ZF 5HP24. Automatic Transmission Spare Parts Catalog

Transcription

1 ZF 5HP24 Automatic Transmission Spare Parts Catalog

2 Warranty Information Warranty coverage for ZF passenger car transmission spare parts and kits covers the first 12 months after installation in the vehicle, or 24 months after purchase from ZF Industries, Inc. Warranty of the product is limited to replacement or repair, if found to be defective in ZF material or workmanship, and specifically does not cover removal, reinstallation, or any costs incidental to the repair of the vehicle, or any kind of consequential damages. All warranty and/or non-warranty returns must be approved. Disclaimer The specifications and information shown in this catalog have been compiled from accepted and reliable sources and is believed to be accurate at the time of publication. While ZF Industries, Inc. believes this information is correct, no guarantee or warranty is made as to the accuracy of the information and ZF Industries, Inc. cannot and does not accept or assume any responsibilities for errors, omissions, or consequential harm or damages. Replacement parts should not be used when they do not appear to fit. ZF Industries, Inc. disclaims all liability and responsibility for any harm resulting from any such modifications. Copyright Printed in USA Copyright 2003 ZF Industries, Inc. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of ZF Industries, Inc. Distributed By

3 Table of Contents 5HP24 Transmission Overview (North American Applications) Make / Model / Model Year 02 5HP24 Technical Information Torque, Gear Ratio & Weight 03 Transmission Oil Reference Guide 03 5HP24 Lubrications 03 5HP24 Technical Literature 03 5HP24 General Transmission Oil Filling Procedure 04 5HP24 Spare Parts How To Use This Catalog 06 Gearbox Housing Group 07 Input Group 10 Oil Sump Group 11 Oil Supply Group 12 Output Group 13 Converter Group 15 Parking Lock Group 16 Brake Group 17 Planetary Drive Groups 18 Clutch Pack Groups 20 5HP24 Valve Body Duct Plate Group 27 Valve Housing Groups 29 5HP24 Selective Shims, Snap Rings & Kit Content 5HP24 Selective Shims & Snap Rings 35 5HP24 Kit Content 38 Miscellaneous Quotation / Order Form All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 1

4 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) /97 09/98 TB /98 TE /98 TF BMW 540i E39 Touring (M60) 1998 TF BMW 740i E38 Sedan (M62) /97 09/98 TB /98 TE /98 TF BMW 740iL E38 Sedan (M62) /97 09/98 TB /98 TE /98 TF BMW 840Ci E31 Coupe PD BMW X5 4.4i E53 SAV 1998 UP BMW X5 4.6is E53 SAV 2001 UK Make / Model / Model Year Jaguar Make Model Engine Model Year OE Part # ZF Part # Jaguar XK8 V8 4.0 Liter 1997 NJA4400AF NJA4400AG NJB4400AB NJB4400BA NNE4400AA NNE4400CA Jaguar XJ8 V8 3.2 Liter NJA4400BD NNE4400BA Jaguar XJ8 V8 4.0 Liter 1998 NJB4400AB NJB4400BA NNE4400AA NNE4400CA Make / Model / Model Year Land Rover Make Model Engine Model Year OE Part # ZF Part # Land Rover Range Rover V8 4.4 liter 2003 TGD Note: This spare parts catalog includes only transmission specification numbers for North American applications. For all other 5HP24 transmission specification numbers, please contact your preferred ZF passenger car transmission distributor for more information about available spare parts and kits. Type Plate: Located on the main housing of transmission. Please refer to ZF transmission specification # when searching for spare parts and kits in this catalog (last three digits). Transmission Serial # ZF Transmission Specification # Vehicle Manufacturer Transmission # All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 2

