Professional Documents
Culture Documents
ZF 8HP45, 845RE, 8HP70 Service Manual PDF
ZF 8HP45, 845RE, 8HP70 Service Manual PDF
Service Information Highlights and Tech News
INTRODUCTION
This month, we have two Master Tech programs. The first program will focus on the three
different 8-speed transmissions offered in Chrysler Group vehicles: the 8HP45, the 845RE,
and the 8HP70 (Fig. 1). We’ll give a brief overview of the 8HP45 before we talk about some
of the things you can look forward to in the near future.
We’ll give a brief overview of the 8HP45 before we talk about some of the things you can
look forward to in the near future. We’ll then turn our attention to the 845RE. After
discussing what vehicles you’ll find the 845RE in, we’ll get into some of the internal
components and discuss some of the service implications, focusing on how it differs from the
8HP45 and 845RE. Then we’re going to spend time looking at the service procedures that
are unique and noteworthy.
November 2012 Page 2
Service Information Update Reference Book
and Tech News
November 2012 Page 3
Service Information Update Reference Book
and Tech News
8SPEED TRANSMISSION OVERVIEW
The 8HP45 was covered in-depth in the In mid-2013, the Ram 1500 will switch
June 2011 Master Tech program. If you from the ZF-built 8HP45 to the Chrysler-
missed that one, you’ll want to go back built 845RE, still paired only with the
and review the program. Here is a quick 3.6L V-6.
overview.
The 8HP45 and 845RE transmissions look
The 8HP45 is built by ZF in Germany. It nearly identical from the outside. It’s only
arrives in the U.S. and is installed as an when you get inside the case that things
assembly. This transmission was start to look different (Fig. 4).
launched in the 2012 model year in the
Dodge Charger and Chrysler 300. For the
2013 model year you’ll also find the 8HP45
in the Ram 1500.
November 2012 Page 4
Service Information Update Reference Book
and Tech News
You’ll also notice a deeper oil pan on the 845RE used in the Grand Cherokee. This gives
not only increased fluid capacity, but also improves lubrication (despite the angle of
installation) (Fig. 6).
The ZF-built transmissions can only be While a few parts are interchangeable,
serviced to a certain extent while under most are not. The 8HP70 is a larger,
warranty. Refer to warranty bulletin D- heavier-duty version of the 8HP45.
12-21 for more information. The 8HP70
8-speed automatic transmission is built by Due to the increased size, you’ll find the
ZF in Germany and received as an majority of the internal components such
assembly. as rotating components, the case, and
output shafts (among others), are not
This new transmission will roll out in the interchangeable. The majority of the
2013 calendar year in the Ram 1500, Jeep service tools, as well as diagnostics, are
Grand Cherokee, and the Dodge Durango. common between the 8HP45 and the
8HP70.
The 8HP70 looks similar to the 8HP45,
being almost the same length, even
having similar components (Fig. 7).
November 2012 Page 5
Service Information Update Reference Book
and Tech News
8SPEED TRANSMISSION SERVICE
The first procedure we’ll cover is the
manual park release. There are two
different procedures: one for cars, and one
for the Ram truck.
November 2012 Page 6
Service Information Update Reference Book
and Tech News
Speaking of fluid, the fluid check and fill When disassembling the transmission, it’s
procedures were covered in depth in our important to note that the gear train
June 2011 release for the 8HP45. It is the needs to be removed vertically. The
same procedure for the 845RE and 8HP70 drums are aluminum and are easily
with the exception of fluid volumes. damaged (Fig. 12).
November 2012 Page 7
Service Information Update Reference Book
and Tech News
The first measurement we need is the depth of the bore in the housing where the B clutch
sits (Fig. 14). This dimension represents the total area filled by the B piston and clutch
pack.
Figure 14: The Bore Where the B Piston and Clutch Sit
The second measurement is the height of the clutch pack after it has been compressed. The
pressure against strain gauge special tool number 10429 must match the specification given
in the service information (Fig. 15). We are using portions of special tool number 8901A
that was designed for the NAG1 transmission.
November 2012 Page 8
Service Information Update Reference Book
and Tech News
The final measurement we need is the height from the B clutch piston to the oil pump
housing mating surface (Fig. 16).
Figure 16: B Clutch Piston to Oil Pump Housing Mating Surface Measurement
Subtract the B piston measurement and the clutch height measurement from the bore
depth and you have your end clearance measurement. We are looking for a clutch pack end
clearance between 1.26 mm and 1.67 mm. To adjust the clutch pack clearance within
specifications, the flange plate is available in different thicknesses. Select the appropriate
size. After replacing the flange plate, take the measurements again.
