ZF Transmissions with Mechatronics
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1 ZF Transmissions with Mechatronics Hans-Peter Bach, Director Serivce ZF Getriebe GmbH, Business Unit Automatic Transmissions mbh, 2006 ZF Getriebe Gm
2 Topics Business unit Automatic transmission The 6HP gearbox-family Hints for the repair shop General hints gearbox change change of a mechatronic change of a oil pan and filter changing or adding oil MK/MKTA/sk 2 APRA_Birmingham, November 2009 ZF confidential
3 P-Division ZF Getriebe GmbH Car Driveline Technology Locations Saarbrücken (AT) 1973 Saarbrücken-Völklingen, Plant 4 Brandenburg (MT/DT) 1991 Germany (DVZ / Logistic) Germany Germany Kressbronn (R&D) 1969 Germany Friedrichshafen (R&D) 1988 Germany Shanghai** (AT) 2006 China ** Joint Venture with SAIC. MK/MKTA/sk 3 APRA_Birmingham, November 2009 ZF confidential
4 Topics Business unit Automatic transmission The 6HP gearbox-family Hints for the repair shop General hints gearbox change change of a mechatronic change of a oil pan and filter changing or adding oil MK/MKTA/sk 4 APRA_Birmingham, November 2009 ZF confidential
5 Product History of the ZF 6-speed Automatic Transmission 1999 IAA in Frankfurt: First Prototype of a fully-automatic six-speed speed transmission 2001 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 30% less components 2005 Presentation of hybrid system (basis: 6HP26) at the IAA in Frankfurt 2006 Introduction of 2 nd generation of automatic 6-speed transmissions with another 3-6% in fuel savings and even faster shift times (partly below the driver s limit of perception) MK/MKTA/sk 5 APRA_Birmingham, November 2009 ZF confidential
6 Cutaway drawing 6HP26 torque converter pump simple planetary gearset clutch gearbox housing brake double pl. gearset parking lock wheel output flange parking lock pawl oilpan oil strainer pressure regulator oil drain plug MK/MKTA/sk 6 APRA_Birmingham, November 2009 ZF confidential
7 6HP Product Family Improvements of the 2nd Generation Nm] ne torque [N engin 2 nd generation MK/MKTA/sk 7 APRA_Birmingham, November 2009 ZF confidential
8 Second Generation of 6-speed Automatic Transmissions The individual, automatic driving pleasure Second generation of the 6HP: Efficiency and increased performance for the leading 6-speed automatic transmission. Considerable contribution to CO 2 and/or fuel economy Increased power-to-weight ratio Optimized shift dynamics and improved subjective driving impression Shift times below the driver s limit of perception MK/MKTA/sk 8 APRA_Birmingham, November 2009 ZF confidential
9 Reduction of CO 2 and Fuel Consumption 6-speed new 3-Gang 3-speed 4-speed Gang 5-speed 5-Gang 6-speed 6-Gang 6-Gang generation TÜ -6% - 2% Verbrauch consumption - 5% Benzin Diesel -3% -6% MK/MKTA/sk 9 APRA_Birmingham, November 2009 ZF confidential
10 Further development of shift dynamics (2nd Generation of 6-speed transmissions) 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 MK/MKTA/sk 10 APRA_Birmingham, November 2009 ZF confidential
11 Improvement shift dynamics Vergleich comparison Reaktionszeiten reaction time HP HP21 DKG in ms 400 Reaktionszeit i reaction time in ms ZHS 23 ZHS 34 ZHS 45 ZHS 56 ZHS 21 ZRS 32 ZRS 43 ZRS 54 ZRS 65 ZRS 21SRS 32SRS 43SRS 54SRS 65SRS 64 ZRS 53 ZRS 42 ZRS MK/MKTA/sk 11 APRA_Birmingham, November 2009 ZF confidential
12 Topics Business unit Automatic transmission The 6HP gearbox-family Hints for the repair shop General hints gearbox change change of a mechatronic change of a oil pan and filter changing or adding oil MK/MKTA/sk 12 APRA_Birmingham, November 2009 ZF confidential
