6 HP Transmission - Engl 4 PDF

6 HP Automatic Transmission
Dirk Fuchs
Philipp Janczewski
MAPQ3
ZF Friedrichshafen AG
1 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

Opening
History of automatic transmission

Opening
Automatic transmission types
12 basic types
in 769 versions

6 HP Automatic transmission
Design sizes
2002 6HP19 → 2007 6HP21 2002 6HP26 → 2007 6HP28 2002 6HP32
Max. Torque 400Nm Max. Torque 600Nm Max. Torque 750Nm

Total view

Lepelletier planetary gear

Systematic exposure

1st gear

2nd gear

3rd gear

4th gear

5th gear

6th gear

R gear

Positions of the pressure regulators
EDS 6 EDS 4 EDS 3 EDS 1
MV 1 EDS 5 EDS 2
EDS-Types
p p p
l l l
Solenoid valve Pressure regulator Pressure regulator
Pressure range 4,6 – 0bar Pressure range 4,6 – 0bar
Resistance 5,05 Ω Resistance 5,5 Ω

EDS-Types
p p p
l l l
Pressure regulator Pressure regulator Pressure regulator
Pressure range 0 – 4,6bar Pressure range 0 – 4,6bar Pressure range 0 – 4,7bar
Resistance 5,05 Ω Resistance 5,5 Ω Resistance 5,05 Ω

Controller matrix E 20/1
Position 1 2 3 4 5 6 7
P-EDS EDS 1 EDS 2 EDS 3 EDS 5 EDS 4 MV 1 EDS 6
Responsible Clutch A Clutch B Brake C System p. Br. D & Cl. E Solenoid v. Cc
Character ↗ ↘ ↗ ↘ ↘ ↗
Parking 0 1 0 -x- 0 0 0
Neutral 0 1 0 -x- 0 0 0
R-gear 0 0 0 -x- 0 0 0
1st gear 1 1 0 -x- 0 0 -x-
2nd gear 1 1 1 -x- 1 0 -x-
3rd gear 1 0 0 -x- 1 0 -x-
4th gear 1 1 0 -x- 0 1 -x-
5th gear 0 0 0 -x- 0 1 -x-
6th gear 0 1 1 -x- 0 1 -x-
Brake closed
Clutch closed

Oil change
Drain the oil

Oil change
Polyamide oil pan

Oil change
Removing the oil pan
Attach all the screws easy

Start at Pos.1 and Pos.2 to
tighten the screws
Tighten the other screws
crosswise from inside to
outside (positional order)
10 Nm of torque for screws
M6 X 28,5

Oil change
ZF Parts Oil change kit
ZF Lifeguard Fluid
Polyamide oil pan with
magnets
Filter
Sealing
Screws for oil pan
Filler plug oil level control

Oil change
Removed oil pan

Oil change
Watch out for grounding!

Oil change
Remove connection socket
External connection
socket
Locking mechanism

Oil change
Mechatronik

Oil change
Demounting mechatronik M-Shift

Oil change
E-shift and M-shift

Oil change
M-shift
Mechanical parking brake

Oil change
E-shift
Electrical parking brake

(Shift-by-wire)

Oil change
Remove adapter for system pressure

Oil change
Evacuate the torque converter

Oil change
Dismounted mechatronik

Oil change
E-shift and M-shift

Oil change
Demounting the Electronic module

Oil change
Demounting the Electronic module
Guiding pins

Oil change
HV WS
Retaining valve Selector pool valve
Dr.Red.V Schm.-V
Pressure reducing valve Lubricating valve
SV WDV
Selector valve Converter pressure valve
SPV Sys.Dr.V
SV reservoir System pressure valve
WKV
Converter lock-up clutch
valve
KV
Clutch valve

Oil change
Opening the mechatronik

Oil change
Opening the mechatronik

Oil change
Opened mechatronik
Intermediate plate
1068 227 051 or 1068 227 052
Pressure regulator damper

