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Transmission Technology
Transmission
External ZF training
P a g e |1
Table of content
Transmission
External ZF training
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Transmission
External ZF training
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Transmission
External ZF training
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Torque converter
Transmission
External ZF training
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1. Sun gear
2. Planetary gear
Transmission
External ZF training
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Transmission
External ZF training
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Ravigneaux - Gear
2 sun gears
1 Ring gear
A Ravigneaux gear set is a Simple gear set on which every planet gear is
replaced by an extra set of planets.
Out of the 2 sets of planets only the outer set meshes the ring gear.
On almost all applications the ring gear is the output component.
Mathematically it adds up to 3 forward inputs of different ratio and 1
reverse motion.
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Transmission
External ZF training
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Lepelletier -gear
Front (primary) planetary gear
Downstream (secondary)
Ravigneaux-gear set
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Transmission
External ZF training
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Transmission
External ZF training
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Freewheel
Gearbox housing
Inner wheel
(planetary carrier)
Rolls
Freewheel
Locking direction
Roll freewheel
Transmission
External ZF training
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6 HP Design Sizes
2002 6HP32
Max. Torque 750Nm
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External ZF training
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Technical description
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Transmission
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Transmission
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Transmission
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Transmission
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Systematic exposure
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External ZF training
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Transmission
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Transmission
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Transmission
External ZF training
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Transmission
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Transmission
External ZF training
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Transmission
External ZF training
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Transmission
External ZF training
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EDS 6
EDS 4
MV 1
EDS 3
EDS 5
EDS 1
EDS 2
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Transmission
External ZF training
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EDS-Types
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External ZF training
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Position
P-EDS
Responsible
Character
Parking
Neutral
R-gear
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
1
EDS 1
Clutch A
0
0
0
1
1
1
1
0
0
2
EDS 2
Clutch B
1
1
0
1
1
0
1
0
1
3
EDS 3
Brake C
0
0
0
0
1
0
0
0
1
4
5
6
EDS 5
EDS 4
MV 1
System p. Br. D & Cl. E Solenoid v.
-x0
0
-x0
0
-x0
0
-x0
0
-x1
0
-x1
0
-x0
1
-x0
1
-x0
1
7
EDS 6
Cc
0
0
0
-x-x-x-x-x-x-
Brake closed
Clutch closed
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Transmission
External ZF training
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Adaption - Introduction
Adaption values are corrective values (so-called offsets) which are either added
to or subtracted from the default values (applied values) permanently stored in
the gearbox control unit.
Transmission
External ZF training
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Adaption - Introduction
Legend:
n_mot = engine speed
n_t
= turbine speed
m_mot = engine torque
P_zu = pressure engaging clutch
P_ab = pressure disengaging clutch
t
= time
A, B, C = adaption phases
Transmission
External ZF training
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Adaption - Introduction
Transmission
External ZF training
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Adaption
Transmission
External ZF training
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Adaption limits
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Transmission
External ZF training
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Charge pressure
Transmission
External ZF training
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Transmission
External ZF training
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Part A
Accelerate the vehicle from standing with very low throttle (15 25%) up to 4th
gear and about 80 km/h. Freewheel the car down to about 40 km/h without using
the brakes. Afterwards stop the car completely and stay in drive position for
about 10 s. Repeat cycle 6 times.
Part B
th
Accelerate the vehicle up to about 70 km/h und select manually 5 gear. Use
your diagnostic tool (VW/Audi block 9) to drive with 100 Nm for about 3 4 km.
th
Accelerate the vehicle up to about 85 km/h und select manually 6 gear. Use
your diagnostic tool (VW/Audi block 9) to drive with 100 Nm for about 3 4 km.
Part C
Accelerate 5 times with low throttle up to about 100 km/h and freewheel the car
down to about 40 km/h without using the brakes.