Besides the snap rings mentioned earlier, the oil pump bolts, the pump housing bolts, as
well as the valve body bolts are one-time use. Refer to service information for more detail.
A note about gear train end play: Because the oil pump housing bolts are one-time use
bolts, it is a good idea to use the old bolts while adjusting the end play. After the correct
end play has been established, use new bolts for the final installation of the oil pump
housing.
November 2012 Page 9
Service Information Update Reference Book
and Tech News
FUEL EFFICIENCY IMPROVEMENTS
There are two unique features introduced with the 2013 Ram truck that we’ll get into now.
Introduced with the 2013 Ram trucks is a thermal management unit (TMU) (Fig. 17).
The 8HP transmission family is such an efficient transmission there is a need for an
auxiliary heater to keep the transmission oil at the proper temperature, about 80°C
(176°F).
Engine coolant is carried back to a heat exchanger via coolant pipes. In this illustration,
the hoses and pipes have been color-coded to show the hot and cold portions of the system
(Fig. 18). The coolant pipes and heat exchanger are serviceable separately.
November 2012 Page 10
Service Information Update Reference Book
and Tech News
The second unique feature we’ll cover is When the engine is running, transmission
the hydraulic impulse storage (HIS) unit oil is pumped into the HIS accumulator
(Fig. 19). The HIS is a spring-loaded and is stored. A locking solenoid keeps
accumulator with a latching solenoid that the piston under tension until the piston
is part of the Stop/Start feature. is released. Spring pressure takes over
and the piston pushes the fluid out of the
HIS and into the transmission.
Figure 19: HIS Unit
November 2012 Page 11
Service Information Update Reference Book
and Tech News
RAM STOP/START
New for the 2013 Ram 1500 is a All Stop/Start equipped vehicles have an
Stop/Start feature that turns off the absorbed glass mat (AGM) battery and
engine when the vehicle comes to rest, heavy-gauge cables, that are able to
restarting it automatically when needed. deliver higher amp loads consistently.
You’ll find a graphic in the reference book
that shows the different components in Naturally, the alternator needs to be
the Stop/Start system. We’ll cover some heavy-duty as well. This one is a 220-amp
of them now. alternator that provides greater charging
capacity immediately after auto-starts.
The powertrain control module (PCM) Inside the transmission, we have the HIS
calibration dictates when the engine will (Fig. 21). The HIS enables the
shut down and restart. This decision is transmission to build full line pressure,
based on brake pedal position, vehicle allowing a nearly instantaneous response
speed, and time stopped, among others. to the driver's input.
Figure 20: DC-to-DC Converter
November 2012 Page 12
Service Information Update Reference Book
and Tech News
Stop/Start Components
November 2012 Page 13
Service Information Update Reference Book
and Tech News
REPAIR ORDER PATH
How many times have you been given a It all begins with the customer expressing
repair order to resolve a customer’s a concern to a service advisor who records
concern only to be unable to duplicate the it for the technician. Naturally, the more
problem? This month we have a bonus detail that is recorded the better.
program: Service Best Practices.
Currently, there are a few different ways
The first thing we’ll do is follow a repair this write-up process is handled, but a
order through the service department new consistent process is in development.
from the first contact with the customer, The next lesson will cover that new
through the technician, and on to the system.
point that the customer picks up the
vehicle. As part of this Service Best After the write-up process, the repair
Practices program, we’ll cover the new order is dispatched to the technician.
Service Advisor Dashboard system. This This can be handled in a few different
new repair order initiation system will ways as well, depending on the
streamline the write-up and repair dealership. Looking over a repair order
processes. when it is first assigned is the best way to
review the customer concern and ask
After exploring the Service Advisor questions about the concerns listed. In
Dashboard system, we’ll cover the two fact, the customer may still be there to
most basic and important aspects of the answer first hand.
repair process; the Six-step
Troubleshooting Procedure and the three At this point in the process, the first C
Cs. (the Concern) is in place. We’ll go into
more details related to the three C’s
The last topic in this bonus program shortly. Now it’s time to fix a car. During
covers the Vehicle Not Repaired Check the diagnostic and repair phase, it’s
Sheet. This check sheet helps to guide recommended to follow the Six-step
you through the inspection process so you Troubleshooting Procedure and document
can document everything and make sure this on the repair order.
all angles are covered.
After the concern is corrected, the
As part of our November Service Best completed repair order is returned to the
Practices program, let’s review the life of dispatcher or manager. From here, the
a repair order. This helps us to better repair order goes through various
understand the processes that will be processes that may include Warranty
discussed shortly. Reimbursement. We will finish our
program with some helpful hints when
submitting warranty claims for Trouble
Not Found concerns.
