ZF 5HP19 Technical Service Information

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Technical Service Information BMW ZF-5HP-19FL PRELIMINARY INFORMATION

FOUND IN: BMW 97-Current, 3 Series E46, 5 Series E39, 7 Series E38. Audi 95-Current, A4, A8, Audi 97-Current, A6, Porsche Boxter 1996-1997 VW Passat 96-Current

This transmission is manufactured in Germany by ZF and carries the designation ZF-5HP-19.. The ZF-5HP-19 Series is an electronically controlled, five speed automatic transmission with a lock-up clutch type torque converter. Two planetary gear sets, one Ravingneaux gear set and one standard planetary gear set on the output side, four rotating multiple disc clutches, three multiple disc brake clutches, and one sprag clutch (Freewheel) are used to provide the five forward speeds and reverse.

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Technical Service Information Refer to Figure 2 for Clutch and Band Application Chart. Refer to Figure 3 and 4 for Manual Shift Lever Operation, and Failsafe Operation.

Refer to Figures 5, 6, and 7 for Solenoid identification and both MV Solenoid Operation and EDS Solenoid Operation and Tests. Refer to Figure 8 for wiring harness identification, internal wiring schematic, and transmission case connector pin identification and functions. Refer to Figure 9 for Shift Solenoid Application chart. Notice that EDS 1 Solenoid is used for line pressure control, and MV-4 is used for converter clutch. Refer to Figure 10 for internal components resistance chart, with the pins identified for both the transmission case connector and the Electronic Control Unit. Refer to Figure 11 for Upper Front Valve Body exploded view and identification of valves. Refer to Figure 12 for Upper Rear Valve Body exploded view and identification of valves. Refer to Figure 13 for Lower Front Valve Body exploded view and identification of valves. Refer to Figure 14 for Lower Rear Valve Body exploded view and identification of valves. Refer to Figure 15 for Channel Plate exploded view and turbine speed sensor location on the channel plate. Refer to Figures 16, 17, and 18 for valve body retainer locations in the various valve bodies. Refer to Figure 19 for the locations of the orifices, checkballs, screens, and the check valves and springs that are located in the channel plate.

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ZF-5HP-19 CLUTCH AND BAND APPLICATION CHART "C" CLUTCH

"B" CLUTCH

"A" CLUTCH

"E" CLUTCH

"D" CLUTCH

"G" CLUTCH "F" CLUTCH

"A" "B" "C" "D" "LOW" "E" "F" CLUT CLUT CLUT CLUT SPRAG CLUT CLUT

"G" GEAR CONV CLUT RATIO CLUT ON ON ON ON ON

* * * * *

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Reverse ON ON 4.08 Neutral "D"-1st ON HOLD 3.66 "D"-2nd ON ON 1.99 "D"-3rd ON ON ON 1.40 "D"-4th ON ON ON 1.00 "D"-5th ON ON ON 0.74 "4" Same as above, Automatic Shift 1st thru 4th, 5th gear is inhibited. "3" Same as above, Automatic Shift 1st thru 3rd, 4th and 5th gear are inhibited. "2" Same as above, Automatic Shift 1st thru 2nd, 3rd, 4th and 5th gear are inhibited. * Converter Clutch may be ON or OFF depending on vehicle speed and throttle position.

Technical Service Information

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Technical Service Information SHIFT QUADRANT Standard Versions

One Touch Control Versions

P = Parking Pawl Engaged P

P

R

R

N

N

D

D

4

4

3

3

2

2

R = Reverse Gear N = Neutral D = Automatic Shifts 1st thru 5th Gears 4 = Automatic Shifts 1st thru 4th Gears. 5th Gear is locked out. = Automatic Shifts 1st thru 3rd Gears. 3 4th and 5th Gear is locked out. 2 = Automatic Shifts 1st thru 2nd Gears. 3rd, 4th and 5th Gear is locked out.

