6HP19 21 Manual

VAG-ID.
RU
Ремонт АКПП
ZF Transmissions
with Mechatronics
Hans-Peter Bach, Director Serivce ([email protected])
ZF Getriebe GmbH, Business Unit Automatic Transmissions
mbH, 2006
© ZF Getriebe Gm
VAG-ID.RU
Topics Ремонт АКПП
Î Business unit „Automatic transmission“

Î The 6HP gearbox-family
Î Hints
Hi t ffor th
the repair
i shop
h
General hints
gearbox change
change of a mechatronic
change of a oil pan and filter
changing or adding oil
MK/MKTA/sk 2 APRA_Birmingham, November 2009 ZF confidential

VAG-ID.RU
P-Division ZF Getriebe GmbH Ремонт АКПП
Car Driveline Technology Locations
Saarbrücken (AT) 1973 Saarbrücken-Völklingen, Plant 4 Brandenburg (MT/DT) 1991

G
Germany (DVZ / Logistic)
L i ti ) Germany
G Germany
Kressbronn (R&D) 1969 Friedrichshafen (R&D) 1988 Shanghai** (AT) 2006

Germany Germany China
** Joint Venture with SAIC.

VAG-ID.RU

Î Hints
Hi t ffor th
the repair
i shop
h
General hints
gearbox change

VAG-ID.RU
Product History of the ZF 6-speedРемонт АКПП
Automatic Transmission
1999 IAA in Frankfurt: First Prototype of a fully-automatic

fully automatic six-speed
six speed transmission
World premiere: Start of volume production for the first automatic

6-speed transmission worldwide, the 6HP26; compared to
2001
automatic 5-speed
5 speed transmissions: weight savings of 13% and
30% less components
2005 Presentation of hybrid system (basis: 6HP26) at the IAA in Frankfurt
Introduction of 2nd generation of automatic 6-speed transmissions with another 3-6% in fuel savings
2006
and even faster shift times (partly below the driver’s limit of perception)

VAG-ID.RU
Cutaway drawing 6HP26 Ремонт АКПП
simple
planetary double pl.
torque gearbox
gearset gearset output
converter pump housing
flange
parking
ki llock
k
clutch brake wheel
parking
lock
pawl
pressure oil drain

g
regulator plug
oilpan oilil
strainer

VAG-ID.RU
6HP… Product Family Ремонт АКПП
Improvements of the 2nd Generation
Nm]
ne torque [N
engin
2 nd generation

VAG-ID.RU
Second Generation of 6-speed Ремонт АКПП
Automatic Transmissions
The individual, automatic driving pleasure

Second
S d generation
i off the
h 6HP
6HP:
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

VAG-ID.RU
Reduction of CO2 and Ремонт АКПП
Fuel Consumption
6-speed new
3-Gang
3-speed 4- Gang
4-speed 5-Gang
5-speed 6-Gang
6-speed generation
6-Gang TÜ
- 6%
- 2%
Verbrauch
consumption
- 5% Benzin
Diesel
- 3%
- 6%

VAG-ID.RU
Further development of shift dynamics Ремонт АКПП
(2nd Generation of 6
6-speed
speed transmissions)
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
switching command
reaction time slippage time
shifting time

VAG-ID.RU
Improvement shift dynamics Ремонт АКПП
Vergleich Reaktionszeiten
comparison reaction time
1200
6HP19
1000 6HP21
DKG
me in ms
Reaktionszeit iin ms
800
eaction tim
600
400
re
R
200
0
S
S
S
SR
SR
SR
SR
SR
ZR
ZR
ZR
ZH
ZH
ZH
ZH
ZH
ZR
ZR
ZR
ZR
ZR
21
32
43
54
65
64
53
42
12
23
34
45
56
21
32
43
54
65

VAG-ID.RU

Î Hints
Hi t ffor th
the repair
i shop
h
General hints
gearbox change

VAG-ID.RU
Towing a vehicle Ремонт АКПП
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

respected the automatic transmission will be severely damaged!
respected,

VAG-ID.RU

Î Hints
Hi t ffor th
the repair
i shop
h
General hints
gearbox change

VAG-ID.RU
Transmission ready to be Ремонт
installed into АКПП
the vehicle

VAG-ID.RU
Transmission to be installed into Ремонт
the АКПП
vehicle

VAG-ID.RU
Handling and Storage of an Ремонт АКПП
Automatic Transmission

VAG-ID.RU
Handling and Assembling Ремонт АКПП
of Automatic
Transmission and Engine
Remove converter strap right before assembling the gearbox to the engine

