ZF4HP22 do it yourself overhaul

Finally got around to stripping the rest of the box after cleaning some space in the shed and buying some plastic tubs to keep all the parts safe from mud wasps.

All the other clutch pack look good. i have a master kit with steels/frictions (no pistons).

Considering it seems just my B pack was dead, is there any investigation I should be doing into this, that might pick something up, not repaired by the rebuild kit ? Ie a problem with its piston ? or something else ? before i start putting it all back together with kit ...

Quote:

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Originally Posted by haydent

Hi Guys! Just starting a repair/rebuild of my d2 td5 4hp22, no reverse and some forward slippage.

I have a rebuild manual. Ive gotten out clutch pack A and B easily, B has several frictions worn down to the metal !!

I cant get out C though. Ive remove the snapring, but the manual says to use mounting tool 5x 56 000 094 im guessing to grip the shaft and pull C and D together.

I tried pulling on the gear teeth avoiding the smooth sealing surfaces but no luck.

Do I need this tool ?

Could It be stuck because I skipped the first few steps in the manual, having not removed the valve body or tranny rear end (extension and park spawl).

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Quote:

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Originally Posted by stevo

just some info on the transmission and finding info on it for a starter the hardest part has been finding a clear manual,

found a good manual online from this mob www.autoepc.com.ua now this did not cover the electronic valve bank as it is a separate manual, so found this on a BMW site twrite.org/shogunnew/files/Jason/4HP22EH.../4HP22EH-Valvebody.html or google ZF 4HP22E valve body repair.

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this link is broken, i found the original
ZF 4HP22E Valve Body Rebuild

also found these

http://at-manuals.com/wp-content/upl...2%20scheme.pdf

4HP22-4HP22.pdf - Google Drive

4HP22-4HP24A.pdf - Google Drive

https://www.bmwe34.net/E34main/Trouble/Data/ZF%20Tech%20Guide.pdf ZF-4HP-22/24 MODEL "E-9", "4 SOLENOID"

Just pulled down my valve block and found a couple of things of mention. Firstly one of the valve caps the screws were all loose enough to undo with fingers, no tool, so obviously forgotten to be torqued by ZF when they rebuilt it !!

Also one of the valve was stuck, such that i had to use pliers to pull it out, when all the rest slid out with a knock if anything. By cleaning it and spinning it in place with drill attached to tip it has loosened up.

Ive also marked 3 bit of difference with the ZF tech guide manual i linked, 2 screens not mentioned and a ball,spring & vent behind the "REAR SIDE COVER" of "Lower Front Valve Body Casting"

Castings cleaned
Attachment 177816

All internals kept organised and separate by snap lock bags
Attachment 177811

Extra part not listed:

Attachment 177818

Where it came from: (plastic insert) behind the "REAR SIDE COVER" of "Lower Front Valve Body Casting"

Attachment 177817

Location of a screen (S1):

Attachment 177812

Location of a screen (S2):
Attachment 177814

My cover plate that was loose: (and possibly loosing pressure)

Attachment 177813

The valve that was stuck: (PRESSURE REDUCING VALVE "2")

Attachment 177815
Ive posted some findings on this valve here:
4hp22eh rebuild disco 2 td5

This is the ZF tech guide pdf linked and shown above but just the 4hp22 excerpt
https://atsgmembers.com/memarea/bulletins/bulletins/03/03-32.pdf

This is the plate that was loose, not torque'd up , and the parts it seals, interestingly one of the parts is "36 "B" CLUTCH REGULATOR VALVE" , the clutch pack I found burnt out. :)

Attachment 177821

I see this guide (ZF 4HP22E Valve Body Rebuild) shows the un listed check valve though he doesnt seem to mention or notice it, maybe because it stayed in the block...

Attachment 177822

I found it mentioned in this decent video guide ZF4HP22 Land Rover Automatic Transmission Filter Service & Valve Body Recondition Fluid Change - YouTube

I think i made a boo-boo taking my valve body apart, and pulling out the modulation valve adjusting plug (as it shows its removable below) but not realising until now that its an adjuster and was likely set for this valve body at the factory....

Not sure what options i have apart from taking it to a repair shop once rebuilt to get it set (assuming that is even possible) ?

Attachment 177838

I know its been cleaned... but is there a shiny spot inside where it sat?

Quote:

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Originally Posted by Pedro_The_Swift

I know its been cleaned... but is there a shiny spot inside where it sat?

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I did just have that thought too, i cleaned it yesterday, maybe ill go have a look, another option would be to just measure off another valve body and hope for best. I have also asked on the bimmer forum, as they seem pretty prolific on the 4hp22 topic. Ill go check in the shed.

as i didnt scrub the inside bore, there is a faint black line where the oring would have sat, measuring the depth of this against the plug, it would sit about right enough to test. i also have a second transmission with valve body, and i took the pan off that for a look, and you can get the the adjuster with VB still attached, so i can measure that one, and if need adjust when on the car.

but ill look into its function more.

Quote:

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Originally Posted by haydent

4HP22-4HP24A.pdf - Google Drive

https://www.bmwe34.net/E34main/Trouble/Data/ZF%20Tech%20Guide.pdf ZF-4HP-22/24 MODEL "E-9", "4 SOLENOID"

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should be

4HP22-4HP24A.pdf - Google Drive

https://www.bmwe34.net/E34main/Trouble/Data/ZF%20Tech%20Guide.pdf

Also here is the start of my posts on bmw forum:
Transmission case sleeves, ZF 4HP22/24 EH valve body questions - Page 14