ZF 6HP26A 61 6HP26A 61. Automatic Transmission Spare Parts Catalog

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1 ZF 6HP26A 61 6HP26A 61 Automatic Transmission Spare Parts Catalog

2 Warranty Information Warranty coverage for ZF passenger car transmission spare parts and kits covers the first 12 months after installation in the vehicle, or 24 months after purchase from ZF Services. Warranty of the product is limited to replacement or repair, if found to be defective in ZF material or workmanship, and specifically does not cover removal, reinstallation, or any costs incidental to the repair of the vehicle, or any kind of consequential damages. All warranty and/or non-warranty returns must be approved. Disclaimer The specifications and information shown in this catalog have been compiled from accepted and reliable sources and is believed to be accurate at the time of publication. While ZF Services believes this information is correct, no guarantee or warranty is made as to the accuracy of the information and ZF Services cannot and does not accept or assume any responsibilities for errors, omissions, or consequential harm or damages. Replacement parts should not be used when they do not appear to fit. ZF Services disclaims all liability and responsibility for any harm resulting from any such modifications. Copyright Printed in USA - Copyright 2008 ZF Services No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of ZF Services. Distributed By

3 Table of Contents 6HP26A 61 Technical Information Torque, Gear Ratio & Weight 2 Oil Capacity 2 6HP26A 61 Lubricants 2 6HP26A 61 Technical Literature 2 6HP26A 61 General Transmission Oil Filling Procedure 3-6 6HP26A 61 Differential Transmission Oil Filling Procedure 7-10 How To Use This Catalog 11 Type Plate Information 12 6HP26A XXX Spare Parts External Gearbox Housing Group 13 Internal Gearbox Housing Group 14 Torque Converter Group Oil Supply Group 17 Front Planetary Group 18 Rear Planetary Group 19 Coupling A Group 20 Coupling B Group 21 Coupling C Group 22 Coupling D Group 23 Coupling E Group 24 Front Axle Output Group 25 Rear Axle Output Group 26 Distributor Group 27 Distributor Group (continued) 28 Front Axle Differential Group 29 Filter Group 30 Mechatronic Group 31 Gear Shift System M-Shift Group 32 Parking Lock Group 33 Selective Shims, Snap Rings, Steel Plate & Kits Content Selective Shims Selective Snap Rings Selective Steel Plate 41 Kits Content For Reference Only 2008 ZF Services - 1

4 Technical Information Torque, Gear Ratio & Weight Input Torque 326 ftlbs to 444 ftlbs (model specific) 1 Gear 2 Gear 3 Gear 4 Gear 5 Gear 6 Gear Rev Gear Drive Weight (incl. oil) RWD ~196 lbs. Oil Capacity 9.4 liters (10 Quarts) + 5 liters (0.53 Quarts) for cooling system 6HP26A 61 Lubricants Amount ZF Part # Oil Grade 20 Liter Canister S ZF LifeGuardFluid Liter Drum S ZF LifeGuardFluid 6+ Note: ZF recommends the use of LifeGuardFluid 6+ for optimal performance. 6HP26A 61 Technical Literature Language English English English ZF Part # Description HP26A 61 REPAIR MANUAL (CD) 6HP26A 61 FUNCTIONAL DESCRIPTION - BMW (CD) HP26A 61 FUNCTIONAL DESCRIPTION - AUDI (CD) For Reference Only 2008 ZF Services - 2

5 6HP26A 61 General Transmission Oil Filling Procedure Adding oil to 6HP26A 61 automatic transmission - general - up to overflow at 40 C Checking Refilling Notes Procedure if leaks are suspected Procedure after repair, exchange of control unit or similar Always note correct oil grade: see page 2 TE ML 11 Place car horizontally on hoist Switch off the hoist and apply the handbrake Connect the tester in order to read off the transmission oil temperature and engine speed Start the engine Select gears with engine running, at idle speed Place car horizontally on hoist Switch off the hoist and apply the handbrake Carry out the repair work Connect the tester in order to read off the transmission oil temperature and engine speed With the engine stopped, add oil until it reaches the overflow lip - Car - Car must stand level on on the the _hoist. - The - The driven wheels or or the the _transmission output must be be at _a_at standstill a standstill for at for least at least two two _minutes before checking the the _oil _oil level. Apply the the handbrake. - Move - selector lever to to P. P. - EGS - must not not be be in in _emergency program. - Switch - the the main consumers, _for _for instance the the air air _conditioning, either on on or or off off _according to to the the car car _manufacturer's _manufactuerer's instructions. Select positions R and D and shift through as far as 3rd gear (manual/winter program) Start the engine Top off the oil immediately to the overflow lip Keep each gear selected for 3 seconds, then engage the parking lock Select gears with engine running, at idle speed Select positions R and D and shift through as far as 3rd gear (manual/winter program) Continued on Page 2 Keep each gear selected for 3 seconds, then engage the parking lock For Reference Only 2008 ZF Services - 3