Transmission
External ZF training
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1 Series 116i
118i
120i
120d
125i
130i
135i
3 Series 320i
320d
323i
325i
335i
5 Series
6 Series
7 Series
X3 E83
X5 E53
X5 E70
X6 E71
Software A
(GS19.02)
--------------------------09/01 10/03
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Software N
Software P
(GS19.04)
(GS19.11)
--09/04 09/07
--09/04 03/07
--09/04 03/07
----GM 6 Transmission
--09/04 03/07
------01/05 04/07
------01/05 09/07
--01/05 09/07
----07/03 03/05
03/05 03/07
09/03 09/05
09/05 09/07
10/03 03/05
08/05 now
--09/05 09/07
09/03 09/06
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Software T
(GS19.11)
------03/07 now
--SOP - now
--03/07 now
----09/07 now
03/07 now
09/07 now
09/07 now
--10/06 now
01/08 now
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External ZF training
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Transmission
External ZF training
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Software N
Transmission
External ZF training
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Software P
Transmission
External ZF training
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Software T
Transmission
External ZF training
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Transmission
External ZF training
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External connection
socket
Locking mechanism
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External ZF training
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Transmission
External ZF training
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Different Mechatronics
E-Shift
M-Shift
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Two different adapters for system pressure
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Transmission
External ZF training
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Transmission
External ZF training
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Transmission
External ZF training
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Transmission
External ZF training
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Guiding pins
Transmission
External ZF training
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Transmission
External ZF training
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Rubber
contamination
Please clean it!!!
Transmission
External ZF training
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Transmission
External ZF training
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Opened Mechatronic
Intermediate plate
Transmission
External ZF training
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Transmission
External ZF training
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Transmission
External ZF training
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Transmission
External ZF training
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When mounting the mechatronic take care of the sensor for drive position. The
picture shows a not correctly installed mechanism which would cause an error
in the control unit. In this condition the car will not start.
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External ZF training
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Transmission
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New generation
Old generation
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Transmission
External ZF training
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Oil Change
Lifeguard Fluid 5 (yellow-red)
Used for:
5HP18 (depending on
manufacturer)
5HP19
5HP24
5HP30 (depending on
manufacturer)
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External ZF training
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Used for
6HP19A
6HP19X (Audi Q7)
6HP28AF
8HP all
Fill in screw
BMW, Jaguar, Ford, Maserati,
Hyundai, Land Rover, Aston Martin,
Rolls Royce, Bentley
For:
6 HP 19/19X/26/26X/32/21/28/28X
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External ZF training
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Transmission
External ZF training
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Bolted driveshaft
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External ZF training
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6 HP Automatic Transmissions
Overhaul
Overhaul - introduction
Since the introduction of the 5HP series, ZF has aimed for a simplistic and
streamlined design. Although the 6HP and the new 8HP series are extremely
sophisticated and a technologically advanced, they are also smaller and lighter
than the predecessors.
The 5HP introduced a simple 3 part design:
- Input, intermediate brake and output.
The 6Hp is no exception. Half of the reaction components are comprised and
housed within the input section. Two brakes and a Ravigneaux planetary make
up the other two reaction components.
Transmission
External ZF training
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Oil pump
Torque converter stator support
Single planetary s Sun gear support
Oil passages for TCC apply and release
Transmission
External ZF training
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Input shaft
E Clutch
Passage for TCC
Passage for E clutch
Single planetary ring gear
Turbine splines
Transmission
External ZF training
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Intermediate shaft
Transmission
External ZF training
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Clutch A
A clutch houses:
Single planetary gear set carrier and planets
Transmission
External ZF training
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Transmission
External ZF training
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Disc carrier
Transmission
External ZF training
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Clutch B
Clutch B contains:
Engages with Brake C friction plates
Splines into Sun Gear 2
Transmission
External ZF training
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Assembled
Transmission
External ZF training
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Assembled
Transmission
External ZF training
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Assembled
Transmission
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Intermediate Brakes
Transmission
External ZF training
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Output components
Transmission
External ZF training
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Assembled
Transmission
External ZF training
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Assembled
Transmission
External ZF training
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A Clutch disassemble
Transmission
External ZF training
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Disassemble
Transmission
External ZF training
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Disassemble
Transmission
External ZF training
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E clutch failure
Transmission
External ZF training
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Transmission
External ZF training
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8 HP Automatic Transmissions
Transmission
External ZF training
P a g e | 89
Torque converter
Transmission
External ZF training
P a g e | 90
ATF-Oil pump
Technical data:
- system pressure 5.5 to 17.5 bar
- Oil delivery rate 7 to 22 l/min
- Pump speed 550 to 8600 rpm
Transmission
External ZF training
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ATF-Cooling
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Transmission
External ZF training
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Transmission
External ZF training
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Transmission
External ZF training
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Clutch C, D and E
Transmission
External ZF training
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Brake A
Brake B
Clutch E
Clutch C
Clutch D
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External ZF training
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
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Transmission
External ZF training
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Transmission
External ZF training
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Transmission
External ZF training
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Ratio
Mechatronic E-Shift
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External ZF training
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1
EDS 1
Brake A
1
1
1
1
1
0
0
0
0
1
1
2
EDS 4
Clutch D
0
0
1
0
0
0
1
1
1
1
1
3
EDS 2
Brake B
1
1
1
1
1
1
1
1
0
0
0
4
EDS 5
Clutch E
0
0
0
0
1
1
1
0
1
0
1
5
EDS 3
Clutch C
1
1
1
0
1
0
1
0
0
0
1
6
EDS 6
Cc
0
0
0
-x-x-x-x-x-x-x-x-
7
EDS 7
System p.
