ZF Transmissions with Mechatronics Hans-Peter Bach, Director Serivce (
[email protected]) ZF Getriebe GmbH, Business Unit Automatic Transmissions
6 0 0 2 , H b m G e b e i r t e G F Z ©
Topics
Business unit „ Automatic Automatic transmission“ transmission“ Business The 6HP 6HP gearbox gearbox-famil -family y
n s or
e r ep a r s o p
General hints
change of a mechatroni c
cha changing nging o r adding oil
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ZF confidential
Topics
Business unit „ Automatic Automatic transmission“ transmission“ Business The 6HP 6HP gearbox gearbox-famil -family y
n s or
e r ep a r s o p
General hints
change of a mechatroni c
cha changing nging o r adding oil
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ZF confidential
P-Division ZF Getriebe GmbH
Saarbrü Saarb rück ck en (A (AT) T) ermany
1973 197 3 Sa Saarbrücken-V arbrücken-Völkl ölkl ingen, Plant 4 ermany og og st c
Br andenbu Branden burg rg (MT/ (MT/DT) DT) Germany
1991 199 1
K r es s b r o n n (R& D)
chshafen shafen (R (R&D) &D) 1969 Friedri ch
Sh an g h ai ** (AT)
2006
1988 19 88
** Joint Venture with SAIC.
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Topics
Business unit „ Automatic transmission“ The 6HP gearbox-family
n s or
e repa r s op
General hints
change of a mechatroni c
changing or adding oi l
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ZF confidential
Product History of the ZF 6-speed
-
-
2001
World premiere: Start of volume production for the first automatic 6-speed transmission worldwide, the 6HP26; compared to 30% less components
2005
Presentation of hybrid system (basis: 6HP26) at the IAA in Frankfurt
2006
Introduction of 2nd 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)
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Cutaway drawing 6HP26 torque converter
simple planetary gearset pump
double pl. gearset
gearbox housing clutch
output flange par ng oc wheel
brake
parking lock pawl
o strainer
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pressure regulator
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oil drain
ZF confidential
6HP… Product Family
] m [ e u q r o t e n i g n e
2 nd generation
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Second Generation of 6-speed
The individual, automatic d riving p leasure econ generat on o t e
:
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
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Reduction of CO2 and 3-Gang 3-speed
4- Gang 4-speed
5-Gang 5-speed
6-Gang 6-speed
6-speed new generation 6-Gang TÜ
- 6% consumption Verbrauch
-
Benzin Diesel
- 3%
- 6%
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Further development of shift dynamics -
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 ti me
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slippage time
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Improvement shift dynamics
Vergleich Reaktionszeiten comparison reaction t ime 1200 6HP19
s m s n 800 i m n e i t i m i e t z s n 600 n o o i i t t k c a a e r
DKG
200
0 S S S S S H Z H Z H Z H Z H Z 2 3 4 5 6 1 2 3 4 5
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S S S S S R Z R Z R Z R Z R Z 1 2 3 4 5 2 3 4 5 6
S S S S S R R R R R S 2 S 3 S S 5 S 1 4 2 3 4 5 6
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S S S R Z R Z R Z 4 3 2 6 5 4
ZF confidential
Topics
Business unit „ Automatic transmission“ The 6HP gearbox-family
n s or
e repa r s op
General hints
change of a mechatroni c
changing or adding oi l
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ZF confidential
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
,
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Topics
Business unit „ Automatic transmission“ The 6HP gearbox-family
n s or
e repa r s op
General hints
change of a mechatroni c
changing or adding oi l
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Transmission ready to be installed into
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Transmission to be installed into the
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Handling and Storage of an
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Handling and Assembling of Automatic
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 torque converter is installed correctly (see manual of the special gearbox)
torque converter
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measuremen o e distance with a deep gauge
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ZF confidential
Pump Gear
r v ng p ns o break
e pump can
Effect: - no power ow
,
driving pin
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Pump Gear
wrong installation of the transmission.
