ZF5HP-19-complete.pdf

1

Oil Pressure Checks

TCC release oil pressure tap Drive at stop cold 30 psi approx min. - 90 psi with throttle Drive at stop hot 10 psi approx min - 90 psi with throttle Drive with TCC commanded in 3rd, 4th & 5th = 35 psi partial apply - 0 psi to 4 psi fully applied

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2

Air Pressure Checks

Clutch E 4th gear

Clutch B Reverse

Clutch C Intermediate

2nd & 5th gear

Clutch G Overrun

Clutch F Overdrive

Direct 3rd gear

Clutch D Low/Rev

Clutch A Forward

Cooler out

TCC Release

TCC apply

3

Clutch B Reverse


Clutch A Forward


Air Pressure Checks

Clutch E 4th

4

Main line pressure tap

Tag - Data Plate

Oil Pan

Transmission ID

Vent

Input shaft

Pump assm.

Case connector

5

Filler plug

Extension housing

Cooler fitting

Cooler fitting Manual shaft

Transmission ID

Output flange

Vent

6

Oil Pan & Filter

Pan bolts #27 torx

7

Oil Pan & Filter

Drain plug8 magnets

Pan Gasket

8

Oil Pan & Filter

Filterbolt

Filter bolt 2 filter #40 Torx .660" Bolts. Torque 90 in lb.

9

Oil Pan & Filter

Filter seal Filter

Filter half metal - half plastic - felt type media

10

Filter bolt boss Filter bolt boss

Oil Pan & Filter

Lower rear valve body

Lower front valve body

11

Valve Body Connectors

Use scribe to pry up lock tab. Then remove

connector.

Use scribe here to unlock

connector.

Filter intake opening

12

Valve Body to Case Bolts

VB to case bolts at "X" locations. Torque 100 in lb.

2.500 #40 Torx bolt 14 pcs

X

XX

X

X

X

X

XX

X

X

X

XX



13

Valve Body EPC Connector

Clip Use scribe to pry clip as shown.

Then remove the connector from the EPC solenoid.

14

Valve Body

Suction pipe Caution:Suction pipes have to be

removed before trying to remove pump body.

Upper front valve body

Upper rear valve body

Transfer plate


15

Drain back valve retainer. Push down and turn to release.

Suction pipe

Bypass pipe

Drain backvalve

Spring Output speed

sensor Input speed sensor

16

"A" 1.715 #27 Torx 10 pcs

"B" 2.500 #27 Torx 11 pcs

"C" 1.920 #27 Torx 7 pcs

Valve Body Bolts

A

A

A

A

B

A

A

A A

AA

B B

B B

BBB

B B

B

C

CC

C C

C

C



17

Transfer plate



18

J Clip faces as shown.


19


Cover plate

1.510 x .420 x .050

1.454 x .365 x .040

1.878 x .383 x .036

1.580 x .305 x .028

Lubrication valve train

Lockup control

TCC pressure control

4-5 traction

20



21

EDS-1 EPC solenoid Clip notnecessary to remove.

Pressed in .044 plastic orifice Clip faces as shown.

EDS-1 EPC solenoid


22

Clip faces as shown.

1.530 x .345 x .044

1.470 x .318 x .047

1.575 x .303 x .027

Modulating pressure

Modulating pressure sleeve

Pressure reduction valve #2

23

EDS-1 EPC solenoid

Pressed in .044 plastic orifice


24


Manualshift valve

25

Clip faces as shown

Alignment dowel


26

Manual shift valve

3.450 x .598 x .044

2.935 x .610 x .067

1.800 x .366 x .032

3.500 x .598 x .065

1.600 x .305 x .028

1.610 x .370 x .032

Clipfaces as shown Cover plate

"E" clutch damper "E" clutch damper reg.

Main reg. valve

5-4 traction

"A" clutch damper

"G" clutch accum. reg.

"C" clutch accum. reg.

27

Clipfaces as shown

Alignment dowel


28

Cup side

1.765 x .360 x .040

1.755 x .360 x .040

"C" clutch shift valve

"G" clutch shift valve

29


30

Clip faces as shown

Clip faces as shown


31

1.630 x .365 x .031

1.745 x .355 x .025

1.505 x .285 x .030

3.490 x .600 x .065

Cup side

3.455 x .555 x .039

1.630 x .365 x .032

1.615 x .365 x .032

Clipfaces as shown

Clipfaces as shown

O-ring

O-ring

1.490 x .355 x .045 Pressure reduction

Number 2 shift

Reverse gear

"F" clutch accum. reg.

"D" clutch accum. reg.

"F" clutch damper

"D" clutch damper

Number 3 shift

TCC release reg.