+

Note: 1st gear, which has an engine braking effect, is selected electronically, dependent on being in Manual Position 2 and at a suitable road speed. ONE-TOUCH CONTROL VERSIONS Standard versions have a shift quadrant using only the left gate as shown above. The versions that are equipped with One-Touch Control, supplied as an option and model dependent, have a two section shift quadrant, also shown above. Positions P, R, N, D, 4, 3, 2, can be selected in the left-hand gate and all shifts are automatic depending on which selection was made. When the selector lever is placed in the right-hand gate, the transmission can be up-shifted manually, by tapping the lever in the direction of the "Plus" symbol, or down-shifted manually by tapping the lever in the direction of the "Minus" symbol. The seperate program switch is no longer needed, as functions A and B have replaced it.

"A" Left-Hand Gate = DSP (Dynamic Shift Program) With the selector lever in the left-hand gate, the Dynamic Shift Program (DSP) looks at the speed of accelerator pedal movement, engine speed, vehicle acceleration via output speed and other important parameters in the control unit. The Electronic Control Unit (ECU) includes modules which will automatically modify the transmissions shift characteristics according to the driving style and the road conditions. These modules effectively replace the program switch. If the engine temperature is below approximately 40°C (104°F) when it is started, the ECU control system enters a special warm-up program in order to shorten the catalytic converter's warming-up phase. This warm-up program is terminated after approximately 2 minutes of operation. Continued on next Page Copyright © 2000 ATSG

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"A" Left-Hand Gate = DSP (Dynamic Shift Program) (Cont'd) If the speed of the accelerator pedal movement is greatly varied, the shift points are modified for maximum fuel economy, or a more sporting driving style accordingly. There are three shift patterns for this purpose. 1. = Comfort Oriented, Economical Driving Style 2. = Average Driving Style 3. = Sports Oriented, High Performance Driving Style When the vehicle is started cold, it moves off in shift pattern number one, provided that the transmission temperature is above 40°C (104°F). This shift pattern places the emphasis on maximum fuel economy. If a more enthusiastic driving style is required, detected by the accelerator opening and closing more rapidly, the ECU switches between the shift patterns and adopting shift pattern three where necessary. If a calmer driving style is resumed, the ECU returns to the lower shift pattern, and will once again place the emphasis on fuel consumption.

"B" Right-Hand Gate = Manual Shift Program When the selector lever is moved to the right-hand gate, the current gear is retained, and the transmission can be shifted to a lower or higher gear using the one-touch function. There are engine speed limits for each gear, as in the transmission can only be shifted down if the maximum engine speed will not be exceeded by doing so. No mandatory upshifts will take place. If the One-Touch feature is not used when the selector lever is in the right-hand gate, for durability concerns, the transmission is allowed to down-shift automatically to 1st gear.

FAILSAFE OPERATION When a system fault is detected which could impair normal reliable operation, the ECU module interrupts the power supply to Pin 12 at the transmission case connector. The ECU module also alerts the driver of any faults by signaling the vehicles "check control" system. To enable the vehicle to be driven to a repair shop, the following manual gear selections are permitted: Selector Lever Position Actual Gear Obtained

PRND432 PRN4444

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Technical Service Information

23

1 0 3 6 1 0 .5 4 3 2 3 7 5 0 . 4 0 3 0

02

EDS-1 Solenoid

95

ZF-5HP-19 SOLENOID IDENTIFICATION AND LOCATIONS

ZF Part Numbers

SPECIAL NOTE: EDS-1 Solenoid .650" Snout Diameter Requires Green "O" Ring

EDS-1 Solenoid 0501 209 875 EDS-2, 3, 4, Solenoid 0501 208 562 MV-1, 2, 3, Solenoid 0501 313 506

EDS-2, 3, 4 Solenoids .670" Snout Diameter Requires Black "O" Ring

MV-1 Solenoid

MV-1, 2, 3 Solenoids Use NO "O" Rings

EDS-2 Solenoid

EDS-4 Solenoid EDS-3 Solenoid MV-2 Solenoid MV-3 Solenoid

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Technical Service Information MV1, 2 AND 3 OPERATION SOLENOID "OFF"

