ZF5HP-19-complete.pdf

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Oil Pressure Checks

TCC release oil pressure tap Drive at stop cold 30 psi approx min. - 90 psi with throttle Drive at stop hot 10 psi approx min - 90 psi with throttle Drive with TCC commanded in 3rd, 4th & 5th = 35 psi partial apply - 0 psi to 4 psi fully applied

1

Clutch E 4th gear

Air Pressure Checks Clutch B Reverse

Cooler out

Clutch D Low/Rev

TCC apply Clutch F Overdrive Direct 3rd gear

Clutch C Intermediate 2nd & 5th gear Clutch A Forward

TCC Release

Clutch G Overrun

2

Air Pressure Checks

Clutch C Intermediate

Clutch A Forward

Clutch E 4th

Clutch B Reverse Clutch C Intermediate

3

Transmission ID Vent

Case connector Input shaft Tag - Data Plate Pump assm.

Oil Pan

Main line pressure tap

4

Transmission ID

Vent

Extension housing

Output flange

Cooler fitting Cooler fitting

Filler plug

Manual shaft

5

Oil Pan & Filter

Pan bolts #27 torx

6

Drain plug

Oil Pan & Filter

8 magnets Pan Gasket

7

Oil Pan & Filter 2 filter #40 Torx .660" Bolts. Torque 90 in lb.

Filter bolt

Filter bolt

8

Oil Pan & Filter Filter seal

Filter

Filter half metal - half plastic - felt type media

9

Lower front valve body

Filter bolt boss

Oil Pan & Filter Filter bolt boss

Lower rear valve body 10

Valve Body Connectors

Filter intake opening

Use scribe here to unlock connector.

Use scribe to pry up lock tab. Then remove connector.

11

Valve Body to Case Bolts 2.500 #40 Torx bolt 14 pcs Lower front valve body X

VB to case bolts at "X" locations. Torque 100 in lb.

X

X X X

X

X

X X

X X

X

X

X

Lower rear valve body 12

Valve Body EPC Connector Use scribe to pry clip as shown.

Clip

Then remove the connector from the EPC solenoid.

13

Valve Body Caution: Suction pipes have to be removed before trying to remove pump body.

Upper rear valve body

Suction pipe

Upper front valve body

Transfer plate

Lower front valve body

14

Drain back valve retainer. Push down and turn to release. Spring

Input speed sensor

Output speed sensor

Suction pipe

Bypass pipe

Drain back valve

15

Valve Body Bolts Lower front valve body

"A" 1.715 #27 Torx 10 pcs "B" 2.500 #27 Torx 11 pcs

B C

C

B "C" 1.920 #27 Torx 7 pcs

A B

C

C

B

B A

C

B

B A

A

Lower rear valve body

C

B

B

A B

A

B

C

A A

A

A

16

Transfer plate

Upper front valve body

Upper rear valve body 17

Upper front valve body

Clip faces as shown.

J

18

Clip faces as shown.

J

Cover plate 1.510 x .420 x .050

Lubrication valve train

Lockup control

1.878 x .383 x .036

1.454 x .365 x .040

TCC pressure control

1.580 x .305 x .028

4-5 traction

19

Clip faces as shown.

J

Upper front valve body

20

EDS-1 EPC solenoid

Upper rear valve body

Clip not necessary to remove.

Pressed in .044 plastic orifice

EDS-1 EPC solenoid

Clip faces as shown.

21

1.530 x .345 x .044

Pressure reduction valve #2

Clip faces as shown.

Modulating pressure sleeve

1.470 x .318 x .047

1.575 x .303 x .027

Modulating pressure

22

Upper rear valve body

EDS-1 EPC solenoid Pressed in .044 plastic orifice

23

Lower front valve body

Manual shift valve

24

Alignment dowel Clip faces as shown

Lower front valve body

25

Manual shift valve Cover plate

Clip faces as shown

3.450 x .598 x .044

"E" clutch damper

"E" clutch damper reg.

2.935 x .610 x .067

Main reg. valve 1.800 x .366 x .032 5-4 traction

3.500 x .598 x .065

"A" clutch damper

1.600 x .305 x .028 "G" clutch accum. reg. "C" clutch accum. reg. 1.610 x .370 x .032 26

Alignment dowel Clip faces as shown

Lower front valve body

27

1.755 x .360 x .040

"G" clutch shift valve

1.765 x .360 x .040

"C" clutch shift valve Cup side

28

Lower front valve body

29

Lower rear valve body Clip faces as shown

Clip faces as shown 30

O-ring

1.630 x .365 x .031 Traction coast valve 1.745 x .355 x .025 TCC release reg. 1.505 x .285 x .030 Cup side

