ATSG ZF-5HP-24 Service Manual

TECHNICIANS DIAGNOSTIC GUIDE

BMW, AUDI, PORSCHE

ZF-5HP-24

DIAGNOSTIC INFORMATION

FOUND IN:

BMW 5 Series E39, 7 Series E38, 8 Series E31 .......... 95-Current

Jaguar XK8 (X100), ..................................................... 96-Current

Jaguar XJ8 (X300), ...................................................... 97-Current

Audi A8 (All Wheel Drive 5HP-24A) ......................... 96-Current

N

S

E

E

R

O

B

N

S

E

8

.

8

E

R

O

B

8

.

8

N

S

E

E

R

O

B

8

.

8

N

S

E

E

R

O

B

8

.

8

INDEX

1

887017

3

8

0

41

80

5

NY

A

F1

M

ER

2077-1

G

IN

E

H

BZ

D

MA

GM

E

IE

RB

T

-GE

F

N

S

E

E

R

O

B

8

.

8

N

S

E

E

R

O

B

8

.

8

N

S

E

E

R

O

B

8

.

8

N

S

E

E

R

O

B

8

.

8

Jaguar Unit Shown

This transmission is manufactured in Germany by ZF and carries the BMW designation A5S 440Z.

The A5S 440Z is an electronically controlled, five speed automatic transmission with a lock-up clutch
type torque converter. Three planetary gear sets (Wilson Gearing), three rotating multiple disc
clutches, three multiple disc brake clutches, and one sprag clutch (Freewheel) are used to provide the
five forward speeds and reverse.

Key to designation:

Automatic

5 Speed Transmission

Overdrive Top Gear

Maximum Torque Capacity (Nm)

110

A 5 S 440 Z

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Manufacturer

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Figure 97

TECHNICIANS DIAGNOSTIC GUIDE

BMW, AUDI, PORSCHE

Refer to Figure 98 for Clutch and Band Application Chart.

Refer to Figure 99 for Manual Shift Lever Operation, and Failsafe Operation.

Refer to Figures 100, and 101 for Solenoid identification and both MV Solenoid Operation and EDS
Solenoid Operation and Tests.

Refer to Figure 102 for wiring harness identification, internal wiring schematic, and transmission
case connector pin identification and functions.

Refer to Figure 103 for Shift Solenoid Application chart. Notice that EDS 1 Solenoid is used for line
pressure control, and MV-4 is used for converter clutch.

Refer to Figure 104 for EDS Solenoid "Principles of Operation", as some are normally open and
some are normally closed.

Refer to Figure 105 for internal components resistance chart, with the pins identified for both the
transmission case connector and the Electronic Control Unit.

INDEX

Refer to Figure 106 for Upper Valve Body exploded view and identification of valves.

Refer to Figure 107 for Lower Front Valve Body exploded view and identification of valves.

Refer to Figure 108 for Lower Rear Valve Body exploded view and identification of valves.

Refer to Figures 109, 110, and 111 for valve body retainer locations in the various valve bodies.

Refer to Figure 112 for Channel Plate screen location on the upper side.

Refer to Figure 113 for the locations of the orifices, checkballs, screens, and the check valves and
springs that are located in the channel plate.

Refer to Figure 114 for external pressure tap locations in the main case.

Refer to Figure 115 for Pump Volume Control Valve location, in the pump cover.

Refer to Figure 116 for explanation of Pump Volume Control Valve operation.

Refer to Figure 119 for all valve body spring specifications, as observed in a used valve body.