SOLENOID "ON"

X

X EXHAUST BLOCKED

PRESSURE FROM SV1,2 OR 3 EXHAUSTED

MV 1,2,3

MV 1,2,3

From Dr.Red. V-1 BLOCKED

From Dr.Red. V-1 OPEN TO SV-1,2 OR 3

From SV-1,2 OR 3

SUMMARY: When MV 1, 2 or 3 is "OFF" Solenoid reducing pressure, from Dr.Red. V-1, is blocked by the solenoid and oil pressure from SV 1, 2 or 3 is exhausted at the rear of the solenoid. When MV 1, 2 or 3 is "ON" Solenoid reducing pressure, From Dr.Red. V-1, is open through the solenoid and is applied to SV 1, 2 or 3. The exhaust at the rear of the solenoid

EDS 2, 3 AND 4 OPERATION SOLENOID "OFF"

SOLENOID "ON"

EDS 2-4

EDS 2-4

EXHAUST X

EXHAUST BLOCKED X

.670" Snout Diameter Requires Black "O" Ring

FROM Dr.Red.V-2 FROM Dr.Red.V-2 AND CLUTCH REGULATING TO CLUTCH REGULATING VALVES VALVES SUMMARY: When EDS 2-5 solenoids are "OFF" they exhaust orificed solenoid reducing pressure, from Dr. Red. V-2, and the oil pressure from the clutch regulating valves releasing them. When EDS 2-5 solenoids are "ON" the exhaust is blocked by the solenoid and solenoid reducing pressure, from Dr. Red. V-2, is applied to operate clutch regulating valves. Copyright © 2000 ATSG

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Technical Service Information EDS-1 OPERATION (Line Pressure Solenoid) SOLENOID "OFF"

SOLENOID "ON"

EDS 1

EDS 1

EXHAUST BLOCKED X

EXHAUST OPEN X

From Dr.Red. V-2 to MOD-V

.650" Snout Diameter Requires Green "O" Ring

From Dr.Red. V-2 and MOD-V SUMMARY:

When EDS 1 solenoid is "OFF," solenoid reducing pressure, from Dr. Red. V-2, is high to MOD-V valve which creates high line pressure. When EDS 1 solenoid is "ON," solenoid reducing pressure, from Dr. Red. V-2, is low to Copyright © 2000 ATSG

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Technical Service Information ZF-5HP-19 INTERNAL WIRE SCHEMATIC Output Speed Sensor

MV 1 Solenoid

EDS-2 Solenoid

EDS-1 Solenoid

EDS-4 Solenoid

Turbine Speed Sensor

EDS-3 Solenoid

View Looking Into Case Connector

2 5

MV 3 Solenoid

1 3

4 8

9 13

MV 2 Solenoid

7

12

6 11

16

10 14

ECU CONNECTOR

15

53

16

52

12

32

4

33

9

30

8 15

1

3

29

7

4

11

5

2

21

14

22

13

16

5

44

6

14

10

42

1

PURPLE PURPLE

PURPLE

PURPLE

PURPLE PURPLE PURPLE

PURPLE

WHITE GREEN GRAY

MV 3

MV 2

MV 1

EDS 2

EDS 3

EDS 4

EDS 1

N OT USED ORAN GE YELLOW RED GRAY WHITE PINK

TOT Sensor (Resistor in Wire)

Turbine Sensor

Output Sensor

BLUE BLUE YELLOW YELLOW

NOTE: Some internal wire colors may vary.

