ZF Trouble Shooting Guide

JLR 13 38 10_2E

General Information The ZF Trouble Shooting Guide (TSG) is a knowledge-based system. It is designed to aid diagnosis of transmission-related faults which have previously been encountered with ZF products in Land Rover applications.

The guide is intended to cover 6 speed transmission vehicles, which include the following;

L319 Discovery L320 Range Rover Sport L322 Range Rover

This file is intended as a supplement to the workshop manuals; specifically to accompany the Description & Operation, and Diagnosis and Testing sections.

It covers problems with both the transmissions themselves, and vehicle-related problems.

It has been compiled using information learned from investigations during assembly, field cases and at dealerships. The guide is a supplement based on 'real time' field issues and as such it will be updated on a regular basis.

If you have comments or questions relating to this publication please use the 'contact us' button on GTR.

November

2007

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Carry Out Double Flush Action

Carry Out Hard Reset (Battery) – Clear Engine Adaptions

Clear Transmission Adaption Values (with Dealer Special Tool)

Does Not Upshift From First Gear

Grinding Noise At Constant Speed

Harsh Roll Out Shifts 2-1 (MY05 and MY06)

Harsh Roll Out Shifts 2-1

Holds 1st Gear After Cold Start (MY07)

Intermittent Slip – Transmission Switches To N - Bump - Jerky - Selector Lever

No Upshift After Acceleration

P0500 Vehicle Speed Sensor – Intermittant Loss Of Drive

P0601 Internal Mechatronic Unit Fault (07MY)

P0659 Unable To Get Transmission Out Of Park

P0736, P073X Intermittent Loss Of Drive

P0784, P078X, P0829 Sporadic Fault (MY05 and MY06)

P081C Transmission Fault On Message Centre – Selector Cable

THIS COMPLAINT IS CAUSED BY A MISMATCH BETWEEN THE GEAR SELECTOR LEVERPOSITION „P“ AND THE AUTO BOX SWITCH POSITION „P“. POTENTIALLY INCORRECTLY SET

GEAR SELECTOR CABLE, POTENTIAL WIRING FAULT ON SELCTOR CONFIRMATION CIRCUIT,POTENTIAL FAULTY SELECTOR MECHANISM OR AUTO BOX „MECHATRONIC UNIT“

FAULT P081C LOGGED, „TRANSMISSION FAULT“ ON THE MESSAGE CENTER

CHECK GEAR SELECTOR CABLE SETTING

DOES THE MESSAGE „TRANSMISSION FAULT“ APPEAR ONTHE INSTRUMENT PACK?

YESNO

FURTHER INVESTIGATION REQUIRED

DOES THE MESSAGE „TRANSMISSION FAULT“ APPEAR ONTHE INSTRUMENT PACK?

YESNO

1. SELECT „P“ WITH GEAR LEVER2. FOOT BRAKE OFF3. MOVE LEVER FORWARD ANDBACKWARD IN THE „P“ POSITION GATESLACK WITHOUT DISENGAGING „P“

1. SELECT „P“ WITH GEAR LEVER2. FOOT BRAKE ON3. PULL THE SELECTOR TO POSITION„R“

MEASURE THE VOLTAGE AT C2658-2 (CENTRECONSOLE) WITH A DVM AND THE IGNITION ON

AS DESCRIBED IN THE FOLLOWING TABLE

CHECK GEAR SELECTOR CABLESETTING

FURTHER INVESTIGATION REQUIRED

SELECTORPOSITION P P R

MOVINGTO N N

MOVINGTO D D

FOOT BRAKE OFF ON OFF OFF OFF OFF OFFVOLTAGE AT

C2658-2 OV 12V 0V 0V 12V 0V 0V

INSTRUMENTDISPLAY P P R N N N D

RE-SET THE GEAR SELECTOR CABLE AND RESOLVE ANYWIRING ISSUES

CHECK THE SETTING OF GEAR SELECTOR CABLE ASINSTRUCTED IN GTR „TRANSMISSION 44-30-04"

P2743 Rear Differential – Not Transmission Temperature Sensor

Poor Shift Quality (General)

Software Calibration Identification

Step In Delay - Bump (MY05 and MY06)

Surge – On Acceleration Under Light Load

Transmission Fault Message On Instrument Pack

Transmission Overheat - Message

Vibration At 70mph – 95kph

ZF Trouble Shooting Guide

General Information

(All Applications)

ZF Trouble Shooting Guide

General Information

(This Application Only)

ZF Trouble Shooting Guide Land Rover 6 SpeedGeneral Information (All Applications)carry out double flush actionpoor shift quality (general)software calibration identification

Discovery (L319)2.7 V6D GS 19.04General Information (This Application Only)carry out hard reset (battery)_clear engine adaptionsclear transmission adaption values (with dealer special tool)transmission fault message on instrument pack

does not upshift from first geargrinding noise at constant speedharsh roll out shifts 2-1no upshift after accelerationP0500 vehicle speed sensor_intermittant loss of driveP0601_internal mechatronic unit fault (07MY)P0659_unable to get transmission out of parkP0736_P073x intermittent loss of driveP081C_transmission fault on message centre_selector cableP2743_rear differential - not transmission temperature sensorsurge_on acceleration under light loadintermittent slip_transmission switches to N / bump / jerky / selector lever