Traction coast valve

32

1.645 x .365 x .032


Number 1 shift

MV-3 solenoid

MV-2 solenoid

EDS-3 solenoid

EDS-4 solenoid

EDS-2 solenoid

MV-1 solenoid

33


34

Spacer Plate

35

Spacer Plate & Gasket

36

Spacer Plate Gasket

37

Tan one way 590x.475x.020

spring down Filter screen Tan plastic

.066 orifice.041 thick

Purple plastic .045 orifice .045 thick 4 pcs.

Brown plastic .096 orifice .039 thick

2 pcs

Black one way .725x.366x.024

spring up

Tan one way .590x.475x.020

spring up

Green plastic .075 orifice .041 thick

Tan plastic .066 orifice.041 thick

Brown plastic .038 orifice .040 thick

Tan plastic .066 orifice.041 thick Tan one way disc

no orifice hole .040 thick

Grey plastic .031 orifice .040 thick

SolenoidAccumulator

White .038 orifice .110 thick

3 pcs

.234 plastic Check ball

.055 orificeBlue .040 thick

.234 plastic check ball

White .038 orifice .110 thick

Same as above

Solenoid Accumulator

Transfer plate

38

Transfer plate

39

Transfer plate

40

Input sensor Output sensor

Low/reverse & overrun housing bolts Park rod

Case Area Parts

41

Rooster comb spring roller

Park rod retainer Park Pawl

Park Pawl spring

Case Area Parts

42

Pump Body

Pump Assembly

Stator housing

O-ring



Pump bolt & washer 2.912 9 pcs #27 Torx Torque to 18-20 Ft lb

43

Pump Plate and gears

Pump plate

Pump gears dimples face up

Align dowel

Align dowel

Pump Assembly

44

Stator Body O-ring

Stator shaft

Seal rings

45

Clutch CIntermediate

housing

46


Housing


PistonReturn spring Retainers

Stator housing

To separate pump Bolts torque 18 lb ft

All bolts are 27 Torx B

A

A

AA

B

AB

C

"B" 1.570 8 pcs

B

B "A" .790 5 pcs Removes stator shaft

B

B

B

"C" 1.880 1 pcs

D

"D" 2.309 1 pcs

47

Internal Components

Clutch B Reverse Pump & "C" clutch assm.