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Technical Service Information ZF-5HP-19 SOLENOID APPLICATION CHART Selector Lever MV 1 MV 2 MV 3 EDS 1 EDS 2 EDS 3 EDS 4 GEAR Position Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid RATIO PARK REVERSE NEUTRAL D-1ST D-2ND D-3RD D-4TH D-5TH Failsafe (4th)

ON ON ON ON ON

OFF

ON ON ON ON

OFF

*

-*

OFF

** ** ** ** ** ** ** **

OFF

* * *

OFF

* * * * OFF

4.08:1

-*-*-*OFF

3.66:1 1.99:1 1.40:1 1.00:1 0.74:1 1.00:1

SOLENOID CHART LEGEND Symbol ON

* ** * -* *-*-

Description MV 1, MV 2 and MV 3 Solenoids are energized by the Electronic Transmission Control unit and have two functions. They are Open or Closed. Energized (On), there is pressure in circuit. MV 3 is turned "ON" if reverse is selected at a high vehicle speed, to inhibit reverse engagement. EDS 1 is used for line pressure control only, and operates from 0 to 0.8 amps. When the solenoid is "OFF" (0 amps), pressure is high. EDS 1 pressure is "Lowered" as the solenoid is modulated by the control unit. EDS 2, EDS 3, and EDS 4 Solenoids are also pulse modulated but are exactly the opposite of EDS 1 Solenoid. When these solenoids are "ON" oil pressure in the hydraulic circuit is high, and when they are "OFF" pressure in the hydraulic circuit is low. Solenoid "OFF" (hydraulic pressure low), then Solenoid "ON" (hydraulic pressure high). Solenoid "ON" briefly (hydraulic pressure high), then Solenoid "OFF" (hydraulic pressure low). The pressure acts briefly on regulator valves to cushion clutch application. EDS 4 Solenoid is used for Torque Converter Clutch apply and release only, and depends on throttle position and vehicle speed as to its application.

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Technical Service Information SOLENOID AND SENSOR RESISTANCE CHART Case Connector Control Unit Connector Resistance Pin Numbers In Ohms Solenoid Pin Numbers MV 1 MV 2 MV 3 EDS 1 EDS 2 EDS 3 EDS 4

8 and 12 9 and 12 4 and 12 2 and 12 3 and 12 7 and 12 11 and 12

30 and 52 33 and 52 32 and 52 5 and 52 1 and 52 29 and 52 4 and 52

TOT OSS TSS

13 and 14 1 and 10 5 and 6

21 and 22 14 and 42 44 and 16

2

1000 W at 25° C 292 - 358 W 292 - 358 W

1

5

3

4 8

9 13

30 - 34 W 30 - 34 W 30 - 34 W 5.2 - 6.8 W 6.2 - 7.8 W 6.2 - 7.8 W 6.2 - 7.8 W

7

12

6 11

16

10 14

15

View Looking Into Case Connector

Electronic Control Unit Connector Pin Identification

28

27 55

88

26 54

87 86

25 53

85

24 52

84

23 51

83 82

22

21

20 19 18 17

50

49

48

47 46

81 80

79

78

77 76

45

16 15 14 44

75 74

43 42 73

72

13 12 11 41 40

71 70

39

10 38

69 68

9

8

37 36 67

66

6

7 35

34

65 64

5 33

63 62

4 32 61

3 31

60

2 30

59 58

1 29

57

56

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Technical Service Information

23

95 11

02

A

F.1

26

95

1 0 3 6 1 0 .5 4 3 2 3 7 5 0 . 4 0 3 0

21 3 1 0 5 6 70 1..513 428 42 . 01 3 4 . 0 0 0 1 5 60 73 F 1/2 10 . 29 3

F1 10

56

-4

2

7 -1

-N

14 7

31

8

10 26

95

10 31 56 4 .53 28 34 01 .00 5 F 1/ 2

9

95

ZF-5HP-19FL UPPER FRONT VALVE BODY

6 7

11

4

12 5

F1

1 10

2

56

-4

27

-1

-N

31

3

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Lu bric a tion V a lv e Tr a in Lu bric a tion V a lv e Re t a in er Lu bric a tion V a lv e Sprin g Lo c k-Up C ontrol V a lv e Sprin g Lo c k-Up C ontrol V a lv e TC C Pressure C ontrol Va lv e TC C Pressure C ontrol Va lv e Sprin g 4-5 Tr a ction Va lv e Sprin g 4-5 Tr a ction Va lv e Up p er Front V a lv e Bo d y Up p er Front V a lv e Bo d y C ov er C ov er Re t a inin g Scre ws (5 Re q uire d)

