability of its assemblies and components, as well as timely routine maintenance, which includes changing the oil in the automatic transmission 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 in 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 transmission oil or, if the oil change was not carried out at all on the zf 4hp16 automatic transmission. Also, quite typical breakdowns for automatic gearboxes of this series are wear of oil seals and bushings, problems with the operation of the OEM gear sensor.

Somewhere around 200 thousand km of run in the box, there may be problems with the valve body, which is often clogged with clutch wear products, as well as due to poor-quality oil cleaning. This happens if the automatic transmission filter is not replaced at 4hp16 or if the scheduled time for changing the oil and the corresponding filter elements is not observed.

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

Repair of automatic transmission zf 4hp16

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

An automatic transmission is an expensive component. There is no point in delaying the repair if it starts to work incorrectly. In a car service, such repairs are expensive. You have to pay for the work of specialists and for the details. Having studied the market and the price range of services in this segment, motorists come to the conclusion that repairing automatic transmissions with their own hands is not such a pointless undertaking. The prices of the workshop masters cannot be called modest, and the professionalism does not always correspond to the price. And, after some thought, motorists can decide to fix the problem on their own.

Wherever you decide to repair the gearbox, the whole process goes according to the following scheme:

• diagnostics,
• dismantling the box,
• disassembly of the box,
• complete set with spare parts,
• assembly (installation),
• installation on a car,
• diagnostics after repair.

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

All automatic transmissions are arranged the same, but there are two types of transmission control - hydraulic and electronic. Their renovation has some differences.

It is important to notice transmission problems at the earliest possible stage. Then, with the correct 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 changing gears or during robotic transmission. It can be crunching, clicks. An unpleasant smell also speaks of problems. It can appear during long-term or short-term operation of the box. It is 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. Red spots will indicate an oil leak from the transmission. Checking the oil level regularly is a must. Normally, it should be translucent, reddish in color. No burning smells or muddy shades! If they appear, it's time to change the oil.

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

Aggressive driving with hard acceleration and braking will erase details. Does not add durability to the box and driving in traffic jams, slipping. All this leads to overheating of the box and has a bad effect on its general condition.

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

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

If a malfunction occurs, the automatic transmission goes into emergency mode, that is, it goes into third speed and does not switch. The corresponding icon appears on the display.

If problems have arisen 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 consult a specialist. Determine what the problem is at the service station, and take care of the repair yourself. Without proper experience and equipment, you will spend a lot of time on diagnostics. There are mechanical and computer diagnostics.

General scheme of diagnostic procedures:

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

If the cause of the malfunctions is electronics problems, 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 transmission ratio 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 the electrical wiring connections.

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

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

1. Damage to friction groups, bushings and housings, calipers, planetary gear sets, pump and other mechanics.
2. Defective transformer. This includes:
   • breaks in the splines of the wires,
   • mechanical destruction of the blades,
   • overrunning clutch,
   • wear of the main blocking clutch,
   • depressurization of the piston oil seal.
   • Problems with the mechanics of the hydraulic plate.

If the diagnostics were successful and you cannot do without dismantling, then we proceed to this stage of the 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 perform this procedure in a specially equipped garage or box. It will not be superfluous to invite several physically strong guys to help you move the removed box. Its weight is beyond the strength 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 scale of the breakdown and start repairing.

Before removing the gearbox, the oil does not need to be drained from it. However, then do not forget to substitute the container at the place where the oil supply pipes are attached 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 on the input shaft of the diaphragm.

It is better to do automatic transmission repair with your own hands, having it at hand proprietary manual and a printed diagram of the gearbox. First you need to inspect all the systems that serve the gearbox, mounts and blocks. Then we proceed to the repair. 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 out parts.
3. Remove the inhibitor block and sump. We clean out the dirt inside. It looks like metal magnetic shavings.
4. We remove the wiring of the ring from the plug and push them inside the plug.
5. Remove the valve body, loosen the brake band bolts. We wash the valve body.
6. We check the clutches, gears and planetary gears for wear. We will replace it 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 term. We use the manual so as not to swap parts.
8. We take out the valves and springs. We wash the valves. Their sticking can be the reason for incorrect operation of the automatic transmission. Replace the accumulator springs if they are broken.
9. Putting everything back into place. It is important not to confuse anything!
10. We replace rings and friction bolts.
11. We check the gear shift assembly and the large piston and put the oil pump in place.

Assembly takes place upside-down.

There are some points that it is advisable to take into account when repairing. Often a transmission problem is related to the filter. It will not be possible 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 valve body completely. The same applies to the accumulator spring from first to second gear. A special stopper does not allow you to remove it without disassembling the valve body. All valve body gaskets are very similar, do not mix them up. Assembling the valve body, we tighten it with a torque wrench. It is important not to overtighten here.

If all the breakdowns are eliminated, we install the automatic transmission. The moment is responsible, haste is inappropriate here. During these works, the following recommendations should be adhered to:

• When installing the automatic transmission in its place, the diaphragm 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 transmission oil is poured into the gas turbine engine and put on the input shaft. You need to achieve a secure connection and a complete fit. Then you need to dock the engine with the box along the guide centering pins. The crankcases must abut completely.
• Tightening the bolts in the box is the next step. After that, the absence of gaps along the entire plane is checked. After connecting all the highways, the correctness of the connections is checked.
• At the final stage, oil is poured and the operation of the automatic transmission is checked at low engine speeds.

Beginning the installation of the box, be sure to check for the presence of centering pins on the crankcase flange - there should be two of them. If at least one is missing, the automatic transmission cannot be attached.

Automatic transmission repair and diagnostics do it yourself - not an easy, but feasible task. Choosing a car with an automatic transmission, novice car enthusiasts believe that repairing it at home is impossible. This is not true. But before deciding to carry out such important work at home, you need to weigh all your possibilities. Then you will not be in for unpleasant surprises during the renovation.