VAG-ID.RU
Installation of the Torque Ремонт АКПП
Converter
Before assembling g the transmission to the engine,

g it is important
p that the
torque converter is installed correctly (see manual of the special gearbox)
distance from bell housing to measurementt off the

th
torque converter distance with a deep gauge

VAG-ID.RU
Pump Gear Ремонт АКПП
Driving
D i i pins
i off th
the pump can
break
Effect:
- no power flow
fl ( R,D
RD)
driving pin

VAG-ID.RU
Pump Gear Ремонт АКПП
This damage is caused by the

wrong installation of the
transmission.
Driving pin is broken

VAG-ID.RU
Leakage between Engine and Ремонт АКПП
Transmission
Effect:
• leakage
ea age be
between
ee e
engine
g ea and
d
transmission
Reasons:
• centre
t bush
b h iis missing
i i iin
crank shaft
• centre pin between engine
and transmission is missing

VAG-ID.RU
Centre Bush Ремонт АКПП
After assembling
Aft bli off th
the ttransmission
i i tto th
the
engine, don‘t forget to build in the centre
centre bush bush!
A missing centre bush cause damages of
the torque converter and the oil pump!
position of the centre bush

VAG-ID.RU
Centre Pins Ремонт АКПП
It is veryy important
p that the centre pins
p
are assembled to the engine case.
Missing centre pins will cause damages
in the transmission
transmission.
center pin
The two A describe the position of

center pin at an engine case the centre pins

VAG-ID.RU
Ремонт АКПП
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

VAG-ID.RU
The whole product family Ремонт АКПП
6HP28A61
6HP28AF
integrated 4x4

VAG-ID.RU
6 speed part numbers Ремонт АКПП
Main Parts List Trans Type Part Number Programmed Description

1071 010 … 6HP19 1071 012 … Rear wheel drive
1071 020 … 6HP19X 1071 022 … External 4x4
1071 040 … 6HP19A 1071 042 … Internal 4x4
4

1068 020 … 6HP26X 1068 022 … External 4x4
1068 030 … 6HP26A61 1068 032 … Internal 4x4

1070 020 … 6HP32A 1070 022 … Internal 4x4
1070 030 … 6HP32X 1070 032 … External 4x4

1071 050 … 6HP21X 1071 052 … External 4x4

1068 050 … 6HP28X 1068 052 … External 4x4
1068 090 … 6HP28A61 1068 092 … Internal 4x4
1084 030 … 6HP28AF 1084 032 … Internal 4x4
VAG-ID.RU
6 speed transmission Ремонт АКПП
identification

VAG-ID.RU
Example transmission applicationРемонт АКПП
BMW 745

VAG-ID.RU
Î Business unit „Automatic transmissions“

Î Hints
Hi t ffor th
the repairshop
i h
General hints
gearbox change
change of a oilpan and filter

VAG-ID.RU
Mechatronic on a special carrier Ремонт АКПП

VAG-ID.RU
6HP..-Mechatronics Ремонт АКПП
left side: E
E-version
version / right side: M
M-Version
Version

VAG-ID.RU
Mechatronik identification Ремонт АКПП

VAG-ID.RU
Mechatronic replacement Ремонт АКПП

VAG-ID.RU

VAG-ID.RU

VAG-ID.RU

VAG-ID.RU

VAG-ID.RU

VAG-ID.RU

VAG-ID.RU

VAG-ID.RU

Î Hints
Hi t ffor th
the repairshop
i h
General hints
gearbox change

VAG-ID.RU
Polyamide oilpan with integrated Ремонт
filter АКПП
6 HP 26 1,6 kg
Î weight reduction app. 40%

VAG-ID.RU
ZF-part number (Polyamide Ремонт АКПП
oilpan)
ZF part number name gearbox Customer
1068 298 033 Oilpan 6HP26 / 28 / 28X / 32 BMW
0501 215 789 Oilpan 6HP26 / 26X Aston Martin, Ford USA, Ford Australia
Jaguar, Range Rover
1071 298 009 Oilpan 6HP19 / 19X / 21 / 21X BMW