13 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, the automatic transmission will be severely damaged! MK/MKTA/sk 13 APRA_Birmingham, November 2009 ZF confidential
14 Topics Business unit Automatic transmission The 6HP gearbox-family Hints for the repair shop General hints gearbox change change of a mechatronic change of a oil pan and filter changing or adding oil MK/MKTA/sk 14 APRA_Birmingham, November 2009 ZF confidential
15 Transmission ready to be installed into the vehicle MK/MKTA/sk 15 APRA_Birmingham, November 2009 ZF confidential
16 Transmission to be installed into the vehicle MK/MKTA/sk 16 APRA_Birmingham, November 2009 ZF confidential
17 Handling and Storage of an Automatic Transmission MK/MKTA/sk 17 APRA_Birmingham, November 2009 ZF confidential
18 Handling and Assembling of Automatic Transmission and Engine Remove converter strap right before assembling the gearbox to the engine MK/MKTA/sk 18 APRA_Birmingham, November 2009 ZF confidential
19 Installation of the Torque Converter Before assembling the transmission to the engine, it is important that the torque converter is installed correctly (see manual of the special gearbox) distance from bell housing to measurement of the torque converter distance with a deep gauge MK/MKTA/sk 19 APRA_Birmingham, November 2009 ZF confidential
20 Pump Gear Di Driving i pins ofthe pump can break Effect: - no power flow (RD) (R,D driving pin MK/MKTA/sk 20 APRA_Birmingham, November 2009 ZF confidential
21 Pump Gear This damage is caused by the wrong installation of the transmission. Driving pin is broken MK/MKTA/sk 21 APRA_Birmingham, November 2009 ZF confidential
22 Leakage between Engine and Transmission Effect: leakage age betweenee engine e and transmission Reasons: centre bush is missing i in crank shaft centre pin between engine and transmission is missing MK/MKTA/sk 22 APRA_Birmingham, November 2009 ZF confidential
23 Centre Bush centre bush After assembling of the transmission i to the engine, don t 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 MK/MKTA/sk 23 APRA_Birmingham, November 2009 ZF confidential
24 Centre Pins It is very important that the centre pins are assembled to the engine case. Missing centre pins will cause damages in the transmission. center pin center pin at an engine case The two A describe the position of the centre pins MK/MKTA/sk 24 APRA_Birmingham, November 2009 ZF confidential
25 Functional test After repair you should make a driving test Before the driving test you have to delete all adoption values using a tester MK/MKTA/sk 25 APRA_Birmingham, November 2009 ZF confidential
26 The whole product family 6HP28A61 6HP28AF integrated 4x4 MK/MKTA/sk 26 APRA_Birmingham, November 2009 ZF confidential
27 6 speed part numbers Main Parts List Trans Type Part Number Programmed Description HP Rear wheel drive HP19X External 4x HP19A Internal 4x HP Rear wheel drive HP26X External 4x HP26A Internal 4x HP Rear wheel drive HP32A Internal 4x HP32X External 4x HP Rear wheel drive HP21X External 4x HP Rear wheel drive HP28X External 4x HP28A Internal 4x HP28AF Internal 4x4 MK/MKTA/sk 27 APRA_Birmingham, November 2009 ZF confidential
28 6 speed transmission identification MK/MKTA/sk 28 APRA_Birmingham, November 2009 ZF confidential
29 Example transmission application BMW 745 MK/MKTA/sk 29 APRA_Birmingham, November 2009 ZF confidential
30 Topics Business unit Automatic transmissions The 6HP gearbox-family Hints for the repairshop General hints gearbox change change of a mechatronic change of a oilpan and filter changing or adding oil MK/MKTA/sk 30 APRA_Birmingham, November 2009 ZF confidential
