Repair Manual 5HP24 - Jagrepair
REPAIR MANUAL5 HP - 24ZF GETRIEBE GMBH SAARBRÜCKENStatus 98/08/01
subject to alterations Copyright 1998 all rights reserved and published byZF Getriebe GmbH, Saarbrücken, Department MKTDNo part of this manual may be reproduced or transmitted in any form orby any means, electronic or mechanical, including photocopying and recording,for any purpose without the express written permission ofZF Getriebe GmbH, SaarbrückenPrinted in Germany
Table of ContentsPreliminary 42.52.62.72.83.3.13.23.33.43.53.63.7PageIIGeneral informationPicture of the transmissionDiagram of power flow(Previously used for the oil supply diagrams, not currently used)Making adjustments1.4.0Measuring the disc sets (procedure)1.4.1Adjusting clearance of brake F(snap ring)1.4.2Adjusting clearance of brake D(snap ring)1.4.3Adjusting clearance of brake E(snap ring)1.4.4Adjusting clearance of clutch C(snap ring)1.4.5Adjusting clearance of clutch A(snap ring)1.4.6Adjusting clearance of clutch B(snap ring)1.4.7Output play(shim)1.4.8Input play(shim)1.4.9Adjusting switch(detent spring)Tightening torquesTransmission test (test bench/vehicle)Special toolsFunction tests1.8.1Position 11.8/1DisassemblyDisassembly of the transmission as of the assembly groupBrake F with freewheel, 1st gearOutputTower I2.4.1Brake D, E and clutch C2.4.2Planetary drive (III, II and I)Tower IIOil supplyTransmission with flow control valve and breatherTransmission with selector mechanism and parking .7/12.8/1Assembly3.1/1Transmission with selector mechanism and parking lock3.1/1Brake F with freewheel, 1st gear3.2/1Tower I3.3/13.3.1Planetary drive (III, II and I)3.3/13.3.2Brake (E and D)3.3/43.3.3Assembly, clutch C3.3/9Output3.4/1Tower II (input with clutches A and B)3.5/13.5.1Clutch A (input)3.5/13.5.2Clutch B (input)3.5/3Oil supply3.6/1Control unit, oil pan and converter3.7/1(Complete control unit, see parts list, technical cover sheet, position Y02)5 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/01I
Preliminary informationThis manual covers the procedure for repairing the complete transmission.The repairing of this transmission is only allowed to persons with an specific training from ZFGetriebe GmbH.The entire disassembly and assembly procedure is described in chronological order.The photographs were kept general in nature so that they can be used with various applications;they are not binding in every case.We use Service Bulletines and training to announce important information andapplication-specific changes that must be taken into consideration in maintenance work.If this repair manual is given to a third party, there will be no modification service.The Service Bulletines regulations and specifications must be followed when making repairs.Depending on the type of damage that has occured, the repair work can be limited to that which isnecessary to repair the damage.Here, you must observe the following: Seals (such as O-rings, shaft seals, gaskets and filters) must always be renewed. All O-rings, rectangular-section rings, and other sealing rings must always be lubricatedwith white petroleum jelly before installation. All bearings must always be in a slightly oiled condition when installed. For transmissions that have been used for a large number of kilometers( 80,000 km), all lined clutch discs and steel discs must be replaced. After clutches/ brakes have been damaged, the converter, oil tubes, and oilcooler, must be cleaned thoroughly. If brake F has been damaged, or if a considerable distance has been covered( 150,000 km), piston F must be replaced.The following requirements should be met before the repair work is started: The required special tools should be available.(The complete set of special tools is listed in Chapter 1.7) A suitable transmission testing rig should be available.The required testing values can be found in the Service Bulletines.II5 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/01