4.0 V6 GS 19.04General Information (This Application Only)carry out hard reset (battery)_clear engine adaptionsclear transmission adaption values (with dealer special tool)transmission fault message on instrument pack

does not upshift from first geargrinding noise at constant speedharsh roll out shifts 2-1no upshift after accelerationP0500 vehicle speed sensor_intermittant loss of driveP0601_internal mechatronic unit fault (07MY)P0659_unable to get transmission out of parkP0736_P073x intermittent loss of driveP081C_transmission fault on message centre_selector cableP2743_rear differential - not transmission temperature sensorintermittent slip_transmission switches to N / bump / jerky / selector lever

4.4 V8 GS 19.04General Information (This Application Only)carry out hard reset (battery)_clear engine adaptionsclear transmission adaption values (with dealer special tool)transmission fault message on instrument pack

does not upshift from first geargrinding noise at constant speedharsh roll out shifts 2-1holds 1st gear after cold start (MY07)no upshift after accelerationP0500 vehicle speed sensor_intermittant loss of driveP0601_internal mechatronic unit fault (07MY)P0659_unable to get transmission out of parkP0736_P073x intermittent loss of driveP081C_transmission fault on message centre_selector cableP2743_rear differential - not transmission temperature sensorstep in delay_bump_(MY05 and MY06)intermittent slip_transmission switches to N / bump / jerky / selector levervibration at 70 mph_95 kph

Range Rover Sport (L320)2.7 V6D GS 19.04General Information (This Application Only)carry out hard reset (battery)_clear engine adaptionsclear transmission adaption values (with dealer special tool)transmission fault message on instrument pack

does not upshift from first geargrinding noise at constant speedharsh roll out shifts 2-1no upshift after accelerationP0500 vehicle speed sensor_intermittant loss of driveP0601_internal mechatronic unit fault (07MY)P0659_unable to get transmission out of parkP0736_P073x intermittent loss of driveP081C_transmission fault on message centre_selector cableP2743_rear differential - not transmission temperature sensorSurge – On Acceleration Under Light Loadintermittent slip_transmission switches to N / bump / jerky / selector lever

3.6 V8D GS 19.04General Information (This Application Only)carry out hard reset (battery)_clear engine adaptionsclear transmission adaption values (with dealer special tool)transmission fault message on instrument pack

does not upshift from first geargrinding noise at constant speedharsh roll out shifts 2-1no upshift after accelerationP0500 vehicle speed sensor_intermittant loss of driveP0601_internal mechatronic unit fault (07MY)P0659_unable to get transmission out of parkP0736_P073x intermittent loss of driveP081C_transmission fault on message centre_selector cableP2743_rear differential - not transmission temperature sensorintermittent slip_transmission switches to N / bump / jerky / selector lever

4.2 SC GS 19.04General Information (This Application Only)LR_GTR_carry out hard reset (battery)_clear engine adaptionsclear transmission adaption values (with dealer special tool)transmission fault message on instrument pack

does not upshift from first geargrinding noise at constant speedharsh roll out shifts 2-1no upshift after accelerationP0500 vehicle speed sensor_intermittant loss of driveP0601_internal mechatronic unit fault (07MY)P0659_unable to get transmission out of parkP0736_P073x intermittent loss of drivep0784_p078x_p0829_sporadic fault (MY05 and MY06)P081C_transmission fault on message centre_selector cableP2743_rear differential - not transmission temperature sensorintermittent slip_transmission switches to N / bump / jerky / selector lever

4.4 V8 GS 19.04General Information (This Application Only)carry out hard reset (battery)_clear engine adaptionsclear transmission adaption values (with dealer special tool)transmission fault message on instrument pack

does not upshift from first geargrinding noise at constant speedharsh roll out shifts 2-1no upshift after accelerationP0500 vehicle speed sensor_intermittant loss of driveP0601_internal mechatronic unit fault (07MY)P0659_unable to get transmission out of parkP0736_P073x intermittent loss of driveP081C_transmission fault on message centre_selector cableP2743_rear differential - not transmission temperature sensorstep in delay_bump_(MY05 and MY06)intermittent slip_transmission switches to N / bump / jerky / selector levervibration at 70 mph_95 kph

RANGE ROVER (L322)3.6 V8D GS 19.04General Information (This Application Only)carry out hard reset (battery)_clear engine adaptionsclear transmission adaption values (with dealer special tool)transmission fault message on instrument pack

grinding noise at constant speedharsh roll out shifts 2-1no upshift after accelerationP0500 vehicle speed sensor_intermittant loss of driveP0601_internal mechatronic unit fault (07MY)P0736_P073x intermittent loss of driveintermittent slip_transmission switches to N / bump / jerky / selector lever

4.2 SC GS 19.04General Information (This Application Only)carry out hard reset (battery)_clear engine adaptionsclear transmission adaption values (with dealer special tool)transmission fault message on instrument pack

grinding noise at constant speedharsh roll out shifts 2-1no upshift after accelerationP0500 vehicle speed sensor_intermittant loss of driveP0601_internal mechatronic unit fault (07MY)P0736_P073x intermittent loss of drivep0784_p078x_p0829_sporadic fault (MY05 and MY06)transmission overheat_messageintermittent slip_transmission switches to N / bump / jerky / selector lever

4.4 V8 GS 19.04General Information (This Application Only)carry out hard reset (battery)_clear engine adaptionsclear transmission adaption values (with dealer special tool)transmission fault message on instrument pack

grinding noise at constant speedharsh roll out shifts 2-1 (MY05 and MY06)harsh roll out shifts 2-1no upshift after accelerationP0500 vehicle speed sensor_intermittant loss of driveP0601_internal mechatronic unit fault (07MY)P0736_P073x intermittent loss of drivestep in delay_bump_(MY05 and MY06)transmission overheat_messageintermittent slip_transmission switches to N / bump / jerky / selector lever