Driving pin is br oken
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Leakage between Engine and
Effect: • leaka e between en ine and transmission
Reasons: • cen re us s m ss ng n crank shaft • centre pin between engine and transmission is missing
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ZF confidential
Centre Bush
er assem ng o e ransm ss on o e engine, don‘t forget to build in the centre bush! A missing centre bush cause damages of the torque converter and the oil pump!
centre bush
position of the centre bush
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Centre Pins
It is ver im orta ortant nt that that the the cent centre re ins ins are assembled to the engine case. Missing centre pins will cause damages .
center in
The two A describe the position of the centre pins
center pin at an engine case
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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 int egrated 4x4 4x4
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6 speed part numbers Main Parts List
Trans Type
Part Number Programmed
Description
1071 010 …
6HP19
1071 012 …
Rear wheel drive
… 1071 040 …
… 6HP19A
1071 042 …
Internal 4x4
1068 010 …
6HP26
1068 012 …
Rear wheel drive
1068 020 …
6HP26X
1068 022 …
External 4x4
1068 030 …
6HP26A61
1068 032 …
Internal 4x4
1070 010 …
6HP32
1070 012 …
Rear wheel drive
1070 020 …
6HP32A
1070 022 …
Internal 4x4
1070 030 …
6HP32X
1070 032 …
External 4x4
1071 030 …
6HP21
1071 032 …
Rear wheel drive
1071 050 …
6HP21X
1071 052 …
External 4x4
1068 040 …
6HP28
1068 042 …
Rear wheel drive
1068 050 …
6HP28X
1068 052 …
External 4x4
4
… 1084 030 … MK/MKTA/sk 27
… 6HP28AF
1084 032 …
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Internal 4x4 ZF confidential
6 speed transmission identification
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Example transmission application
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Topics
Business unit „ Automatic transmissions“ The 6HP gearbox-family
n s or
e repa rs op
General hints
change of a mechatroni c
changing o r adding oil
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ZF confidential
Mechatronic on a special carrier
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6HP..-Mechatronics -
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-
ZF confidential
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
n s or
e repa rs op
General hints
change of a mechatroni c
changing o r adding oil
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ZF confidential
Polyamide oilpan with integrated filter
6 HP 26
1,6 kg
weight reduction app. 40%
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ZF confidential
ZF-part number (Polyamide oilpan)
ZF part number
name
gearbox
Customer
1068 298 033
Oilpan
6HP26 / 28 / 28X / 32
BMW
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:
ZF-part number
Name
Gearbox
pan
Customer or
1068 203 044
Oilpan
6 HP 26 X
BMW
1068 203 046
Oilpan
6 HP 26
Maserati
1068 203 048
Oilpan
6 HP 26
Ford Australia
0501 213 359
Filter
1068 303 017
Sealing
1068 203 043
Oilpan
6 HP 26 A
Audi, Bentley
0501 212 974
Filter
1068 303 012
Sealing
1068 203 047
Oilpan
6 HP 26 A
Audi, Bentley
0501 212 974
Filter
0501 322 155
Sealing
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ZF Part Number: ZF-part number
Name
Gearbox
Customer
1070 203 010
Oilpan
6 HP 32
BMW
0501 213 359
Filter
1068 301 017
Sealing
1070 203 008
Oilpan
6 HP 32 A
VW
0501 212 974
Filter
1070 303 009
Sealing
1071 203 038
Oilpan
6 HP 19 A
Audi, VW
0501 212 401
Filter
1071 303 006
Sealing
1071 203 039
Oilpan
6 HP 19 A
Audi, VW
0501 212 401
Filter
0501 322 078
Sealing
1071 203 040
Oilpan
6 HP 19 X
Audi
0501 214 315
Filter
0501 322 077
Sealing
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Topics
Business unit „ Automatic transmissions“ The 6HP gearbox-family
n s or
e repa rs op
General hints
change of a mechatroni c
changing or adding oi l
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ZF confidential
General Hints on Transmission Oil
• Do not mix different oils unless this is ex ressl
rescribed.