31 Mechatronic on a special carrier MK/MKTA/sk 31 APRA_Birmingham, November 2009 ZF confidential
32 6HP..-Mechatronics left side: E-version / right side: M-Version MK/MKTA/sk 32 APRA_Birmingham, November 2009 ZF confidential
33 Mechatronik identification MK/MKTA/sk 33 APRA_Birmingham, November 2009 ZF confidential
34 Mechatronic replacement MK/MKTA/sk 34 APRA_Birmingham, November 2009 ZF confidential
35 Mechatronic replacement MK/MKTA/sk 35 APRA_Birmingham, November 2009 ZF confidential
36 Mechatronic replacement MK/MKTA/sk 36 APRA_Birmingham, November 2009 ZF confidential
37 Mechatronic replacement MK/MKTA/sk 37 APRA_Birmingham, November 2009 ZF confidential
38 Mechatronic replacement MK/MKTA/sk 38 APRA_Birmingham, November 2009 ZF confidential
39 Mechatronic replacement MK/MKTA/sk 39 APRA_Birmingham, November 2009 ZF confidential
40 Mechatronic replacement MK/MKTA/sk 40 APRA_Birmingham, November 2009 ZF confidential
41 Mechatronic replacement MK/MKTA/sk 41 APRA_Birmingham, November 2009 ZF confidential
42 Topics Business unit Automatic transmissions The 6HP gearbox-family Hints for the repairshop General hints gearbox change change of a mechatronic change of a oilpan and filter changing or adding oil MK/MKTA/sk 42 APRA_Birmingham, November 2009 ZF confidential
43 Polyamide oilpan with integrated filter 6 HP 26 1,6 kg weight reduction app. 40% MK/MKTA/sk 43 APRA_Birmingham, November 2009 ZF confidential
44 ZF-part number (Polyamide oilpan) ZF part number name gearbox Customer Oilpan 6HP26 / 28 / 28X / 32 BMW Oilpan 6HP26 / 26X Aston Martin, Ford USA, Ford Australia Jaguar, Range Rover Oilpan 6HP19 / 19X / 21 / 21X BMW MK/MKTA/sk 44 APRA_Birmingham, November 2009 ZF confidential
45 Plate Oilpan and Oilfilter MK/MKTA/sk 45 APRA_Birmingham, November 2009 ZF confidential
46 ZF Part Number: Plate oilpan and Oilfilter 1 ZF-part number Name Gearbox Customer Oilpan 6HP26X Ford USA Oilpan 6 HP 26 X BMW Oilpan 6 HP 26 Maserati Oilpan 6 HP 26 Ford Australia Filter Sealing Oilpan 6 HP 26 A Audi, Bentley Filter Sealing Oilpan 6 HP 26 A Audi, Bentley Filter Sealing MK/MKTA/sk 46 APRA_Birmingham, November 2009 ZF confidential
47 ZF Part Number: Plate oilpan and Oilfilter 2 ZF-part number Name Gearbox Customer Oilpan 6 HP 32 BMW Filter Sealing Oilpan 6 HP 32 A VW Filter Sealing Oilpan 6 HP 19 A Audi, VW Filter Sealing Oilpan 6 HP 19 A Audi, VW Filter Sealing Oilpan 6 HP 19 X Audi Filter Sealing MK/MKTA/sk 47 APRA_Birmingham, November 2009 ZF confidential
48 Topics Business unit Automatic transmissions The 6HP gearbox-family Hints for the repairshop General hints gearbox change change of a mechatronic change of a oilpan and filter changing or adding oil MK/MKTA/sk 48 APRA_Birmingham, November 2009 ZF confidential
49 General Hints on Transmission Oil Do not mix different oils unless this is expressly 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. MK/MKTA/sk 49 APRA_Birmingham, November 2009 ZF confidential
50 6HPxx transmission fluid level procedures MK/MKTA/sk 50 APRA_Birmingham, November 2009 ZF confidential
51 6HPxx transmission fluid level procedures MK/MKTA/sk 51 APRA_Birmingham, November 2009 ZF confidential
52 ATF Oil-Check 6HP19 A 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) C Oil volume: 9 l transmission oil No. S (yellow) 1,05 l differential oil No. S and 0,528 l Torsen differential oil No. S and 0,022 l Sturaco oil No. S only these 4 MPL!! VW Audi MK/MKTA/sk 52 APRA_Birmingham, November 2009 ZF confidential
