zf8hp rebuild
DESCRIPTION
ZF8HP RebuildTRANSCRIPT
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JUNE 6/6/15 -- Tulsa, OK AUGUST 8/8/15 -- Albuquerque, NM 8/15/15 -- Portland, OR 8/22/15 -- Atlanta, GA 8/29/15--Anaheim, CA SEPTEMBER 9/12/15 -- Billings, MT 9/19/15 -- Chicago, IL 9/26/15-- Clark-Newark, NJ OCTOBER ATRA's Powertrain Expo October 29 - November 1 NOVEMBER 11/7/15 -- Baltimore, MD
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ZF8HP Rebuild
Presented by: Mike Souza ATRA Senior
Research Technician ZF8HP Rebuild Webinar 2015 ATRA. All Rights Reserved.
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Transmission Identification With all the different variations of parts found in several vehicle models, its always important to use the transmission ID information when ordering parts.
Location may vary per vehicle and model
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Clutch & Gear Set Identification
P1 P2 P3 P4
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Clutch Application Chart
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Splines into pump housing
Splines into main case
Splines into C & E clutch drum
Splines into D Clutch Drum
A Clutch
B Clutch
E Clutch
C Clutch
D Clutch
Clutch Layout
Pump Housing
Case
Carefully removed vertically as one assembly to prevent damage to the P4 annulus drum (shell).
C & E Clutch Drum
D Clutch Drum
Splines into C & E clutch drum
P4 Annulus Drum (shell)
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One Time Use Selective Snap Ring
Align With Rivet
Drivetrain Assembly
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Drivetrain Assembly Carefully remove the snap ring to prevent damage to the P4 annulus drum (shell). This should be done with a factory tool or something similar such as a large hose clamp.
The material of the shell is very brittle and can be broken or distorted easily.
To remove the snap ring start at 180 degrees opposite of the snap ring opening
Special thanks to Niel Speetjens for some of the photos used in this handout.
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Miller Tools $115.00 Kits #10394 #10394A #10394B 2012 (LD, LX) 2013 (DS, LD, LX) 2014 (DS, LD, LX, WD, WK) Seen on the internet at lower & higher prices.
Package of 3
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P1 Ring Gear
P1 Planet
P1 & P2 Sun Gear
P2 Planet
P2 Ring Gear / P3 Sun Gear
P1 & P2 Planet Assemblies
P4 Sun Gear Shell (C & E Clutch Drum)
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P3 Planet
P4 Sun Gear Shell (C & E Clutch Drum)
P4 Planet (D Clutch
Drum)
P4 Annulus
P3 & P4 Planet Assemblies
C Clutch
E Clutch
D Clutch
P3 Ring Gear
D Clutch Hub
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E Clutch Assembly
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C Clutch Assembly
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D Clutch Assembly
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D Clutch Assembly
Riveted D Clutch Piston
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Balance Pistons As with any transmission with balance pistons, this is basically how they work.
Forward Clutch
Lube
Baffle Plate
Return Cup Spring Balance Oil Function Apply Piston
This Oil Prevents The Clutches From Appling Due To Centrifugal Force More Reliable Clutch Engagement & Release Control At Any Speed
Improves Shift Refinement
Seal
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B Clutch Clearance Measurement
Factory Method Total clearance should be 1.52mm to 1.93mm (.060 to .076) There are selective Pressure Plates available.
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B Clutch Clearance Measurement
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B Clutch Clearance Measurement
Then flip the H-Gauge over and place onto the pump at the to case mating area. Measure the clearance at the apply piston.
This method will work with the rest of the clutch assemblies throughout the rest of this and other transmissions.
1.52mm to 1.93mm (.060 to .076)
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Clutch clearance is measured with the clutch components compressed within the drum with at least 45 lbs. of downward force on the pressure plate. Measure clearance with a feeler gauge between the pressure plate and the snap ring. Clutch Clearance Adjusted By Clutch A : 1.41mm to 1.7mm (.055 to .066) Snap Rings Clutch B : 1.52mm to 1.93mm (.060 to .076) Backing Plates Clutch C : 1.62mm to 2.01mm (.063 to .079) Backing Plates Clutch D : 1.37mm to 1.66mm (.053 to .065) Snap Rings Clutch E : 1.62mm to 2.01mm (.063 to .079) Backing Plates
Clutch Clearances
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Pry here to separate halves
Pry here to separate halves
The idea is to keep the separator plate with the upper valve body and contain the small parts
Lower Valve Body
Upper Valve Body
Valve Body Information
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Valve Body Separator Plate (Silk Screen)
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Flat side of accumulator
faces up
Rocker Ball
Screen
Filter
Upper Valve Body Information
7
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Upper Valve Body Information
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Small Parts Installation
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Small Parts Installation
Must Protrude Above The Channel Plate
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Upper Valve Body Information
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The B clutch NIC valve is controlled by the computer during an idle stop in drive. The computer will release the clutch partially to reduce engine drag at a stop for improved fuel economy
Upper Valve Body Information
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Upper Valve Body Information
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Lower Valve Body Information
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Bore Plug Installation
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Lower Valve Body Information
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Torque Converter & Pump Drive Assembly This ZF unit is designed with a chain driven, double stroke vane pump. The torque converter hub is splined to a drive sprocket that turns a chain to rotate the pump
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Torque Converter & Pump Drive Assembly
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The stator support houses all the pump components. The stator support also houses the A clutch and B clutch piston and cylinder.
