AUDI A6 User Manual

ZF 6HP19 / 6HP21

6HP19 6HP21

Automatic Transmission Spare Parts Catalog

Warranty Information

Disclaimer

Copyright

Warranty coverage for ZF passenger car transmission spare parts and kits covers the first 12 months after

workmanship, and specifically does not cover removal, reinstallation, or any costs incidental to the repair of the

sources and is believed to be accurate at the time of publication. While ZF Services believes this information is

installation in the vehicle, or 24 months after purchase from ZF Services.

Warranty of the product is limited to replacement or repair, if found to be defective in ZF material or

vehicle, or any kind of consequential damages.

All warranty and/or non-warranty returns must be approved.

The specifications and information shown in this catalog have been compiled from accepted and reliable

correct, no guarantee or warranty is made as to the accuracy of the information and ZF Services cannot and does not accept or assume any responsibilities for errors, omissions, or consequential harm or damages. Replacement parts should not be used when they do not appear to fit. ZF Services disclaims all liability and responsibility for any harm resulting from any such modifications.

Printed in USA - Copyright © 2008 ZF Services No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of ZF Services.

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ZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts CatalogZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts Catalog

Table of Contents

6HP19 / 6HP21

Technical Information

Torque, Gear Ratio & Weight__________________________________________________________

Oil Capacity___________________________________________________

6HP19 / 6HP21 Lubricants___________________________________________________

6HP19 / 6HP21 Technical Literature___________________________________________________

6HP19 / 6HP21 General Transmission Oil Filling Procedure___________________________________________________

How To Use This Catalog___________________________________________________

Type Plate Information_______________________________________________

6HP19 1071 010 XXX / 6HP21 1071 030 XXX

Gearbox Housing Group____________________________________________

Torque Converter Group____________________________________________

Oil Supply Group__________________________________________________

Front Planetary Group____________________________________________

Rear Planetary Group____________________________________________

Coupling A Group_______________________________________________

Coupling B Group______________________________________________

Coupling C Group______________________________________________

Coupling D Group______________________________________________

Coupling E Group______________________________________________

Output Group__________________________________________________

Filter Group_____________________________________________________

Mechatronic Group_______________________________________________

Gear Shift System E-Shift Group____________________________________________

Gear Shift System M-Shift Group____________________________________________

Selective Snap Rings_________________________________________________________

Kits Content________________________________________________________________________________________

Spare Parts

Parking Lock Group____________________________________________ 23

2 2 2 2 3 - 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Selective Shims, Snap Rings & Kits Content

Selective Shims_______________________________________________ 24

25 - 26 27 - 29

For a distributor in your area call ZF at 1-800-451-2595 or visit our website at www.zf.com/na.

For Reference Only

ZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts CatalogZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts Catalog

Technical Information

Torque, Gear Ratio & Weight

1

2

3

4

5

6

Rev

Gear

Weight

(incl. oil)

(model specific)

Oil Capacity

6HP19 / 6HP21 Lubricants

Note:

ZF recommends the use of LifeGuardFluid 6 for optimal performance.

6HP19 / 6HP21 Technical Literature

Language

Input Torque

258 ftlbs to 295 ftlbs

9 liters (9.51 Quarts) + 0.5 liter for cooling system

209 Liter Drum ZF LifeGuardFluid 6 20 Liter Canister 1 Liter Bottle

English English English English

Gear

4.17 2.34 1.52 1.14 0.87 0.69 3.40 RWD ~165 lbs.

ZF Part #

1071 766 701 1071 751 701 1068 766 701 6HP19 / 6HP21 FUNCTIONAL DESCRIPTION - BMW (CD) 1068 766 704 6HP19 / 6HP21 FUNCTIONAL DESCRIPTION - AUDI (CD)

Gear

ZF Part # Oil GradeAmount

S671 090 252 S671 090 253 S671 090 255

6HP19 REPAIR MANUAL (CD) 6HP21 REPAIR MANUAL (CD)

Gear

ZF LifeGuardFluid 6 ZF LifeGuardFluid 6

Gear

Description

Gear

Drive

For a distributor in your area call ZF at 1-800-451-2595 or visit our website at www.zf.com/na.

For Reference Only

ZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts CatalogZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts Catalog

6HP19 / 6HP21 General Transmission Oil Filling Procedure

- Car must stand level on the

_

Switch off the hoist and apply the

Procedure after repair, exchange

Switch off the hoist and apply the

With the engine stopped, add oil

- Car must stand level on the

_

Top off the oil immediately to the

Adding oil to 6HP19 / 6HP21 automatic transmission

- general - up to overflow at 40°C

Checking NotesRefilling

Always note correct oil grade:

Procedure if leaks are suspected

of control unit or similar

see list of oils

TE ML 11

Place car horizontally on hoist

handbrake

Connect the tester in order to

read off the transmission oil

temperature and engine speed

Start the engine

Select gears with engine

running, at idle speed

Select positions R and D and

shift through as far as 3rd gear

(manual/winter program)

Place car horizontally on hoist

handbrake

Carry out the repair work

Connect the tester in order to

read off the transmission oil

temperature and engine speed

until it reaches the overflow lip

Start the engine

overflow lip

hoist.

- The driven wheels or the

transmission output must be at

transmission output must be

a standstill for at least two

at a standstill for at least two

minutes before checking the

oil level.

Apply the handbrake.

- Move selector lever to P.

- EGS must not be in

emergency program.

- Switch the main consumers,

for instance the air

conditioning, either on or off

according to the car

manufactuerer's instructions.

Keep each gear selected for 3

seconds, then engage the

parking lock

Continued on Page 2

For a distributor in your area call ZF at 1-800-451-2595 or visit our website at www.zf.com/na.