Clip faces as shown

Number 3 shift

3.490 x .600 x .065 Clip faces as "D" clutch accum. reg. shown

"D" clutch damper O-ring

3.455 x .555 x .039 "F" clutch damper "F" clutch accum. reg. Reverse gear

1.630 x .365 x .032 1.615 x .365 x .032

Number 2 shift 1.490 x .355 x .045

Pressure reduction 31

Lower rear valve body MV-1 solenoid

EDS-2 solenoid

EDS-4 solenoid

EDS-3 solenoid

MV-2 solenoid

MV-3 solenoid 1.645 x .365 x .032 Number 1 shift 32

Lower rear valve body

33

Spacer Plate

34

Spacer Plate & Gasket

35

Spacer Plate Gasket

36

Tan one way disc no orifice hole .040 thick

Grey plastic .031 orifice .040 thick

Tan plastic .066 orifice .041 thick

Green plastic .075 orifice .041 thick

Transfer plate

Brown plastic .096 orifice .039 thick 2 pcs

Solenoid Accumulator

Tan one way .590x.475x.020 spring up

.234 plastic Check ball

Black one way .725x.366x.024 spring up

White .038 orifice .110 thick 3 pcs

Brown plastic .038 orifice .040 thick

.055 orifice Blue .040 thick .234 plastic check ball White .038 orifice .110 thick Same as above Tan one way 590x.475x.020 spring down

Filter screen Solenoid Accumulator

Tan plastic .066 orifice .041 thick

Purple plastic .045 orifice .045 thick 4 pcs.

Tan plastic .066 orifice .041 thick

37

Transfer plate

38

Transfer plate

39

Input sensor

Case Area Parts Low/reverse & overrun housing bolts

Park rod

Output sensor

40

Case Area Parts Rooster comb spring roller

Park rod retainer

Park Pawl

Park Pawl spring

41

Pump bolt & washer 2.912 9 pcs #27 Torx Torque to 18-20 Ft lb

Pump Assembly Pump Body

Clutch C Intermediate Clutch C Intermediate O-ring

Stator housing

42

Pump Assembly Pump Plate and gears Pump plate Pump gears dimples face up Align dowel

Align dowel

43

Stator Body O-ring

Seal rings

Stator shaft

44

Clutch C Intermediate housing

45

Stator housing B

"A" .790 5 pcs Removes stator shaft

B

A

B

A

B A

D

B

A

Clutch C Intermediate Housing

C

To separate pump Bolts torque 18 lb ft

B A B

All bolts are 27 Torx

B

"B" 1.570 8 pcs

"C" 1.880 1 pcs

"D" 2.309 1 pcs

Return spring

Retainers

Clutch C Intermediate Piston

46

Internal Components

Pump & "C" clutch assm.

Clutch A Forward

Clutch B Reverse

Clutch E 4th

4th clutch hub

47

Clutch A Forward Clutch hub

Snap ring

Internal Components

Output planet Shell

Intermediate shaft

Shell

Ring gear

48

Internal Components

Low/Reverse & Overrun housing

Overdrive ring gear & hub

Overdrive direct drum

Output flange & extension housing

Overdrive planet & ring gear

49

Clutch C Intermediate Clutch B Reverse .040-.050 clearance

Shim selective Bearing Clutch C Intermediate .030-.040 clearance

50

Clutch C Intermediate Snap Ring .087 thick .163 width .157 steel .063 friction .130 steel .063 friction .130 steel .063 friction .130 steel

.034 wavy

51

Clutch C Intermediate piston assembly

Spring retainer

Piston return spring

Clutch C piston Stator Body

piston o-ring seals

Clutch C piston housing

52

Clutch B Reverse

Snap Ring .062 thick .168 width .177 steel .079 friction .071 steel

Clearance .040-.050

.079 friction

.071 steel

.038 wavy

53

Clutch B Reverse drum disassembly Retaining half ring clips

Piston return spring

Clutch B piston

Piston o-ring seals

Clutch B drum

54

Clutch A Forward Clutch E 4th

Snap ring

Piston o-ring seals

Clutch E piston Clutch piston spring Clutch E piston Clutch A piston spring

Clutch E Piston o-ring seals

Clutch A piston

Input shaft

Snap ring

Clutch A piston o-ring seals

55

Snap Ring .077 thick .064 width

Clutch A Forward Clutches .177 steel .063 friction .071 steel .063 friction .071 steel .063 friction .071 steel .063 friction .071 steel

.063 friction .071 steel .040 wavy

56

Snap Ring .132 thick .157 width

Clutch E 4th Clutch

.137 steel .063 friction .070 steel .063 friction .070 steel .063 friction .070 steel .063 friction .070 steel .063 friction .070 steel .034 wavy

57

Race Bearing Race Race Bearing Race

Clutch E 4th hub

Clutch E 4th hub

58

Bearing

Clutch E 4th hub Shell

Bearing

Output planet

Race Bearing Race

Forward Clutch hub

59

Output Planet

Ring gear

Connecting shell

Snap ring

Intermediate shaft

Low /reverse & overrun housing 60

Low/Reverse & Overrun Housing fasteners

3 bolts 2.555x.388 50 Torx

61

Low/Reverse & Overrun Housing

Clutch D Low/Reverse .080 clearance faces pump

Clutch G Overrun .070 clearance faces rear

62

Low Sprag

Sprag Rotation

63

Clutch D Front Snap Ring .132 thick .157 width .070 steel .063 friction .070 steel Clearance .080 .063 friction .070 steel .063 friction .070 steel .063 friction .070 steel .063 friction .070 steel .063 friction .070 steel .044 wavy

