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

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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

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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

-

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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

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parking
lock
pawl

oil
strainer

pressure
re

ulator

oil drain

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Improvements of the 2nd Generation

m]

N

n

e torque [

engi

6HP… Product Family

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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%

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-6%

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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

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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

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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

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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

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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

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,

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

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Transmission ready to be installed into

the vehicle

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Transmission to be installed into the

vehicle

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Handling and Storage of an

Automatic Transmission

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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

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driving pin

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Pump Gear

This damage is caused by the

wrong installation of the
transmission.

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Driving pin is broken

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Leakage between Engine and

Transmission

eakage be

een engine and

ea age be ee e g e a d

Effect:

•l

tw

transmission

Reasons:

•centre bush is missing in
crank shaft

• centre pin between engine
and transmission is missing

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Centre Bush

Aft

bli

f

centre bush

position of the centre bush

er assem

ng of the transmission to the
engine, don‘t forget to build in the centre
bush!
A missing centre bush cause damages o
the torque converter and the oil pump!

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Centre Pins

yp p

in the transmission

center pin

It is very important that the centre pins
are assembled to the engine case.
Missing centre pins will cause damages

.

center pin at an engine case

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The two A describe the position of
the centre pins

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Functional test

Î After repair you should make a driving test
Î Before the driving test you have to delete all adoption values using a tester

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The whole product family

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6HP28A61

6HP28AF

integrated 4x4

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6 speed part numbers

1071 020

6HP19X

1071 022

External 4x4

1068 090

6HP28A61

1068 092

Internal 4x4

Main Parts List Trans Type Part Number Programmed Description
1071 010 … 6HP19 1071 012 … Rear wheel drive

…

…

1071 040 … 6HP19A 1071 042 … Internal 4x4

4

1068 010 … 6HP26 1068 012 … Rear wheel drive
1068 020 … 6HP26X 1068 022 … External 4x4
1068 030 … 6HP26A61 1068 032 … Internal 4x4

1070 010 … 6HP32 1070 012 … Rear wheel drive
1070 020 … 6HP32A 1070 022 … Internal 4x4
1070 030 … 6HP32X 1070 032 … External 4x4

1071 030 … 6HP21 1071 032 … Rear wheel drive
1071 050 … 6HP21X 1071 052 … External 4x4

1068 040 … 6HP28 1068 042 … Rear wheel drive
1068 050 … 6HP28X 1068 052 … External 4x4

…

…

1084 030 … 6HP28AF 1084 032 … Internal 4x4

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6 speed transmission identification

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Example transmission application

BMW 745

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Topics

Î

Hints f



gearbox change



change of a oilpan and filter

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

or the repairshop

 General hints

 change of a mechatronic

 changing or adding oil

MK/MKTA/sk 30

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Mechatronic on a special carrier

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6HP..-Mechatronics

left side: E

version / right side: M

Version

-

-

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Mechatronik identification

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Mechatronic replacement

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Mechatronic replacement

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Mechatronic replacement

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Mechatronic replacement

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Mechatronic replacement

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Mechatronic replacement

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Mechatronic replacement

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Mechatronic replacement

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Topics

Î

Hints f



gearbox change



change of a oilpan and filter

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

or the repairshop

 General hints

 change of a mechatronic

 changing or adding oil

MK/MKTA/sk 42

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Polyamide oilpan with integrated filter

6 HP 26 1,6 kg

Î weight reduction app. 40%

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ZF-part number (Polyamide oilpan)

Z F part number nam e gearbox Customer

1068 298 033 Oil pan 6HP26 / 28 / 28X / 32 B M W

0501 215 789 Oil pan 6HP26 / 26X Aston M art i n, F ord USA, Ford Aust ral i a

Jaguar, Range Rover

1071 298 009 Oil pan 6HP19 / 19X / 21 / 21X BMW

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Plate Oilpan and Oilfilter

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ZF Part Number:

Plate oilpan and Oilfilter 1

1068 203 042

Oil

6 HP 26 X

Ford USA

ZF-part
number Name Gearbox Customer

pan

1068 203 044
1068 203 046
1068 203 048

0501 213 359 Filter
1068 303 017 Sealing
1068 203 043 Oilpan 6 HP 26 A Audi, Bentley
0501 212 974 Filter
1068 303 012 Sealing
1068 203 047 Oilpan 6 HP 26 A Audi, Bentley
0501 212 974 Filter
0501 322 155 Sealing

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Oilpan
Oilpan
Oilpan

APRA_Birmingham, November 2009 ZF confidential

6 HP 26 X BMW
6 HP 26 Maserati
6 HP 26 Ford Australia

ZF Part Number:

Plate oilpan and Oilfilter 2

1068 301 01

S

ZF-part
number Name Gearbox Customer

1070 203 010 Oilpan 6 HP 32 BMW

0501 213 359 Filter

7
1070 203 008 Oilpan 6 HP 32 A VW
0501 212 974 Filter
1070 303 009 Sealing
1071 203 038 Oilpan 6 HP 19 A Audi, VW
0501 212 401 Filter
1071 303 006 Sealing
1071 203 039 Oilpan 6 HP 19 A Audi, VW
0501 212 401 Filter
0501 322 078 Sealing
1071 203 040 Oilpan 6 HP 19 X Audi
0501 214 315 Filter
0501 322 077 Sealing

ealing

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Topics

Î

Hints f



gearbox change



change of a oilpan and filter

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

or the repairshop

 General hints

 change of a mechatronic

 changing or adding oil

MK/MKTA/sk 48

APRA_Birmingham, November 2009 ZF confidential

General Hints on Transmission Oil

p

pyp

•Do not mix different oils unless this is ex

ressly prescribed.