5 5HP24 Technical Information Torque, Gear Ratio & Weight 1 st 2 nd 3 rd 4 th 5 th Rev Input Torque Weight Oil Capacity Gear Gear Gear Gear Gear Gear (approximate) (approximate) 420 Nm ~95 kg (209 lbs.) ~9.9 liter (10.5 quart) Transmission Oil Reference Guide Make Oil Grade Type Plate (color) ZF Part # OE Part # BMW ESSO LT Green Jaguar ESSO LT Green NJA4400AF NJA4400AG NJA4400BD NJB4400AB NJB4400BA NNE4400AA NNE4400CA NNE4400BA Land Rover ESSO LT Green TGD HP24 Lubrications Amount ZF Part # Description 20 Liter Oil ESSO LT (Canister) All 205 Liter Oil ESSO LT (Drum) All 5HP24 Technical Literature Language ZF Part # Description English 5HP24FD 5HP24 Functional Description All English 5HP24REP 5HP24 Repair Manual All Eng/Ger HP24 Wall Chart All English 5HPVBMAN 5-Speed Valve Body Manual All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 3

6 5HP24 Technical Information (continued) 5HP24 General Transmission Oil Filling Procedure Position vehicle horizontally on hoist and apply the handbrake. Connect tester to read off transmission oil temperature and engine speed. With the engine stopped, add ATF, only use lubricants as to specification (see Page 3), through the fill hole up to the edge of the overflow hole. Install fill plug (Pos ). Start the engine (large consumers, such as A/C should be switched on). Shift through gears with engine running at idle speed. Select R and D and use step shift (manual-winter program) to shift through to 3 rd gear. Hold each gear for 3 seconds and engage the parking lock. Idle speed should be n eng = rpm (according to vehicle manufacturer s directive). Oil temperature should be between 86º 95ºF (30º 35ºC). NO YES Depending on value allow oil to cool down or warm up. Shift through gears with engine at idle speed. Select R and D and use step shift (manualwinter program) to shift through to 3 rd gear. Hold each gear for 3 seconds and engage the parking lock. Remove fill plug (Pos ) on housing. Continues on next page All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 4

7 5HP24 Technical Information (continued) 5HP24 General Transmission Oil Filling Procedure (continued) Continues from previous page Oil emerges at oil temperature below 95ºF (35ºC). NO YES Oil level in transmission is below minimum. Add ATF, only use lubricants as to specification (see Page 3), through the fill hole until oil emerges from fill hole. Wait until oil temperature reaches 104ºF ±18ºF (40ºC ±10ºC). Oil temperature must not exceed 122ºF (50ºC). Allow time for excess oil to drip then install Fill Plug (Pos ). Torque Fill Plug to 35Nm ±3.5Nm (see also Repair Manual). Fill Plug All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 5

8 How To Use This Catalog Table of Contents Each transmission group of this catalog is listed in the table of contents. This spare parts catalog includes only transmission specification numbers for North American applications. Technical Information All technical information is specific to the transmission models that are referenced in this catalog. Weight and oil capacity information are only approximate and may vary by actual transmission specification. For any technical inquiry, please contact your preferred ZF passenger car transmission distributor for assistance. For a list of technical literature available from ZF or for answers to frequently asked questions about ZF transmissions visit us at Spare Parts Each transmission is divided into groups (e.g. gearbox housing group). The position number (Pos #) is used to identify the location of each spare part in the transmission. A position number like is either a spare part or an assembly. A position number like /110 is a subcomponent of an assembly. Please contact your preferred ZF passenger car transmission distributor about availability of assemblies and subcomponents. The part number (ZF part #) is used to identify a specific spare part and is usually ten-digits (kits, lubricants, and technical literature have exceptions). Please use this part number, when ordering ZF spare parts. The description (Description) identifies the spare part. The quantity (Qty) is the amount of spare parts included in one transmission model for a certain position number. The quantity may vary depending on the transmission specification and certain spare parts may be used in multiple positions in the transmission. This catalog includes only spare parts for North American specifications of a ZF transmission application. The where used column ( ( )) shows the last three digits of the transmission specification that uses the listed spare part. If the column indicates All, then all North American transmission specification use this spare part. The notes column () gives more information about the spare part (e.g. included in a kit). Example: ( ) Gearbox Housing 1 087/ Gearbox Housing / Gearbox Housing 1 087/ Gearbox Housing Selective Shims, Snap Rings & Kit Content Each list for selective shims or snap rings is listed in this section of the catalog. Please measure the clearance according to the repair manual and select the required spare part from the table. The kit content section shows all available kits for the transmission models that are referenced in this catalog, including the content of each kit. All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 6

