ZF 4HP 16 Automatic Transaxle Introduction
The ZF 4 HP 16 is a four-speed automatic transaxle designed for cars with front-wheel drive and a transversely mounted engine.
The transaxle has a hydrodynamic torque converter with a controlled slip lock-up clutch.
A planetary gear train establishes the mechanical gear ratios. The integral constant ratio can be adapted to the engine's power output and the vehicle's weight. The electronic-hydraulic control makes controlled power shifts and various shift programs possible. In selector lever position "P", the output is locked mechanically.
The special feature of this transaxle is that it operates without freewheels. Shifting between individual gears takes place by means of overlapping clutch engagement and release.
The advantage of overlap shifting is as follows
- The transaxle can be of more compact design and is lighter on account of the absence of freewheels and the lower number of shift elements.
- Lower drag losses, i.e. higher efficiency.
- Lower peak torques acting on the components and driveline.
However, overlap shifting necessitates high-performance hardware and software, and precision engine signals.
Scheme 4
ZF 4HP 16 Automatic Transaxle Description
The ZF 4HP 16 automatic transaxle consists primarily of the following components.
Diagnostic Trouble Code (DTC) Identification
| DTC | Description | Indication | Default Action |
|---|---|---|---|
| P0562 | System Voltage Low | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P0563 | System Voltage High | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P0601 | Internal Control Module Memory Checksum Error | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P0603 | Internal Control Module Keep Alive Memory (KAM) Error | MIL ON | The TCM will record operating conditions at he time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P0604 | Internal Control Module Random Access Memory (RAM) Error | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/ Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P0606 | Transaxle Control Module Processor Fault | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P0703 | Brake Switch Circuit Malfunction | No Change | TCM assume that the brake light always active. Open lock up clutch. |
| P0705 | Transaxle Range Sensor Circuit Malfunction (PRNDL Input) | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control, position P, R and N also possible. |
| P0710 | Transaxle Fluid Temperature out of Range | Hold Lamp Flashing | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. TCM assume the transaxle fluid temperature is 60 °C (140 °F). No influence at vehicle running. |
| P0711 | Transaxle Fluid Temperature Sensor Circuit Range/Performance | Hold Lamp Flashing | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. TCM assume the transaxle fluid temperature is 60 °C (140 °F). No influence at vehicle running. |
| P0712 | Transaxle Fluid Temperature Sensor Circuit Shorted to Ground | Hold Lamp Flashing | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. TCM assume the transaxle fluid temperature is 60 °C (140 °F). No influence on driveability. |
| P0713 | Transaxle Fluid Temperature Sensor Circuit Shorted to Power and Open | Hold Lamp Flashing | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. TCM assume the transaxle fluid temperature is 60 °C (140 °F). No influence on driveability. |
| P0715 | Input Speed Sensor Circuit Malfunction | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control, position P, R and N also possible. Open lock up clutch. |
| P0716 | Input Speed Sensor Circuit Range/Performance | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control, position P, R and N also possible. Open lock up clutch. |
| P0717 | Input Speed Sensor Circuit No Signal | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control, position P, R and N also possible. Open lock up clutch. |
| P0720 | Output Speed Sensor Circuit Malfunction | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear. Open lock up clutch. |
| P0721 | Output Speed Sensor Circuit Range/Performance | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear. Open lock up clutch. |
| P0722 | Output Speed Sensor Circuit No Signal | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Vehicle running remains actual gear. Open lock up clutch. |
| P0725 | Engine Speed Input Circuit Malfunction | No Change | Adopt Emergency/Substitute mode and constant 4th gear. Open lock up clutch. |
| P0726 | Engine Speed Input Circuit Range/Performance | Hold Lamp Flashing | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear. Open lock up clutch. |
| P0727 | Engine Speed Input Circuit No Signal | Hold Lamp Flashing | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear. Open lock up clutch. |
| P0731 | Gear 1 Incorrect Ratio | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear. High line pressure. |
| P0732 | Gear 2 Incorrect Ratio | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 3rd gear. High line pressure. |
| P0733 | Gear 3 Incorrect Ratio | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear. High line pressure. |
| P0734 | Gear 4 Incorrect Ratio | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. High line pressure. |
| P0741 | TCC (Torque Converter Clutch) Circuit Stuck OFF | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Open lock up clutch. |
| P0742 | TCC (Torque Converter Clutch) Circuit Stuck ON | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Open lock up clutch. |
| P0781 | 1 - 2 Shift Malfunction | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 1st gear. Open lock up clutch. |
| P0782 | 2 - 3 Shift Malfunction | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 2nd gear. Open lock up clutch. |
| P0783 | 3 - 4 Shift Malfunction | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 3rd gear. Open lock up clutch. |