Select gears with engine

running, at idle speed

Select positions R and D and

shift through as far as 3rd gear

(manual/winter program)

Keep each gear selected for 3

seconds, then engage the

parking lock

For Reference Only

ZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts CatalogZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts Catalog

6HP19 / 6HP21 General Transmission Oil Filling Procedure (continued)

Select gears with engine

Transmision contains too

NO

YES

Oil temperature must not

Wait until oil temperature

Oil temperature must not

Transmision contains too

NO

Oil temperature must not

Wait until oil temperature

Oil temperature must not

Depending on condition,

Idle speed n_Mot = 650-950 1_Min according to manufacturer's specification.

NO YES

Oil temperature between

Engine fault:

Oil adjustment not

possible

30°C and 35°C

YESNO

Eliminate the fault

according to the engine

repair manual

Oil emerges at an oil temperature below 35°C

little oil

allow oil to cool down or

run engine until warm

idling

Select R and D by

means of manual/winter

program as far as 3rd

gear

Hold each gear for 3

seconds and engage

parking lock

Open the filler plug on

the housing

reaches 40°C + 10°C

Open filler plug on the

housing

Oil emerges at an oil temperature below 35°C

little oil

Increase oil level by

adding oil until it flows

out

reaches 40°C + 10°C

exceed 50°C in any

circumstances

Allow time to drip, then

close the filler plug again

reaches 40°C + 10°C

exceed 50°C in any

circumstances

Allow time to drip, then

close the filler plug again

Increase oil level by

adding oil until it flows

out

reaches 40°C + 10°C

exceed 50°C in any

circumstances

Allow time to drip, then

close the filler plug again

exceed 50°C in any

circumstances

Allow time to drip, then

close the filler plug again

For a distributor in your area call ZF at 1-800-451-2595 or visit our website at www.zf.com/na.

For Reference Only

ZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts CatalogZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts Catalog

6HP19 / 6HP21 General Transmission Oil Filling Procedure (continued)

Oil service 6HP19 / 6HP21

Tightening torque 35 Nm ± 3.5 Nm

Oil filler screw and M18X1.5 oil level screw

Internal hexagon 8 mm

For a distributor in your area call ZF at 1-800-451-2595 or visit our website at www.zf.com/na.

Oil drain plug M16X1.5

Internal hexagon 8 mm

Tightening torque 8 Nm

For Reference Only

ZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts CatalogZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts Catalog

Table of Contents

Technical Information

Spare Parts

OIL SUPPLY GROUP

Selective Shims, Snap Rings & Kits Content

number. The quantity may vary depending on the transmission specification and certain spare parts may be used

How To Use This Catalog

Each transmission group of this catalog is listed in the table of contents. This spare parts catalog includes only transmission specification numbers for North American applications.

All technical information is specific to the transmission models that are referenced in this catalog. Weight and oil capacity information are only approximate and may vary by actual transmission specification. For any technical inquiry, please contact your preferred ZF passenger car transmission distributor for assistance. For a list of technical literature available from ZF or for answers to frequently asked questions about ZF transmissions visit us at www. zf.com/na.

Each transmission is divide into groups (e.g. gearbox housing group). The position number (Position #) is used to identify the location of each spare part in the transmission. A position number like 01.010 is either a spare part or an assembly. A position number like 01.010/110 is a subcomponent of an assembly. Please contact your preferred ZF passenger car transmission distributor about availability of assemblies and subcomponents.

Contact ZF for the most updated part number (for example: 6HP19 1071 040 XXX). Please, have the position number and model number prepared when you call. Thank you.

Use our toll free Service-Hotline: 1-800-451-2595.

The description (Description) identifies the spare part.

The quantity (Quantity) is the amount of spare parts included in one transmission model for a certain position

in multiple positions in the transmission.

The notes column (Notes) gives more information about the spare part (e.g. included in a kit).

Example

Position # Quantity

10.010 1

10.010/150 1

10.090 1

Each list for selective shims or snap rings is listed in this section of the catalog. Please measure the clearance according to the repair manual and select the required spare part from the table.

The kits content section shows all available kits for the transmission models that are referenced in this catalog, including the content of each kit.

Description Notes

PUMP NEEDLE SLEEVE SHIM

Selective shim; see page 24.

Mechatronic and Valve Body are only available as complete Service-Mechatronic.

For a distributor in your area call ZF at 1-800-451-2595 or visit our website at www.zf.com/na.

For Reference Only

ZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts CatalogZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts Catalog

Type Plate Information

Transmission Serial #

ZF Transmission Specification #

Vehicle Manufacturer Transmission #

010 005

The type plate is located on the main housing of the transmission. Please refer to the ZF transmission specification # when searching for spare parts and kits in this catalog.

For a distributor in your area call ZF at 1-800-451-2595 or visit our website at www.zf.com/na.

For Reference Only

ZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts CatalogZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts Catalog

6HP19 1071 010 XXX / 6HP21 1071 030 XXX

GEARBOX HOUSING GROUP

Position # Description Quantity Notes

01.010 GEARBOX HOUSING 1

01.030 SEALING SLEEVE 2 Included in overhaul kit; see page 29.

01.040 SEALING SLEEVE 1 Included in overhaul kit; see page 29.

01.050 SEALING SLEEVE 1 Included in overhaul kit; see page 29.

01.070 BREATHER TUBE 1

01.080 BREATHER COVER 1

01.100 SCREW PLUG 1 M10X1.0; Included in overhaul kit; see page 29.

01.110 CYLINDRICAL PIN 1

01.140 SCREW PLUG 1 M18X1.5; Included in overhaul kit; see page 29.

01.220 SHIPPING PLUG 1

For a distributor in your area call ZF at 1-800-451-2595 or visit our website at www.zf.com/na.

For Reference Only