• 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
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6HPxx transmission fluid level
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ATF Oil-Check 6HP19 A Before driv e test the ATF have to be fil led up with the L ife u ar df lu id 6
ZF
Fill up instru ction: The idle speed should be neng = 750 rpm and the transmi ssion oil pan temperature CGT 30 … 50 °C Oil vol ume:
9 l transmission oil No. S671.090.255 (yellow) 1,05 l di fferential 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
VW
Au di
1071 040 010
1071 040 014
1071 040 022 MK/MKTA/sk 52
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ZF confidential
ATF Oil-Check 6HP26A61 Audi Before driv e test the ATF have to be fil led up with the Lifeguardfluid 6
ZF
Fill up instru ction: The idle speed should be neng = 750 rpm and the transmi ssio n oil pan temperature (CGT) 30 … 50 °C Oil volu me: 10 l transmission oil No. S671.090.255 (yellow) and 1,2 l differential oil No. S671.090.163
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Version 1:
0,96 l Torsen differential oil No. S671.090.163 and 0,04 l Stu raco oil No. S671.090.167
Version 2:
1,152 l Torsen differential oil No. S671.090.163 and 0,048 l Sturaco oil No. S671.090.167
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ZF confidential
ATF Oil-Check 6HP26A61 Bentley Before driv e test t he ATF have to be fil led up with the ZF Lifeguardf luid 6 = and the transmi ssio n oil pan temperature (CGT) 30 … 50 °C , . . . 1,20 l di fferential oil No. S671.090.163
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Version 1:
1,20 l Torsen differential oil No. S671.0920.163 , . . .
Version 2:
1,680 l Torsen differential oil No. S671.090.163 and 0,12 l Sturaco oil No. S671.090.163 onl 1 MPL
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ZF confidential
ATF Oil-Check 6HP32A VW Before driv e test the ATF have to be fil led up with the Lifeguardfluid 6
ZF
eng
and the transmi ssion oil pan temperature (CGT) 30 … 50 °C
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. . . 0,816 l differential oil No. S671.090.163 and 1,104 l Torsen di fferential oil No. S671.090.163 and 0,046 l Sturaco oil No. S671.090.167
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ZF confidential
Colour of Lifeguardfluid 6 (yellow)
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ATF Oil-Check 6HP26A61 (W12) Before driv e test the ATF have to be fil led up with the Lifeguardfluid 6 Plus
ZF
Fill u instruction: The idle s eed should be n eng = 750 r m and the transmi ssion oil pan temperature (CGT) 30 … 50 °C Oil volume: 10 l transmis sion oi l No. S671.090.281 blue and 1,2 l differential o il No. S671.090.163
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Version 1:
1,104 l Torsen differential oi l No. S671.090.163 and 0,096 l Sturaco oil No. S671.090.167
Version 2:
1,008 l Torsen differential oi l No. S671.090.163 and 0,092 l Sturaco oil No. S671.090.167
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ZF confidential
Colour of Lifeguardfluid 6 Plus (blue)
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ATF Oil-Check 6HP19A / X VW, Audi Before driv e test the ATF have to be fil led up with the Lifeguardfluid 8
ZF
Fill up instruc tion: The idle speed should be neng = 750 rpm and the transmi ssion oil pan temperature (CGT) 30 … 50 °C Oil vol ume:
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9 l transmissi on oil No. S671.090.311 (green) and 1,05 l differential oil No. S671.090.163 and 0,528 l Torsen differential oil . . . and 0,022 l Sturaco oil No. S671.090.167
APRA_Birmingham, November 2009
ZF confidential
ATF Oil-Check 6HP28AF Audi Before driv e test the ATF have to be fil led up with the Lifeguardfluid 8
ZF
Fill up instru ction: The idle speed should be neng = 750 rpm and the transmi ssio n oil pan temperature (CGT) 30 … 50 °C Oil vol ume: 10l transmissi on o il No. S671.090.311 (green) and 1,0 l differential o il No. S671.090.163 and 0,96 l Torsen differenti al oil . . . and 0,04 l Stu raco 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 Bentle
6HP19/26/32/21/28/19X/26X/28X
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Lifetime Oil for 6-speed / 8-speed
AA00 601 304
Artikel-Nr. / Part-No.
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Lifetime Oil for 6-speed Transmissions
Artikel-Nr. / Part-No.
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S671.090.255
ZF confidential
Lifetime Oil for 6-speed Transmissions
plus Artikel-Nr. / Part-No.
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S671.090.281
ZF confidential
