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ZF Transmissions with Mechatronics

Hans-Peter Bach, Director Serivce (hans-peter.bach@zf.com) ZF Getriebe GmbH, Business Unit Automatic Transmissions

ZF Getriebe Gm mbH, 2006

Topics

Business unit Automatic transmission The 6HP gearbox-family Hints for the Hi t f th repair shop i h General hints gearbox change change of a mechatronic change of a oil pan and filter changing or adding oil

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ZF confidential

P-Division ZF Getriebe GmbH Car Driveline Technology Locations

Saarbrcken (AT) Germany G

1973 Saarbrcken-Vlklingen, Plant 4 (DVZ / Logistic) G L i ti ) Germany

Brandenburg (MT/DT) Germany

1991

Kressbronn (R&D) Germany


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1969 Friedrichshafen (R&D) Germany


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1988

Shanghai** (AT) China

2006

** Joint Venture with SAIC.

ZF confidential

Topics

Business unit Automatic transmission The 6HP gearbox-family Hints for the Hi t f th repair shop i h General hints gearbox change change of a mechatronic change of a oil pan and filter changing or adding oil

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Product History of the ZF 6-speed Automatic Transmission

1999

IAA in Frankfurt: First Prototype of a fully-automatic six-speed transmission fully automatic six speed World premiere: Start of volume production for the first automatic 6-speed transmission worldwide, the 6HP26; compared to automatic 5-speed transmissions: weight savings of 13% and 5 speed 30% less components Presentation of hybrid system (basis: 6HP26) at the IAA in Frankfurt Introduction of 2nd generation of automatic 6-speed transmissions with another 3-6% in fuel savings and even faster shift times (partly below the drivers limit of perception)

2001

2005

2006

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Cutaway drawing 6HP26


torque converter pump simple planetary gearset gearbox housing clutch brake double pl. gearset ki lock parking l k wheel output flange

parking lock pawl

oilpan

oil il strainer

pressure regulator g

oil drain plug

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6HP Product Family Improvements of the 2nd Generation

engin torque [N ne Nm]

2 nd generation

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Second Generation of 6-speed Automatic Transmissions

The individual, automatic driving pleasure


Second generation of the 6HP S d i f h 6HP: Efficiency and increased performance for the leading 6-speed automatic transmission.
Considerable contribution to CO2 and/or fuel economy Increased power-to-weight ratio Optimized shift dynamics and improved subjective driving impression Shift times below the drivers limit of perception

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Reduction of CO2 and Fuel Consumption


3-Gang 3-speed 4- Gang 4-speed
5-speed 5-Gang

6-Gang 6-speed

6-speed new generation 6-Gang T

- 6% - 2%

consumption Verbrauch

- 5%
Diesel

Benzin

- 3%

- 6%

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Further development of shift dynamics


(2nd Generation of 6 speed transmissions) 6-speed

Shift dynamic is one of the most significant characteristics of the vehicle performance The direct shift gearbox has set new standards in shifting dynamics

engine torque

switching command

reaction time

slippage time

shifting time

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Improvement shift dynamics

Vergleich Reaktionszeiten comparison reaction time


1200 1000
R Reaktionszeit in ms re eaction timi in ms me

6HP19 6HP21 DKG

800 600 400 200 0


S S S S S S S S S S S S S S S SR SR SR SR SR S S ZR 53 42 ZH ZH ZH ZH ZH ZR ZR ZR ZR ZR 21 32 43 54 65 12 23 34 45 56 21 32 43 54 65 64 ZR ZR S

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Topics

Business unit Automatic transmission The 6HP gearbox-family Hints for the Hi t f th repair shop i h General hints gearbox change change of a mechatronic change of a oil pan and filter changing or adding oil

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Towing a vehicle

Towage of a vehicle only on its driven wheels at no more than 70 km/h road speed and a maximum distance of 500 kilometres

Selector lever in N (neutral)

If the above mentioned speed and distance limits are not respected, respected the automatic transmission will be severely damaged!

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Topics

Business unit Automatic transmission The 6HP gearbox-family Hints for the Hi t f th repair shop i h General hints gearbox change change of a mechatronic change of a oil pan and filter changing or adding oil

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Transmission ready to be installed into the vehicle

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Transmission to be installed into the vehicle

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Handling and Storage of an Automatic Transmission

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Handling and Assembling of Automatic Transmission and Engine


Remove converter strap right before assembling the gearbox to the engine

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Installation of the Torque Converter


Before assembling the transmission to the engine, it is important that the g g p torque converter is installed correctly (see manual of the special gearbox)

distance from bell housing to torque converter

t f th measurement of the distance with a deep gauge

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Pump Gear

Driving i D i i pins of th pump can f the break

Effect:
- no power fl flow ( R,D ) RD

driving pin

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Pump Gear

This damage is caused by the wrong installation of the transmission.