Note:This manual treats the automatic control unit as a complete unit, which should not be disassembled without special knowledge; it should be exchanged as a complete unit.A separate repair manual is planned for the automatic control unit.Important:The transmission is filled with life-time oil.The oil does not have to be changed until it has been in use for ten years.The transmission may only be delivered with the oil type and oil amount specified in the corresponding parts list documentation (see ELCAT), otherwise there is danger of gearbox failure.Techn. After Sales ServiceTechn. DocumentationAfter Sales Service SchoolBachReusSchultz5 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/01III
1.1.1General informationPicture of the transmission5 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/011.1/1
1.2 Power flow diagramGang Gear ratio5 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/011.2/1
1.4Making adjustments1.4.0 Measuring the clutch pack(procedure)Place the two intermediate pieces5p01 000 329 on the marked positions onmeasuring fixture 5p01 000 330.98009Use knurled screw to turn adjusting device 5p01 001 458 to upper limit position.Attach force-measuring unit 5p01 000329 to adjusting device 5p01 001 458.98011Fasten adjusting device with 4 knurledscrews to the measuring fixture using theintermediate pieces.Connect measuring plate 5p01 040 330to force-measuring unit using fixing pin.Use knurled screw to clamp the clutchpack to be measured (with corrugatedsteel clutch plate – if present – at the bottom) in device at 200 N.980125 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/011.4/1
Check the value on the force-measuringunit.98017Then put measuring bar 5p01 060 330 onthe measuring plate, insert the measuringbase of the dial gauge into the groove ofthe measuring plate on the top plate ofthe pack and set the dial gauge to zero.98018Now measure down to the base plateusing the measuring bar.Read off the measurement value MXNote!In each case, index X in MX standsfor the clutch pack that was put in for theclutches/brakes (A, B, C, D, E, F)1.4/25 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/01
1.4.1 Adjusting clearance of brake F(snap ring)Determine installation space EF for brakeF with measuring bar 5p01 000 330. Todo this, put measuring bar 5p01 000 330on the edge of the cylinder for brake F.Put the measuring base on the highestpoint of the disc supporting surface onthe piston and set the dial gauge to“0”.Pull the measuring sensor upwards, guideit into the snap-ring groove and press itthere against the groove’s upper edge.98020Read measured value on the dial WFDetermine thickness MF of the brake Fclutch pack according toChapter 1.4.0: Measuring the clutch pack. MFInstallation space EF is equal to WF plusthe thickness of the base F. EFTest value PF is equal to installationspace EF minus MF98019The PF value must lie between 5.0-6.6 mm.Setting specification 1055 700 100.Use test value PF to select snap ring SF.Calculation:E F WF FPF EF - MFClutch clearance LF should be 2.4 2.9 mm with 6 lined clutch discs.5 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/011.4/3
Example (for 1.4.2):FWFMF 1.48 mm (base thickness) 32.32 mm 27.82 mmEF PFSF32.32 1.4833.8 mm33.8 - 27.825.98 mm 3.4 mmLF 5.98 - 3.4 LF 2.58 mm1.4/45 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/01