6 6HP26A 61 General Transmission Oil Filling Procedure (continued) Idle speed n_mot = _Min according to manufacturer's specification. NO YES Engine fault: Oil adjustment not possible Eliminate the fault according to the engine repair manual Depending on condition, allow oil to cool down or run engine until warm Select gears with engine idling NO Oil temperature between 30 C and 35 C Open filler plug on the housing Oil emerges at an oil temperature below 35 C NO YES YES Select R and D by means of manual/winter program as far as 3rd gear Hold each gear for 3 seconds and engage parking lock Transmision contains too little oil Increase oil level by adding oil until it flows out Wait until oil temperature reaches 40 C + 10 C Oil temperature must not exceed 50 C in any circumstances Open the filler plug on the housing Wait until oil temperature reaches 40 C + 10 C Allow time to drip, then close the filler plug again Oil emerges at an oil temperature below 35 C NO YES Oil temperature must not exceed 50 C in any circumstances Transmision contains too little oil Increase oil level by adding oil until it flows out Wait until oil temperature reaches 40 C + 10 C Oil temperature must not exceed 50 C in any circumstances Allow time to drip, then close the filler plug again Wait until oil temperature reaches 40 C + 10 C Allow time to drip, then close the filler plug again Oil temperature must not exceed 50 C in any circumstances Allow time to drip, then close the filler plug again For Reference Only 2008 ZF Services - 4

7 6HP26A 61 General Transmission Oil Filling Procedure (continued) Oil service 6HP26A 61 Audi Oil drain plug Internal hexagon Tightening torque M10X1 5 mm 12 Nm ± 1.2 Nm Oil filler screw and oil level screw Internal hexagon Tightening torque M30X mm 80 Nm ± 8 Nm For Reference Only 2008 ZF Services - 5

8 6HP26A 61 General Transmission Oil Filling Procedure (continued) Oil service 6HP28 AF Audi Oil drain plug Internal hexagon Tightening torque M10X1 5 mm 12 Nm ± 1.2 Nm Oil filler screw and oil level screw Internal hexagon Tightening torque M30X mm 80 Nm ± 8 Nm For Reference Only 2008 ZF Services - 6

9 6HP26A 61 Differential Transmission Oil Filling Procedure Adding oil to 6HP26A 61 transfer case - Audi Transfer case with separate oil content Transer case with Torsen differential (RA) Oil content ex-factory: Transfer case total filling (separate) Transfer case in combined transmission 1.04 liters SAF AG liter STURACO FM liters SAF AG liter STURACO FM 1992 WARNING: The "STURACO FM 1992" additive is only needed after renewal (exchange) of the Torsen differential. After assembly, pour the additive directly (axially) into the Torsen differential with the transfer case in a vertical position. For Reference Only 2008 ZF Services - 7

