ZF6HP19/26/32, FoRd 6R60 ZIP KIT

PaRT NUMBER zF6-6R60-zIP

Torque Specifications
Mechatronic to Case or Valve Body Halves Bolts 6Nm/53 in-lb Plastic Oil Pan to Case 10Nm/89 in-lb Output Shaft Flange Nut 60Nm/44 ft-lb Metal Oil Pan to Case 14Nm/10 ft-lb Pump Bolts to Case 10Nm/89 in-lb

TEchNIcal BOOKlET

Cautions
Electronics
Do not use an ohm meter with more than .6 voltage supply. The TCM is capable of limited solenoid adaptation without reprogramming. After any service, resetting adapts/clearing KAM is suggested. In many instances, solenoids can be replaced with new OE or with qualified used. Original solenoids, if reused, should be returned to their same location due to a learned flow rate by the TCM. Make every effort to avoid mixing up the solenoids. It is not advised to attempt circuit testing through the 16-pin connector. Check the solenoid resistance (5.0 ohms at 20oC/68oF) with the circuit board removed. There are three types of EDS solenoids color coded in blue, black and yellow.

Clearance & Endplay

Rear Unit Endplay (flanged output) 0.15-0.35mm/.006-.013" Input Shaft Endplay 0.2-0.4mm/.008-.015"

Clutch clearance and material is critical (refer to OE clutch travel specifications). These have fluid balanced clutch pistons.

Visual Identification
The ZF6 has two generations: 20022005 ZF6HP19/26/32 2006-later ZF6HP21/28/34 The 19, 26 and 32 refer to the sequentially larger amounts of torque capacity. In 2006, the mechatronic was upgraded to increase oil flow, which reduced the duration of the shift. The 21, 28 and 34 are the higher flow versions of the first generation units. The 06-later casting does not have the SS1/reverse engagement accumulator bore. The 06-later also has updated solenoids. Within both vintages, there is an M version for the manual valve and an E solenoid controlled manual valve. The E version in both the early and late generations will have two additional solenoids.

Fluid
Ford 6R60 extension housing has an allen head fill plug and/or the front corner of the case has a hex head fill plug. A dipstick lives within this plug. Note: The thermal element must open (88oC, 190oF) to purge the cooler before verifying the fluid level! Complete Fill Required 9.5 qt./9 ltr. Ford Fluid XT-6-QSP, Mercon SP Service Fill Approx. 4.2 qt./4 ltr. ZF Fluid S671 090 0255Shell M-1375.4

Drive-Cycle Relearn
Ford requires six light throttle up and coastdown shift cycles (after obtaining 80oC/175oF) for a partial relearn.

Technical Tips
Reprogramming
As indicated on the photo (Figure 1) an engraved number identifies this Mechatronic as a service unit. This exchange unit may also have a blue paint dot, (Figure 2) on the solenoid end of the plastic frame, next to the bar code part number. This blue dot indicates it is NOT programmed and that the unit must be flashed with vehicle application prior to installation.
Figure 2 Blue Paint Dot Location

Figure 1 Engraved Number I.D. Location

A white dot in the same area indicates the unit HAS been programmed without the transmission.
OE Serviced Valve Body

A pin dot identification in the same area with a fifth, sixth or seventh digit of 128 indicates this is a NEW unit, not a serviced mechatronic.

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Figure 3 Thermal Bypass Valve

Technical Tips

(continued)

Transmission Specifications & Reassembly Tips

ZF suggests the body-to-case, pump in/out adapter be replaced on every valve body R-R. The overall seal height on these vary depending on application. Make sure you have the correct one (Figure 3). 6HP19/21 is 15.4 mm. in height 6HP26/28/32 is 14.4mm in height There are four mechatronic-to-case center support seals. The longest (blue) resides next to the manual linkage, medium (green) next to it. The two shortest ones (black) are furthest from the linkage (Figure 3). The Ford 6R60 thermal bypass valve lives in the front corner, between case and valve body. The spring installs into the case, followed by the thermal valve small tip end upward.