Driving pin is broken

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Leakage between Engine and Transmission


Effect: leakage be ee e g e a d ea age between engine and transmission

Reasons: centre bush i missing i t b h is i i in crank shaft centre pin between engine and transmission is missing

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Centre Bush

centre bush

After Aft assembling of th t bli f the transmission t th i i to the engine, dont forget to build in the centre bush! A missing centre bush cause damages of the torque converter and the oil pump!

position of the centre bush

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Centre Pins
It is very important that the centre p y p pins are assembled to the engine case. Missing centre pins will cause damages in the transmission transmission.
center pin

center pin at an engine case

The two A describe the position of the centre pins

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Functional test
After repair you should make a driving test Before the driving test you have to delete all adoption values using a tester

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The whole product family

6HP28A61

6HP28AF integrated 4x4

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6 speed part numbers


Main Parts List 1071 010 1071 020 1071 040
4

Trans Type 6HP19 6HP19X 6HP19A 6HP26 6HP26X 6HP26A61 6HP32 6HP32A 6HP32X 6HP21 6HP21X 6HP28 6HP28X 6HP28A61 6HP28AF

Part Number Programmed 1071 012 1071 022 1071 042 1068 012 1068 022 1068 032 1070 012 1070 022 1070 032 1071 032 1071 052 1068 042 1068 052 1068 092 1084 032

Description Rear wheel drive External 4x4 Internal 4x4 Rear wheel drive External 4x4 Internal 4x4 Rear wheel drive Internal 4x4 External 4x4 Rear wheel drive External 4x4 Rear wheel drive External 4x4 Internal 4x4 Internal 4x4
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1068 010 1068 020 1068 030 1070 010 1070 020 1070 030 1071 030 1071 050 1068 040 1068 050 1068 090 1084 030
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6 speed transmission identification

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Example transmission application BMW 745

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Topics

Business unit Automatic transmissions The 6HP gearbox-family Hints for the Hi t f th repairshop i h General hints gearbox change change of a mechatronic change of a oilpan and filter changing or adding oil

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Mechatronic on a special carrier

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6HP..-Mechatronics
left side: E version / right side: M Version E-version M-Version

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Mechatronik identification

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Mechatronic replacement

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Mechatronic replacement

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Mechatronic replacement

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Mechatronic replacement

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Mechatronic replacement

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Mechatronic replacement

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Mechatronic replacement

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Mechatronic replacement

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Topics

Business unit Automatic transmissions The 6HP gearbox-family Hints for the Hi t f th repairshop i h General hints gearbox change change of a mechatronic change of a oilpan and filter changing or adding oil

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Polyamide oilpan with integrated filter

6 HP 26

1,6 kg

weight reduction app. 40%

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ZF-part number (Polyamide oilpan)

ZF part number 1068 298 033

name Oilpan

gearbox 6HP26 / 28 / 28X / 32 BMW

Customer

0501 215 789

Oilpan

6HP26 / 26X

Aston Martin, Ford USA, Ford Australia Jaguar, Range Rover

1071 298 009

Oilpan

6HP19 / 19X / 21 / 21X

BMW

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Plate Oilpan and Oilfilter

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ZF Part Number: Plate oilpan and Oilfilter 1


ZF-part number
1068 203 042 1068 203 044 1068 203 046 1068 203 048 0501 213 359 1068 303 017 1068 203 043 0501 212 974 1068 303 012 1068 203 047 0501 212 974 0501 322 155

Name
Oilpan Oil Oilpan Oilpan Oilpan Filter Sealing Oilpan Filter Sealing Oilpan Filter Sealing

Gearbox
6 HP 26 X 6 HP 26 X 6 HP 26 6 HP 26

Customer
Ford F d USA BMW Maserati Ford Australia

6 HP 26 A

Audi, Bentley

6 HP 26 A

Audi, Bentley

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ZF Part Number: Plate oilpan and Oilfilter 2


ZF-part number
1070 203 010 0501 213 359 1068 301 01 017 1070 203 008 0501 212 974 1070 303 009 1071 203 038 0501 212 401 1071 303 006 1071 203 039 0501 212 401 0501 322 078 1071 203 040 0501 214 315 0501 322 077
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Name
Oilpan Filter Sealing S Oilpan Filter Sealing Oilpan Filter Sealing Oilpan Filter Sealing Oilpan Filter Sealing

Gearbox
6 HP 32

Customer
BMW

6 HP 32 A

VW

6 HP 19 A

Audi, VW

6 HP 19 A

Audi, VW

6 HP 19 X

Audi

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Topics

Business unit Automatic transmissions The 6HP gearbox-family Hints for the Hi t f th repairshop i h General hints gearbox change change of a mechatronic change of a oilpan and filter changing or adding oil

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General Hints on Transmission Oil


Do not mix different oils unless this is expressly p p y prescribed.

