Sonnax ZF8 Webinar Part 2 of 2

Dodge TorqueFlite® 8 (ZF8)
A Look Inside of the Torque Converter

& Transmission
ZF8 Webinar Series Part 2 of 2
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WELCOME
• Connections
• Handout
• Questions
• jad@sonnax.com
FREE Online Sonnax Tech Resources

www.sonnax.com
Tech Articles • Vacuum Test Guides • Valve Body Layouts • Videos & More
Sonnax Tech Support

Call: (800) 843-2600 or +1 (802) 463-0288
8:30 a.m. to 7:00 p.m. ET, Mon. – Fri.
Email: sonnaxtechsupport@sonnax.com
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Case & Torque Converter
Components
External Component ID
TorqueFlite® 8 (ZF8) Case & Torque Converter Components
PZT Tap
From Cooler
Linkage Shaft for
To Cooler Park Release Cable
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External Component ID
Linkage Arm for

Park Release Cable
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TC Disassembly & Component ID
3-Path Torque Converter Oil Circuit Passage ID
TCC Apply
TC Return Pressure
TC Charge Pressure
NOTE: BMW application shown.
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Pump Drive Inside

Impeller Hub
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Flex Plate Adapter

Connected to Cover
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Stator
Impeller
(Furnace-Brazed)
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Stator Houses
Roller Clutch &
Race Assembly
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Turbine
Rear View Front View
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NOTE: There are

numerous design
dampeners
between vehicle
manufacturers
and engine sizes,
including a Speed
Dampener Assembly Adaptive vibration
dampener and
Dodge’s torsional
turbine dampener,
which houses an
Some dampeners additional spring
have two spring assemblies. assembly.
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Turbine Shaft
Insert
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Turbine Shaft Insert Closeup

1. Sonnax Thrust Washer
ZF-WP-1
2. Sonnax O-Ring
ZF-O-5V
3. Sonnax Seal
ZF-O-2
O-Ring 2
Sealing Ring 3
The insert has external compound finger joint sealing ring and an O-ring on the I.D.
The thrust washer below is relief cut for TCC apply pressure feed.
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TC Clutch Assembly
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Two Frictions, Two Steels, One Pressure Plate & Snap Ring
1. Sonnax Clutch Plate

ZF-CP-10S
ZF-CP-9S 2 3
ZF-CP-11P
4. Sonnax Friction Plate 1
ZF-CP-8F
Rear View Front View
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TCC Piston Removed
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Torque Converter Cover
Inner Piston
Seal Location
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TCC Piston Seal ID
1. Sonnax
Outer Seal
ZF-O-3V
1 2. Sonnax
Inner Seal
ZF-O-4V
Inner Piston Seal (4-Lobed) Outer Piston Seal (D-Ring)

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Transmission Disassembly
& Component ID
Composite Pan Disassembly
TorqueFlite® 8 (ZF8) Transmission Disassembly & Component ID
Remove 13 bolts and composite pan.
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Filter is part of composite pan.
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Suction Port
& O-Ring
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Valve Body & Mechatronic Removal
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Remove four bolts.
Bottom bolt holds OSS onto case.
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Lift up metal mechatronic

connector retainer.
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Metal-Clad Seal
Gently pull connector

out of the case. O-Ring
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The park piston will lift out of the park rod when the valve body is removed.
Park Piston
Park Pawl Rod
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Remove 14 T40 Torx® bolts.
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Valve Body & Mechatronic ID
OSS
TSS
Suction
Park Sensor
Output
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Valve Body & Mechatronic ID
Park Pawl Rod
Magnet for Park Sensor
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Transmission Internal Component
Disassembly & ID
Pump Assembly Removal
TorqueFlite® 8 (ZF8) Transmission Internal Component Disassembly & ID
Remove B release rubber feed tube.
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Remove output shaft metal-clad seal.
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Remove retaining snap ring and shim.
Retaining Snap
Ring Shim &
Output Shaft
Seal
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Remove 13 pump assembly T50 Torx® bolts.
NOTE: These are aluminum bolts with metal-clad seals. They must be replaced.
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Remove turbine shaft O-ring.
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Gently pry pump out of case near the suction and output ports on the pump
(this takes little effort). Do not pry in the sealing surfaces of the case and pump.
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Pump & Brake Disassembly
After the pump assembly is removed, grab the turbine shaft and the complete
internal components will come out vertically from the case.
Turbine Shaft
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Complete Internal Components
Output Shaft
Turbine Shaft
B Brake
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Pump, A Brake & B Brake Piston Disassembly
A Brake
B Brake Piston
Remove pump cover

plate T40 Torx® bolt.
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Gently pry up the steel B release housing and the B piston will come up with it.
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B Release Housing Outer Seal
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B release housing
inner seal is bonded.
The B release circuit