10 6HP26A 61 Differential Transmission Oil Filling Procedure (continued) Adding oil to differential / transfer case of 6HP26A 61 (Audi) Differential / transfer case with shared oil content 1.) General information: The system is filled while cold (between 20 C and 50 C) until the oil overflows. The vehicle must be standing in a level position on the hoist; the engine must be stopped. Oil content ex-factory: Transfer case only See combined drive train Transfer case in combined drive train ca. 1.0 ltr. SAF-AG4 incl. 4% Sturaco FM 1992 Front-axle differential ca. 1.2 ltr. SAF-AG4 incl. 4% Sturaco FM 1992 Volume of oil in oil cooler and pipes ca. 0.2 ltr SAF-AG4 incl. 4% Sturaco FM 1992 Total oil volume: 2.4 ltr. SAF-AG4 incl. 4% Sturaco FM 1992 The 2.4-liter oil volume is the total oil volume for the transfer case, differential and oil cooler. Note! When adjusting the oil level during After Sales Service, no Sturaco needs to be added. Adjust to the correct level with SAF AG4 only. Since the two volumes of oil (in the differential and the transfer case) are combined, the amounts of oil in the front-axle differential and the transfer case vary when the vehicle is driven. For this reason, always check the oil levels in the front-axle differential and the transfer case at the same time. The oil level is only correct if oil begins to escape from both overflow holes (remove the screw plugs). Because it is positioned lower on the vehicle, the oil cooler is always filled until no further air bubbles escape. For Reference Only 2008 ZF Services - 8

11 6HP26A 61 Differential Transmission Oil Filling Procedure (continued) 2.) Filling the transfer case / differential The transfer case and the differential share the same oil content, but are at different heights on the vehicle. Since the oil levels are different, both of them must be filled separately until oil begins to escape from the overflow hole. Adding oil is best done with an angled pipe and a syringe or pump. Filling procedure: 1. Fill the system when it is cold (between approx. 20 C and 50 C), until oil begins to escape at the overflow hole. The vehicle must be standing level (lengthways and sideways) on the hoist; the engine must be stopped. 2. Remove the screw plugs at the transfer box and differential. Screw plug on transfer case: use a 6 mm Allen key Screw plug on differential: use an 8 mm Allen key 3. Add oil (SAF AG4) to the transfer case until it begins to escape from the overflow hole. Volume of oil if transfer case was empty: max. 1 liter. 4. Add oil (SAF AG4) to the differential until it begins to escape from the overflow hole. Volume of oil if transfer case was empty: max. 1.2 liters. 5. Allow oil to escape from the overflow holes on the transfer case and differential until the flow of oil breaks off. 6. Close the filler holes by inserting the screw plugs. Filler plug on transfer case: M12 x 1,5 / Innen 6kt. 6 mm / 20 Nm Filler plug on differential: M18 x 1,5 / Innen 6kt. 8 mm / 35 Nm 7. To make sure that the pipe system and oil cooler are correctly filled with oil, drive the vehicle for about 5 minutes at 40 km/h (distance > 4 km). 8. Repeat steps 1 to 6 as described above. Depending on the waiting period, some oil will normally escape at the front-axle differential, and app. 0.3 liter will need to be added at the transfer case (until the oil begins to overflow). This situation is due to the distribution of oil between the front-axle differential and the transfer case when the vehicle is operated. Important! Oil must escape from both overflow holes, otherwise the total oil content will be too low. For Reference Only 2008 ZF Services - 9

12 6HP26A 61 Differential Transmission Oil Filling Procedure (continued) Adding oil to 6HP26A 61 differential - Audi Differential with separate oil content Content ex-factory: 1.2 liters SAF AG For Reference Only 2008 ZF Services - 10

13 How To Use This Catalog Table of Contents Each transmission group of this catalog is listed in the table of contents. This spare parts catalog includes only transmission specification numbers for North American applications. Technical Information All technical information is specific to the transmission models that are referenced in this catalog. Weight and oil capacity information are only approximate and may vary by actual transmission specification. For any technical inquiry, please contact your preferred ZF passenger car transmission distributor for assistance. For a list of technical literature available from ZF or for answers to frequently asked questions about ZF transmissions visit us at www. zf.com/na. Spare Parts Each transmission is divide into groups (e.g. gearbox housing group). The position number (Position #) is used to identify the location of each spare part in the transmission. A position number like is either a spare part or an assembly. A position number like /110 is a subcomponent of an assembly. Please contact your preferred ZF passenger car transmission distributor about availability of assemblies and subcomponents. Contact ZF for the most updated part number (for example: 6HP XXX). Please, have the position number and model number prepared when you call. Thank you. Use our toll free Service-Hotline: The description (Description) identifies the spare part. The quantity (Quantity) is the amount of spare parts included in one transmission model for a certain position number. The quantity may vary depending on the transmission specification and certain spare parts may be used in multiple positions in the transmission. The notes column (Notes) gives more information about the spare part (e.g. included in a kit). Example OIL SUPPLY GROUP Position # Description Quantity PUMP /150 NEEDLE SLEEVE SHIM 1 Notes Selective shim; see page 34. Selective Shims, Snap Rings, Steel Plate & Kits Content Each list for selective shims, snap rings or steel plate is listed in this section of the catalog. Please measure the clearance according to the repair manual and select the required spare part from the table. The kits content section shows all available kits for the transmission models that are referenced in this catalog, including the content of each kit. Mechatronic and Valve Body are only available as complete Service-Mechatronic. For Reference Only 2008 ZF Services - 11

