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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

Clutch Layout
Carefully removed vertically as one assembly to prevent damage to the P4 annulus drum (shell).
Splines into pump housing

A Clutch
Pump
Housing

Splines into main case

B Clutch
Splines into C & E clutch drum

E Clutch

Case

Splines into C & E clutch drum

C Clutch
Splines into D Clutch Drum

D Clutch

P4 Annulus
Drum (shell)

C&E
Clutch Drum
D Clutch
Drum

Drivetrain Assembly

Align With Rivet

One Time Use Selective Snap Ring

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

Package of 3
2012 (LD, LX)
2013 (DS, LD, LX)
2014 (DS, LD, LX, WD, WK)
Seen on the internet at lower & higher prices.

P1 & P2 Planet Assemblies

P1 Ring Gear

P1 Planet

P2 Ring
Gear / P3
Sun Gear

P2 Planet

P1 & P2
Sun Gear

P4 Sun Gear Shell

(C & E Clutch Drum)

P3 & P4 Planet Assemblies

P3 Planet

D Clutch Hub

P3 Ring
Gear

E Clutch

C Clutch

D Clutch

P4 Planet
P4 Sun Gear Shell
(C & E Clutch Drum)

(D Clutch
Drum)

P4 Annulus

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.
Balance Oil Function

Apply Piston

Return Cup Spring

Baffle Plate

Lube

Forward Clutch

Seal

This Oil Prevents The Clutches From Appling Due To Centrifugal Force
More Reliable Clutch Engagement & Release Control At Any Speed
Improves Shift Refinement

B Clutch Clearance Measurement

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

B Clutch Clearance Measurement

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.

1.52mm to 1.93mm
(.060 to .076)

This method will work with the rest of the clutch assemblies throughout the rest of this and other transmissions.

Clutch Clearances
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

Clutch A : 1.41mm to 1.7mm (.055 to .066)

Clutch B : 1.52mm to 1.93mm (.060 to .076)
Clutch C : 1.62mm to 2.01mm (.063 to .079)
Clutch D : 1.37mm to 1.66mm (.053 to .065)
Clutch E : 1.62mm to 2.01mm (.063 to .079)

Adjusted By
Snap Rings
Backing Plates
Backing Plates
Snap Rings
Backing Plates

Valve Body Information

Lower Valve
Body

Pry here to
separate
halves

The idea is to keep

the separator plate
with the upper valve
body and contain
the small parts

Pry here to
separate
halves

Upper Valve
Body

Valve Body Separator Plate (Silk Screen)

Upper Valve Body Information

Filter

Screen
Flat side of
accumulator
faces up

7
Rocker
Ball

Upper Valve Body Information

Small Parts Installation

Small Parts Installation

Must Protrude Above
The Channel Plate

Upper Valve Body Information

Upper Valve Body Information

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

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

Stator Support & Pump 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

Stator Support & Pump Assembly

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

Pump Assembly
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 Function
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

Inlet

Outlet

Outlet

Inlet
System pressure 80 psi to 250 psi (max. 460 psi)
Displacement 1,85 US gallons to 5,81 US gallons a minute

Pump Function
Reduces Cavitation & Noise

Pump Exploded View

Sprocket
Side

Faces
Down

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

TCC

Lube
E Clutch

E Clutch

C Clutch

C Clutch

Case Air Checks

Front of Transmission

Air checks should be done with

no more than 30 psi. of
regulated air pressure.

D Clutch

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).

Torque Specifications
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.

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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