1068 227 039

Oil change
Pressure regulator damper

Oil change
Balls
Ball
1043 326 037

Oil change
Single parts

Oil change
Sensor for drive position

Oil change
Mounting connection socket
Level position
Close carefully

Oil change
Lifeguard Fluid 5 (yellow-red)
Used for:
5HP18 (depending on
manufacturer)
5HP19
5HP24
5HP30 (depending on
manufacturer)

Oil change
Lifeguard Fluid 6
BMW, Jaguar, Ford, Maserati,

Hyundai, Land Rover, Aston Martin,
Rolls Royce, Bentley
For
6 HP 19/19X/26/26X/32/21/28/28X

Oil change
Lifeguard Fluid 6 (yellow)
Used for
6HP19
6HP19X (except Audi Q7)
6HP/21/26/28 + X
6HP26A61 (except Audi W12)
6HP28A61
6HP32 + X, 6HP32A

Oil change
Oil level control (Audi / VW)
Gearbox temperature 35°

Start engine
Take screw B out
Screw worn
No fluid coming
fill up until ATF runs down

Oil change
Lifeguard Fluid 6 Plus (blue)
Used for
6HP26A61 (Audi W12)

Oil change
Lifeguard 6 Plus (Audi / VW W12)
Engine rpm 750 1/min

Gearbox temperature between
30 and 50 °

Oil change
Lifeguard Fluid 8 (green)
Used for
6HP19A
6HP19X (Audi Q7)
6HP28AF
8HP all

Oil change
Adaption drive
Part A
Accelerate the vehicle from standing with very low throttle (15 – 25%) up to 4th gear and about 80 km/h.
Freewheel the car down to about 40 km/h without using the brakes. Afterwards stop the car completely and
stay in position “D” for about 10 s. Repeat cycle 6 times.
Part B
Accelerate the vehicle up to about 70 km/h und select manually 5th gear. Use your diagnostic tool (VW/Audi
block 9) to drive with 100 Nm for about 3 – 4 km.
Accelerate the vehicle up to about 85 km/h und select manually 6th gear. Use your diagnostic tool (VW/Audi
block 9) to drive with 100 Nm for about 3 – 4 km.
Part C
Accelerate 5 times with low throttle up to about 100 km/h and freewheel the car down to about 40 km/h
without using the brakes.

Oil change
Transmission identification
Serial number
Main parts list
Transmission part number

Troubleshooting
Bolted driveshaft

Troubleshooting
Flexible disc


Modular construction system

Torque converter

Sealing gearbox input shaft
Always change the gasket ring
Otherwise converter malfunction

ATF-Oil pump
Torque converter
Intake holes Input hub with serration and

sprocket
Pressure holes
Roller chain
ATF-Pump

ATF-Oil pump
Technical data:
- system pressure 5.5 to 17.5 bar

- Oil delivery rate 7 to 22 l/min
- Pump speed 550 to 8600 rpm

ATF-Cooling
ATF-Cooler
ATF-Cooler-approach
ATF-Cooler-reflux
Oil temperature controller

(Thermostat)

ATF-Cooler
Express coupling of the hydraulic pipe for the

cooler
Before dismounting the gearbox the cooler must

be removed

E-Shift (BMW)
Mechanical unlocking
the parking lock

E-Shift (Audi A8)
Parking brake emergency

release

M-Shift
Parking brake emergency

release

Planetary gear sets / shift elements

Shift elements

Gearbox diagram

1. gear

2. gear

3. gear

4. gear

5. gear

6. gear

7. gear

8. gear

R. gear

Ratio

Mechatronik M-Shift

Controller matrix general
Position 1 2 3 4 5 6 7 8
P-EDS EDS 1 EDS 4 EDS 2 EDS 5 EDS 3 EDS 6 EDS 7 MV 1
Zuständig Bremse A Kupplung D Bremse B Kupplung E Kupplung C WK Systemdr. Magnetv.
Charakter
Parksperre
Neutral
R-Gang
1. Gang
2. Gang
3. Gang
4. Gang
5. Gang
6. Gang
7. Gang
8. Gang
Bremse geschlossen
Kupplung geschlossen

