Professional Documents
Culture Documents
6HP26 Repair Manual
6HP26 Repair Manual
6 HP- 26
subject to alterations
Copyright 2002 all rights reserved and published by
ZF Getriebe GmbH, Saarbrcken, Department MKTD
No part of this manual may be reproduced or transmitted in any form or
by any means, electronic or mechanical, including photocopying and recording,
for any purpose without the express written permission of
ZF Getriebe GmbH, Saarbrcken
Printed in Germany
Contents
Advance Information
1.
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
2.
2.1
2.2
2.3
2.4
2.5
2.6
2.7
3.
3.1
3.2
3.3
3.4
3.5
3.6
3.7
General
Illustration of transmission
Power flow diagram
Specifications
1.3.1 Screw specifications
1.3.1.1 Mechatronic type E
1.3.1.2 Mechatronic type M
Adjusting procedure
1.4.0 Measuring clutch packs
1.4.1 Clearance setting, brake C
1.4.2 Clearance setting, brake D
1.4.3 Clearance setting, clutch B
1.4.4 Clearance setting, clutch A
1.4.5 Clearance setting, clutch E
1.4.6 Clearance - output
1.4.7 Clearance - input
(M type only)
1.4.8 Switch setting
Tightening torques
Transmission test (test bench)
Special tools
Oilflow chart (Position N)
(E - type)
(M - type)
iii
1.1/1
1.1/1
1.2/1
1.3/1
1.3/1
1.3/1
1.3/1
1.4/1
1.4/1
1.4/3
1.4/5
1.4/7
1.4/9
1.4/11
1.4/13
1.4/14
(procedure)
(snap ring)
(snap ring)
(snap ring)
(snap ring)
(snap ring)
(disk)
(disk)
(detent spring)
1.4/15
1.5/1
1.6/1
1.7/1
1.8/1
1.8/1
1.8/2
Disassembly
Transmission disassembly according to component groups
Dismantling
Turret (with clutches A and E)
Oil supply
Clutch B
Brakes C and D
Output shaft with parking lock
Transmission casing with shiftcontrol and parking lock
2.1/1
2.1/1
Assembly
Transmission casing with shift control and parking lock
Output shaft with parking lock and planetary gear set
Brakes C and D
Clutch B
Turret (drive with clutches A and E)
3.5.1 Clutch E (drive)
3.5.2 Clutch A (input)
Oil supply
Mechatronics, oil pan and converter
(Complete mechatronics, see spare parts list, technical cover sheet, item YO2)
3.1/1
3.1/1
3.2/1
3.3/1
3.4/1
3.5/1
3.5/1
3.5/4
3.6/1
CD
2.2/1
2.3/1
2.4/1
2.5/1
2.6/1
2.7/1
3.7/1
ii
CD
Advance Information
These instructions contain the procedure for repair work on the complete transmission.
The repair instructions will only be understood sufficiently in combination with ZFS training.
Neglecting this could lead to installation errors.
All disassembly and assembly work is listed in chronological order.
Photos and illustrations for the various applications are general in character and not binding for every
individual case.
Important changes and those relevant to specific applications that have to be considered during repair
work are announced in Technical Circular Letters and training courses.
During the repair work ELCAT regulations and specifications must be observed.
The following requirements should be satisfied before starting the repair work:
Availability of the necessary special tools otherwise assembly faults are possible.
Chapter 1.8 lists the complete set of special tools.
Availability of a suitable transmission test rig.
For the necessary test values, please refer to the Technical Circular Letters.
CD
iii
Note:
In the instructions the shift control unit is considered as a complete unit. It must not be dismantled
without special experience, but should be exchanged as a complete unit.
Warning:
The transmission is filled for life with oil.
An oil change is not necessary before 160 000 km or 10 years.
Make sure that the transmission is delivered with the oil quantity and oil type specified in the relevant
part list document (see ELCAT).
.
Techn. KD
Techn. Documentation
KD Training
Bach
Reus
Schultz
iv
CD
1.
