ZF4HP22 do it yourself overhaul

OMG, I found some more differences between the ATSG guide version floating around on the net !! Even though they both state the same year, and i thought one was just an excerpt taken from the larger one.


Luckily i had a second transmission in the shed to pull apart to double check. I initially was tipped off by what appeared to be markings to indicate where the retainer had been taken from by ZF when they rebuilt it, and after putting in more retainers they had markings too, though clearer. Also if I put the retainer (71) in the spot shown in the incorrect (for us) guide the valve it retains could never reach its end cap/retainer (75/74)

I guess this is why it pays to take photos of your own process rather than purely rely on a guide to get something back together...


There may be other differences, this is the first I notice, but it seems the smaller excerpt 03-32.pdf is correct

Incorrect: "ZF Tech Guide.pdf" - do not use
https://www.bmwe34.net/E34main/Troub...ch%20Guide.pdf

Attachment 177844

Correct: "03-32.pdf"
https://atsgmembers.com/memarea/bull...s/03/03-32.pdf

Attachment 177845
This is a freshly taken of MV5 Solenoid Body (off another tranny to check)

Attachment 177846

And here is the one im rebuilding, you can see very faint markings that match the retainer pattern which got made me very suspicious
Attachment 177847

Also another (minor) difference between both manuals and the valve body I actually have, is that this spring does not exist: (checked both valve bodies)
33 "C" CLUTCH DAMPER PISTON INNER SPRING

Attachment 177848

Having finished putting my VB back together, here is summary of difference I found between my 'LR' VB and the ATSG guide 03-32.pdf

- Unlisted screen/filter in "channel plate" (in bmw as well)
- Unlisted screen/filter in "mv1 mv2 body" (not in bmw)
- Unlisted 3 hole vented ball valve behind "REAR SIDE COVER" of "LOWER FRONT VALVE BODY CASTING" (in bmw as well)
- Missing spring 33 and 10 in LOWER "FRONT" VALVE BODY, (not missing in bmw)
- Different check ball sizes:

Im working on a transmission rebuilt by ZF australia with low km since, so these ball sizes may not be 'factory', previous differences ive checked against a seperate body i have, but not the ball sizes yet, anyway here they are.

CHANNEL PLATE
- listed as .218", measured at 0.173"
- listed as .250" measured at .232"
LOWER "FRONT" VALVE BODY
- listed as .175" measured at .174"

Also a note that my Modulator valve adjuster is set with 2.8mm protruding from the body, ~2.5 turns out from full in.

Also I did not have ability to measure hole size of accumulator cups.

Things are progressing, ive got the body all back together, the only issue was that my D brake frictions had the 58 teeth variant, and the kit I ordered came with the 48 ones.

Maybe this is because it has been rebuilt by ZF before, not sure if 4hp22 can have both or the 58T is from 4hp24 and zf put it in mine as a 'free' upgrade...

Anyway, I just used the old frictions for that cluthh as they looked fine and you could still read the writing on them so no wear.

What Im trying to work out now though, is where to get the shim thrust washers for between the pump and a drum, to set the axle clearance.

Need about 1.7mm thick...

One of the few mentions I could find online of variants was from JPAT pdf, but theres a big jump between 0.059" / 1.49mm (what i currently have) and the next thickest, 0.081" / 2mm, so maybe i have to use 2 thinner ones ??

Code:

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69210..............Race, ZF3HP22/ZF4HP22 Stator To Front Drum (Front) .042”.......................................................1 ......................0730104149
69210A ...........Race, ZF3HP22/ZF4HP22 Stator To Front Drum (Front) .040”.......................................................1 ......................0301302047
69210B ...........Race, ZF3HP22/ZF4HP22 Stator To Front Drum (Front) .059”.......................................................1 ......................0730104150
69210C ...........Race, ZF3HP22/ZF4HP22 Stator To Front Drum (Front) .056”.......................................................1 ......................0730104151
69210D ...........Race, ZF3HP22/ZF4HP22 Stator To Front Drum (Front) .081”.......................................................1 ......................0730104152
69210E ...........Race, ZF3HP22/ZF4HP22 Stator To Front Drum (Front) .084”.......................................................1 ......................0730104153
69210F ...........Race, ZF3HP22/ZF4HP22 Stator To Front Drum (Front) .090”.......................................................1 ......................0730104154
69210G ...........Race, ZF3HP22/ZF4HP22 Stator To Front Drum (Front) .098”.......................................................1 ......................0730104155
69210H ...........Race, ZF3HP22/ZF4HP22 Stator To Front Drum (Front) .107”.......................................................1 ......................0730104156
69210J ............Race, ZF3HP22/ZF4HP22 Stator To Front Drum (Front) .115” .......................................................1 ......................0730104157

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Also my output oil seal was the wrong size, but luckily i noticed this before destroying the current one which is not leaking.

Just realised that even if I got 2 of the smallest, it would still be 0.08" so i cant get less than that... oh well, im only 0.15mm over the 0.2-0.4mm recommendation, so i dont think ill worry about it, hopefully the gasket will compress a little, ive torqued it up in the shed and will leave it a while to see.

In other matters, I cant find anywhere mention of the torque for the bolt in the end of the extension output shaft.

Also I noticed ashcroft transmissions sell these cheap thermometer stickers that record the maximum temp reached, so simple and cheap to keep an eye on your tranny temp. Stick it on the sump or cooler pipe.

I found an australian company that sells something similar and order a pack of 10 for all my cars and some friends.

https://au.rs-online.com/web/p/tempe...labels/7799772

Attachment 178254
So I got a quote for a washer from germany, 175 Euro !!

Attachment 178255