APRA Birmingham Hans-Peter Bach ZF Transmissions With Mechatronics

ZF Transmissions with Mechatronics
Hans-Peter Bach, Director Serivce (hans-peter.bach@zf.com) ZF Getriebe GmbH, Business Unit Automatic Transmissions
ZF Getriebe Gm mbH, 2006
Topics
Business unit Automatic transmission The 6HP gearbox-family Hints for the Hi t f th repair shop i h General hints gearbox change change of a mechatronic change of a oil pan and filter changing or adding oil
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APRA_Birmingham, November 2009
ZF confidential
P-Division ZF Getriebe GmbH Car Driveline Technology Locations
Saarbrcken (AT) Germany G
1973 Saarbrcken-Vlklingen, Plant 4 (DVZ / Logistic) G L i ti ) Germany
Brandenburg (MT/DT) Germany
1991
Kressbronn (R&D) Germany

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1969 Friedrichshafen (R&D) Germany

1988
Shanghai** (AT) China
2006
** Joint Venture with SAIC.
ZF confidential
Topics
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ZF confidential
Product History of the ZF 6-speed Automatic Transmission
1999
IAA in Frankfurt: First Prototype of a fully-automatic six-speed transmission fully automatic six speed World premiere: Start of volume production for the first automatic 6-speed transmission worldwide, the 6HP26; compared to automatic 5-speed transmissions: weight savings of 13% and 5 speed 30% less components Presentation of hybrid system (basis: 6HP26) at the IAA in Frankfurt Introduction of 2nd generation of automatic 6-speed transmissions with another 3-6% in fuel savings and even faster shift times (partly below the drivers limit of perception)
2001
2005
2006
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ZF confidential
Cutaway drawing 6HP26

torque converter pump simple planetary gearset gearbox housing clutch brake double pl. gearset ki lock parking l k wheel output flange
parking lock pawl
oilpan
oil il strainer
pressure regulator g
oil drain plug
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ZF confidential
6HP Product Family Improvements of the 2nd Generation
engin torque [N ne Nm]
2 nd generation
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ZF confidential
Second Generation of 6-speed Automatic Transmissions
The individual, automatic driving pleasure

Second generation of the 6HP S d i f h 6HP: Efficiency and increased performance for the leading 6-speed automatic transmission.
Considerable contribution to CO2 and/or fuel economy Increased power-to-weight ratio Optimized shift dynamics and improved subjective driving impression Shift times below the drivers limit of perception
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ZF confidential
Reduction of CO2 and Fuel Consumption

3-Gang 3-speed 4- Gang 4-speed
5-speed 5-Gang
6-Gang 6-speed
6-speed new generation 6-Gang T
- 6% - 2%
consumption Verbrauch
- 5%
Diesel
Benzin
- 3%
- 6%
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ZF confidential
Further development of shift dynamics

(2nd Generation of 6 speed transmissions) 6-speed
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 time
slippage time
shifting time
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Improvement shift dynamics
Vergleich Reaktionszeiten comparison reaction time

1200 1000
R Reaktionszeit in ms re eaction timi in ms me
6HP19 6HP21 DKG
800 600 400 200 0

S S S S S S S S S S S S S S S SR SR SR SR SR S S ZR 53 42 ZH ZH ZH ZH ZH ZR ZR ZR ZR ZR 21 32 43 54 65 12 23 34 45 56 21 32 43 54 65 64 ZR ZR S
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ZF confidential
Topics
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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 respected, respected the automatic transmission will be severely damaged!
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ZF confidential
Topics
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ZF confidential
Transmission ready to be installed into the vehicle
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ZF confidential
Transmission to be installed into the vehicle
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ZF confidential
Handling and Storage of an Automatic Transmission
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ZF confidential
Handling and Assembling of Automatic Transmission and Engine

Remove converter strap right before assembling the gearbox to the engine
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ZF confidential
Installation of the Torque Converter

Before assembling the transmission to the engine, it is important that the g g p torque converter is installed correctly (see manual of the special gearbox)
distance from bell housing to torque converter
t f th measurement of the distance with a deep gauge
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ZF confidential
Pump Gear
Driving i D i i pins of th pump can f the break
Effect:
- no power fl flow ( R,D ) RD
driving pin
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ZF confidential
Pump Gear
This damage is caused by the wrong installation of the transmission.
Driving pin is broken
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ZF confidential
Leakage between Engine and Transmission

Effect: leakage be ee e g e a d ea age between engine and transmission
Reasons: centre bush i missing i t b h is i i in crank shaft centre pin between engine and transmission is missing
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ZF confidential
Centre Bush
centre bush
After Aft assembling of th t bli f the transmission t th i i to the engine, dont forget to build in the centre bush! A missing centre bush cause damages of the torque converter and the oil pump!
position of the centre bush
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ZF confidential
Centre Pins
It is very important that the centre p y p pins are assembled to the engine case. Missing centre pins will cause damages in the transmission transmission.
center pin
center pin at an engine case
The two A describe the position of the centre pins
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ZF confidential
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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ZF confidential
The whole product family
6HP28A61
6HP28AF integrated 4x4
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ZF confidential
6 speed part numbers