14 Type Plate Information The type plate is located on the main housing of the transmission. Please refer to the ZF transmission specification # when searching for spare parts and kits in this catalog Transmission Serial # ZF Transmission Specification # Vehicle Manufacturer Transmission # For Reference Only 2008 ZF Services - 12

15 6HP26A XXX EXTERNAL GEARBOX HOUSING GROUP Position # Description Quantity Notes BREATHER CABLE TERMINAL SCREW PLUG SCREW PLUG 3 Included in overhaul kit; see page 45. For Reference Only 2008 ZF Services - 13

16 INTERNAL GEARBOX HOUSING GROUP Position # Description Quantity Notes GEARBOX HOUSING NEEDLE SLEEVE SNAP RING BUSHING SEALING SLEEVE 1 Included in overhaul kit; see page SEALING SLEEVE 2 Included in overhaul kit; see page SEALING SLEEVE 1 Included in overhaul kit; see page DOWL NEEDLE SLEEVE SHAFT SEAL 1 Included in overhaul kit; see page 45. For Reference Only 2008 ZF Services - 14

17 TORQUE CONVERTER GROUP Position # Description Quantity Notes CONVERTER CONVERTER BELL SHAFT SEAL 1 Included in overhaul kit; see page BREATHER ROUND SEALING RING 1 Included in overhaul kit; see page MAGNET TORX SCREW 3 M16x SEALING RING 2 Included in overhaul kit; see page OIL BAFFLE PLATE ASSEMBLY /120 GASKET 1 Included in overhaul kit; see page OIL COOLER TORX SCREW 3 M6X TORX SCREW 18 M8X ROUND SEALING RING 1 Included in overhaul kit; see page COVER ASSEMBLY /120 SHAFT SEAL 1 Included in overhaul kit; see page TORX SCREW 11 M8X SNAP RING OUTPUT FLANGE PLUG ROUND SEALING RING TORX SCREW 1 M6X SEALING RING 2 Included in overhaul kit; see position # SCREW PLUG 1 See Front Axle Differential Group; page 29. Continued on next page. For Reference Only 2008 ZF Services - 15

18 TORQUE CONVERTER GROUP (continued) For Reference Only 2008 ZF Services - 16

19 OIL SUPPLY GROUP Position # Description Quantity Notes PUMP ASSEMBLY /150 NEEDLE SLEEVE /160 SNAP RING /170 SHAFT SEAL 1 Included in overhaul kit; see page ROUND SEALING RING 1 Included in overhaul kit; see page INTERMEDIATE PLATE ASSEMBLY /110 INTERMEDIATE PLATE /130 CENTERING PLATE /150 COUNTER SCREW /160 PISTON RING 1 Included in overhaul kit; see page /170 PISTON RING 1 Included in overhaul kit; see page /180 COUNTER SCREW 4 M6X COUNTER SCREW 11 M6X ROUND SEALING RING 1 Included in overhaul kit; see page TORX SCREW TORX SCREW 1 Included in overhaul kit; see page SHIM 1 Selective shim; see page 34. For Reference Only 2008 ZF Services - 17

20 FRONT PLANETARY DRIVE GROUP Position # Description Quantity Notes PLANETARY DRIVE /200 AXIAL NEEDLE BEARING /210 SUN GEAR /220 SNAP RING AXIAL NEEDLE BEARING OIL TRAY 1 For Reference Only 2008 ZF Services - 18