1.1
General
Illustration of transmission
CD
1.1/1
1.2
CD
1.2/1
1.3
Specifications
1.3.1 Screw specifications
1.3.1.1 Mechatronic type E
Tighten screws of the type E mechatronic
in the order of the numbering (see diagram)
1 2 3 ... 10
Important!
Specification 1068 700 152
(Tightening torque: see Chapter 1.5)
Important!
Specification 1068 700 152
(Tightening torque: see Chapter 1.5)
CD
1.3/1
1.4
Adjusting procedure
1.4.0 Measuring clutch packs
(procedure)
Place the two intermediate pieces
5p01 050 329/5p01 060 329 on the
marked position on measuring fixture
5p01 000 330.
98009
98011
CD
1.4/1
98017
98018
Note!
In each case, the X index in MX stands
for the brake/ clutch clutch packs that are
put in (A, B, C, D, E).
1.4/2
CD
CD
1.4/3
EC
=
=
=
=
PC
SC
29.05 + 1.48
30.53 mm
30.53 25.49
5.04 mm
= 3.36 mm
LC = 5.04 3.36
LC = 1.68 mm
1.4/4
CD
02027
01271
02028
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
1.4/5
01270
=
=
=
=
247.9 mm
214.5 mm
23.23 mm
4.3 mm
ED
=
=
=
=
247.9 214.7
33.2 mm
23.23 + 4.3
27.53 mm
PD
SD
= 3.3 mm
CD
CD
1.4/7
EB
=
=
=
=
PB
SB
25.8 + 1.48
27.28 mm
27.28 21.92
5.36 mm
= 3.8 mm
LB = 5.36 mm 3.8 mm
LB = 1.56 mm
1.4/8
CD
CD
1.4/9
EA
=
=
=
=
PA
SA
26.15 + 1.48
27.63 mm
27.63 22.38
5.25 mm
= 3.4 mm
LA = 5.25 3.4
LA = 1.85 mm
1.4/10
CD
CD
1.4/11
EE
=
=
=
=
PE
SE
30.27 + 1.48
31.75 mm
31.75 27.43
4.32 mm
= 2.4 mm
LE = 4.32 2.4
LE = 1.92 mm
1.4/12
CD
01266
01267
= 0.15 mm
= 0.15 to 0.35 mm
disk o.k.
CD
1.4/13
Requirements:
Shim 10.090 (thickness = 2.6 mm,
thinnest according to WTB) is in position
01322
01321
1.4/14
CD
(M type only)
1.4.8 Switch setting (detent spring)
Set locking disk with appropriate tool or
manually to N position (neutral).
02022
02023
02024
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
1.4/15
1.5
Tightening torques
No. Designation
Part ListItem-No.
Wrench size
No.
Page
Tightening
torque [Nm]
12 Nm
(1.2 Nm)
1 Screw plug
(transmission housing)
01.100
Hexagonal socket
Size = 5 mm
3.1/2
2 Machine screw
(detent spring M type)
06.090
TORX - TX 27 H
1.4/15 10 Nm + 30
3.1/3 (0.3 Nm 10)
3 Machine screw
(guide plate)
24.120
TORX - TX 27
3.1/4
10 Nm
(1.0 Nm)
24.020
Hexagonal socket
Size = 6 mm
3.1/4
23 Nm
(2.3 Nm)
5 Hex bolt
(lever)
06.190
Hex
Size = 13 mm
3.1/5
9.5 Nm
(1.0 Nm)
6 Machine screw
(emergency release, E type)
06.210
TORX - TX 27
3.1/5
10 Nm
(1.0 Nm)
7 Castellated nut
14.160
(output without Helium-WDR)
(output with Helium-WDR)
Socket wrench
5X46 002 456
5X46 002 456
3.2/3
80 Nm
(8.0 Nm)
60 Nm
(6.0 Nm)
8 Machine screw
10.040/150 TORX - TX 27
(stator shaft/intermediate plate)
3.6/3
15 Nm
(1.5 Nm)
9 Machine screw
10.040/180 TORX - TX 27
(intermediate plate/centering plate)
3.6/3
10 Nm
(1.0 Nm)
10 Machine screw
10.050
(stator shaft/centering plate)
TORX - TX 27
3.6/3
15 Nm
(1.5 Nm)
11 Countersunk screw
(intermediate plate/pump)
10.080
TORX - TX 27
1.4/14
3.6/4
10 Nm
(1.0 Nm)
12 Countersunk screw
(intermediate plate/pump)
10.084
TORX - TX 27
1.4/14
3.6/4
10 Nm
(1.0 Nm)
13 Machine screw
(Mechatronic)
27.450
27.500
TORX - TX 30
1.3/1
3.7/3
8 Nm
(0,8 Nm)
14 Machine screw
(oil pan)
03.020
TORX - TX 27
3.7/4
8 Nm
(0,8 Nm)
01.140
Hexagonal socket
Size = 8 mm
3.7/4
35 Nm
(3,5 Nm)
CD
1.5/1
No. Designation
Part ListItem-No.
