zf8hp rebuild

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ZF8HP Rebuild

Presented by: Mike Souza ATRA Senior

Research Technician ZF8HP Rebuild Webinar 2015 ATRA. All Rights Reserved.

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

Clutch & Gear Set Identification

P1 P2 P3 P4

Clutch Application Chart

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)

One Time Use Selective Snap Ring

Align With Rivet

Drivetrain Assembly

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.

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

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)

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

E Clutch Assembly

C Clutch Assembly

D Clutch Assembly

D Clutch Assembly

Riveted D Clutch Piston

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

B Clutch Clearance Measurement

Factory Method Total clearance should be 1.52mm to 1.93mm (.060 to .076) There are selective Pressure Plates available.


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)

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

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

Valve Body Separator Plate (Silk Screen)

Flat side of accumulator

faces up

Rocker Ball

Screen

Filter

Upper Valve Body Information

7

Small Parts Installation

Small Parts Installation

Must Protrude Above The Channel Plate

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


Lower Valve Body Information

Bore Plug Installation

Lower Valve Body Information

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

Torque Converter & Pump Drive Assembly

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

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


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


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

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

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

Reduces Cavitation & Noise

Pump Function

Pump Exploded View

Faces Down

Sprocket Side

Air check C & E Clutch with 30 psi. of regulated shop air.

E Clutch C Clutch

Lube TCC C Clutch E Clutch

Case Air Checks

Air checks should be done with no more than 30 psi. of regulated air pressure.

D Clutch

Front of Transmission

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

Recommended Fluid ZF Lifeguard is the recommended type of fluid to be used. Fluid capacities are model dependent.

Service & Fill Procedure Using a scan tool or the vehicle information center, verify that the transmission fluid temperature is below 30C (86F).

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

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.

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

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