21 REAR PLANETARY DRIVE GROUP Position # Description Quantity Notes PLANET CARRIER /250 AXIAL SHIM mm /260 AXIAL NEEDLE BEARING /280 AXIAL NEEDLE BEARING /290 AXIAL SHIM mm /310 AXIAL SHIM RING GEAR SNAP RING OUTPUT SHAFT AXIAL SHIM mm AXIAL NEEDLE BEARING 1 For Reference Only 2008 ZF Services - 19

22 COUPLING A GROUP Position # Description Quantity Notes CYLINDER PISTON PROFILED SEALING RING 1 Included in overhaul kit; see page ROUND SEALING RING 1 Included in overhaul kit; see page CUP SPRING OIL DAM PROFILED SEALING RING 1 Included in overhaul kit; see page K-RING UNDULATING SPRING STEEL PLATE ; Included in steel kit; see pages 43 & FRICTION PLATE 4 Included in friction kit; see page SNAP RING 1 Selective snap ring; see page 39. For Reference Only 2008 ZF Services - 20

23 COUPLING B GROUP Position # Description Quantity Notes SUN GEAR SHAFT PISTON ROUND SEALING RING 1 Included in overhaul kit; see page ROUND SEALING RING 1 Included in overhaul kit; see page CUP SPRING OIL DAM ROUND SEALING RING 1 Included in overhaul kit; see page SNAP RING FIXING SHIM SNAP RING UNDULATING SPRING STEEL PLATE ; Included in steel kit; see pages 43 & END PLATE 1 Included in steel kit; see pages 43 & FRICTION PLATE 4 Included in friction kit; see page SNAP RING 1 Selective snap ring; see page SEALING RING 2 Included in overhaul kit; see page AXIAL NEEDLE BEARING AXIAL NEEDLE BEARING 1 For Reference Only 2008 ZF Services - 21

24 COUPLING C GROUP Position # Description Quantity Notes CYLINDER /140 FITTING KEY PISTON ROUND SEALING RING 1 Included in overhaul kit; see page ROUND SEALING RING 1 Included in overhaul kit; see page CUP SPRING STOP-RING SNAP RING UNDULATING SPRING FRICTION PLATE 4 Included in friction kit; see page STEEL PLATE ; Included in steel kit; see pages 43 & END PLATE ; Included in steel kit; see pages 43 & SNAP RING 1 Selective snap ring; see page ANGLE DISC SNAP RING AXIAL NEEDLE BEARING 1 For Reference Only 2008 ZF Services - 22

25 COUPLING D GROUP Position # Description Quantity Notes PISTON ROUND SEALING RING 1 Included in overhaul kit; see page ROUND SEALING RING 1 Included in overhaul kit; see page OIL DAM ROUND SEALING RING 1 Included in overhaul kit; see page ROUND SEALING RING 1 Included in overhaul kit; see page SPLIT RING SPLIT RING CUP SPRING SPLIT RING UNDULATING SPRING STEEL PLATE ; Included in steel kit; see pages 43 & FRICTION PLATE 6 Included in friction kit; see page END PLATE 1 Selective steel plate; see page 41. Included in steel kit; see pages 43 & 44. For Reference Only 2008 ZF Services - 23

26 COUPLING E GROUP Position # Description Quantity Notes INPUT SHAFT PISTON ROUND SEALING RING 1 Included in overhaul kit; see page ROUND SEALING RING 1 Included in overhaul kit; see page CUP SPRING OIL DAM ROUND SEALING RING 1 Included in overhaul kit; see page FIXING PLATE SNAP RING UNDULATING SPRING STEEL PLATE 6 Included in steel kit; see pages 43 & FRICTION PLATE 6 Included in friction kit; see page END PLATE 1 Included in steel kit; see pages 43 & SNAP RING 1 Selective snap ring; see page PISTON RING 3 Included in overhaul kit; see page SUN GEAR SHAFT AXIAL NEEDLE BEARING INTERMEDIATE SHAFT AXIAL NEEDLE BEARING DISC CARRIER SNAP RING ANGLE DISC 1 For Reference Only 2008 ZF Services - 24

