LAND ROVER Range Rover Sport User Manual

ZF Transmissions

m

with Mechatronics

Hans-Peter Bach, Director Serivce ([e-mail])
ZF Getriebe GmbH, Business Unit Automatic Transmissions

bH, 2006© ZF Getriebe G

Topics

Î

Hints f



gearbox change



change of a oil pan and filter

Î Business unit „Automatic transmission“
Î The 6HP gearbox-family

or the repair shop

 General hints

 change of a mechatronic

 changing or adding oil

MK/MKTA/sk 2

APRA_Birmingham, November 2009 ZF confidential

P-Division ZF Getriebe GmbH

Car Driveline Technology Locations

G

(DVZ / Logistic)

Germany

Germany

China

Saarbrücken (AT) 1973

ermany

Kressbronn (R&D) 1969

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Saarbrücken-Völklingen, Plant 4

Germany

Friedrichshafen (R&D) 1988

APRA_Birmingham, November 2009 ZF confidential

Brandenburg (MT/DT) 1991

Germany

Shanghai** (AT) 2006

** Joint Venture with SAIC.

Topics

Î

Hints f



gearbox change



change of a oil pan and filter

Î Business unit „Automatic transmission“
Î The 6HP gearbox-family

or the repair shop

 General hints

 change of a mechatronic

 changing or adding oil

MK/MKTA/sk 4

APRA_Birmingham, November 2009 ZF confidential

Product History of the ZF 6-speed

Automatic Transmission

1999

IAA in Frankfurt: First Prototype of a fully

automatic six

speed transmission

automatic 5

speed transmissions: weight savings of 13% and

-

World premiere: Start of volume production for the first automatic

2001

2005 Presentation of hybrid system (basis: 6HP26) at the IAA in Frankfurt

2006

6-speed transmission worldwide, the 6HP26; compared to

-

30% less components

nd

Introduction of 2
and even faster shift times (partly below the driver’s limit of perception)

generation of automatic 6-speed transmissions with another 3-6% in fuel savings

-

MK/MKTA/sk 5

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torque

ki

g

oilpan

plug

g

converter

pump

Cutaway drawing 6HP26

simple
planetary
gearset

gearbox
housing

clutch brake

double pl.
gearset

par
wheel

output
flange

ng lock

MK/MKTA/sk 6

parking
lock
pawl

oil
strainer

pressure
re

ulator

oil drain

APRA_Birmingham, November 2009 ZF confidential

Improvements of the 2nd Generation

m]

N

n

e torque [

engi

6HP… Product Family

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APRA_Birmingham, November 2009 ZF confidential

2 nd generation

Second Generation of 6-speed

Automatic Transmissions

S

6HP

The individual, automatic driving pleasure

econd generation of the

:
Efficiency and increased performance for the
leading 6-speed automatic transmission.

 Considerable contribution to CO2 and/or

fuel economy

 Increased power-to-weight ratio
 Optimized shift dynamics and

improved subjective driving impression

 Shift times below the driver’s limit of

perception

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Reduction of CO2and

Fuel Consumption

-

2%

-

5%

6-speed new

3-Gang

3-speed 4-speed 5-speed 6-speed

4- Gang 6-Gang

5-Gang

-6%

consumption

Verbrauch

generation

6-Gang TÜ

Benzin

Benzin

Diesel

Diesel

-3%

MK/MKTA/sk 9

-6%

APRA_Birmingham, November 2009 ZF confidential

Further development of shift dynamics

(2nd Generation of 6

speed transmissions)

shifting time

-

Î Shift dynamic is one of the most significant characteristics of the vehicle performance
Î The direct shift gearbox has set new standards in shifting dynamics

engine torque

MK/MKTA/sk 10

switching command

reaction time slippage time

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V

1200

1000

6HP21

i

m

400

R

e

800

n ms

e in ms

600

action ti

eaktion szei t

r

Improvement shift dynamics

ergleich Reaktionszeiten

comparison reaction time

6HP19

DKG

200

0

23 ZHS

12 ZHS

MK/MKTA/sk 11

34 ZHS

45 ZHS

56 ZHS

21 ZRS

32 ZRS

43 ZRS

54 ZRS

65 ZRS

21S RS

32S RS

43S RS

54S RS

65S RS

64

Z

RS

53

Z

RS

42

Z

RS

APRA_Birmingham, November 2009 ZF confidential

Topics

Î

Hints f



gearbox change



change of a oil pan and filter

Î Business unit „Automatic transmission“
Î The 6HP gearbox-family

or the repair shop

 General hints

 change of a mechatronic

 changing or adding oil

MK/MKTA/sk 12

APRA_Birmingham, November 2009 ZF confidential

Towing a vehicle

respected

the

automatic transmission

will be severely

damaged

!

Î Towage of a vehicle only on its driven wheels at no more than

70 km/h road speed and a maximum distance of 500 kilometres

Î Selector lever in N (neutral)

Î If the above mentioned speed and distance limits are not

MK/MKTA/sk 13

,

APRA_Birmingham, November 2009 ZF confidential

Topics

Î

Hints f



gearbox change



change of a oil pan and filter

Î Business unit „Automatic transmission“
Î The 6HP gearbox-family

or the repair shop

 General hints

 change of a mechatronic

 changing or adding oil

MK/MKTA/sk 14

APRA_Birmingham, November 2009 ZF confidential

Transmission ready to be installed into

the vehicle

MK/MKTA/sk 15

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Transmission to be installed into the

vehicle

MK/MKTA/sk 16

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Handling and Storage of an

Automatic Transmission

MK/MKTA/sk 17

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Handling and Assembling of Automatic

Transmission and Engine

Remove converter strap right before assembling the gearbox to the engine

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Installation of the Torque Converter

ggp

distance from bell housing to

t of th

Before assembling the transmission to the engine, it is important that the
torque converter is installed correctly (see manual of the special gearbox)

torque converter

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measuremen

distance with a deep gauge

e

Pump Gear

Drivi

)

ng pins of the pump can

break

Effect:

- no power flow ( R,D

MK/MKTA/sk 20

driving pin

APRA_Birmingham, November 2009 ZF confidential