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111

112

ZF-5HP-24 INTERNAL COMPONENT APPLICATION CHART

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 98

Copyright © 2003 ATSG

"B" CLUTCH

"A"

GEAR

PARK

REV

NEUT

D-1ST ON

D-2ND

D-3RD

D-4TH

D-5TH

M-1

CLUT

ON

ON

ON

ON

"C" CLUTCH

"A" CLUTCH

"D" BRAKE

APPLICATION CHART

"B"

CLUT

ON

ON

"C"

CLUT

"D"

BRAK

ON

ON

"E"

BRAK

ON

"F"

BRAK

ON

ONON

ON

ON

"E" BRAKE

"F" BRAKE

LOW

SPRAG

HOLD

HOLD

GEAR

RATIO

4.10:1

3.57:1

2.20:1

1.51:1

1.00:1

0.80:1

3.57:1

LOW SPRAG

TECHNICIANS DIAGNOSTIC GUIDE

BMW, AUDI, PORSCHE

INDEX

TECHNICIANS DIAGNOSTIC GUIDE

BMW, AUDI, PORSCHE

SELECTOR LEVER POSITIONS
= Park, and should only be selected when the vehicle is at a standstill. First apply the hand brake, and

P

then select the Park position with the manual lever. Refer to Figure 99.

= Reverse, and should only be selected when the vehicle is at a standstill with engine at idle.

R

Refer to Figure 99.

= Neutral, and may be selected when the vehicle is at a standstill, but first applying the handbrake. May

N

also be selected while vehicle is moving, to restart the engine or to counteract a skidding concern.
Refer to Figure 99.

= Drive, is the standard position for normal driving in the XE program (AGS) and provides automatic

D

upshifts from 1st to 5th and automatic downshifts from 5th to 1st gear. The adaptive transmission
control (AGS) system contains various driving programs such as Stop and Go, Trailer Towing,
Mountain Driving, City Driving and Highway Driving (constant speed). These programs are selected
by the Electronic Control Unit (ECU), which automatically modifies the transmissions shift character­ istics according to rolling resistance, engine load, accelerator pedal movement and vehicle speed.
The standard "Drive" position is position "1", as shown in Figure 99.

"S" - Program

The "S" Program is a performance oriented program, where the gear changing characteristics of the
transmission are moved up to higher engine speeds. To select the "S" Program, the selector lever is shifted
to the left-hand gate (position "2" in Figure 99), without moving shift lever towards plus or minus. The "S"
Program provides automatic upshifts from 1st to 4th and automatic downshifts from 4th to 1st gear. 5th
gear is inhibited when the "S" Program is selected.

INDEX

"M" - Program

The "M" Program is a manual shift program which is activated by simply pushing the selector lever
towards the minus sign for sequential downshifts and towards the plus sign for sequential upshifts, while
the shift lever is in the left-hand gate (position "2" in Figure 99). It is possible to drive off in 1st gear, 2nd
gear or 3rd gear, however, 4th gear can be manually selected only at a speed of approximately 40 km per
hour and 5th gear at approximately 60 km per hour.

4th Gear, Select this position if the transmission tends to hunt between 5th-4th/4th-5th gears under certain
driving conditions.

3rd Gear, Select this position if the transmission tends to hunt between 3rd and 5th gears under certain
driving conditions. Also recommended for lengthy descents in mountainous areas.

2nd Gear, Select this position when driving over mountain passes with lengthy ascents and descents.

1st Gear, This position can be selected for engine braking effect, depending on vehicle speed.

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113

TECHNICIANS DIAGNOSTIC GUIDE

BMW, AUDI, PORSCHE

Typical BMW Shift Lever

P

R
N

12 D

INDEX

Copyright © 2003 ATSG

Figure 99

FAILSAFE OPERATION:

When a system fault is detected which would impair normal reliable operation, the transmission control module
interrupts the power supply to Pin 12 at the transmission case connector. The transmission control module also
alerts the driver of any faults by signaling the vehicle's "check control" system. To enable the vehicle to be
driven to a repair shop, the following manual gear selections are permitted:

Selector Lever Position
Actual Gear Obtained

P R N D 4 3 2

P R N 5 5 5 5

114

AUTOMATIC TRANSMISSION SERVICE GROUP

TECHNICIANS DIAGNOSTIC GUIDE

BMW, AUDI, PORSCHE

MV1, 2 AND 3

INDEX

SOLENOID "OFF"