1.4.2 Adjusting clearance of brake D(snap ring)Determine installation space ED for brakeD with measuring bar 5p01 000 330. Todo this, put measuring bar 5p01 000 330on the edge of the cylinder for brake D.Put the measuring base on the highestpoint of the disc supporting surface onthe piston and set the dial gauge to“0”.Pull the measuring sensor upwards, guideit into the snap-ring groove and press itthere against the groove’s upper edge.98022Read measured value on the dial WDDetermine thickness MD of the brake Dclutch pack according toChapter 1.4.0: Measuring the clutch pack. MDInstallation space ED is equal to WF plusthe thickness of the base F. EDTest value PD is equal to installationspace ED minus MD.98021The PD value must lie between 3.72 - 5.52 mm.Setting specification 1058 700 067 Version BUse test value PD to select snap ring SD.Calculation:ED WD FPD ED - MDClutch clearance LD should be 1.35 1.65 mm with 4 lined clutch discs.5 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/011.4/5
Example (for 1.4.2):FWDMD 1.48 mm (base thickness) 26.6 mm 23.54 mmED PDSD26.6 1.4828.08 mm28.08 - 23.544.54 mm 3.0 mmLD 4.54 - 3.0 LD 1.54 mm1.4/65 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/01
1.4.3 Adjusting clearance of brake E(snap ring)Determine installation space EE for brakeE with measuring bar 5p01 000 330. Todo this, put measuring bar 5p01 000 330on the edge of the cylinder for brake E.Put the measuring base on the highestpoint of the disc supporting surface onthe piston and set the dial gauge to“0”.Pull the measuring sensor upwards, guideit into the snap-ring groove and press itthere against the groove’s upper edge.98024Read measured value on the dial WEDetermine thickness ME of the brake Eclutch pack according toChapter 1.4.0: Measuring the clutch pack. MEInstallation space EE is equal to WE plusthe thickness of the base F. EETest value PE is equal to installationspace EE minus ME.98025The PE value must lie between 3.8 -5.4 mm.Setting specification 1058 700 029Version BUse test value PE to select snap ring SE.Calculation:E E WE FPE EE - MEClutch clearance LE should be 1.4 1.7 mm with 5 lined clutch discs.5 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/011.4/7
Example (for 1.4.3):FWEME 1.48 mm (base thickness) 30.0 mm 26.83 mmEE 30.0 1.48 31.48 mm 31.48 - 26.83 4.65 mmPESE 3.2 mmLE 4.65 - 3.2 LE 1.45 mm1.4/85 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/01
1.4.4 Adjusting clearance of clutch C(snap ring)Determine installation space EC for clutchC with measuring bar 5p01 000 330. Todo this, put measuring bar 5p01 000 330on the edge of the cylinder for clutch C.Put the measuring base on the highestpoint of the disc supporting surface onthe piston and set the dial gauge to“0”.Pull the measuring sensor upwards, guideit into the snap-ring groove and press itthere against the groove’s upper edge.98027Read measured value on the dial WCDetermine thickness MC of the clutch Cclutch pack according toChapter 1.4.0: Measuring the clutch pack. MCInstallation space EC is equal to WC plusthe thickness of the base F. ECTest value PC is equal to installationspace EC minus MC.98026The PC value should be between 3.55 -4.95 mm.Setting specification 1058 700 087Use test value PC to select snap ring SC.Calculation:EC WC FPC EC - MCClutch clearance LC should be 1.35 1.65 mm with 4 lined clutch discs.5 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/011.4/9
Example (for 1.4.4):FWCMC 1.48 mm (base thickness) 23.55 mm 20.7 mmEC PCSC23.55 1.4825.03 mm25.03 - 20.74.33 mm 2.8 mmLC 4.33 - 2.8 LC 1.53 mm1.4/105 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/01
