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ZF8HP Rebuild
Presented by: Mike Souza ATRA Senior Research Technician ZF8HP Rebuild Webinar ©2015 ATRA. All Rights Reserved.
Transmission Identification With all the different variations of parts found in several vehicle models, it’s always important to use the transmission ID information when ordering parts.
Location may vary per vehicle and model
Clutch & Gear Set Identification
P1
P2
P3
P4
Clutch Application Chart
Clutch Layout Carefully removed vertically as one assembly to prevent damage to the P4 annulus drum (shell). Splines into pump housing
A Clutch Pump Housing
Splines into main case
B Clutch Splines into C & E clutch drum
E Clutch
Case
Splines into C & E clutch drum
C Clutch Splines into D Clutch Drum
D Clutch
P4 Annulus Drum (shell)
C&E Clutch Drum D Clutch Drum
Drivetrain Assembly
Align With Rivet
One Time Use Selective Snap Ring
Drivetrain Assembly Carefully remove the snap ring to prevent damage to the P4 annulus drum (shell). This should be done with a factory tool or something similar such as a large hose clamp. The material of the shell is very brittle and can be broken or distorted easily.
To remove the snap ring start at 180 degrees opposite of the snap ring opening
Special thanks to Niel Speetjens for some of the photos used in this handout.
Miller Tools $115.00 Kits #10394 #10394A #10394B
Package of 3 2012 (LD, LX) 2013 (DS, LD, LX) 2014 (DS, LD, LX, WD, WK) Seen on the internet at lower & higher prices.
P1 & P2 Planet Assemblies P1 Ring Gear
P1 Planet
P2 Ring Gear / P3 Sun Gear
P2 Planet
P1 & P2 Sun Gear
P4 Sun Gear Shell (C & E Clutch Drum)
P3 & P4 Planet Assemblies P3 Planet
D Clutch Hub
P3 Ring Gear
E Clutch
C Clutch
D Clutch
P4 Planet P4 Sun Gear Shell (C & E Clutch Drum)
(D Clutch Drum)
P4 Annulus
E Clutch Assembly
C Clutch Assembly
D Clutch Assembly
D Clutch Assembly
Riveted D Clutch Piston
Balance Pistons As with any transmission with balance pistons, this is basically how they work. Balance Oil Function
Apply Piston
Return Cup Spring
Baffle Plate
Lube
Forward Clutch
Seal
This Oil Prevents The Clutches From Appling Due To Centrifugal Force More Reliable Clutch Engagement & Release Control At Any Speed Improves Shift Refinement
B Clutch Clearance Measurement
Factory Method Total clearance should be 1.52mm to 1.93mm (.060” to .076”) There are selective Pressure Plates available.
B Clutch Clearance Measurement
B Clutch Clearance Measurement Then flip the H-Gauge over and place onto the pump at the to case mating area. Measure the clearance at the apply piston.
1.52mm to 1.93mm (.060” to .076”)
This method will work with the rest of the clutch assemblies throughout the rest of this and other transmissions.
Clutch Clearances Clutch clearance is measured with the clutch components compressed within the drum with at least 45 lbs. of downward force on the pressure plate. Measure clearance with a feeler gauge between the pressure plate and the snap ring. Clutch
Clearance
Clutch A : 1.41mm to 1.7mm (.055” to .066”) Clutch B : 1.52mm to 1.93mm (.060” to .076”) Clutch C : 1.62mm to 2.01mm (.063” to .079”) Clutch D : 1.37mm to 1.66mm (.053” to .065”) Clutch E : 1.62mm to 2.01mm (.063” to .079”)
Adjusted By Snap Rings Backing Plates Backing Plates Snap Rings Backing Plates
Valve Body Information Lower Valve Body
Pry here to separate halves
The idea is to keep the separator plate with the upper valve body and contain the small parts
Pry here to separate halves
Upper Valve Body
Valve Body Separator Plate (Silk Screen)
Upper Valve Body Information Filter
Screen Flat side of accumulator faces up
7 Rocker Ball
Upper Valve Body Information
Small Parts Installation
Small Parts Installation Must Protrude Above The Channel Plate
Upper Valve Body Information
Upper Valve Body Information The B clutch NIC valve is controlled by the computer during an idle stop in drive. The computer will release the clutch partially to reduce engine drag at a stop for improved fuel economy
Upper Valve Body Information
Lower Valve Body Information
Bore Plug Installation
Lower Valve Body Information
Torque Converter & Pump Drive Assembly This ZF unit is designed with a chain driven, double stroke vane pump. The torque converter hub is splined to a drive sprocket that turns a chain to rotate the pump
Torque Converter & Pump Drive Assembly
Stator Support & Pump Assembly The stator support houses all the pump components. The stator support also houses the “A” clutch and “B” clutch piston and cylinder. The B1 clutch apply piston does not use return springs. The apply and release functions are controlled by the computer.