• Clean the oil cooler in the opposite direction from normal flow
before fitting the transmission unit, i.e. starting from the
transmission feed (VK) and not from the return (ZK). Cleaning unit

is commercially available.

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6HPxx transmission fluid level

procedures

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6HPxx transmission fluid level

procedures

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ATF Oil-Check 6HP19 A

g

(

()

,

,

only these 4 MPL!!

1071 040 044

Before drive test the ATF have to be filled up with the ZF

Lifeguardfluid 6

Fill up instruction: The idle speed should be neng = 750 rpm

and the transmission oil pan temperature

CGT) 30 … 50 °C

Oil volume: 9 l transmission oil No. S671.090.255 (yellow)

1,05 l differential oil No. S671.090.163

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and 0

528 l Torsen differential oil
No. S671.090.163
and 0,022 l Sturaco oil No. S671.090.167

VW
1071 040 010
1071 040 022

APRA_Birmingham, November 2009 ZF confidential

Audi
1071 040 014

ATF Oil-Check 6HP26A61 Audi

(yell

diff

S671.090.167

Before drive test the ATF have to be filled up with the ZF

Lifeguardfluid 6

Fill up instruction: The idle speed should be neng = 750 rpm

and the transmission oil pan temperature
(CGT) 30 … 50 °C

Oil volume: 10 l transmission oil No. S671.090.255

ow) and 1,2 l

S671.090.163

Version 1: 0,96 l Torsen differential oil No. S671.090.163

and 0,04 l Sturaco oil No.

Version 2: 1,152 l Torsen differential oil No. S671.090.163

and 0,048 l Sturaco oil No. S671.090.167

erential oil No.

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ATF Oil-Check 6HP26A61 Bentley

Fill up instruction: The idle speed should be n

eng

750 rpm

Oil volume:

11,2 l transmission oil No. S671.090.255 (yellow)

and 0,1 l Sturaco oil No. S671.090.167

(only 1 MPL)

Before drive test the ATF have to be filled up with the

ZF Lifeguardfluid 6

=
and the transmission oil pan temperature (CGT)
30 … 50 °C

1,20 l differential oil No. S671.090.163

Version 1: 1,20 l Torsen differential oil No. S671.0920.163

Version 2: 1,680 l Torsen differential oil No. S671.090.163

and 0,12 l Sturaco oil No. S671.090.163

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ATF Oil-Check 6HP32A VW

Fill up instruction: The idle speed should be n

= 750 rpm

Oil volume:

transmission oil No.S671.090.255 (yellow)

Before drive test the ATF have to be filled up with the ZF

Lifeguardfluid 6

eng

and the transmission oil pan temperature
(CGT) 30 … 50 °C

10 l

0,816 l differential oil No. S671.090.163
and 1,104 l Torsen differential oil No.
S671.090.163
and 0,046 l Sturaco oil
No. S671.090.167

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Colour of Lifeguardfluid 6 (yellow)

MK/MKTA/sk 56

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ATF Oil-Check 6HP26A61 (W12)

g

p

pp

g

p

(

)

()

Before drive test the ATF have to be filled up with the ZF

Lifeguardfluid 6 Plus

Fill up instruction: The idle speed should be nen

= 750 r

and the transmission oil pan temperature
(CGT) 30 … 50 °C

Oil volume: 10 l transmission oil No. S671.090.281

blue

and 1,2 l differential oil No. S671.090.163

Version 1: 1,104 l Torsen differential oil No. S671.090.163

and 0,096 l Sturaco oil No. S671.090.167

Version 2: 1,008 l Torsen differential oil No. S671.090.163

and 0,092 l Sturaco oil No. S671.090.167

m

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Colour of Lifeguardfluid 6 Plus (blue)

PLUS

MK/MKTA/sk 58

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ATF Oil-Check 6HP19A / X VW, Audi

No. S671.090.163

Before drive test the ATF have to be filled up with the ZF

Lifeguardfluid 8

Fill up instruction: The idle speed should be neng = 750 rpm

and the transmission oil pan temperature
(CGT) 30 … 50 °C

Oil volume: 9 l transmission oil No. S671.090.311 (green)

and 1,05 l differential oil No. S671.090.163
and 0,528 l Torsen differential oil

and 0,022 l Sturaco oil No. S671.090.167

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ATF Oil-Check 6HP28AF Audi

No. S671.090.163

Before drive test the ATF have to be filled up with the ZF

Lifeguardfluid 8

Fill up instruction: The idle speed should be neng = 750 rpm

and the transmission oil pan temperature
(CGT) 30 … 50 °C

Oil volume: 10l transmission oil No. S671.090.311 (green)

and 1,0 l differential oil No. S671.090.163
and 0,96 l Torsen differential oil

and 0,04 l Sturaco oil No. S671.090.167

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Colour of Lifeguardfluid 8 (green)

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Checking and top up the Oil

,

y

,y

for the gearbox types

Lifeguardfluid 6 (yellow)

BMW, Jaguar, Ford,

Maserati, Hyundai, L.Rover,

Aston Martin, RR,

BMW

Bentle

6HP19/26/32/21/28/19X/26X/28X

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Lifetime Oil for 6-speed / 8-speed

Transmissions

A

A

MK/MKTA/sk 63

rtikel-Nr . / Part-No.

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A00 601 304

Lifetime Oil for 6-speed Transmissions

A

rtikel-Nr . / Part-No. S671.090.255

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Lifetime Oil for 6-speed Transmissions

A

plus

rtikel-Nr . / Part-No. S671.090.281

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Thank you very much for your attention!

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