64

Snap Ring .070 thick .157 width

Clutch G Rear .177 steel .063 friction .071steel

Clearance .070

.063 friction .071steel .063 friction .071 steel .063 friction .071 steel .035 wavy

65

Clutch D piston return spring snap ring

Retainer 3 tab Clutch G piston

Low Sprag

Clutch G piston o-ring seals

Teflon rings

race Clutch G Drum low/rev overrun housing O-ring seals 66

Clutch F Overdrive Direct

.100 clearance

67

Snap Ring .070 width .157 width

Clutch F Overdrive Direct .118 steel .063 friction .118 steel .063 friction .118 steel

Clearance .100

.063 friction .118 steel .063 friction .118 steel .063 friction .118 steel .035 wavy

68

Clutch F Overdrive Direct

piston retainer return spring

Clutch F piston o-rings Clutch F piston

Clutch F drum

69

Overdrive Planet Assembly Bearing race

Snap ring

Bearing

Bearing race

Overdrive ring gear hub

Overdrive ring gear & hub

Overdrive Ring gear

70

Overdrive Planet Assembly Bearing race Bearing

Bearing Bearing race

Overdrive ring gear & hub

Overdrive planet assembly

Spacer Snap ring

71

Overdrive Planet Assembly

Bearing Bearing

Overdrive sun gear Overdrive planet Bearing Exciter Ring Park wheel

72

Extension housing Output flange Extension housing

Out shaft flange O-ring Output flange Extension housing

Output flange

73

Extension housing Output shaft assembly

O-ring seal

74

Extension housing Output shaft assembly

Output seal

Ball bearing Bearing race

Ball bearing

Snap ring

Out shaft nut

Out shaft flange

Extension housing

75

Clutch-Solenoid Application Chart & Gear Ratios

Park MV1 Reverse MV1 & EDS3 Reverse inhibited MV1, EDS3 & MV3 Neutral MV1, MV2 & EDS3 1st MV1, MV2 & EDS3 2nd MV1, MV2, EDS3 & EDS2 3rd MV2, & EDS2 4th No power 5th MV3 & EDS2 TCC can be applied in 3rd, 4th & 5th

Park G Reverse G, B & D Neutral G 1st G, A & Low sprag 2nd G, A & C 3rd A, C & F 4th A, E & F 5th C, E & F TCC is applied in 3rd, 4th & 5th

Gear

Gear

Clutch

Solenoids

Gear Ratios

3.66 1.99 1.40 1.00 .74

1st 2nd 3rd 4th 5th

4.08

Reverse

76

Case Connector, Solenoids & Sensors TOT sensor in harness

Internal Harness

Clip

77

Case Connector, Solenoids & Sensors

Pin Identification 14 10 6

15 11

16 12

7

13

8 4

3 1

9 5

2

MV1 MV2 MV3 EDS1 EDS2 EDS3 EDS4 TOT ISS OSS

8 &16 9 & 16 4 & 16 2 & 16 3 & 12 7 & 12 11 & 16 13 & 14 5&6 1 & 10

30 OHMS 30 OHMS 30 OHMS 5.5 OHMS 6.5 OHMS 6.5 OHMS 6.5 OHMS 934 @ 70F 325 OHMS 325 OHMS

78

Case Connector, Solenoids & Sensors

ISS 325 OHMS

OSS 325 OHMS

TOT sensor is built into the harness.

79

Notes & Complaints Complaint: No reverse. Cause: Malfunctioning MV3 solenoid. This solenoid is used to inhibit reverse. If it is stuck or is commanded on by the controller there is no reverse. The controller will command this solenoid "ON" if it sees vehicle speed greater than 6 mph to inhibit reverse. Solution: Fix or repair solenoid or speed sensors as necessary. Check for amperage at this solenoid to see if the controller is causing reverse to be inhibited. Do the reverse lights work? The shift indicator and lever switch working correctly. Complaint: Rough shifts and downshift clunks after an O'haul. Cause: Controller has adapted to a worn or failed transmission. Solution: After an O'haul the controller should have the shift adapts reset with a scan tool. It may take 100 mile of adaptive learn before the trans begins to work smoothly. Notes: A generic scan tool may retrieve most codes but the factory scan tool is necessary to reset adaptive learn. Complaint: 2-3 and 4-5 spin up or slip at light and medium throttle. "F" clutch has good sealing rings in bore of drum or may have had late type drum update. "F" direct/ OD drum air checks well making one think problem is not drum. Cause: Low calibration of the "EDS2 solenoid" Factory tried to address this complaint with drum updates but it takes a higher calibration solenoid to fix the complaint. Solution: Replace "EDS2 solenoid". Replacement solenoids have a higher calibration to correct this complaint. Some vehicles had a light throttle 2-3 spin up and soft 4-5 shift brand new.

80