Main Parts List 1071 010 1071 020 1071 040
4
Trans Type 6HP19 6HP19X 6HP19A 6HP26 6HP26X 6HP26A61 6HP32 6HP32A 6HP32X 6HP21 6HP21X 6HP28 6HP28X 6HP28A61 6HP28AF
Part Number Programmed 1071 012 1071 022 1071 042 1068 012 1068 022 1068 032 1070 012 1070 022 1070 032 1071 032 1071 052 1068 042 1068 052 1068 092 1084 032
Description Rear wheel drive External 4x4 Internal 4x4 Rear wheel drive External 4x4 Internal 4x4 Rear wheel drive Internal 4x4 External 4x4 Rear wheel drive External 4x4 Rear wheel drive External 4x4 Internal 4x4 Internal 4x4
ZF confidential
1068 010 1068 020 1068 030 1070 010 1070 020 1070 030 1071 030 1071 050 1068 040 1068 050 1068 090 1084 030
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6 speed transmission identification
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ZF confidential
Example transmission application BMW 745
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ZF confidential
Topics
Business unit Automatic transmissions The 6HP gearbox-family Hints for the Hi t f th repairshop i h General hints gearbox change change of a mechatronic change of a oilpan and filter changing or adding oil
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ZF confidential
Mechatronic on a special carrier
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ZF confidential
6HP..-Mechatronics
left side: E version / right side: M Version E-version M-Version
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ZF confidential
Mechatronik identification
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ZF confidential
Mechatronic replacement
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ZF confidential
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ZF confidential
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ZF confidential
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ZF confidential
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ZF confidential
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ZF confidential
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ZF confidential
Topics
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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 1068 298 033
name Oilpan
gearbox 6HP26 / 28 / 28X / 32 BMW
Customer
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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ZF confidential
Plate Oilpan and Oilfilter
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ZF confidential
ZF Part Number: Plate oilpan and Oilfilter 1

ZF-part number
1068 203 042 1068 203 044 1068 203 046 1068 203 048 0501 213 359 1068 303 017 1068 203 043 0501 212 974 1068 303 012 1068 203 047 0501 212 974 0501 322 155
Name
Oilpan Oil Oilpan Oilpan Oilpan Filter Sealing Oilpan Filter Sealing Oilpan Filter Sealing
Gearbox
6 HP 26 X 6 HP 26 X 6 HP 26 6 HP 26
Customer
Ford F d USA BMW Maserati Ford Australia
6 HP 26 A
Audi, Bentley
6 HP 26 A
Audi, Bentley
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ZF confidential
ZF Part Number: Plate oilpan and Oilfilter 2

ZF-part number
1070 203 010 0501 213 359 1068 301 01 017 1070 203 008 0501 212 974 1070 303 009 1071 203 038 0501 212 401 1071 303 006 1071 203 039 0501 212 401 0501 322 078 1071 203 040 0501 214 315 0501 322 077
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Name
Oilpan Filter Sealing S Oilpan Filter Sealing Oilpan Filter Sealing Oilpan Filter Sealing Oilpan Filter Sealing
Gearbox
6 HP 32
Customer
BMW
6 HP 32 A
VW
6 HP 19 A
Audi, VW
6 HP 19 A
Audi, VW
6 HP 19 X
Audi
ZF confidential
Topics
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ZF confidential
General Hints on Transmission Oil

Do not mix different oils unless this is expressly p p y prescribed.
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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ZF confidential
6HPxx transmission fluid level procedures
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ZF confidential
6HPxx transmission fluid level procedures
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ZF confidential
ATF Oil-Check 6HP19 A

Before drive test the ATF have to be filled up with the Lifeguardfluid 6 g ZF
Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature ( (CGT) 30 50 C ) Oil volume: 9 l transmission oil No. S671.090.255 (yellow) 1,05 l differential 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
only these 4 MPL!! VW 1071 040 010 1071 040 022

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Audi 1071 040 014 1071 040 044

ZF confidential
ATF Oil-Check 6HP26A61 Audi

Before drive test the ATF have to be filled up with the Lifeguardfluid 6 ZF Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature (CGT) 30 50 C Oil volume: 10 l transmission oil No. S671.090.255 (yellow) d 1 2 diff ( ll ) and 1,2 l differential oil No. i l il N S671.090.163 Version 1: Version 2: 0,96 l Torsen differential oil No. S671.090.163 and 0,04 l Sturaco oil No. S671.090.167 d 0 04 St il N S671 090 167 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 drive test the ATF have to be filled up with the ZF Lifeguardfluid 6 Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature (CGT) 30 50 C Oil volume: 11,2 l transmission oil No. S671.090.255 (yellow) 1,20 l differential oil No. S671.090.163 Version 1: Version 2: 1,20 l Torsen differential oil No. S671.0920.163 and 0,1 l Sturaco oil No. S671.090.167 1,680 l Torsen differential oil No. S671.090.163 and 0,12 l Sturaco oil No. S671.090.163 (only 1 MPL)
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ZF confidential
ATF Oil-Check 6HP32A VW