Blue, Long Green, Medium Black, Short Black, Short Pump Adapter Seal

Transmission Case

Release Tab

Figure 4 ESD (Electro-Static Discharge) WARNING! Do NOT touch pins or contacts! Wear ground strap when handling TCM. Connector Retainer

Zip Kit Instructions

1. Valve Body Removal from Case
a. Press release tab and lift connector retainer (Figure 4). b. Pull connector sleeve out of case. c. Remove 10 or 11 bolts to drop valve body from case (Figure 5).

2. Valve Body disassembly

a. Remove seven bolts to remove TCM from valve body (Figure 6). b. Remove TCM (Figure 7). c. Pry valve body halves from separator plate where indicated (Figure 8).

M-Circuit = shown Circuit I.D Location

E-Circuit = same

AWD unit = extra bolt, #11

Figure 6

6 2 3 4 7 1 5

9 8

10
Figure 5

6 7

11

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ZF6HP19/26/32, FoRd 6R60 ZIP KIT

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Figure 7

Figure 8

ESD (Electro-Static Discharge) WARNING! Wear ground strap when handling TCM. Bonded Separator Plate Plates are specifically calibrated, requiring either the transmission part number or an existing plate I.D. number for reorder from ZF/Ford or aftermarket sources (Figure 9). The plate has a bonded gasket which may delaminate during disassembly (Figure 10).

Figure 9

Figure 10

3. Installation
Install Zip Kit parts as shown on diagram of separate quick guide sheet included in this Zip Kit. The locations of the replacement solenoids O-rings (step 6) are shown below. Sonnax recommends vacuum testing critical wear areas not covered by this kit to determine whether additional Sonnax parts are required (see pages 45).
Figure 11 Figure 12

O-Ring 11 O-Ring 13.5

E Version Only, No O-Rings Six Variable Force Solenoids (VFS); M & E Valve Bodies On/Off Solenoid: M Valve Body: O-Ring 14 Inboard, O-Ring 16 Outboard E Valve Body: O-Ring 14 Inboard, O-Ring 15 Outboard VFS

E Valve Body Only: O-Ring 14 Inboard O-Ring 15 Outboard

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Critical Wear Areas & Vacuum Test Locations

NOTE: OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear and Sonnax parts noted for replacement.

Lower Valve Body Jaguar ZF6HP26M Shown Here

Solenoid Pressure Regulator Valve
Soft Shifts, poor line rise High line pressure during stall test Loss of 1-2 or 4-5 upshift Delayed forward/reverse engagement 5-4 or 4-3 Flare Gear ratio codes Replace with Sonnax Part No. 95740-17K Test 2: Test this port with valve in regulating position. Block valve inboard with enclosed testing spring. Use Testing Spring Vacuum test these plugs at the retainer slot. This checks both diameters of the plug.

Test 1: In Rest

Clutch A Control Pressure Regulator Valve

Delayed/Harsh forward engagement Flare/Neutral on 5-4 downshift No 4-5 Shift VFS 1/A solenoid control code Replace with Sonnax Part Nos. 95740-09K Oversized Clutch A Control Valve Kit 95740-21K* Clutch A Control Boost Valve & Sleeve

Clutch E Control Pressure Regulator Valve

Bumpy 1-2 upshift 2-1 Downshift flare or neutral EDS 3 control code Replace with Sonnax Part No. 95740-08K**

Bypass Clutch Control Regulator Valve

Converter overheat and low release pressure Excessive TCC slip/cycling RPM Firm up/downshifts TCC related codes Replace with Sonnax Part No. 95740-13K Test 1: In Rest

Main Pressure Regulator Valve

Delayed/No reverse Poor shift quality Slip forward/reverse Erratic or high/low line pressure Replace with Sonnax Part Nos. 95740-01K Oversized PR Valve Kit 95740-03* Pressure Regulator Sleeve **NOTE: The ZF6HP21/26 E version in the 700 series BMWs have a smaller end plug at the clutch E control pressure regulator valve and a different pressure regulator valve diameter. Sonnax part number 95740-08K will not fit these locations.
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Test 2: Test this port with valve in inverted position. Hold valve and spring in place with enclosed testing end plug.