Controller matrix M-shift
Position 1 2 3 4 5 6 7 8
Responsible Brake A Clutch D Brake B Clutch E Clutch C Cc System p. Solenoid v.
Character ↗ ↘ ↗ ↘ ↘ ↗ ↘
Parking 1 1 1 1 1 0 -x-
Neutral 1 1 1 1 1 0 -x-
R-gear 1 0 1 1 1 0 -x-
1st gear 1 1 1 1 0 -x- -x-
2nd gear 1 1 1 0 1 -x- -x-
3rd gear 0 1 1 0 0 -x- -x-
4th gear 0 0 1 0 1 -x- -x-
5th gear 0 0 1 1 0 -x- -x-
6th gear 0 0 0 0 0 -x- -x-
7th gear 1 0 0 1 0 -x- -x-
8th gear 1 0 0 0 1 -x- -x-
Brake closed
Clutch closed

Mechatronik E-Shift

Controller matrix E-Shift
Position 1 2 3 4 5 6 7 8
Responsible Brake A Clutch D Brake B Clutch E Clutch C Cc System p. Solenoid v.
Character ↗ ↗ ↗ ↗ ↘ ↗ ↘
Parking 1 0 1 0 1 0 -x- 0
Neutral 1 0 1 0 1 0 -x- 1
R-gear 1 1 1 0 1 0 -x- 1
1st gear 1 0 1 0 0 -x- -x- 1
2nd gear 1 0 1 1 1 -x- -x- 1
3rd gear 0 0 1 1 0 -x- -x- 1
4th gear 0 1 1 1 1 -x- -x- 1
5th gear 0 1 1 0 0 -x- -x- 1
6th gear 0 1 0 1 0 -x- -x- 1
7th gear 1 1 0 0 0 -x- -x- 1
8th gear 1 1 0 1 1 -x- -x- 1
Brake closed
Clutch closed

8 HP Automatikgetriebe
EDS-Typen
p p p
l l l
Magnetventil Druckventil Druckventil
Druckbereich 4,7 – 0 bar Druckbereich 0 – 4,7 bar
Widerstand 5,05 Ω Widerstand 5,5 Ω

Sensor for drive position

Changing the mechatronik
Parts needed
Connection socket
Oil reflux cartridge
Sealing ring oil approach
cartridge
Sealing cartridge

Sealing oil pipes

Sealing cartridge

Guiding pins for mounting the

mechatronik

Oil level control
Gearbox temperature 35°

Start engine
Take screw B out
Screw worn
No fluid coming
fill up until ATF runs down

Hydraulic Impulse Memory (HIS)
Automatic transmission
Mechatronik
HIS

HIS-setting
Hydraulic
Solenoid for attachment
pressure storage Ball grid mechanism Piston
Choke kickback valve

Spring
HIS-charging
Anchor
Solenoid
energized
Head gap

HIS-loaded with engine stopped
Solenoid
energized

HIS-discharging
Solenoid
not
energized

6 HP Transmission - Engl 4 PDF

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6 HP Automatic Transmission

1 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

2 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

3 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

4 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

5 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

6 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

7 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

8 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

9 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

10 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

11 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

12 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

13 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

14 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

EDS 6 EDS 4 EDS 3 EDS 1

16 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

17 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

18 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

19 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

20 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

Attach all the screws easy

21 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

22 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

23 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

24 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

25 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

26 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

27 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

28 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

Mechanical parking brake

29 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

Electrical parking brake

30 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

31 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

32 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

34 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

35 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

36 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

37 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

38 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

39 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

40 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

Pressure regulator damper

41 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

42 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

43 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

44 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

45 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

46 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

47 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

BMW, Jaguar, Ford, Maserati,

48 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

49 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

Gearbox temperature 35°

50 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

51 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

Engine rpm 750 1/min

52 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

53 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

54 2014-01-14 MAPQ3, 6 HP Automatic transmission, ZF internal © ZF Friedrichshafen AG, 2013

Main parts list

Transmission part number