XX

PRESSURE FROM

SV1,2 OR 3

EXHAUSTED

MV

1,2,3

From

Dr.Red. V-1

BLOCKED

From

SV-1,2 OR 3

SUMMARY:

When MV 1, 2 or 3 is "OFF" Solenoid reducing pressure, from Dr.Red. V-1, is blocked by the

solenoid and oil pressure from SV 1, 2 or 3 is exhausted at the rear of the solenoid.

When MV 1, 2 or 3 is "ON" Solenoid reducing pressure, From Dr.Red. V-1, is open through the

solenoid and is applied to SV 1, 2 or 3. The exhaust at the rear of the solenoid is closed.

EXHAUST
BLOCKED

SOLENOID "ON"

MV

1,2,3

From

Dr.Red. V-1

OPEN

TO

SV-1,2 OR 3

EDS 2, 3, 4, 5,

SOLENOID "OFF"

EDS

EXHAUST

XX

FROM Dr.Red.V-2

AND CLUTCH REGULATING

When EDS 2 thru 5 solenoids are "OFF" they exhaust orificed solenoid reducing pressure,

from Dr. Red. V-2, and the oil pressure from the clutch regulating valves releasing them.

When EDS 2 thru 5 solenoids are "ON" the exhaust is blocked by the solenoid and solenoid

reducing pressure, from Dr. Red. V-2, is applied to operate clutch regulating valves.

2-5

VALVES

EXHAUST
BLOCKED

SUMMARY:

Figure 100

SOLENOID "ON"

EDS

2-5

"Black"

"O" Ring

FROM Dr.Red.V-2

TO CLUTCH REGULATING

VALVES

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AUTOMATIC TRANSMISSION SERVICE GROUP

115

EXHAUST
BLOCKED

INDEX

TECHNICIANS DIAGNOSTIC GUIDE

BMW, AUDI, PORSCHE

EDS 1 (Line Pressure)

SOLENOID "OFF" SOLENOID "ON"

EDS 1EDS 1

EXHAUST

OPEN

XX

"Green"

"O" Ring

From Dr.Red. V-2

to MOD-V

SUMMARY:

When EDS 1 solenoid is "OFF," solenoid reducing pressure, from Dr. Red. V-2, is high to

MOD-V valve which creates high line pressure.

When EDS 1 solenoid is "ON," solenoid reducing pressure, from Dr. Red. V-2, is low to

Figure 101

From Dr.Red. V-2

and MOD-V

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116

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TECHNICIANS DIAGNOSTIC GUIDE

BMW, AUDI, PORSCHE

ZF-5HP-24 INTERNAL WIRE SCHEMATIC

View Looking Into Case

Turbine

Speed Sensor

MV 3 Solenoid

MV 2 Solenoid

MV 1 Solenoid

EDS 5 Solenoid

Connector Setting In The vehicle

EDS 2 Solenoid

EDS 3 Solenoid

EDS 4 Solenoid

15

1614

10 11 12 13

89

76

35

4

1

2

EDS 1 Solenoid

INDEX

16

12

15

11

14

13

10

Output

Speed Sensor

PURPLE

PURPLE

4

9

8

3

7

2

5

6

1

WHITE

GREEN

GRAY

BLUE

ORANGE

YELLOW

RED

GRAY

WHITE

ORANGE

YELLOW

YELLOW

BROWN

BROWN

PURPLE PURPLE PURPLE PURPLE

MV 3

TOT Sensor

(Resistor in Wire)

MV 1MV 2 EDS 1EDS 4EDS 3EDS 2EDS 5

Output
Sensor

NOTE: Some internal wire colors may vary.

PURPLE

PURPLE PURPLE

Turbine

Sensor

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Figure 102

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117