ZF 6HP-26 Repair Manual.pdf

REPAIR MANUAL

HP-

ZF GETRIEBE GMBH SAARBRÜCKEN

Version 02/11/01

subject to alterations

ZF Getriebe GmbH, Saarbrücken, Department MKTD

No part of this manual may be reproduced or transmitted in any form or

by any means, electronic or mechanical, including photocopying and recording,

for any purpose without the express written permission of

ZF Getriebe GmbH, Saarbrücken

Printed in Germany

Contents

Advance Information

iii

1. General

1.1/1

1.1 Illustration of transmission

1.1/1

1.2 Power flow diagram

1.2/1

1.3 Specifications

1.3/1

1.3.1 Screw speciications

1.3/1

1.3.1.1 Mechatronic type E

1.3/1

1.3.1.2 Mechatronic type M

1.3/1

1.4 Adjusting procedure

1.4/1

1.4.0 Measuring clutch packs

(procedure)

1.4/1

1.4.1 Clearance setting, brake C (snap ring)

1.4/3

1.4.2 Clearance setting, brake D (snap ring)

1.4/5

1.4.3 Clearance setting, clutch B (snap ring)

1.4/7

1.4.4 Clearance setting, clutch A (snap ring)

1.4/9

1.4.5 Clearance setting, clutch E (snap ring)

1.4/11

1.4.6 Clearance - output

(disk)

1.4/13

1.4.7 Clearance - input

(disk)

1.4/14

(M type only)

1.4.8 Switch setting

(detent spring)

1.4/15

1.5 Tightening torques

1.5/1

1.6 Transmission test (test bench)

1.6/1

1.7 Special tools

1.7/1

1.8 Oilflow chart (Position N)

1.8/1

(E - type)

1.8/1

(M - type)

1.8/2

2. Disassembly

2.1/1

2.1 Transmission disassembly according to component groups

2.1/1

Dismantling

2.2 Turret (with clutches A and E)

2.2/1

2.3 Oil supply

2.3/1

2.4 Clutch B

2.4/1

2.5 Brakes C and D

2.5/1

2.6 Output shaft with parking lock

2.6/1

2.7 Transmission casing with shift–control and parking lock

2.7/1

3. Assembly

3.1/1

3.1 Transmission casing with shift control and parking lock

3.1/1

3.2 Output shaft with parking lock and planetary gear set

3.2/1

3.3 Brakes C and D

3.3/1

3.4 Clutch B

3.4/1

3.5 Turret (drive with clutches A and E)

3.5/1

3.5.1 Clutch E (drive)

3.5/1

3.5.2 Clutch A (input)

3.5/4

3.6 Oil supply

3.6/1

3.7 Mechatronics, oil pan and converter

(Complete mechatronics, see spare parts list, technical cover sheet, item YO2)

3.7/1

02/11/01

02/11/01

Advance Information

These instructions contain the procedure for repair work on the complete transmission.

The repair instructions will only be understood sufficiently in combination with ZFS training.

Neglecting this could lead to installation errors.

All disassembly and assembly work is listed in chronological order.

Photos and illustrations for the various applications are general in character and not binding for every

individual case.

Important changes and those relevant to specific applications that have to be considered during repair

work are announced in Technical Circular Letters and training courses.

During the repair work ELCAT regulations and specifications must be observed.

Please note the following:

• Seals, e.g. O-rings, shaft sealing rings, gaskets and filters must always be renewed.

• During assembly, all O-rings, cylindrical rings and other sealing rings must be greased with

Vaseline before mounting.

• All bearings must be slightly oiled when installed.

• Exchange all lining and steel disks in transmissions with higher distance readings (> 80,000

kilometers / 50,000 miles).

• After clutch / brake damage, converters, oil pipes and oil coolers must be cleaned out

thoroughly and sufficiently with an appropriate cleaning agent.

• After damage to brake F, if the distance reading is high (> 80,000 km / 50,000 miles), piston

F must be renewed.

The following requirements should be satisfied before starting the repair work:

• Availability of the necessary special tools otherwise assembly faults are possible.

Chapter 1.8 lists the complete set of special tools.

• Availability of a suitable transmission test rig.

For the necessary test values, please refer to the Technical Circular Letters .

02/11/01

iii

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