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Technical Service Information ZF-5HP-19FL UPPER REAR VALVE BODY

20 21 19

22

18 17

23

23

25

16 14

95

24

13

23

95 11

02

A 95

1 0 3 6 1 0 .5 4 3 2 3 7 5 0 . 4 0 3 0

21 3 1 0 5 6 70 1..513 428 42 . 01 3 4 . 0 0 0 1 5 60 73 F 1/2 10 . 29 3

F.1

26

15

95

1 0 3 6 1 0 .5 4 3 2 3 7 5 0 . 4 0 3 0

02

26

F1 10

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

Mo d ul a tion Pressure V a lv e Sprin g No.1 Mo d ul a tion Pressure V a lv e Mo d ul a tion Pressure V a lv e Re t a in er Mo d ul a tion Pressure V a lv e Sprin g No. 2 Mo d ul a tion Pressure Sle e v e Mo d ul a tion Pressure Bore Plu g Mo d u a ltion Pressure V a lv e Tr a in Re t a in er Pressure Re d u ction V a lv e No. 2 Re t a in er Pressure Re d u ction V a lv e No. 2 Sprin g Pressure Re d u ction V a lv e No. 2 Up p er Re a r V a lv e Bo d y EDS-1 Sole noid Re t a in er EDS-1 Sole noid Re t a in er Scre w EDS-1 Sole noid a n d "O" Rin g (Pressure Re g ul a tin g)

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56

-4

27

-1

-N

31

14 7

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Technical Service Information ZF-5HP-19FL LOWER FRONT VALVE BODY 39

46 47

44

40 42

45

41 37

43

38

59

32

36 35

48

33 31

27 28

34

49 51

58

29

50

30 52

26

53 54

55

56

57

26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42.

M a nu a l Shift V a lv e (W-S) "E" C lutc h D a m p er V a lv e "E" C lutc h D a m p er V a lv e Sprin g "E" C lutc h D a m p er V a lv e Sprin g Se a t "E" C lutc h A c c umul a tor Re g ul a tor V a lv e "E" C lutc h A c c umul a tor Re g ul a tor V a lv e Ret a in er M a in Pressure Re g ul a tor V a lv e Sprin g M a in Pressure Re g ul a tor V a lv e "D" C lutc h O n e-W a y C h e c k Va lv e Asse m bly 5-4 Tr a ction Va lv e 5-4 Tr a ction Va lv e Sprin g 5-4 Tr a ction V a lv e Bore Plu g 5-4 Tr a ction V a lv e Tr a in Ret a in er "A" C lutc h D a m p er V a lv e "A" C lutc h D a m p er V a lv e Sprin g "A" C lutc h D a m p er V a lv e Sprin g Se a t "A" C lutc h A c c umul a tor Re g ul a tor V a lv e Ret a in er

43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59.

"A" C lutc h A c c umul a tor Re g ul a tor V a lv e "G" C lutc h A c c umul a tor Re g ul a tor V a lv e "G" C lutc h A c c umul a tor Re g ul a tor V a lv e Sprin g "C" C lutc h A c c umul a tor Re g ul a tor V a lv e "C" C lutc h A c c umul a tor Re g ul a tor V a lv e Sprin g Low er Front V a lv e Bo d y "C" C lutc h Shift V a lv e "C" C lutc h Shift V a lv e Sprin g "C" C lutc h Shift V a lv e Ret a in er "G" C lutc h Shift V a lv e "G" C lutc h Shift V a lv e Sprin g "G" C lutc h Shift V a lv e Ret a in er Filter Se a l O il Filter O il Filter Ret a inin g Scre ws Low er V a lv e Bo d y C ov er Low er V a lv e Bo d y C ov er Scre ws (8 Re q uire d)

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Technical Service Information ZF-5HP-19FL LOWER REAR VALVE BODY

60

71

72

70 69

73

68

74

67

76

75 78

65

79

77 80

84

81

83

86

94

91

90

99

60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84.