1.4.5 Adjusting clearance of clutch A(snap ring)Determine installation space EA for clutchA with measuring bar 5p01 000 330. Todo this, put measuring bar 5p01 000 330on the edge of the cylinder for clutch A.Put the measuring base on the highestpoint of the disc supporting surface onthe piston and set the dial gauge to“0”.Pull the measuring sensor upwards, guideit into the snap-ring groove and press itthere against the groove’s upper edge.98030Read measured value on the dial WADetermine thickness MA of the clutch Aclutch pack according toChapter 1.4.0: Measuring the clutch pack. MAInstallation space EA is equal to WA plusthe thickness of the base F. EA98029Important!The final disc has a step in it.When measuring the set thicknes, measuredown to the final disc’s lowest step.Test value PA is equal to installationspace EA minus MA.Value PA should be between 3.75 -5.75 mm.Setting specification 1058 700 021Use test value PA to select snap ring SA.Calculation:EA WA FPA EA - MAClutch clearance LA should be 1.95 2.25 mm with 6 lined clutch discs.5 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/011.4/11
Example (for 1.4.5):FWAMA 1.48 mm (base thickness) 30.26 mm 26.65 mmEA PASA30.26 1.4831.74 mm31.74 - 26.655.09 mm 3.0 mmLA 5.09 - 3.0 LA 2.09 mm1.4/125 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/01
1.4.6 Adjusting clearance of clutch B(snap ring)Determine installation space EB for clutchB with measuring bar 5p01 000 330. Todo this, put measuring bar 5p01 000 330on the edge of the cylinder for clutch B.Put the measuring base on the highestpoint of the disc supporting surface onthe piston and set the dial gauge to“0”.Pull the measuring sensor upwards, guideit into the snap-ring groove and press itthere against the groove’s upper edge.98032Read measured value on dial WBDetermine thickness MB of the clutch Bclutch pack according toChapter 1.4.0: Measuring the clutch pack. MBInstallation space EB is equal to WB plusthe thickness of the base F. EBThe test value PB is equal to installationspace EB minus MB.98031Value PB should be between 4.52 - 6.72 mm.Setting specification 1058 700 065Use test value PB to select snap ring SB.Calculation:E B WB FPB EB - MBClutch clearance LB should be 1.95 2.25 mm with 6 lined clutch discs.5 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/011.4/13
Example (for 1.4.6):FWBMB 1.48 mm (base thickness) 36.64 mm 32.86 mmEB PBSB36.64 1.4838.12 mm38.12 - 32.865.26 mm 3.2 mmLB 5.26 mm - 3.2 mm LB 2.06 mm1.4/145 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/01
1.4.7 Output play (shim)Determine distance A between themachined face on the extension and theoutput flange hub using a depth gaugeand measuring bar.97143Important!To prevent falsification of the measurement, press down the hub and do notplace the gearbox extension on the outputflange during measuring.Using a depth gauge and a measuring bar,determine distance B between the machinedface of the transmission housing and themachined face of the parking lock wheel.Nominal axial play C 0.25 to 0.45 mm(acc. to Setting specification 1058 700 122).Thickness of washer S is now equal to Bminus A minus C.Calculation:S B -A - C97245Example: (for 1.4.7)ABC 42.7 mm 44.9 mm 0.25 to 0.45 mmS 44.9 - 42.7 - (0.25 to 0.45) 2.2 mm - (0.25 to 0.45) S 1.75 to 1.95 mmNote!The dimensions A and B are indicatedwithout the thickness of measuring bar.5 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/011.4/15