Clean the oil cooler in the opposite direction from normal flow before fitting the transmission unit, i.e. starting from the transmission feed (VK) and not from the return (ZK). Cleaning unit
is commercially available.

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6HPxx transmission fluid level procedures

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6HPxx transmission fluid level procedures

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ATF Oil-Check 6HP19 A


Before drive test the ATF have to be filled up with the Lifeguardfluid 6 g ZF

Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature ( (CGT) 30 50 C ) Oil volume: 9 l transmission oil No. S671.090.255 (yellow) 1,05 l differential oil No. S671.090.163 and 0,528 l Torsen differential oil , No. S671.090.163 and 0,022 l Sturaco oil No. S671.090.167

only these 4 MPL!! VW 1071 040 010 1071 040 022


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Audi 1071 040 014 1071 040 044


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ATF Oil-Check 6HP26A61 Audi


Before drive test the ATF have to be filled up with the Lifeguardfluid 6 ZF Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature (CGT) 30 50 C Oil volume: 10 l transmission oil No. S671.090.255 (yellow) d 1 2 diff ( ll ) and 1,2 l differential oil No. i l il N S671.090.163 Version 1: Version 2: 0,96 l Torsen differential oil No. S671.090.163 and 0,04 l Sturaco oil No. S671.090.167 d 0 04 St il N S671 090 167 1,152 l Torsen differential oil No. S671.090.163 and 0,048 l Sturaco oil No. S671.090.167

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ATF Oil-Check 6HP26A61 Bentley


Before drive test the ATF have to be filled up with the ZF Lifeguardfluid 6 Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature (CGT) 30 50 C Oil volume: 11,2 l transmission oil No. S671.090.255 (yellow) 1,20 l differential oil No. S671.090.163 Version 1: Version 2: 1,20 l Torsen differential oil No. S671.0920.163 and 0,1 l Sturaco oil No. S671.090.167 1,680 l Torsen differential oil No. S671.090.163 and 0,12 l Sturaco oil No. S671.090.163 (only 1 MPL)

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ATF Oil-Check 6HP32A VW


Before drive test the ATF have to be filled up with the Lifeguardfluid 6 ZF

Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature (CGT) 30 50 C Oil volume: 10 l transmission oil No S671 090 255 (yellow) No.S671.090.255 0,816 l differential oil No. S671.090.163 and 1,104 l Torsen differential oil No. S671.090.163 and 0,046 l Sturaco oil No. S671.090.167

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Colour of Lifeguardfluid 6 (yellow)

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ATF Oil-Check 6HP26A61 (W12)


Before drive test the ATF have to be filled up with the Lifeguardfluid 6 Plus ZF

Fill up instruction: The idle speed should be neng = 750 rpm p p g p and the transmission oil pan temperature (CGT) 30 50 C ( ) Oil volume: 10 l transmission oil No. S671.090.281 (blue) and 1,2 l differential oil No. S671.090.163 Version 1: 1,104 l Torsen differential oil No. S671.090.163 and 0,096 l Sturaco oil No. S671.090.167 Version 2: 1,008 l Torsen differential oil No. S671.090.163 and 0,092 l Sturaco oil No. S671.090.167

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Colour of Lifeguardfluid 6 Plus (blue)

PLUS

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ATF Oil-Check 6HP19A / X VW, Audi


Before drive test the ATF have to be filled up with the Lifeguardfluid 8 ZF

Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature (CGT) 30 50 C Oil volume: 9 l transmission oil No. S671.090.311 (green) and 1,05 l differential oil No. S671.090.163 and 0,528 l Torsen differential oil No. S671.090.163 No S671 090 163 and 0,022 l Sturaco oil No. S671.090.167

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ATF Oil-Check 6HP28AF Audi


Before drive test the ATF have to be filled up with the Lifeguardfluid 8 ZF

Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature (CGT) 30 50 C Oil volume: 10l transmission oil No. S671.090.311 (green) and 1,0 l differential oil No. S671.090.163 and 0,96 l Torsen differential oil No. S671.090.163 No S671 090 163 and 0,04 l Sturaco oil No. S671.090.167

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Colour of Lifeguardfluid 8 (green)

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Checking and top up the Oil

Lifeguardfluid 6 (yellow) BMW, Jaguar, Ford, Maserati, Hyundai, L.Rover, Aston Martin, RR, BMW, Bentley , y

for the gearbox types 6HP19/26/32/21/28/19X/26X/28X

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Lifetime Oil for 6-speed / 8-speed Transmissions

Artikel-Nr. / Part-No.

AA00 601 304

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Lifetime Oil for 6-speed Transmissions

Artikel-Nr. / Part-No.

S671.090.255

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Lifetime Oil for 6-speed Transmissions

plus
Artikel-Nr. / Part-No.

S671.090.281

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Thank you very much for your attention!

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