1.5/2
Wrench size
No.
CD
Page
Tightening
torque [Nm]
3.7/5
9 Nm
(-1.0 Nm)
3.7/5
15 Nm
(1.5 Nm)
3.7/5
15 Nm
(1.5 Nm)
Size = 13 mm
Size = 17 mm
1.6
CD
1.6/1
1.7
Special tools
OBJECT
Order-No. / Application
Remarks
identical
4 HP 20
5 HP 19
5 HP 19 FL/A
5 HP 24
5 HP 24 A
98008
2
identical
4 HP 20
5 HP 19
5 HP 19 FL/A
5 HP 24
5 HP 24 A
98034
3
identical
4 HP 18 Q
4 HP 20
5 HP 19
5 HP 19 FL/A
5 HP 24
5 HP 24 A
97301
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
1.7/1
Remarks
Order-No. / Application
OBJECT
02001
identical
5 HP 18
02014
1.7/2
CD
OBJECT
Order-No. / Application
Remarks
identical
4 HP 18 Q
5 HP 24
5 HP 24 A
97306
8
identical
4 HP 18 Q
5 HP 19
98135
9
identical
5 HP 18
5 HP 24 A
5 HP 30
91190
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
1.7/3
Remarks
identical
Order-No. / Application
OBJECT
10
4 HP 20
5 HP 18
5 HP 30
91199
identical
11
5 HP 24
5 HP 24 A
5 HP 30
92214
identical
12
5 HP 19
5 HP 19 FL/A
5 HP 24
5 HP 24 A
92223
1.7/4
CD
OBJECT
13
Order-No. / Application
Remarks
identical
5 HP 24
97307
14
15
02002
02003
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
1.7/5
Remarks
Order-No. / Application
OBJECT
16
02004
17
02005
18
02006
1.7/6
CD
OBJECT
Order-No. / Application
19
20
21
Remarks
02007
02008
02009
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
1.7/7
Remarks
identical
Order-No. / Application
OBJECT
22
5 HP 24
5 HP 24 A
97312
23
02011
24
02012
1.7/8
CD
OBJECT
Order-No. / Application
25
26
Remarks
76046
97315
27, 28, 29
02036
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
1.7/9
Remarks
Order-No. / Application
OBJECT
30
(M type only)
5w04 000 583
Torsional measuring device,
detent spring assembly
98002
31
02026
1.7/10
CD
1.8
CD
1.8/1
(M - type)
1.8/2
CD
2.
2.1
Disassembly
Transmission disassembly
according to component groups
01202
01203
Warning!
Oil may be spilled.
Do not damage converter bearings and
shaft sealing ring of the pump.
01204
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
2.1/1
02016
01205
01206
2.1/2
CD
01207
01208
01209
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
2.1/3
Warning!
The second angled thrust washer is
located in the hub of internal disk carrier
B and could be loosened during cleaning.
01210
Risk of loss!