4th clutch hub Clutch A Forward Clutch E

4th

48

Internal Components

Clutch A Forward Clutch hub

Ring gear

Intermediate shaft Shell

Output planet

Snap ring

Shell

49

Internal Components

Low/Reverse & Overrun housing

Overdrive ring gear & hub Overdrive planet & ring gear

Overdrive direct drum

Output flange & extension housing

50


.030-.040clearance

Clutch B Reverse.040-.050clearance

Bearing

Shim selective


51


Snap Ring .087 thick .163 width

.157 steel

.063 friction

.130 steel

.063 friction

.130 steel

.063 friction

.130 steel

.034 wavy

52

Clutch C Intermediate piston assembly

piston o-ring seals

Spring retainer

Piston return spring

Clutch C piston

Clutch C piston housing

Stator Body

53

Clutch B Reverse


.177 steel

.079 friction

.071 steel

.079 friction

.071 steel

.038 wavy

Clearance .040-.050

54

Clutch B Reverse drum disassembly

Retaining half ring clips

Piston return spring

Piston o-ring seals

Clutch B piston

Clutch B drum

55

Clutch A Forward Clutch E 4th

Input shaft

Clutch A piston

Clutch E piston

Clutch piston spring

Clutch A piston spring

Piston o-ring seals

Clutch E Pistono-ring seals

Snap ring Clutch A

piston o-ring seals

Snap ring

Clutch E piston

56

Clutch A Forward Clutches .177 steel

.063 friction

.071 steel

.063 friction

.071 steel

.063 friction

.071 steel

.063 friction

.071 steel

.063 friction

.071 steel

.040 wavy


57

Clutch E 4th Clutch

.137 steel

.063 friction

.070 steel

.063 friction

.070 steel

.063 friction

.070 steel

.063 friction

.070 steel

.063 friction

.070 steel

.034 wavy

Snap Ring.132 thick .157 width

58

Clutch E 4th hub

Clutch E 4th hub

Race

Bearing

Race

Race

Bearing

Race

59

Clutch E 4th hub

Output planet

Shell

Bearing

Bearing

Forward Clutch hub

Race

Bearing

Race

60

Output Planet

Low /reverse & overrun housing

Ring gear

Snap ring

Intermediate shaft

Connecting shell

61

Low/Reverse & Overrun Housing fasteners

3 bolts 2.555x.388

50 Torx

62

Low/Reverse & Overrun Housing

Clutch D Low/Reverse .080 clearance

faces pump

Clutch G Overrun .070 clearance

faces rear

63

Sprag Rotation

Low Sprag

64

Clutch D Front

.070 steel .063 friction

.063 friction .070 steel




.063 friction

.070 steel

.044 wavy

.070 steel


Clearance .080

65

Clutch G Rear Snap Ring.070 thick .157 width

.177 steel

.063 friction

.071steel

.063 friction

.071steel

.063 friction

.071 steel

.063 friction

.071 steel

.035 wavy

Clearance .070

66

Low Sprag

race

Clutch G piston

Teflon rings

O-ring seals

Retainer 3 tab

Clutch G piston o-ring seals

Clutch D piston return spring

snap ring

Clutch G Drum low/rev overrun

housing

67

Clutch F Overdrive Direct

.100 clearance

68

Clutch F Overdrive Direct Snap Ring.070 width .157 width

.118 steel

.063 friction

.118 steel

.063 friction

.118 steel

.063 friction

.118 steel

.063 friction

.118 steel

.035 wavy

.118 steel

.063 friction

Clearance .100

69

Clutch F Overdrive Direct

Clutch F piston

piston retainer

return spring

Clutch F piston o-rings

Clutch F drum

70

Bearing race

Bearing

Bearing race

Overdrive ring gear & hub Overdrive Ring gear

Overdrive ring gear hub

Snap ring

Overdrive Planet Assembly

71

Overdrive ring gear & hub

Bearing

Snap ring

Spacer

Overdrive planet assembly

Bearing race

Bearing

Bearing race


72

Bearing

Overdrive sun gear

Bearing

BearingOverdrive planet

Exciter Ring

Park wheel


73

Output flange

Output flange

Output flange

Extension housing

Extension housing

Extension housing

O-ring

Out shaft flange

74

O-ring seal

Extension housing Output shaft assembly

75

Extension housing Output shaft assembly

Extension housing

Out shaft flange

Output seal

Ball bearing

Bearing race

Out shaft nut

Ball bearing

Snap ring

76

Clutch-Solenoid Application Chart & Gear Ratios

GearClutchPark G Reverse G, B & D Neutral G 1st G, A & Low sprag 2nd G, A & C 3rd A, C & F 4th A, E & F 5th C, E & F TCC is applied in 3rd, 4th & 5th

Gear Ratios

Reverse 4.08

1st 3.66 2nd 1.99 3rd 1.40 4th 1.00 5th .74

GearSolenoidsPark MV1 Reverse MV1 & EDS3 Reverse inhibited MV1, EDS3 & MV3 Neutral MV1, MV2 & EDS3 1st MV1, MV2 & EDS3 2nd MV1, MV2, EDS3 & EDS2 3rd MV2, & EDS2 4th No power 5th MV3 & EDS2 TCC can be applied in 3rd, 4th & 5th

77

Clip

Case Connector, Solenoids & Sensors

Internal Harness

TOT sensor in harness

78


16

2 1

9 8 7 6

5 4 3

15 14

13 12 11 10

Pin Identification MV1 8 &16 30 OHMS MV2 9 & 16 30 OHMS MV3 4 & 16 30 OHMS EDS1 2 & 16 5.5 OHMS EDS2 3 & 12 6.5 OHMS EDS3 7 & 12 6.5 OHMS EDS4 11 & 16 6.5 OHMS

TOT 13 & 14 934 @ 70F ISS 5 & 6 325 OHMS OSS 1 & 10 325 OHMS

79


OSS 325 OHMS

ISS 325 OHMS

TOT sensor is built into the harness.

80

Notes & Complaints

Complaint:No reverse. Cause: Malfunctioning MV3 solenoid. This solenoid is used to inhibit reverse. If it is stuck or is commanded on by the controller there is no reverse. The controller will command this solenoid "ON" if it sees vehicle speed greater than 6 mph to inhibit reverse. Solution: Fix or repair solenoid or speed sensors as necessary. Check for amperage at this so-lenoid to see if the controller is causing reverse to be inhibited. Do the reverse lights work? The shift indicator and lever switch working correctly.

Complaint:Rough shifts and downshift clunks after an O'haul. Cause: Controller has adapted to a worn or failed transmission.Solution: After an O'haul the controller should have the shift adapts reset with a scan tool. It may take 100 mile of adaptive learn before the trans begins to work smoothly.

Notes:A generic scan tool may retrieve most codes but the factory scan tool is necessary to reset adaptive learn.

Complaint:2-3 and 4-5 spin up or slip at light and medium throttle. "F" clutch has good seal-ing rings in bore of drum or may have had late type drum update. "F" direct/ OD drum air checks well making one think problem is not drum. Cause: Low calibration of the "EDS2 solenoid" Factory tried to address this complaint with drum updates but it takes a higher calibration solenoid to fix the complaint. Solution: Replace "EDS2 solenoid". Replacement solenoids have a higher calibration to correct this complaint. Some vehicles had a light throttle 2-3 spin up and soft 4-5 shift brand new.

ZF5HP-19-complete.pdf

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