VAG-ID.RU
Plate Oilpan and Oilfilter Ремонт АКПП

VAG-ID.RU
ZF Part Number: Ремонт АКПП
Plate oilpan and Oilfilter 1
ZF-part
number Name Gearbox Customer
1068 203 042 Oil

Oilpan 6 HP 26 X F d USA
Ford
1068 203 044 Oilpan 6 HP 26 X BMW
1068 203 046 Oilpan 6 HP 26 Maserati
1068 203 048 Oilpan 6 HP 26 Ford Australia
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

VAG-ID.RU
ZF Part Number: Ремонт АКПП
Plate oilpan and Oilfilter 2
ZF-part
number Name Gearbox Customer
1070 203 010 Oilpan 6 HP 32 BMW

0501 213 359 Filter
1068 301 01
017 S
Sealing
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

VAG-ID.RU

Î Hints
Hi t ffor th
the repairshop
i h
General hints
gearbox change

VAG-ID.RU
General Hints on Transmission Ремонт АКПП
Oil
• Do not mix different oils unless this is expressly

p ypprescribed.
• 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.

VAG-ID.RU
6HPxx transmission fluid level Ремонт АКПП
procedures

VAG-ID.RU
6HPxx transmission fluid level Ремонт АКПП
procedures

VAG-ID.RU
ATF Oil-Check 6HP19 A Ремонт АКПП
Before drive test the ATF have to be filled up with the ZF

Lifeguardfluid
g 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
and 0,528
, l Torsen differential oil
No. S671.090.163
and 0,022 l Sturaco oil No. S671.090.167
only these 4 MPL!!

VW Audi
1071 040 010 1071 040 014
1071 040 022 1071 040 044

VAG-ID.RU
ATF Oil-Check 6HP26A61 Audi Ремонт АКПП
Lifeguardfluid 6
(CGT) 30 … 50 °C
Oil volume: 10 l transmission oil No. S671.090.255
( ll ) and
(yellow) d 1,2
1 2 l differential
diff i l oil
il No.
N
S671.090.163
Version 1: 0,96 l Torsen differential oil No. S671.090.163
andd 0,04
0 04 l Sturaco
St oil
il No.
N S671.090.167
S671 090 167

VAG-ID.RU
ATF Oil-Check 6HP26A61 Ремонт АКПП
Bentley
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
Oil volume: 11,2 l transmission oil No. S671.090.255 (yellow)
(only 1 MPL)

VAG-ID.RU
ATF Oil-Check 6HP32A VW Ремонт АКПП

Lifeguardfluid 6
(CGT) 30 … 50 °C
Oil volume: 10 l transmission oil NoNo.S671.090.255
S671 090 255 (yellow)
and 1,104 l Torsen differential oil No.
S671.090.163
and 0,046 l Sturaco oil
No. S671.090.167

VAG-ID.RU
Colour of Lifeguardfluid 6 (yellow)Ремонт АКПП

VAG-ID.RU
ATF Oil-Check 6HP26A61 (W12)Ремонт АКПП
Lifeguardfluid 6 Plus
Fill up
p instruction: The idle speed
p should be nengg = 750 rpm
p
(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

VAG-ID.RU
Colour of Lifeguardfluid 6 Plus Ремонт АКПП
(blue)
PLUS

VAG-ID.RU
ATF Oil-Check 6HP19A / X Ремонт АКПП
VW, Audi

Lifeguardfluid 8
(CGT) 30 … 50 °C
Oil volume: 9 l transmission oil No. S671.090.311 (green)
and 0,528 l Torsen differential oil
No S671
No. S671.090.163
090 163

VAG-ID.RU
ATF Oil-Check 6HP28AF Audi Ремонт АКПП

Lifeguardfluid 8
(CGT) 30 … 50 °C
Oil volume: 10l transmission oil No. S671.090.311 (green)
and 0,96 l Torsen differential oil
No S671
No. S671.090.163
090 163

VAG-ID.RU
Colour of Lifeguardfluid 8 (green)Ремонт АКПП

VAG-ID.RU
Checking and top up the Oil Ремонт АКПП
Lifeguardfluid 6 (yellow)
BMW, Jaguar, Ford,
Maserati, Hyundai, L.Rover,
Aston Martin, RR,
BMW,, Bentleyy
for the gearbox types

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

VAG-ID.RU
Lifetime Oil for 6-speed / 8-speedРемонт АКПП
Transmissions
Artikel-Nr. / Part-No. AA00 601 304

VAG-ID.RU
Lifetime Oil for 6-speed Ремонт АКПП
Transmissions
Artikel-Nr. / Part-No. S671.090.255

VAG-ID.RU
Lifetime Oil for 6-speed Ремонт АКПП
Transmissions
plus
Artikel-Nr. / Part-No. S671.090.281

VAG-ID.RU
Thank you very much for your Ремонт АКПП
attention!