27 FRONT AXLE OUTPUT GROUP Position # Description Quantity Notes OIL FEED SHIM 1 Selective shim; see page WASHER SIDE SHAFT HEXAGON BOLT PROTECTING TUBE PLUG SHAFT SEAL 1 Included in overhaul kit; see page MAGNET 1 For Reference Only 2008 ZF Services - 25

28 REAR AXLE OUTPUT GROUP Position # Description Quantity Notes DISTRIBUTOR HOUSING SHAFT SEAL 1 Included in overhaul kit; see page BALL BEARING OUTPUT FLANGE RETAINING RING RETAINING RING ROUND SEALING RING 1 Included in overhaul kit; see page TORX SCREW 7 M8X45 For Reference Only 2008 ZF Services - 26

29 DISTRIBUTOR GROUP Position # Description Quantity Notes INTERMEDIATE HOUSING FRONT AXLE SHAFT ASSEMBLY /120 NEEDLE SLEEVE /140 TAPER ROLLER BEARING /150 TAPER ROLLER BEARING INPUT GEAR TAPER ROLLER BEARING SHIM 1 Selective shim; see page BEARING HOUSING TORX SCREW 1 M12X OUTPUT GEAR TAPER ROLLER BEARING TAPER ROLLER BEARING BEARING RING SCREW PLUG 1 M12X1.5; Included in overhaul kit; see page DIFFERENTIAL BALL BEARING PUMP TORX SCREW 4 M6X30 Continued on next page. For Reference Only 2008 ZF Services - 27

30 DISTRIBUTOR GROUP (continued) Position # Description Quantity Notes SHIM 1 Selective shim; see page SCREW PLUG 1 10X1; Included in overhaul kit; see page BREATHER TUBE BREATHER COVER SHIM 1 Selective shim; see page PLUG ROUND SEALING RING X TORX SCREW 1 M6X GASKET 1 Included in overhaul kit; see page TORX SCREW 19 M8X45 For Reference Only 2008 ZF Services - 28

31 FRONT AXLE DIFFERENTIAL GROUP Position # Description Quantity Notes BEVEL GEAR SET /120 TAPER ROLLER BEARING /150 TAPER ROLLER BEARING TAPER ROLLER BEARING NUT SHIM 1 Selective shim; see pages 36 & COUNTER SCREW RETAINING RING SHAFT SEAL 1 Included in overhaul kit; see page SHIM 1 Selective shim; see page SHIM 1 Selective shim; see page FLANGE SHAFT ASSEMBLY /110 FLANGE SHAFT /120 COVER /130 BALL BEARING /140 CURVED RING /150 COMPRESSION SPRING /160 TAPPET SCREW PLUG TORX SCREW 3 For Reference Only 2008 ZF Services - 29

32 FILTER GROUP Position # Description Quantity Notes OIL SUMP ASSEMBLY /110 OIL SUMP /120 SCREW PLUG 1 M10X1; Included in overhaul kit; see page /130 SCREW PLUG 1 M30X1.5; Included in overhaul kit; see page /140 MAGNET /150 MAGNET /160 CAP TORX SCREW 13 M6X GASKET 1 Included in overhaul kit; see page FILTER /010 SEALING RING 1 Included in overhaul kit; see page 46. / For Reference Only 2008 ZF Services - 30

33 MECHATRONIC GROUP Position # Description Quantity Notes /020 GASKET 2 Only available in overhaul kit; see page /030 GASKET 2 Only available in overhaul kit; see page GUIDE SLEEVE CAP CAPACITOR CLAMP /120 ROUND SEALING RING 2 Only available in overhaul kit; see page 46. N/A MECHATRONIC 1 Only complete Service-Mechatronics are available / / /120 CAUTION! Only complete Service-Mechatronics are available. Contact your local ZF Parts distributor for more information. For Reference Only 2008 ZF Services - 31

34 GEAR SHIFT SYSTEM M-SHIFT GROUP Position # Description Quantity Notes SHAFT SEAL 1 Included in overhaul kit; see page SELECTOR SHAFT /110 SELECTOR SHAFT /120 GEAR SHIFT LEVER /130 CLAMPING SLEEVE ROOSTER COMB CLAMPING SLEEVE PIPE DETENT SPRING TORX SCREW 2 M6X For Reference Only 2008 ZF Services - 32