96

89 98

97

62

64

93 100

95

87

63

61

92

85

82 88

66

103

101 102

104 105

Low er Re a r V a lv e Bo d y Num b er 1Shift V a lv e Num b er 1Shift V a lv e Sprin g Num b er 1Shift V a lv e Bore Plu g Num b er 1Shift V a lv e Ret a in er MV-3 Sole noid (O n-O ff) MV-2 Sole noid (O n-O ff) EDS-3 Sole noid a n d "O" Rin g (Pressure Re g ul a tin g) EDS-4 Sole noid a n d "O" Rin g (Pressure Re g ul a tin g) EDS-2 Sole noid a n d "O" Rin g (Pressure Re g ul a tin g) MV-1 Sole noid (O n-O ff) Sole noid Ret a inin g Br a c k ets (2 Re q uire d) Sole noid Ret a inin g Br a c k et Scre ws (4 Re q uire d) Tra ction C o a st Va lv e Tra ction C o a st Va lv e Sprin g Tra ction C o a st V a lv e Tr a in Ret a in er TC C Rele ase Re g ul a tor Va lv e TC C Rele ase Re g ul a tor Va lv e Sprin g TC C Rele ase Re g ul a tor Va lv e Tr a in Ret a in er Num b er 3 Shift V a lv e Num b er 3 Shift V a lv e Sprin g Num b er 3 Shift V a lv e Tr a in Bore Plu g Num b er 3 Shift V a lv e Tr a in Ret a in er "D" C lutc h A c c umul a tor Re g ul a tor V a lv e "D" C lutc h A c c umul a tor Re g ul a tor V a lv e Ret a in er

108

85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95. 96. 97. 98. 99. 100. 101. 102. 103. 104. 105. 106. 107. 108.

106 107

"D" C lutc h D a m p er V a lv e Sprin g Se a t "D" C lutc h D a m p er V a lv e O uter Sprin g "D" C lutc h D a m p er V a lv e Inn er Sprin g "D" C lutc h D a m p er V a lv e "D" C lutc h V a lv e Tr a in Bore Plu g "O" Rin g "D" C lutc h V a lv e Tr a in Bore Plu g "D" C lutc h V a lv e Tr a in Bore Plu g Ret a in er "F" C lutc h A c c umul a tor Re g ul a tor V a lv e Ret a in er "F" C lutc h A c c umul a tor Re g ul a tor V a lv e "F" C lutc h D a m p er V a lv e Sprin g Se a t "F" C lutc h D a m p er V a lv e Sprin g "F" C lutc h D a m p er V a lv e "F" C lutc h V a lv e Tr a in Bore Plu g "O" Rin g "F" C lutc h V a lv e Tra in Bore Plu g "F" C lutc h V a lv e Tra in Bore Plu g Ret a in er Re v erse G e ar V a lv e Re v erse G e ar V a lv e Sprin g Re v erse G e ar V a lv e Tra in Ret a in er Num b er 2 Shift V a lv e Num b er 2 Shift V a lv e Sprin g Num b er 2 Shift V a lv e Tr a in Ret a in er Pressure Re d u ction V a lv e Pressure Re d u ction V a lv e Sprin g Pressure Re d u ction V a lv e Tr a in Ret a in er

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Technical Service Information ZF-5HP-19FL TRANSFER PLATE, SPACER PLATE, AND TURBINE SPEED SENSOR 112

111

110

95 11

109

A 21 70 . 1 42 . 01 60 73 10 . 29 3

113 114

115

116

109. 110. 111. 112. 113. 114. 115. 116.