The B1 clutch apply piston does not use return springs. The apply and release functions are controlled by the computer.
Stator Support & Pump Assembly
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To remove the A clutch pack from the stator support housing, remove the snap ring and lift the A clutch hub off of the stator support. The A clutch waved plate will remain in the stator support housing to be retrieved later. Once the Hub is removed, remove clutches from the hub for inspection.
Remove the snap ring
Stator Support & Pump Assembly
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To remove the cover from the stator support and pump assembly, the A clutch piston and return spring must be removed from the stator support.
Remove the bolts to split the halves
Stator Support & Pump Assembly
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Stator Support & Pump Assembly
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Use a screwdriver to gently pry the pump body out of the stator support assembly. The drive gear, chain and pump body must be lifted off the stator support as an assembly
Pump Assembly
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This vane type pump comes apart using a small pair of snap ring pliers. Remove the snap ring from the drive shaft and remove the cover. This vane type pump assembly is very small but efficient.
Pump Assembly
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Inlet
Inlet Outlet
Outlet
This is a very small vane pump. The pump is built with two chambers. This means there are two inlets and two outlets to the pump body
Pump Function
System pressure 80 psi to 250 psi (max. 460 psi) Displacement 1,85 US gallons to 5,81 US gallons a minute
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Reduces Cavitation & Noise
Pump Function
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Pump Exploded View
Faces Down
Sprocket Side
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Air check C & E Clutch with 30 psi. of regulated shop air.
E Clutch C Clutch
Lube TCC C Clutch E Clutch
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Case Air Checks
Air checks should be done with no more than 30 psi. of regulated air pressure.
D Clutch
Front of Transmission
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Sump (pan) Differences There is a deeper sump (pan) for the 845RE found in the Jeep Grand Cherokee. This pan will increase fluid capacity and improve lubrication.
Filter is part of the Sump
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Recommended Fluid ZF Lifeguard is the recommended type of fluid to be used. Fluid capacities are model dependent.
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Service & Fill Procedure Using a scan tool or the vehicle information center, verify that the transmission fluid temperature is below 30C (86F).
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Extension Housing to Transmission Bolt ...................... 20 Ft. Lbs. Manual Park Release Cable to Case Bolt....................... 15 Ft. Lbs. Manual Park Release Lever Shaft Nut ............................ 89 In. Lbs. Manual Park Release Lever Assembly Nut .................... 89 In. Lbs. Oil Pan Drain Plug ............................................................ 80 In. Lbs. Oil Fill Plug ........................................................................ 26 Ft. Lbs. Oil Pan Bolt ....................................................................... 89 In. Lbs. Oil Pump Assembly to Case Bolt..................................... 44 In. Lbs. + 45 Oil Pump Housing to Cover Bolt...................................... 44 In. Lbs. + 45 Output Speed Sensor Bolt ............................................... 71 In. Lbs. Torque Converter Bolt...................................................... 31 Ft. Lbs. Park Pawl Lock Rod Guide Plate Bolt ............................ 89 In. Lbs. Park Pawl Shaft Plug ........................................................ 26 Ft. Lbs. Propeller Shaft Flange Nut............................................... 44 Ft. Lbs. Shifter Assembly Bolts..................................................... 65 In. Lbs. Shifter Knob Lower Shroud Bolt..................................... 65 In. Lbs. Torque Converter to Flex Plate Bolt ............................... 31 Ft. Lbs. Transfer Case to Transmission Nut ................................ 20 Ft. Lbs. Transmission Mount to Adapter...................................... 24 Ft. Lbs. Valve Body Bolt................................................................. 71 In. Lbs. Transmission Heater to Transmission............................ 18 Ft. Lbs.
Torque Specifications
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TCM Adaptation It is necessary to perform a drive cycle to provide the proper baseline transmission adaptation. The adaptation procedure should be performed if any of the following procedures are performed: Transmission Assembly Replacement Transmission Control Module Assembly (TCMA) Replacement Internal Transmission repairs Torque Converter Replacement 1. With the scan tool, clear any DTCs that may be set. 2. Drive the vehicle until the vehicle temperature is greater than 30C (86F). 3. After the vehicle has reached normal operating temperature, and with the scan tool, monitor actual gear state. Drive the vehicle normally with the accelerator pedal between 10% and 20% until 7th gear has been achieved, approximately 76 km/h (47 mph). After 7th gear has been achieved, coast down to 30 mph with no application of the brake or accelerator to allow a 6-5 shift. Brake the vehicle to a stop. Repeat this procedure 5 times.
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Audi ATF Venting System The ATF system ventilates into the converter bell housing through ducts inside the gear case. The front axle differential breather is present only in transmissions with a separate oil system. Dont mistake oil from the vent as a front seal leak.
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ZF8HP Rebuild Webinar 2015 ATRA. All Rights Reserved.
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