6HP19 21 Manual

Uploaded by

Copyright:

Available Formats

6HP19 21 Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

6HP19 21 Manual

Uploaded by

Copyright:

Available Formats

VAG-ID.

Î Business unit „Automatic transmission“

MK/MKTA/sk 2 APRA_Birmingham, November 2009 ZF confidential

Saarbrücken (AT) 1973 Saarbrücken-Völklingen, Plant 4 Brandenburg (MT/DT) 1991

Kressbronn (R&D) 1969 Friedrichshafen (R&D) 1988 Shanghai** (AT) 2006

MK/MKTA/sk 3 APRA_Birmingham, November 2009 ZF confidential

Î Business unit „Automatic transmission“

MK/MKTA/sk 4 APRA_Birmingham, November 2009 ZF confidential

1999 IAA in Frankfurt: First Prototype of a fully-automatic

World premiere: Start of volume production for the first automatic

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

MK/MKTA/sk 5 APRA_Birmingham, November 2009 ZF confidential

pressure oil drain

MK/MKTA/sk 6 APRA_Birmingham, November 2009 ZF confidential

MK/MKTA/sk 7 APRA_Birmingham, November 2009 ZF confidential

The individual, automatic driving pleasure

 Considerable contribution to CO2 and/or

 Increased power-to-weight ratio

 Optimized shift dynamics and

 Shift times below the driver’s limit of

MK/MKTA/sk 8 APRA_Birmingham, November 2009 ZF confidential

MK/MKTA/sk 9 APRA_Birmingham, November 2009 ZF confidential

reaction time slippage time

MK/MKTA/sk 10 APRA_Birmingham, November 2009 ZF confidential

MK/MKTA/sk 11 APRA_Birmingham, November 2009 ZF confidential

Î Business unit „Automatic transmission“

MK/MKTA/sk 12 APRA_Birmingham, November 2009 ZF confidential

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

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

Î Business unit „Automatic transmission“

MK/MKTA/sk 14 APRA_Birmingham, November 2009 ZF confidential

MK/MKTA/sk 15 APRA_Birmingham, November 2009 ZF confidential

MK/MKTA/sk 16 APRA_Birmingham, November 2009 ZF confidential

MK/MKTA/sk 17 APRA_Birmingham, November 2009 ZF confidential

MK/MKTA/sk 18 APRA_Birmingham, November 2009 ZF confidential

Before assembling g the transmission to the engine,

distance from bell housing to measurementt off the

MK/MKTA/sk 19 APRA_Birmingham, November 2009 ZF confidential

MK/MKTA/sk 20 APRA_Birmingham, November 2009 ZF confidential

This damage is caused by the

Driving pin is broken

MK/MKTA/sk 21 APRA_Birmingham, November 2009 ZF confidential

MK/MKTA/sk 22 APRA_Birmingham, November 2009 ZF confidential

position of the centre bush

MK/MKTA/sk 23 APRA_Birmingham, November 2009 ZF confidential

The two A describe the position of

MK/MKTA/sk 24 APRA_Birmingham, November 2009 ZF confidential

Î After repair you should make a driving test

MK/MKTA/sk 25 APRA_Birmingham, November 2009 ZF confidential

MK/MKTA/sk 26 APRA_Birmingham, November 2009 ZF confidential

Main Parts List Trans Type Part Number Programmed Description

1068 010 … 6HP26 1068 012 … Rear wheel drive

1070 010 … 6HP32 1070 012 … Rear wheel drive

1071 030 … 6HP21 1071 032 … Rear wheel drive

1068 040 … 6HP28 1068 042 … Rear wheel drive

MK/MKTA/sk 28 APRA_Birmingham, November 2009 ZF confidential

MK/MKTA/sk 29 APRA_Birmingham, November 2009 ZF confidential

Î Business unit „Automatic transmissions“

Considerable contribution to CO2 and/or

Increased power-to-weight ratio

Optimized shift dynamics and

Shift times below the driver’s limit of