| P1604 | Data Check of Internal & Extended Ram Failed | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1606 | Failure of External Watchdog | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1779 | Engine Torque Input Signal (CAN) Malfunction | No Change | Adjustable value, calculated over the substitute map throttle position. (engine speed, engine torque) |
| P1791 | Throttle Position Input Signal (CAN) Malfunction | No Change | Adjustable value, calculated over the substitute map throttle position. (engine speed, engine torque) |
| P1839 | EDS3 Output Shorted To Ground | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1840 | EDS3 Output Shorted To Power | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1841 | EDS3 Output Open | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1850 | Solenoid 1 Output Shorted To Ground | Hold Lamp Flashing | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. |
| P1851 | Solenoid 1 Output Shorted To Power | Hold Lamp Flashing | Hold lamp will blink. The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. |
| P1852 | Solenoid 1 Output Open | Hold Lamp Flashing | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. |
| P1853 | Solenoid 2 Output Shorted To Ground | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. |
| P1854 | Solenoid 2 Output Shorted To Power | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. |
| P1855 | Solenoid 2 Output Open | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. |
| P1861 | EDS4 Output Shorted To Ground | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1862 | EDS4 Output Shorted To Power | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1863 | EDS4 Output Open | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1864 | EDS5 Output Shorted To Ground | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1865 | EDS5 Output Shorted To Power | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1866 | EDS5 Output Open | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1867 | EDS6 Output Shorted To Ground | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1868 | EDS6 Output Shorted To Power | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1869 | EDS6 Output Open | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1871 | EDS Valve Power Supply Circuit Shorted To Power | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. Power supply cut OFF to the EDS valve. |
| P1874 | Solenoid Valve Power Supply Circuit Shorted To Power | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. |
| P1881 | 2 - 1 Shift Malfunction | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 3rd gear. Open lock up clutch. |
| P1883 | 3 - 2 Shift Malfunction | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 3rd gear. Open lock up clutch. |
| P1884 | 4 - 3 Shift Malfunction | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear. Open lock up clutch. |
| P1885 | 3 - 1 Shift Malfunction | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 3rd gear. Open lock up clutch. |
| U0073 | CAN Bus OFF Failure | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. |
| U0100 | CAN Receive ECM Message Failure | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. |
| U0101 | CAN Transmit Message Failure | MIL ON | The TCM will record operating conditions at the time the diagnostic fails. This information will be stored in the Failure Records buffer. Adopt Emergency/Substitute mode and constant 4th gear by hydraulic control. After ignition OFF/ON: 3rd gear by hydraulic control. Possible P, R and N also possible. |
DIAGNOSTIC TROUBLE CODE REFERENCE CHART
Scheme 5
Solenoid Valve, Clutch and Brake Operation
Refer to Solenoid Valve, Clutch and Brake Operation .
Refer to Solenoid Valve, Clutch and Brake Operation .
Refer to Solenoid Valve, Clutch and Brake Operation .
Refer to Solenoid Valve, Clutch and Brake Operation .
Refer to Solenoid Valve, Clutch and Brake Operation .
Refer to Solenoid Valve, Clutch and Brake Operation .
Refer to Solenoid Valve, Clutch and Brake Operation .
Refer to Solenoid Valve, Clutch and Brake Operation .
Refer to Solenoid Valve, Clutch and Brake Operation .
Refer to Solenoid Valve, Clutch and Brake Operation .
Refer to Solenoid Valve, Clutch and Brake Operation .
Refer to Solenoid Valve, Clutch and Brake Operation .
Refer to Solenoid Valve, Clutch and Brake Operation .
| Range | Park/Neutral | Reverse | D | 3 | 2 | 1 | ||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Gear | N | R | 1st | 2nd | 3rd | 4th | 1st | 2nd | 3rd | 1st | 2nd | 1st |
| Solenoid Valve 1 | ON | ON/OFF | ON/OFF | ON/OFF | ON/OFF | ON/OFF | ON/OFF | ON/OFF | ON/OFF | ON/OFF | ON/OFF | ON/OFF |
| Solenoid Valve 2 | ON | ON | ON | OFF | OFF | OFF | ON | OFF | OFF | ON | OFF | ON |
| Line Pressure Control Solenoid Valve 3 (EDS 3) | OFF | OFF | OFF | ON | ON/OFF | ON/OFF | OFF | ON | ON/OFF | OFF | ON | OFF |
| Line Pressure Control Solenoid Valve 4 (EDS 4) | ON | OFF | ON | ON | ON | OFF | ON | ON | ON | ON | ON | ON |
| Line Pressure Control Solenoid Valve 5 (EDS 5) | OFF | OFF | ON | ON | OFF | OFF | ON | ON | OFF | ON | ON | ON |
| Line Pressure Control Solenoid Valve 6 (EDS 6) | ON | OFF | ON | ON | ON | OFF | ON | ON | ON | ON | ON | ON |
| Clutch B | A | A | A | A | A | A | A | A | ||||
| Brake C | H | |||||||||||
| Brake D | H | |||||||||||
| Clutch E | A | A | A | A | A | A | ||||||
| Brake F | H | H | H | H | H | H | H | |||||
| Lock-up Clutch | A | |||||||||||
| A = Applied | ||||||||||||
| H = Holding | ||||||||||||
| ON = The solenoid is energized. | ||||||||||||
| OFF = The solenoid is de-energized. | ||||||||||||
| ** = Manual Second-Third gear is only available above approximately 100 km/h (62 mph). | ||||||||||||
| *** = Manual First-Second gear is only available above approximately 60 km/h (37 mph). | ||||||||||||
| NOTE: Manual First-Third gear is also possible at high vehicle speed as a safety feature. | ||||||||||||
| NOTE |
|---|
| Manual First-Third gear is also possible at high vehicle speed as a safety feature. |
SOLENOID VALVE, CLUTCH AND BRAKE OPERATION CHART