(B2) controls the
release rate of
the B brake
(area between the
two green arrows).
B Apply Piston (B1)

NOTE: The B brake received a return spring assembly in 2014 and is not used on all models.
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A Brake Hub A Brake Assembly
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Remove half-moon retainers from A piston return spring.
NOTE: A modified Forward ring gear from 4R/5R55 works here.
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Remove retainers, return spring and A piston.
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Remove six remaining pump plate retaining T40 Torx® bolts (aluminum).
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Pump Plate
Pump Bearing
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Remove pump from pump cover.
31
Pump is slightly overdriven. 34
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High-Efficiency Vane-Type Pump
Remove retainer clip from Remove cover.

pump driveshaft.
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Planetary Disassembly
Internal Component Disassembly
Remove B brake and ring gear.
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B Brake
Planetary 1 Ring Gear
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Stand the assembly

in a fixture or vice
to disassemble.
A support ring must be

used so the aluminum
connecting shell is not Snap Ring
damaged during snap
ring removal.
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Stand the assembly

in a fixture or vice to
disassemble.
Remove snap ring to
remove planetary 1
carrier.
Support ring is made

from an E4OD
intermediate piston
turned on the I.D.
Tool Availability
ZF8HP70-90: ZF Part # AA00 558 209
ZF8HP45: ZF Part # AA00 558 210
Chrysler Tool Part # 10378
Also available from Adapt-A-Case
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Planetary 1 Carrier & Snap Ring Removed
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Remove turbine Turbine Shaft

shaft and double
sun gear.
Sun gear is used for

both planetary 1 and 2.
Turbine shaft
is splined to
planetary carrier 2.
Planetary Carrier 2
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Turbine Shaft/Planetary 2 Carrier Removed
Turbine sensor reads

segmented magnetic ring
through the aluminum
connecting shell.
Sun gear internal spline goes toward pump,

connects to A brake hub.
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Turbine shaft is splined to the planetary carrier 2.
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Remove
planetary 2
ring gear.
Planetary 2 ring gear is splined

to the E clutch housing.
Planetary 2 ring gear is connected

to planetary 3 sun gear.
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Planetary Carrier 3 Remove

planetary 3
carrier and
housing from
connecting shell.
NOTE: The
connecting shell
houses the ring gear
for planetary 4.
We will come back
Connecting Shell to this at the end of
the presentation.
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Planetary 3 Carrier & Housing Removed
This assembly houses Connecting

the planetary 3 carrier Shell
and ring gear, the E
and C clutch assemblies,
planetary 4 sun shell and
sun gear. The connecting
shell is the hub for the
D clutch.
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Planetary Carrier, E & C Clutch Removal
A support ring must

be used to remove
the snap ring or the
connecting shell
can be damaged.
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Planetary 3 Carrier Snap Ring Removal
Install support ring here. Remove the snap ring opposite

A 4th/Intermediate E4OD housing the opening as there are two stands
turned on the I.D. works here. that prevent removal.
Snap Ring Opening
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The connecting shell will drop once the snap ring is removed.
Connecting Shell
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Planetary Carrier 3 Removed
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Remove sun shell assembly from connecting shell.
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Remove planetary 3 ring gear from sun shell.
There are two snap

rings, one on either
side of the ring gear.
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Planetary 3 Ring Gear & Snap Rings Removed
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Clutch Disassembly
Remove E clutch drum.
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Clutch Disassembly
E Clutch Drum
Front Side Rear Side
Planetary 2 ring gear External, two-sided

is splined to the clutch plates connect
E clutch housing. to I.D. of sun shell.
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Clutch Disassembly
E Clutch Disassembly
Remove round snap ring.
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Clutch Disassembly
Remove E clutch apply/balance piston.