53 ATF Oil-Check 6HP26A61 Audi 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) C Oil volume: 10 l transmission oil No. S (yellow) and 1,2 l differential oil No. S Version 1: Version 2: 0,96 l Torsen differential oil No. S and 0,04 l Sturaco oil No. S ,152 l Torsen differential oil No. S and 0,048 l Sturaco oil No. S MK/MKTA/sk 53 APRA_Birmingham, November 2009 ZF confidential
54 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) C Oil volume: 11,2 l transmission oil No. S (yellow) 1,20 l differential oil No. S Version 1: Version 2: 1,20 l Torsen differential oil No. S and 0,1 l Sturaco oil No. S ,680 l Torsen differential oil No. S and 0,12 l Sturaco oil No. S (only 1 MPL) MK/MKTA/sk 54 APRA_Birmingham, November 2009 ZF confidential
55 ATF Oil-Check 6HP32A VW Before drive test the ATF have to be filled up with the ZF Lifeguardfluid 6 Fill up instruction: The idle speed should be neng n = 750 rpm and the transmission oil pan temperature (CGT) C Oil volume: 10 l transmission oil No.S (yellow) 0,816 l differential oil No. S and 1,104 l Torsen differential oil No. S and 0,046 l Sturaco oil No. S MK/MKTA/sk 55 APRA_Birmingham, November 2009 ZF confidential
56 Colour of Lifeguardfluid 6 (yellow) MK/MKTA/sk 56 APRA_Birmingham, November 2009 ZF confidential
57 ATF Oil-Check 6HP26A61 (W12) Before drive test the ATF have to be filled up with the ZF Lifeguardfluid 6 Plus Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature (CGT) C Oil volume: 10 l transmission oil No. S (blue) and 1,2 l differential oil No. S Version 1: Version 2: 1,104 l Torsen differential oil No. S and 0,096 l Sturaco oil No. S ,008 l Torsen differential oil No. S and 0,092 l Sturaco oil No. S MK/MKTA/sk 57 APRA_Birmingham, November 2009 ZF confidential
58 Colour of Lifeguardfluid 6 Plus (blue) PLUS MK/MKTA/sk 58 APRA_Birmingham, November 2009 ZF confidential
59 ATF Oil-Check 6HP19A / X VW, Audi Before drive test the ATF have to be filled up with the ZF Lifeguardfluid 8 Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature (CGT) C Oil volume: 9 l transmission oil No. S (green) and 1,05 l differential oil No. S and 0,528 l Torsen differential oil No. S and 0,022 l Sturaco oil No. S MK/MKTA/sk 59 APRA_Birmingham, November 2009 ZF confidential
60 ATF Oil-Check 6HP28AF Audi Before drive test the ATF have to be filled up with the ZF Lifeguardfluid 8 Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature (CGT) C Oil volume: 10l transmission oil No. S (green) and 1,0 l differential oil No. S and 0,96 l Torsen differential oil No. S and 0,04 l Sturaco oil No. S MK/MKTA/sk 60 APRA_Birmingham, November 2009 ZF confidential
61 Colour of Lifeguardfluid 8 (green) MK/MKTA/sk 61 APRA_Birmingham, November 2009 ZF confidential
62 Checking and top up the Oil Lifeguardfluid 6 (yellow) BMW, Jaguar, Ford, Maserati, Hyundai, L.Rover, Aston Martin, RR, BMW, Bentley for the gearbox types 6HP19/26/32/21/28/19X/26X/28X MK/MKTA/sk 62 APRA_Birmingham, November 2009 ZF confidential
63 Lifetime Oil for 6-speed / 8-speed Transmissions Artikel-Nr. / Part-No. AA MK/MKTA/sk 63 APRA_Birmingham, November 2009 ZF confidential
64 Lifetime Oil for 6-speed Transmissions Artikel-Nr. / Part-No. S MK/MKTA/sk 64 APRA_Birmingham, November 2009 ZF confidential
65 Lifetime Oil for 6-speed Transmissions plus Artikel-Nr. / Part-No. S MK/MKTA/sk 65 APRA_Birmingham, November 2009 ZF confidential
66 Thank you very much for your attention! MK/MKTA/sk 66 APRA_Birmingham, November 2009 ZF confidential
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