35 PARKING LOCK GROUP Position # Description Quantity Notes PIN ROUND SEALING RING 1 Included in overhaul kit; see page PAWL LEG SPRING CONNECTING BAR GUIDING PLATE TORX SCREW 4 M6X20 For Reference Only 2008 ZF Services - 33

36 6HP26A XXX SELECTIVE SHIMS 6HP26A 61 SELECTIVE SHIM Position # Select. Parts Description Quantity Notes OIL SUPPLY SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM HP26A 61 SELECTIVE SHIM Position # Select. Parts Description Quantity Notes FRONT AXLE OUTPUT SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM For Reference Only 2008 ZF Services - 34

37 6HP26A XXX SELECTIVE SHIMS 6HP26A 61 SELECTIVE SHIM Position # Select. Parts Description Quantity Notes DISTRIBUTOR SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM HP26A 61 SELECTIVE SHIM Position # Select. Parts Description Quantity Notes DISTRIBUTOR SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM For Reference Only 2008 ZF Services - 35

38 6HP26A XXX SELECTIVE SHIMS 6HP26A 61 SELECTIVE SHIM Position # Select. Parts Description Quantity Notes DISTRIBUTOR SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM HP26A 61 SELECTIVE SHIM Position # Select. Parts Description Quantity Notes FRONT AXLE DIFFERENTIAL SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM For Reference Only 2008 ZF Services - 36

39 6HP26A XXX SELECTIVE SHIMS 6HP26A 61 SELECTIVE SHIM Position # Select. Parts Description Quantity Notes FRONT AXLE DIFFERENTIAL SHIM (continued) SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM HP26A 61 SELECTIVE SHIM Position # Select. Parts Description Quantity Notes FRONT AXLE DIFFERENTIAL SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM For Reference Only 2008 ZF Services - 37

40 6HP26A XXX SELECTIVE SHIMS 6HP26A 61 SELECTIVE SHIM Position # Select. Parts Description Quantity Notes FRONT AXLE DIFFERENTIAL SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM For Reference Only 2008 ZF Services - 38

41 6HP26A XXX SELECTIVE SNAP RINGS 6HP26A 61 SELECTIVE SNAP RING Position # Select. Parts Description Quantity Notes COUPLING A SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING HP26A 61 SELECTIVE SNAP RING Position # Select. Parts Description Quantity Notes COUPLING B SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING HP26A 61 SELECTIVE SNAP RING Position # Select. Parts Description Quantity Notes COUPLING C SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING For Reference Only 2008 ZF Services - 39

42 6HP26A XXX SELECTIVE SNAP RINGS 6HP26A 61 SELECTIVE SNAP RING Position # Select. Parts Description Quantity Notes COUPLING E SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING For Reference Only 2008 ZF Services - 40

43 6HP26A XXX SELECTIVE STEEL PLATE 6HP26A 61 SELECTIVE SHIM Position # Select. Parts Description Quantity Notes COUPLING D STEEL PLATE STEEL PLATE STEEL PLATE STEEL PLATE STEEL PLATE STEEL PLATE STEEL PLATE STEEL PLATE For Reference Only 2008 ZF Services - 41

44 Kits Content 6HP26A 61 Kits Content 6HP26A 61 Friction Kit Position # ZF Part # Description Quantity Where used (1068 ) Friction Plate A 5 See Chart Below Friction Plate E 7 See Chart Below Friction Plate B 5 See Chart Below Friction Plate D 7 See Chart Below Friction Plate C 5 See Chart Below Notes 6HP26A to to to to to to HP26A 61 Friction Kit Position # ZF Part # Description Quantity Where used (1068 ) Friction Plate A 5 See Chart Below Friction Plate E 6 See Chart Below Friction Plate B 5 See Chart Below Friction Plate D 7 See Chart Below Friction Plate C 5 See Chart Below Notes 6HP26A to to to For Reference Only 2008 ZF Services - 42