-x-x-x-x-x-x-x-x-x-x-x-
8
MV 1
Solenoid v.
0
1
1
1
1
1
1
1
1
1
1
Brake closed
Clutch closed
EDS-Types
Transmission
External ZF training
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Transmission
External ZF training
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Transmission
External ZF training
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Transmission
External ZF training
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E
C
B1
D
B2
Transmission
External ZF training
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Transmission
External ZF training
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Parts needed
Connection socket
Oil reflux cartridge
Sealing ring oil approach cartridge
Sealing cartridge
Transmission
External ZF training
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Sealing cartridge
Transmission
External ZF training
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Transmission
External ZF training
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Gearbox temperature 35
Start engine
Take screw B out
Screw worn
No fluid coming fill up until ATF runs down
Transmission
External ZF training
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HIS
Mechatronic
Transmission
External ZF training
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The HIS hydraulic impulse oil storage is a spring piston accumulator which fills
with oil as the car is being driven, thus tensioning a spring.
This reserve has a capacity of around 100 centiliters which is fed back into the
hydraulic system lightning-quick by the spring when the engine is started to
supply oil to the shift elements in the transmission required for moving away.
This means that the car is ready to move away just 350 milliseconds after the
engine has been started. Without the bridging created by the hydraulic impulse
oil storage system this would take around 800 milliseconds which would
therefore mean a perceptible loss of driving dynamics for
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External ZF training
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Solenoid
not
energized
Transmission
External ZF training
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Transmission
External ZF training
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Transmission
External ZF training
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Transmission
External ZF training
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Fiat group
Transmission
External ZF training
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Volkswagen group
Transmission
External ZF training
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External ZF training
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Troubleshooting
While freewheeling and changing from second into first gear (for example when
approaching traffic lights) a kick happens.
Transmission
External ZF training
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Transmission
External ZF training
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Audi towing
The vehicle can be towed at a maximum vehicle speed of 50 km/h over a
maximum distance of 50 km using the drive wheels. The transmission must be
mechanically unlocked.
That means:
The parking lock must be released by means of a Bowden cable. The automatic
transmission can be seriously damaged if the above-mentioned boundary values
are not maintained.
BMW towing
The precondition for towing a vehicle with an unraised drive axle is that the
parking lock be opened by means of a Bowden cable emergency release. If this
is the case, towing with a maximum speed of 50 km/h over a maximum distance
of 50 km is possible.
The automatic transmission can be seriously damaged if the above-mentioned
boundary values are not maintained.
Vehicles on which the parking lock must be opened with an unlocking screw
cannot be towed. In case of breakdown, the vehicle must be raised with a crane
and delivered to the workshop for repair on a flatbed tow truck.
Four-wheel-driven vehicles
Vehicles with four-wheel drive must not be towed with one axle lifted.
Transmission
External ZF training
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Pushing
The engine cannot be started by pushing the vehicle. That is to say, if the
engine is stopped, there is no transmission of power from the hydrodynamic
coupling of the engine and transmission and the pressure-less shift elements.
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Transmission
External ZF training
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Transmission
External ZF training
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