Aluminum piston seals apply chamber in steel piston.
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Clutch Disassembly
E Clutch Apply/Balance Piston
Steel Piston Apply Chamber
Aluminum Piston
Upside Down
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Clutch Disassembly
E Clutch Balance Circuit
ID of E Clutch Drum Bottom of the E Clutch Piston

(Bonded Side)
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Clutch Disassembly
E Clutch Plates
Thick Steel Plate Cushion Plate
External, two-sided clutch plates Internal steel plates

connect to I.D. of sun shell. connect to E drum.
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Clutch Disassembly
Remove C clutch drum from sun shell.
Empty Sun Shell
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Clutch Disassembly
C Clutch Drum Front View C Clutch Drum Rear View

Internal steel
plates connect
to C drum.
External, two-sided clutch plates C clutch drum is splined

connect to I.D. of sun shell. to turbine shaft.
The C clutch piston assemblies are set up like the E clutch with the
apply circuit on one side and the balance circuit on the I.D. of the C clutch drum.
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Clutch Disassembly
Connecting Shell Planetary 4 Carrier
Connecting shell houses Planetary 4 carrier is connected to

planetary 4 ring gear. the D clutch and the output shaft.
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Clutch Disassembly
D Clutch Assembly
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Clutch Disassembly
D Clutch Spring Retainer
D Clutch
Balance Circuit
Depress retainer, then rotate to remove.
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Clutch Disassembly
D Clutch Apply Passage
OSS Reluctor
Compound Finger Joint Sealing Rings
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Turbine Shift Passage ID
For Clutches & Balance Circuits
E Clutch
Lube/Balance C Clutch
E Clutch C Clutch
NOTE: There are
numerous lube circuits
and not all are shown.
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Case Passage ID
D Clutch apply passage goes through the case to a sleeve that feeds the D clutch.
TCC Apply TC Return
TC Charge
To Cooler
From Cooler
A Brake B Brake B Brake
Release
E Clutch
C Clutch
D Clutch
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Additional Resources
FREE Online Sonnax Tech Resources

www.sonnax.com
Tech Articles • Vacuum Test Guides • Valve Body Layouts • Videos & More
Sonnax Tech Support

Call: (800) 843-2600 or +1 (802) 463-0288
8:30 a.m. to 7:00 p.m. ET, Mon. – Fri.
Email: sonnaxtechsupport@sonnax.com
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Thank You
QUESTIONS?
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Dodge TorqueFlite® 8 (ZF8)

A Look Inside of the Torque Converter

FREE Online Sonnax Tech Resources

Sonnax Tech Support

Linkage Arm for

3-Path Torque Converter Oil Circuit Passage ID

NOTE: BMW application shown.

Pump Drive Inside

NOTE: BMW application shown.

Flex Plate Adapter

NOTE: BMW application shown.

NOTE: BMW application shown.

NOTE: BMW application shown.

Rear View Front View

NOTE: BMW application shown.

NOTE: There are

NOTE: BMW application shown.

NOTE: BMW application shown.

Turbine Shaft Insert Closeup

NOTE: BMW application shown.

1. Sonnax Clutch Plate

Rear View Front View

NOTE: BMW application shown.

TCC Piston Removed

NOTE: BMW application shown.

Torque Converter Cover

NOTE: BMW application shown.

TCC Piston Seal ID

Inner Piston Seal (4-Lobed) Outer Piston Seal (D-Ring)

Remove 13 bolts and composite pan.

Filter is part of composite pan.

Remove four bolts.

Bottom bolt holds OSS onto case.

Lift up metal mechatronic

Gently pull connector

Park Pawl Rod

Remove 14 T40 Torx® bolts.

Park Pawl Rod

Magnet for Park Sensor

Remove B release rubber feed tube.

Remove output shaft metal-clad seal.

Remove retaining snap ring and shim.

Remove 13 pump assembly T50 Torx® bolts.

Remove turbine shaft O-ring.

Complete Internal Components

Pump, A Brake & B Brake Piston Disassembly

Remove pump cover

B Release Housing Outer Seal

The B release circuit

B Apply Piston (B1)

A Brake Hub A Brake Assembly

Remove half-moon retainers from A piston return spring.

NOTE: A modified Forward ring gear from 4R/5R55 works here.

Remove retainers, return spring and A piston.

Remove pump from pump cover.

High-Efficiency Vane-Type Pump

Remove retainer clip from Remove cover.

Internal Component Disassembly

Remove B brake and ring gear.

Planetary 1 Ring Gear

Stand the assembly

A support ring must be

Stand the assembly

Support ring is made