45 Kits Content 6HP26A 61 Kits Content 6HP26A 61 Steel Kit Position # ZF Part # Description Quantity Where used (1068 ) Steel Plate A 6 See Chart Below Steel Plate E 6 See Chart Below End Plate E 1 See Chart Below Steel Plate B 5 See Chart Below End Plate B 1 See Chart Below Steel Plate D 7 See Chart Below End Plate D See Chart Below End Plate D See Chart Below End Plate D See Chart Below End Plate D See Chart Below End Plate D See Chart Below End Plate D See Chart Below End Plate D See Chart Below End Plate D See Chart Below End Plate D See Chart Below Steel Plate C 5 See Chart Below End Plate C 1 See Chart Below Notes 6HP26A to For Reference Only 2008 ZF Services - 43

46 Kits Content 6HP26A 61 Kits Content 6HP26A 61 Steel Kit Position # ZF Part # Description Quantity Where used (1068 ) Steel Plate A 6 See Chart Below Steel Plate E 7 See Chart Below End Plate E 1 See Chart Below Steel Plate B 5 See Chart Below End Plate B 1 See Chart Below Steel Plate D 7 See Chart Below End Plate D See Chart Below End Plate D See Chart Below End Plate D See Chart Below End Plate D See Chart Below End Plate D See Chart Below End Plate D See Chart Below End Plate D See Chart Below End Plate D See Chart Below End Plate D See Chart Below Steel Plate C 5 See Chart Below End Plate C 1 See Chart Below Notes 6HP26A to to to to to to to For Reference Only 2008 ZF Services - 44

47 Kits Content 6HP26A 61 Kits Content 6HP26A 61 Overhaul Kit Position # ZF Part # Description Quantity Where used Notes Sealing Sleeve 2 All Gearbox housing Sealing Sleeve 1 All Gearbox housing Sealing Sleeve 1 All Gearbox housing Screw Plug 5 As needed. Gearbox housing Shaft Seal 1 All Gearbox housing Shaft Seal 1 6HP32A only Torque converter Round Sealing Ring 1 All Torque converter Sealing Ring 6 As needed. Torque converter / Gasket 1 All Torque converter Round Sealing Ring 1 All Torque converter / Shaft Seal 1 All Torque converter / Shaft Seal 1 All Oil supply Round Sealing Ring 1 All Oil supply / Piston Ring 1 All Oil supply / Piston Ring 1 All Oil supply Round Sealing Ring 1 All Oil supply Usit Ring 14 All Oil supply Profiled Seal Ring 1 All Coupling A Round Sealing Ring 3 All Coupling A Round Sealing Ring 1 All Coupling A Profiled Seal Ring 1 All Coupling A Round Sealing Ring 1 All Coupling B Round Sealing Ring 1 All Coupling B Round Sealing Ring 1 All Coupling B Sealing Ring 2 All Coupling B Round Sealing Ring 1 All Coupling C Round Sealing Ring 1 All Coupling C Round Sealing Ring 1 All Coupling D Round Sealing Ring 1 All Coupling D Round Sealing Ring 1 All Coupling D Round Sealing Ring 1 All Coupling D Round Sealing Ring 1 All Coupling D Round Sealing Ring 1 All Coupling E Round Sealing Ring 1 All Coupling E Round Sealing Ring 1 All Coupling E Piston Ring 3 All Coupling E Sealing Ring 3 All Coupling E Shaft Seal 1 All Front axle output Shaft Seal 1 All Rear axle output Shaft Seal 1 All Rear axle output Round Sealing Ring 1 All Rear axle output Continued on next page. For Reference Only 2008 ZF Services - 45

48 Kits Content 6HP26A 61 Kits Content 6HP26A 61 Overhaul Kit (continued) Position # ZF Part # Description Quantity Where used Notes Screw Plug 1 All Distributor Screw Plug 1 All Distributor Gasket 1 All Distributor Shaft Seal 1 All Front axle differential / Screw Plug 3 All Filter / Round Sealing Ring 1 All Filter / Round Sealing Ring 2 All Filter / Sealing Ring 1 All Filter Gasket 1 All Filter Pan Gasket 1 All Filter / Gasket 2 All Mechatronic / Gasket 2 All Mechatronic / Round Sealing Ring 2 All Mechatronic Shaft Seal 1 All Gearshift system Round Sealing Ring 1 All Parking lock For Reference Only 2008 ZF Services - 46