Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

1 von 20

08.01.2008 16:47

This was originally posted at

http://www.bimmer.info/forum/showthread.php?t=780

. I've posted

them here so Winfred can get some of his web space back.

#1 Teflon seals replacement

#2 Converter seal replacement

===

#1 I took a few pics of core tranny parts to give a strong idea on how to repair this common
defect, this tranny is in m20 bimmers, m30 bimmers after about 84, volvo 740 without overdrive
non turbo, Peugeot and jag don't know which. this is how to repair the main problem with the
tranny, when the car will only move in reverse and in extreme cases not move at all.

this is the cause of the problem, these steel seals leak and send pressure to the 1st gear clutch
pack and burn it up.

These are the bolts to take out to remove the bell housing and pump as a unit, unless you need
to replace the converter bushing you do not need to take the pump apart or off of the bell
housing (i will describe the procedure for that and why at the end of the post) .

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

2 von 20

08.01.2008 16:47

Here's the bell housing/pump assembly off:

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

3 von 20

08.01.2008 16:47

here's the front of the rest of the tranny and case

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

4 von 20

08.01.2008 16:47

grab the a-clutch basket and yank it out of the bell housing/pump assembly

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

5 von 20

08.01.2008 16:47

here's the back side of the a-clutch basket, there's a steel bearing surface missing in this pic
that you will have, between all rotating parts there's a bearing race (looks like a washer) flat
roller bearing and another race

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

6 von 20

08.01.2008 16:47

you can leave the shaft in a-clutch basket or pop it out so the basket will sit flat on a bench, of
you can just leave the whole thing in the bell housing/pump assembly while you do the clutches.
there's a spring clip that holds the basket together that you remove with a screwdriver

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

7 von 20

08.01.2008 16:47

inspect the basket for cracks, i've found a few blown up from people who didn't take no for a
answer, also look at the grove the spring clip was in, those ears can break

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

8 von 20

08.01.2008 16:47

here's the pack of disks and plates, there's a black wavy disk on the top and bottom of the pack
that you reuse

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

9 von 20

08.01.2008 16:47

this pressure plate is under all of the clutches, you can see some of the burnt clutch on it, clean
that off and clean under it

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

10 von 20

08.01.2008 16:47

here's a new disc and steel, soak the discs in fresh ATF a few minutes before installing

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

11 von 20

08.01.2008 16:47

with the teflon seals there should be a drill bit and a sandpaper flap drill thingie, i've never
drilled the hole in the 25-30 trannys i've done, it's up to you, it's to relieve any future leak
pressure, i've been doing these for over 5 years and have yet to have one of my repairs fail. the
sandpaper drill thingie is used to knock down any burrs left from the steel seals here

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

12 von 20

08.01.2008 16:47

seals

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

13 von 20

08.01.2008 16:47

and where they go

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

14 von 20

08.01.2008 16:47

after cleaning the bore from honing it, stick the input shaft back in the a-clutch basket (if you
removed it) lube the seals and bore with ATF, make sure the three pieces of the bearing are in
place and slide the a-clutch assembly back into the bell housing/pump assembly, it will seat with
a thunk and spin freely
put this bearing race on the of the input shaft/a-clutch assembly, then the bearing and last the
other race, it will be the smallest of all the races

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

15 von 20

08.01.2008 16:47

then insert this gear into the a-clutch assembly

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

16 von 20

08.01.2008 16:47

till it's bottomed out in the clutch pack

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

17 von 20

08.01.2008 16:47

if you didn't break the paper gasket that seals the pump to the tranny you can reuse it, a new
one is a bitch to fit onto the pump without ripping it, all that's left is to reinstall the bell
housing/pump assembly into the tranny, get comfy this can be fun sometimes, what the object
is is to slip the fingers on the back of the a-clutch into the slots of the 2nd gear clutches in the
tranny case, twisting the input shaft helps you gotta feal your way in, there will be no gap
between the pump and tranny case when seated, tighten the 17mm bolts in a cross pattern,
and you are done.
take your time, look carefully at how everything came apart, if in doubt dump ATF all over it if it's
inside of the tranny, the Bentley manual has a exploded view of the tranny if i remember right,
when installing the converter make sure it's all the way in, if the tranny and motor won't go
together find out why, don't pull it together with the bolts, you can destroy the pump and
converter.

i get most of my parts from these guys, but there's almost always a tranny parts place or two in
town

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

18 von 20

08.01.2008 16:47

#2 new problem
the converter seal is leaking you just replaced it and it's leaking again, the bushing behind the
seal has walked forward and is blocking the drain, time for a new bushing

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

19 von 20

08.01.2008 16:47

it's hiding here

Two ZF 4HP22 repairs (per Winfred)

file:///E:/Eigene%20Dateien/BMW/Getriebe/ZF/4%20HP22%20trann...

20 von 20

08.01.2008 16:47

take the bell housing pump assembly off as seen in the a-clutch repair and take the rest of the
bolts out of it and separate the pump from the bell housing and take the bolts out of the back of
the pump, then you can strip the pump all the way down and press the new bushing in,
reassembly is covered in the a-clutch repair.

ERROR: syntaxerror
OFFENDING COMMAND: --nostringval--

STACK:

/Title
()
/Subject
(D:20080108164731+01’00’)
/ModDate
()
/Keywords
(PDFCreator Version 0.9.5)
/Creator
(D:20080108164731+01’00’)
/CreationDate
(Wolfgang)
/Author
-mark-