1.4.8 Input play (shim)Fasten the converter bell in the inner ringusing two long, machine screws 22.100on opposite sides.(See Chapter 1.5 for tightening torque)Requirement:Axial needle roller bearing 02.250 andspacer 02.260 (thickness 1.4 mm,thinnest acc. to optional technical kit),the gasket, intermediate plate, and converter bell housing must be in place.97179Clamp the measuring sleeve for device5p01 001 415 on to the stator shaft usingthe three fastening screws, no playallowed.Push measuring device 5p01 001 415over the splines of the input shaft andsecure with set screw about 2 mm abovethe meausurement sleeve in such a waythat it can not tilt.Set dial gauge to “0”.97180Determine axial play by pressing andpulling on the handle (repeat measurement several times)Nominal axial play 0.2 - 0.4 mm at aforce of 200 N (dry in acc.withSetting specification 1058 700 119)If a deviation arises, compensate with awasher 02.260 with the appropriate thickness. Pre-check the axial play.1.4/165 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/01
1.4.9 Adjusting the switch(detent spring)Move the detent disc to the N (neutral)position with a suitable tool or by hand.97083Place position gauge 5p01 002 839 onthe selector shaft, turn the position gaugeso that the locating pin in the transmission housing enters the cutout in theposition gauge and eliminate any play byturning the knurled screw.97084Important!For JAGUAR and older BMW transmission housings 1058 301 077, use positiongauge 5p01 002 567 (follow the ELCATinstructions).Align the detent spring’s roller on thecenter of the detent disc, and screw ittight with helping tool 5w04 000 583 inthis position.(See Chapter 1.5 for tightening torque)980045 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/01Release the position gauge and move theselector shaft from position N to P andthen back to position N.If the installation has been performedcorrectly, the position gauge can easily beplaced on the selector shaft until it comesinto contact with the transmission housing.1.4/17
1.5 Tightening torquesNo. DesignationELCATPos.-No.Wrench sizeNo.PageTighteningtorque1 Screw plug(Transmission housing)01.650Hexagonal socketSAF 5 mm3.1/312 Nm( 1.2Nm)2 Screw plug(Transmission housing)01.210Hexagonal socketSAF 6 mm3.1/325 Nm( 2.5 Nm)3 Transport plug(Transmission housing)01.23001.240HexagonalSAF 17 mm3.1/32 Nm( 0.2 Nm)4 Screw plug M14x1.5(Leg spring)01.090Hexagonal socketSAF 6 mm3.1/520 Nm( 2.0 Nm)5 Machine screw(Guiding plate)01.080TORX - TX 273.1/510 Nm( 1.0 Nm)6 Machine screw(Detent spring)01.010/200 TORX - TX 27 H1.4/17 10 Nm 30 ( 0.3 Nm 10 )7 Hexagon screw(Selector mechanism)01.59001.620HexagonalSAF 10 mm3.1/510 Nm( 1.0 Nm)8 Countersunk screw(Cylinder F)77.210TORX - TX 403.2/623 Nm( 2.3 Nm)9 Slotted nut(Output)14.030Socket wrench5x46 000 7873.4/2120 Nm( 12.0 Nm)14.070HexagonalSAF 13 mm3.4/323 Nm( 2.3 Nm)11 Machine screw10.020/130 TORX - TX 27(Stator shaft/ centering plate)3.6/310 Nm( 1.0 Nm)12 Screw plug, M14x1.510.090(Intermediate plate/lub. pressure)3.6/325 Nm( 2.5 Nm)13 Screw plug, M22x1.501.020/180 Hexagonal(Intermediate plate/flow reg.valve)SAF 19 mm3.6/350 Nm( 5.0 Nm)14 Countersunk screw(Intermediate plate/ pump)10.070TORX - TX 273.6/410 Nm( 1.0 Nm)15 Countersunk screw(Intermediate plate/ pump)10.074TORX - TX 273.6/45 Nm( 0.5 Nm)10 Hexagon screw(Output)Hexagonal socketSAF 6 mm5 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/011.5/1
No. DesignationELCATPos.-No.Wrench sizeNo.PageTighteningtorque46 Nm( 4.6 Nm)16 Hexagon screw(Bell housing)22.09022.100SAF 17 mm1.4/163.6/517 Machine screw(Oil tube bracket)10.150TORX - TX 273.7/210 Nm( 1.0 Nm)18 Machine screw(Control unit)27.40027.410TORX - TX 273.7/38 Nm( 0.8 Nm)19 Machine screw(Inductive transmitter)27.520TORX - TX 273.7/48 Nm( 0.8 Nm)20 Machine screw(Filter)27.470TORX - TX 273.7/45 Nm( 0.5 Nm)21 Machine screw(Oil pan)03.050TORX - TX 273.7/410 Nm( 1.0 Nm)22 Screw plug, M18x1.5(Transmission housing)01.220Hexagonal socketSAF 8 mm3.7/535 Nm( 3.5 Nm)23 Screw plug, M16x1.5(Oil pan)03.010/130 Hexagonal socketSAF 8 mm3.7/530 Nm( 3.0 Nm)24 Hexagonal screw(Cable clip)01.5803.7/510 Nm( 1.0 Nm)3.7/620 Nm( 2.0 Nm)3.7/620 Nm( 2.0 Nm)SAF 10mm25 Hexagon screw M8x5522.410(Converter retaining bracket)26 Hexagon screw, M10x1622.430(Converter retaining bracket)1.5/2SAF 13 mmSAF 17 mm5 HP 24 ZF Getriebe GmbH Saarbrücken, 98/08/01