Use Test End Plug

2012 Sonnax Industries, Inc. 800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com

ZF6HP19/26/32, FoRd 6R60 ZIP KIT

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20 25

15

10

0 30 VACUUM TEST

For specific vacuum test information, refer to individual part instructions included in kits and available at www.sonnax.com.

Upper Valve Body Jaguar ZF6HP26M Shown Here

End Plugs
Inconsistent shift quality Replace with Sonnax Part No. 95740-25K* OE accumulator pistons should be flush with the casting. It is common for the rubber insert to lose tension. Each of these pistons can be vacuum tested from the exhaust hole on the opposite side of the casting.

Accumulator Pistons
Firm up/downshifts and harsh engagement Erratic EDS solenoid control/EDS codes Replace with Sonnax Part No. 95740-15K*

Lubrication Control Valve

Excessive cooler pressure (ruptured hoses or cooler) Bushing and/or planet overheat Replace with Sonnax Part No. 95740-11K

End Plugs, Multiple Locations

Inconsistent shift quality Replace with Sonnax Part No. 95740-19K* Can be vacuum tested from the outside bore face. Use the large rubber cone found in many hand pump kits, or drill a hole through a rubber ball.

Converter Release Regulator Valve

Excessive TCC slip RPM and related codes Harsh lockup apply and release Harsh downshifts Converter overheat Replace with Sonnax Part No. 95740-05K

Clutch d1 Control Pressure Regulator Valve

Bumpy 1-2 upshift 2-1 Downshift flare or neutral EDS 3 control code Replace with Sonnax Part No. 95740-08K

*Part numbers with an asterisk (*) are included in this Zip Kit.
2012 Sonnax Industries, Inc. 800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com ZF6-6R60-ZIP-Booklet 02-17-12 Page 5

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oE Exploded View
Lower Valve Body Jaguar ZF6HP26M Shown Here
NOTE: Depending upon vehicle application, the OE springs shown may not be present.

116

115

112 113

109 111 110

Lower Valve Body descriptions

I.D No.
101 102 103 104 105 106 107** 108 109 110 111 112 113 115 116

Description
Manual Valve Lubrication Control Valve Converter Release Regulator Valve Main Pressure Regulator Valve Bypass Clutch Control Regulator Valve Clutch E Latch Valve Clutch E Control Pressure Regulator Valve Clutch A Control Pressure Regulator Valve Delay Accumulator Piston Solenoid Multiplex Valve Drive Enable Valve Clutch D1 Latch Valve Solenoid Pressure Regulator Valve Clutch B Latch Valve Clutch A Latch Valve

107 106

105

102 108 103

**NOTE: The ZF6HP21/26 E version in the 700 series BMWs have a smaller end plug at the clutch E control pressure regulator valve and a different pressure regulator valve diameter. Sonnax part number 95740-08K will not fit these locations.
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101

104
2012 Sonnax Industries, Inc.

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Upper Valve Body Jaguar ZF6HP26 Shown Here

Accumulator Pistons

201
Clutch Exhaust

204

202

205

203

Drainback

Upper Valve Body descriptions

I.D. No.
201 202 203 204 205

Description
Clutch B Regulator Valve Clutch D2 Regulator Valve Clutch D2 Latch Valve Clutch C Regulator Valve Clutch D1 Control Pressure Regulator Valve

2012 Sonnax Industries, Inc. 800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com

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Sonnax has valve bodies on the brain.

The valve body is the brains of a transmission. That transmission isnt fixed until the valve body is right. And that means getting to the root cause of the problem, not just treating the symptoms.

Nobody knows valve bodies like Sonnax.

TM

1 Automatic Drive P.O. Box 440 Bellows Falls, VT 05101-0440 USA 800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com Sonnax is an Employee-Owned Company