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ZF 5HP18 Transmission Repair Manual

ZF

This manual contains precise details of how to repair the complete transmission.

A1 dismantling and assembly work is described in the correct order.

The photographs have been selected to cover various types of transmission and may therefore differ from the vehicle on which you are working.

The component list precisely defines which version of the transmission you are working and this is also reflected In the parts list.

If any major modifications have to be taken into account when repairs are carried out, you will be notified by Technical Bulletin.

Depending on the nature of the fault, It may be possible to limit the repair to the actual components and areas of the transmission that have failed.

In this connection, please note:

  • Always renew the pistons if there is a fault on clutch F or brake G. Never re-use seals, for example 0-rlngs and shaft sealing rings.
  • If the transmission has been run for a considerable distance (> 50.000 km), renew all lined and steel discs.
  • If clutch damage has occurred the converter, oil cooler lines and the oil cooler itself must be thoroughly flushed out with a suitable cleaning agent.

The following conditions must be satisfied:

  • The necessary special tools must be available The complete set Is listed in Section 1.8 of this manual.
  • A suitable transmission test rig should be available.

Refer to the Technical Bulletins for the relevant test values.

CONTENTS

Preliminary information

  • 1. General remarks
    • 1.1 Drawing of transmission
    • 1.2 Power flow schematic
    • 1.3 Oil flow charts
    • 1.4 Adjustment work
      • 1.4.1 Release clearance at clutch F (snap ring)
      • 1.4.2 Release clearance at brake G (snap ring)
      • 1.4.3 Release clearance at brake D (snap ring)
      • 1.4.4 Clearance at output side (washer)
      • 1.4.5 Release clearance at clutch E (snap ring)
      • 1.4.6 Release clearance at clutch A (snap ring)
      • 1.4.7 Release clearance at brake C1 (snap ring)
      • 1.4.8 Transmission axiale clearance (washer)
      • 1.4.9 Release clearance at brake C2 (two washers)
    • 1.5 Tightening torques
    • 1.6 Troubleshooting (faults, causes and remedies)
    • 1.7 Checking the transmission
    • 1.8 Special tools
  • 2. Dismantling
    • 2.1 Dismantling according to assembly groups
    • 2.2 Output side
    • 2.3 Planetary gears, complete
      • 2.3.1 Planetary gear set III
      • 2.3.2 Clutch F
      • 2.3.3 Brake DG with 1st gear freewheel
    • 2.4 Input side
      • 2.4.1 Clutch E
      • 2.4.2 Clutch A
      • 2.4.3 Clutch B and 3rd gear freewheel
      • 2.4.4 Brake C
    • 2.5 Oil supply unit with brake C
    • 2.6 Housing with shift and parking pawl
  • 3. Assembling according to assembly groups
    • 3.1 Housing with shift and parking pawl
    • 3.2 Planetary gear set, complete
      • 3.2.1 Planetary gear set III
      • 3.2.2 Clutch F
      • 3.2.3 Brake DG with 1st gear freewheel
    • 3.3 Output side
    • 3.4 Planetary gear sets I and II
    • 3.5 Input side
      • 3.5.1 Clutch E
      • 3.5.2 Clutch A
      • 3.5.3 Clutch B and 3rd gear freewheel
      • 3.5.4 Brake C
    • 3.6 Oil supply unit with brake C
    • 3.7 Selector unit, oil sump and converter

Language: English
Format: PDF
Pages: 121

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