1.6 Transmission test (test bench)The following points must be checked:Oil level correctProper oil level; observe the vehicle manufacturer’s specifications and ELCAT.Oil level too lowThis can result in:- Engine over-reving or no power flow in curves or when starting from a stop- Valve chatter due to air pockets in the oil- General malfunctionsAmong other things, burned clutches can be the result.Oil level too highDanger of loss due to splashing, formation of foam, strong increases in temperature at highroad speeds. Loss of oil via breather; among other things, burned clutches and shifting problems can be the result.Proper engine settingsCorrect idle speed; follow specifications from vehicle manufacturer.Power flow, forward and reverseCorrect adjustment of selector linkage or control cable; observe the vehicle manufacturer’sspecifications.Cooler bypass respectively cooler connection on test benchDo not overheat transmission, maximum 120 C5
2.5 Tower II 2.5/1 2.6 Oil supply 2.6/1 2.7 Transmission with flow control valve and breather 2.7/1 2.8 Transmission with selector mechanism and parking lock 2.8/1 3. Assembly 3.1/1 3.1 Transmission with selector mechanism and parking lock 3.1/1 3.2 Brake F with freewheel, 1st gear 3.2/1 3.3
# 5hp24 valve body sring (mp 10) 1 5hp24.spr01 valve body spring main pressure regulator 1 5hp24.spr02 146 valve body to case short rubber (& 5hp24) (mp x10) 2 - 3 5hp19.rub02 411 5hp24 a clutch diaphragm springs 1 - 2 5hp24.dia02 414 5hp24 e-clutch diaphragm springs 1 5hp24.dia03 415 f clutch diaphragm 1 5hp30.dia05 417 5hp19 bmw pump stator .
ZF 5HP24 Automatic Transmission - Spare Parts Catalog 5HP24 Transmission Overview (North American Applications) Make / Model / Model Year – BMW (A5S 440Z) Make Model Style Model Year From – Up to Code OE Part # ZF Part # BMW 540i E39 Sedan (M60)
zf 0b6 100 135 0005 3 0bk 100 135 0013 3 5hp19 300 135 0001 5 5hp19 fl 100 135 0001 2 5hp19 fla 100 135 0001 2 5hp24 300 135 0002 6 . 5hp19 fl 100 135 0001 2 5hp19 fla 100 135 0001 2 5hp24 300 135 0002 6 5hp24 a 100 135 0002 2 6hp19 300 135 0004 6 6hp19 a 100 135 0003 3 6hp19 x 300 135 0004 6
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ZF 5HP24 Automatic Transmission - Spare Parts Catalog 5HP24 Transmission Overview (North American Applications) Make / Model / Model Year – BMW (A5S 440Z) Make Model Style Model Year From – Up to Code OE Part # ZF Part # BMW 540i E39 Sedan (M60)
AN INTRODUCTION TO THE ZF 5HP24 TRANSMISSION CONTROL SYSTEM FITTED TO THE NEW JAGUAR XKS bv P G Whiffin B.Eng. mons) A.M.I.E.E. Project Engineer. Jamar Cars Ltd Abstract The launch of the Jaguar XK8 (codenamed X1 00), also sees the launch of a brand new powertrain into Jaguar Vehicles. The new powertrain co
applications. For all other 5HP24 transmission specification numbers, please contact your preferred ZF passenger car transmission distributor for more in formation about available spare parts and kits. Type Plate: Located on the main housing of transmission. Please refer to ZF transmission
be directed to various components of the thermal system. The coolant-based heat distribution is adaptable and saves signifi - cant amounts of refrigerant per vehicle. Also, a coolant-based system reduces refrigerant emissions by requiring fewer refrig - erant pipe joints. The authors present bench-level test data and simulation analysis and describe a preliminary control scheme for this system .