01211
01212
2.1/4
CD
01213
01214
03001
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
2.1/5
01215
2.1/6
CD
2.2
Dismantling
Turret (with clutches A and E)
01221
01222
01223
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
2.2/1
Note:
Drive shaft is splined to clutch E.
01224
01225
01226
2.2/2
CD
01227
02015
01229
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
2.2/3
01230
01231
Pull the O-ring seal and 3 rectangularsection rings off the drive shaft.
Note!
Unclip needle roller bearing if defective.
2.2/4
CD
01232
6 HP 26 ZF Getriebe GmbH Saarbrcken 02/11/01
2.3
Oil supply
01216
01217
01218
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
2.3/1
Remark
Needle roller bearing will be destroyed
und must be renewed
01219
01220
2.3/2
CD
2.4
Clutch B
01233
01234
01235
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
2.4/1
01236
2.4/2
CD
2.5
Brakes C and D
01237
02029
02030
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
2.5/1
02031
01241
2.5/2
CD
2.6
01242
CD
2.6/1
2.7
01243
(for E Version)
Drive clamping sleeve out of parking
disk with a suitable mandrel and pull out
selector shaft.
Remove sleeve and spring.
Next, take out parking disk with
connecting rod. Lever out the shaft
sealing ring with a screwdriver.
Loosen the 2 Torx screws for the
emergency release angle and take it off.
01244
(for M Version)
Drive clamping sleeve out of detent disk
with a suitable mandrel and pull out
selector shaft.
Next take out the detent disk with
connecting rod. Lever out the shaft seal
ring with a screwdriver.
The detent spring normally remains in
the transmission casing.
To remove it, loosen the two Torx screws.
(Wrench size = Torx - TX 27 H)
02020
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
2.7/1
01245
01246
01247
2.7/2
CD
01248
01249
CD
2.7/3
3.
3.1
Assembly
Transmission casing with shift control and parking lock
24.020
24.010
24.060
24.040
24.080
24.110
24.120
01.070
01.010
06.210
/110
01.100
01.220
/120
06.050
E-Typ
06.170
06.090
/130
06.070
06.030
06.094
06.100
06.060
E-Typ
06.010
06.150
06.190
06.050
M-Typ
CD
3.1/1
Warning!
This is only necessary with a new
transmission casing.
01250
01252
01251
3.1/2
CD
01255
(With M type and new housing only)
Attach detent spring 06.090 loosely with
2 Torx screws 06.100, so that the detent
spring can still be repositioned slightly.
02019
Warning!
Renewal of transmission casing, detent
spring, detent disk or selector shaft, or
loosening of the detent spring, requires
new adjustment of the switch (detent
spring).
01256
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
Warning!
For the E type, first push spring 06.090
over selector shaft.
CD
3.1/3
(E type only)
Drive in new dowel pin 06.060
with striker pin 5x46 000 291 or an
appropriate mandrel in the correct
position.
Warning: E type
Slight spring pre-tensioning is required
to permit installation of the parking lock
when there is no current flow.
01257
(M type only)
Drive in new dowel pin 06.060
with striker pin 5x46 000 291 or an
appropriate mandrel in the correct
position.
Warning!
Adjustment required ! Chapter 1.4.8
02021
01258
3.1/4
CD
01259
(E type only)
Attach emergency release angle 06.170
with two Torx screws 06.210
Fasten lever 06.150 facing the oil pan
side with nut 06.190.
(for tightening torque see Chapter 1.5)
01260
CD
3.1/5
3.2
42.010
/260
/290
/250
/280
42.180
/310
42.190
42.170
42.200
42.210
14.140
14.110
14.150
14.160
14.130
14.090
14.070
14.050
14.040
14.020
01249
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
3.2/1
01261
01262
01264
3.2/2
CD
01265
02038
02037
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
3.2/3
03001
01268
Warning!
Insert sun wheel 2 with large turned
groove on top.