November 2012 Page 14
Service Information Update Reference Book
and Tech News
WIADVISOR
In an effort to simplify the service write-up process and improve our customer satisfaction,
Chrysler Group has developed a new tool for service advisors called wiADVISOR (Fig. 22).
The wiADVISOR program will extend the wiTECH network that is currently installed in
your shop into the service drive. What’s the advantage of this new system?
November 2012 Page 15
Service Information Update Reference Book
and Tech News
November 2012 Page 16
Service Information Update Reference Book
and Tech News
An optional subscription to
features like the Electronic Vehicle
Inspection Module, which provides
technicians with the ability to
perform inspections electronically
November 2012 Page 17
Service Information Update Reference Book
and Tech News
THREE Cs AND SIX STEPS
From the technician’s perspective, there The third step is to analyze the
are few things that affect your day more symptoms. Are the symptoms related, or
than the three Cs and the Six-step did you discover something the customer
Troubleshooting Procedure. The six steps should be made aware of? The fourth step
ensure a proper and complete repair while is to isolate the cause.
the three Cs make sure everything is
documented. We’re going to lump these Use published service information to
together because they are completed at determine the cause of the concern. This
the same time. is where the second of the three Cs comes
in (the Cause). Write detailed notes of the
The first C (the Concern) is documented cause of the concern on the repair order.
by the service advisor (Fig. 27). This This will aid not only your warranty
information is the most important piece of administrator when the claim is being
information you will use when repairing prepared but also will provide important
the vehicle. details to Chrysler to help in improving
the quality of our products.
November 2012 Page 18
Service Information Update Reference Book
and Tech News
VEHICLE NOT REPAIRED CHECK SHEET
Sometimes technicians will simply not be The first portion in this section is for
able to address a customer’s concern, no documenting situations like this. There
matter how hard they may try. Many are situations when the concern cannot be
times, the technician will simply write duplicated. That’s what the second
TNF or something similar on the repair portion is for. It allows you to document
order and move on to the next job as that you checked the system(s) in
quickly as possible. question, checked for trouble codes,
Service Bulletins, Recalls, or rapid
This usually ends up with a frustrated response transmittals. You’ll also find a
customer and technician, and we all know place to document a call to the STAR
these vehicles come back at some point in center, or to document if other dealership
the near future anyway. In the event that personnel road tested the vehicle.
you were not able to duplicate a concern
for any reason, it’s a good idea to fill out The third portion in this section is for
the Vehicle Not Repaired Check Sheet. situations where the part is not available
Let’s look at the high points now. to repair the car. Fill out the appropriate
field to document the issue.
To access the check sheet, from the
Service tab in TechCONNECT scroll down The final section of the check sheet is to
to the Repair Information section. From document the final outcome. Record the
there, open the Other menu and open the mileage in and mileage out whether or not
Vehicle Not Repaired Check Sheet (Fig. the customer has been advised of the
28). situation, and the conclusion of the repair
order. Attach this check sheet to the
repair order.
November 2012 Page 19
Service Information Update Reference Book
and Tech News
November 2012 Page 20
Service Information Update Reference Book
and Tech News
TECH’S CORNER
In our Master Tech program for October, As you know, we also included a segment
Mopar Accessories and Performance in the October program on the new Mopar
Parts, we reviewed some of the new JK-8 conversion kit for the Jeep Wrangler
accessories available on Chrysler products Unlimited. Some of you said that you
such as the rear center tail light assembly enjoyed learning about the JK-8
with the race track graphic available on conversion and tips related to the process.
the 2013 Dodge Dart, the Mopar signal Others felt that JK-8 pertains more to
mirror kit, and the new digital brake body shop techs than to service
trailer controller available on the Dodge technicians. Another tech’s response
Durango and Jeep Grand Cherokee. indicated that there was too much on
installation of accessories, but went on to
say that the JK-8 installation info was
In reviewing your surveys for the October, just right. So, as you can see, we do
it appears that the program was well review your surveys. In fact, we also use
received with one technician telling us them to come up with future Tech News
that it contained “very interesting info on topics, which allow us to answer your
new products and installation.” Another specific concerns. So, please continue to
tech felt that addressing accessories and send in your ideas and suggestions.
modifications to Chrysler vehicles shows
the customer’s desire to customize and
upgrade a vehicle’s capacity. We agree,
and due to the popularity of these
accessories, in addition to offering a
Master Tech program on Mopar in
October 2011, we decided to produce
another one this October.
November 2012 Page 21
Service Information Update Reference Book
and Tech News
Can you guess the cars below? You can put your answers in your surveys.
1)
2)
November 2012 Page 22