Tr a nsf er Pl a te Asse m bly Turbin e Sh a ft Sp e e d Se nsor Sp e e d Se nsor Sp a c ers (2 Re q uire d) Sp e e d Se nsor Re t a inin g Bolts (2 Re q uire d) Intern a l W irin g H a rn ess Asse m bly Intern a l W ire H a rn ess Re t a inin g Br a c k e t Sp a c er Pl a te To Tr a nsf er Pl a te G a sk e t V a lv e Bo d y Sp a c er Pl a te

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Technical Service Information ZF-5HP-19FL LOWER FRONT VALVE BODY

8 1

2 6

7 5

3

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

9

10

4

"C" CLUTC H A C CUMULATOR REGULATOR VALVE TRAIN LINE-UP. "G" CLUTC H A C CUMULATOR REGULATOR VALVE TRAIN LINE-UP. "C" CLUTC H SHIFT VALVE TRAIN LINE-UP. "G" CLUTC H SHIFT VALVE TRAIN LINE-UP. "A" CLUTC H A C CUMULATOR REGULATOR VALVE TRAIN LINE-UP. 5-4 TRA CTIO N VALVE TRAIN LINE-UP. MAIN PRESSURE REGUL ATOR VALVE TRAIN LINE-UP. "D" CLUTC H O NE-WAY C HECK VALVE ASSEMBLY. "E" CLUTC H A C CUMULATOR REGULATOR VALVE TRAIN LINE-UP. MANUAL SELECTOR SHIFT VALVE.

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Technical Service Information ZF-5HP-19FL UPPER FRONT VALVE BODY

3 2

1

4

1. 2. 3. 4.

LUBRIC ATIO N VALVE TRAIN LINE-UP. LO CK-UP C O NTROL VALVE TRAIN LINE-UP. LO CK-UP PRESSURE C O NTROL VALVE LINE-UP. 4-5 TRA CTIO N VALVE TRAIN LINE-UP.

ZF-5HP-19FL UPPER REAR VALVE BODY

EDS-1 6

5

5. M O DUL ATIO N PRESSURE VALVE TRAIN LINE-UP. 6. PRESSURE REDUCTIO N VALVE NUMBER TWO LINE-UP.

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BAC K B ACK

Technical Service Information ZF-5HP-19FL LOWER REAR VALVE BODY

MV-1

EDS-2

EDS-4

4

EDS-3

MV-2

MV-3

9

5 8

1

1. 2. 3. 4. 5. 6. 7. 8. 9.

2

6

3

7

TRA CTIO N C O AST VALVE TRAIN LINE-UP. TC C RELEASE REGULATOR VALVE TRAIN LINE-UP. NUMBER 3 SHIFT VALVE TRAIN LINE-UP. "D" CLUTC H A C CUMULATOR REGULATOR VALVE TRAIN LINE-UP. "F" CLUTC H A C CUMULATOR REGULATOR VALVE TRAIN LINE-UP. REVERSE GEAR VALVE TRAIN LINE-UP. NUMBER 2 SHIFT VALVE TRAIN LINE-UP. NUMBER 1 SHIFT VALVE TRAIN LINE-UP. PRESSURE REDUCTIO N VALVE TRAIN LINE-UP.

Copyright © 2000 ATSG

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BAC K B ACK

Technical Service Information ZF-5HP-19FL CHANNEL PLATE LOCATIONS

.042" Thick .098" Orifice

.236" Green Check Ball

Check Valve & Long Spring .042" Thick .074" Orifice

.042" Thick .046" Orifice

.042" Thick .066" Orifice

.042" Thick .046" Orifice

.042" Thick .098" Orifice

.042" Thick .038" Orifice Screen .042" Thick .038" Orifice

.042" Thick .022" Orifice

Check Valve & Short Spring

.042" Thick No Orifice

.236" Checkball

Rubber Plug

Rubber Plug

Rubber Plug

These 4 Plastic Orifice Plugs Are .112" Thick & .039" Orifice (All Others Are .042" Thick)

These are illustrations of an actual valve body for a ZF-5HP-19FL Model. Orifice locations and sizes may vary from model to model.

Copyright © 2000 ATSG

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