3.2/4
CD
03005
6 HP 26 ZF Getriebe GmbH Saarbrcken 02/11/01
3.3
Brakes C and D
75.040
75.050
75.030
75.070
75.080
75.084
73.260
73.320
75.100
75.140
75.120
73.230
75.160
75.180
73.120
73.250
73.240
73.130
73.210
73.060
73.110
73.070
73.010
73.020
73.080
73.100
73.030
75.010
75.010/140
01272
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
3.3/1
01273
02031
01275
3.3/2
CD
01276
02032
01281
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
Note:
For adjusting work see Chapter 1.4.2
CD
3.3/3
01283
Note:
For adjusting work see Chapter 1.4.3
01282
01284
3.3/4
CD
02034
Note
Dismount the handle of the tool for a
better usibility.
CD
3.3/5
3.4
Clutch B
72.050
72.020
72.060
72.100
72.080
72.110
72.070
72.130
72.140
72.120
72.124
72.150
73.300
72.144
72.010
72.200
75.200
72.170
01285
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
3.4/1
01286
Warning!
For adjusting work see Chapter 1.4.3
01289
Turn the cylinder and pull 2 rectangularsection rings 72.200 onto cylinder B.
Clip bearing 73.300 onto cylinder B.
Warning!
Secure new rectangular-section rings in
the groove with Vaseline.
3.4/2
CD
01290
6 HP 26 ZF Getriebe GmbH Saarbrcken 02/11/01
01291
CD
3.4/3
3.5
Turret (drive with clutches A and E)
3.5.1 Clutch E (drive)
71.180
71.150
71.160
71.150
71.140
71.100
71.080 71.094
71.090
71.060
71.020
71.030
71.010
71.040
71.190
32.100
01292
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
3.5/1
01293
01294
01295
3.5/2
CD
01298
Note:
For adjusting work, see Chapter 1.4.5
CD
3.5/3
32.010
/210
/220
70.080
70.100
70.090
70.060
70.030
70.040
71.240
70.050
71.290
70.010
71.280
10.090
70.170
71.260
70.140
71.310
71.330
72.210
70.150
70.140
70.130
71.300
01299
3.5/4
CD
01300
01301
01304
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
Note:
For adjusting work, see Chapter 1.4.4
CD
3.5/5
01305
01306
01307
3.5/6
CD
01308
01309
01310
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
3.5/7
Check measurement:
Upper edge of cylinder A to oil supply
sealing face approx. 12 mm.
Note:
This measurement does not include the
thickness of the measuring bar.
3.5/8
CD
01311
3.6
Oil supply
10.040
/160
/150
/170
/110
10.050
/130
/180
10.070
10.020
10.010
10.084
10.080
/150
/160
/170
01312
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
3.6/1
01313
01314
01315
3.6/2
CD
01316
01318
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
Note:
Check pump with sleeve 5x46 000 306
for free running. Pump wheels must
rotate easily when turned.
CD
3.6/3
01319
Note:
For adjusting work, see Chapter 1.4.7
3.6/4
CD
01320
3.7
01.080
01.140
97.020
97.010
97.020
22.010
97.030
27.700
01.050
01.050
01.060
01.064
27.520
27.460
27. 500
27. 500
27. 500
27. 450
27. 450
/010
/020
03.010
/030
03.020
CD
03.080
3.7/1
Warning!
Note the correct lengths of the sealing
sleeves. All of them must project by the
same amount.
01323
01324
01325
3.7/2
CD
01326
Note:
For screw specifications, see
Chapter 1.3.1
01327
01328
02/11/01 6 HP 26 ZF Getriebe GmbH Saarbrcken
CD
3.7/3
Warning!
For BMW cars a label 03.080 (oil filling)
must be attached to the oil pan.
01329
01330
01331
3.7/4
CD
01332
Warning!
When inserting, make sure that the drive
pins are not damaged.
01333
Warning!
Converter fastening screw 97.030 must
not be too long - recommended length
16 mm - otherwise there is a risk of
damaging the converter and thus causing
the lock-up clutch to malfunction.
CD
3.7/5
Note!
Right-hand-drive cars have 2 plugs at the
selector shaft.
3.7/6
CD
01334