Before drive test the ATF have to be filled up with the Lifeguardfluid 6 ZF
Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature (CGT) 30 50 C Oil volume: 10 l transmission oil No S671 090 255 (yellow) No.S671.090.255 0,816 l differential oil No. S671.090.163 and 1,104 l Torsen differential 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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ZF confidential
ATF Oil-Check 6HP26A61 (W12)

Before drive test the ATF have to be filled up with the Lifeguardfluid 6 Plus ZF
Fill up instruction: The idle speed should be neng = 750 rpm p p g p and the transmission oil pan temperature (CGT) 30 50 C ( ) Oil volume: 10 l transmission oil No. S671.090.281 (blue) and 1,2 l differential oil No. S671.090.163 Version 1: 1,104 l Torsen differential oil No. S671.090.163 and 0,096 l Sturaco oil No. S671.090.167 Version 2: 1,008 l Torsen differential oil 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)
PLUS
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ZF confidential
ATF Oil-Check 6HP19A / X VW, Audi

Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature (CGT) 30 50 C Oil volume: 9 l transmission oil No. S671.090.311 (green) and 1,05 l differential oil No. S671.090.163 and 0,528 l Torsen differential oil No. S671.090.163 No S671 090 163 and 0,022 l Sturaco oil No. S671.090.167
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ZF confidential
ATF Oil-Check 6HP28AF Audi

Fill up instruction: The idle speed should be neng = 750 rpm and the transmission oil pan temperature (CGT) 30 50 C Oil volume: 10l transmission oil No. S671.090.311 (green) and 1,0 l differential oil No. S671.090.163 and 0,96 l Torsen differential oil No. S671.090.163 No S671 090 163 and 0,04 l Sturaco oil No. S671.090.167
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ZF confidential
Colour of Lifeguardfluid 8 (green)
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ZF confidential
Checking and top up the Oil
Lifeguardfluid 6 (yellow) BMW, Jaguar, Ford, Maserati, Hyundai, L.Rover, Aston Martin, RR, BMW, Bentley , y
for the gearbox types 6HP19/26/32/21/28/19X/26X/28X
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Lifetime Oil for 6-speed / 8-speed Transmissions
Artikel-Nr. / Part-No.
AA00 601 304
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Lifetime Oil for 6-speed Transmissions
S671.090.255
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Lifetime Oil for 6-speed Transmissions
plus
S671.090.281
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ZF confidential
Thank you very much for your attention!
MK/MKTA/sk 66
ZF confidential

APRA Birmingham Hans-Peter Bach ZF Transmissions With Mechatronics

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APRA Birmingham Hans-Peter Bach ZF Transmissions With Mechatronics

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ZF Transmissions with Mechatronics

ZF Getriebe Gm mbH, 2006

APRA_Birmingham, November 2009

P-Division ZF Getriebe GmbH Car Driveline Technology Locations

Saarbrcken (AT) Germany G

1973 Saarbrcken-Vlklingen, Plant 4 (DVZ / Logistic) G L i ti ) Germany

Brandenburg (MT/DT) Germany

Kressbronn (R&D) Germany

1969 Friedrichshafen (R&D) Germany

Shanghai** (AT) China

** Joint Venture with SAIC.

APRA_Birmingham, November 2009

Product History of the ZF 6-speed Automatic Transmission

APRA_Birmingham, November 2009

Cutaway drawing 6HP26

parking lock pawl

oil drain plug

APRA_Birmingham, November 2009

6HP Product Family Improvements of the 2nd Generation

engin torque [N ne Nm]

APRA_Birmingham, November 2009

Second Generation of 6-speed Automatic Transmissions

The individual, automatic driving pleasure

APRA_Birmingham, November 2009

Reduction of CO2 and Fuel Consumption

6-speed new generation 6-Gang T

APRA_Birmingham, November 2009

Further development of shift dynamics

APRA_Birmingham, November 2009

Improvement shift dynamics

Vergleich Reaktionszeiten comparison reaction time

6HP19 6HP21 DKG

800 600 400 200 0

APRA_Birmingham, November 2009

APRA_Birmingham, November 2009

Selector lever in N (neutral)

APRA_Birmingham, November 2009

APRA_Birmingham, November 2009

Transmission ready to be installed into the vehicle

APRA_Birmingham, November 2009

Transmission to be installed into the vehicle

APRA_Birmingham, November 2009

Handling and Storage of an Automatic Transmission

APRA_Birmingham, November 2009

Handling and Assembling of Automatic Transmission and Engine

APRA_Birmingham, November 2009

Installation of the Torque Converter

distance from bell housing to torque converter

t f th measurement of the distance with a deep gauge

APRA_Birmingham, November 2009

Driving i D i i pins of th pump can f the break

APRA_Birmingham, November 2009

This damage is caused by the wrong installation of the transmission.

Driving pin is broken

APRA_Birmingham, November 2009

Leakage between Engine and Transmission

APRA_Birmingham, November 2009

position of the centre bush

APRA_Birmingham, November 2009

center pin at an engine case

The two A describe the position of the centre pins

APRA_Birmingham, November 2009

APRA_Birmingham, November 2009