Stator Support & Pump Assembly To remove the “A” clutch pack from the stator support housing, remove the snap ring and lift the “A” clutch hub off of the stator support. The “A” clutch waved plate will remain in the stator support housing to be retrieved later. Once the Hub is removed, remove clutches from the hub for inspection. Remove the snap ring
Stator Support & Pump Assembly To remove the cover from the stator support and pump assembly, the “A” clutch piston and return spring must be removed from the stator support.
Remove the bolts to split the halves
Stator Support & Pump Assembly
Pump Assembly Use a screwdriver to gently pry the pump body out of the stator support assembly. The drive gear, chain and pump body must be lifted off the stator support as an assembly
Pump Assembly This vane type pump comes apart using a small pair of snap ring pliers. Remove the snap ring from the drive shaft and remove the cover. This vane type pump assembly is very small but efficient.
Pump Function This is a very small vane pump. The pump is built with two chambers. This means there are two inlets and two outlets to the pump body
Inlet
Outlet
Outlet
Inlet System pressure 80 psi to 250 psi (max. 460 psi) Displacement 1,85 US gallons to 5,81 US gallons a minute
Pump Function Reduces Cavitation & Noise
Pump Exploded View
Sprocket Side
Faces Down
Air check C & E Clutch with 30 psi. of regulated shop air.
TCC
Lube E Clutch
E Clutch
C Clutch
C Clutch
Case Air Checks Front of Transmission
Air checks should be done with no more than 30 psi. of regulated air pressure.
D Clutch
Sump (pan) Differences There is a deeper sump (pan) for the 845RE found in the Jeep Grand Cherokee. This pan will increase fluid capacity and improve lubrication.
Filter is part of the Sump
Recommended Fluid ZF Lifeguard is the recommended type of fluid to be used. Fluid capacities are model dependent.
Service & Fill Procedure Using a scan tool or the vehicle information center, verify that the transmission fluid temperature is below 30˚C (86˚F).
Torque Specifications Extension Housing to Transmission Bolt ...................... 20 Ft. Lbs. Manual Park Release Cable to Case Bolt....................... 15 Ft. Lbs. Manual Park Release Lever Shaft Nut ............................ 89 In. Lbs. Manual Park Release Lever Assembly Nut .................... 89 In. Lbs. Oil Pan Drain Plug ............................................................ 80 In. Lbs. Oil Fill Plug ........................................................................ 26 Ft. Lbs. Oil Pan Bolt ....................................................................... 89 In. Lbs. Oil Pump Assembly to Case Bolt..................................... 44 In. Lbs. + 45˚ Oil Pump Housing to Cover Bolt...................................... 44 In. Lbs. + 45˚ Output Speed Sensor Bolt ............................................... 71 In. Lbs. Torque Converter Bolt...................................................... 31 Ft. Lbs. Park Pawl Lock Rod Guide Plate Bolt ............................ 89 In. Lbs. Park Pawl Shaft Plug ........................................................ 26 Ft. Lbs. Propeller Shaft Flange Nut............................................... 44 Ft. Lbs. Shifter Assembly Bolts..................................................... 65 In. Lbs. Shifter Knob Lower Shroud Bolt..................................... 65 In. Lbs. Torque Converter to Flex Plate Bolt ............................... 31 Ft. Lbs. Transfer Case to Transmission Nut ................................ 20 Ft. Lbs. Transmission Mount to Adapter...................................... 24 Ft. Lbs. Valve Body Bolt................................................................. 71 In. Lbs. Transmission Heater to Transmission............................ 18 Ft. Lbs.
TCM Adaptation It is necessary to perform a drive cycle to provide the proper baseline transmission adaptation. The adaptation procedure should be performed if any of the following procedures are performed: • Transmission Assembly Replacement • Transmission Control Module Assembly (TCMA) Replacement • Internal Transmission repairs • Torque Converter Replacement 1. With the scan tool, clear any DTCs that may be set. 2. Drive the vehicle until the vehicle temperature is greater than 30˚C (86˚F). 3. After the vehicle has reached normal operating temperature, and with the scan tool, monitor actual gear state. Drive the vehicle normally with the accelerator pedal between 10% and 20% until 7th gear has been achieved, approximately 76 km/h (47 mph). After 7th gear has been achieved, coast down to 30 mph with no application of the brake or accelerator to allow a 6-5 shift. Brake the vehicle to a stop. Repeat this procedure 5 times.
Audi ATF Venting System The ATF system ventilates into the converter bell housing through ducts inside the gear case. The front axle differential breather is present only in transmissions with a separate oil system. Don’t mistake oil from the vent as a front seal leak.
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