9 5HP24 Spare Parts - Gearbox Housing Group Gearbox Housing 1 016/021/ Gearbox Housing 1 009/013/014/015/024/ 026/027/ Gearbox Housing Gearbox Housing 1 029/ Gearbox Housing / Gearbox Housing 1 016/021/ Gearbox Housing Gearbox Housing 1 009/013/014/015/024/ 026/027/ Gearbox Housing Gearbox Housing 1 029/ / Shaft Seal 1 016/021/022 * Available in kit Shaft Seal 2 005/014/015/024/026/ 027/028/029/032/ / Selector Shaft 1 005/029/ Selector Shaft 1 016/021/ Selector Shaft Selector Shaft / Pipe / Detent Disc 1 All / Clamping Sleeve 1 All / Detent Disc 1 All / Torx Screw M6x13 2 All / Cylindrical Pin / Slotted Pin 1 All / Cylindrical Pin 1 009/013/014/015/024/ 026/027/ /009/013/014/015/ 024/026/027/028/029/ 032/ /016/021/022/029/ 032/ /013/014/015/024/ 026/027/028 * Available in kit All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 7

10 5HP24 Spare Parts - Gearbox Housing Group (continued) Pin 1 All Pawl 1 All Leg Spring 1 All Connecting Bar 1 All Guiding Plate 1 All Torx Screw M6x20 4 All Screw Plug M12x1.5 1 All * Available in kit Oil Tube 1 All Oil Tube 1 All Oil Tube 1 All Plug 1 All Bracket 1 All Torx Screw M6x15 1 All Screw Plug M14x1.5 2 All * Available in kit Screw Plug M18x1.5 1 All * Available in kit Plug 1 All Plug 1 All Sealing Sleeve 2 All * Available in kit Compression Spring 2 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 8

11 5HP24 Spare Parts - Gearbox Housing Group (continued) Retaining Ring 2 All Switch Switch 1 009/013/014/015/024/ 026/027/ Position Switch 1 016/021/022/029/ Switch Terminal 2 005/029/ Terminal 3 016/021/ Terminal Screen Sheet 1 005/029/032/ Hexagon Screw M6x /013/014/015/024/ 026/027/ Hexagon Screw M6x /029/032/ Cable Terminal 2 009/013/014/015/024/ 026/027/028/ Bracket 1 016/021/022/029/ Bracket Bracket Bracket Hexagon Screw M6x Hexagon Screw M6x Hexagon Screw M6x /021/022/029/032/ /016/021/022/029/ 032/ /016/021/022/029/ 032/ /016/021/022/029/ 032/ Screw Plug M10x1 1 All * Available in kit All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 9

12 5HP24 Spare Parts - Input Group Bearing Set 1 All Axial Needle Bearing 1 All See Page 35 Intermediate Plate Shim 1 All Selective Shim All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 10

13 5HP24 Spare Parts Oil Sump Group Oil Sump 1 All / Oil Sump 1 All / Magnet 4 All / Screw Plug M16x1.5 1 All Gasket 1 All Torx Screw M6x22 22 All Stick-On Label 1 005/016/021/022/029/ 032/034 * Available in kit * Available in kit 5HP24FK * Available in kit * Available in kit 5HP24FK All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 11

14 5HP24 Spare Parts - Oil Supply Group Pump 1 All / Sealing Ring 1 All * Available in kit / Needle Bearing 1 All / Washer 1 All / Shaft Seal 1 All * Available in kit / Snap Ring 1 All / Sleeve 1 All O-Ring 1 All * Available in kit Intermediate Sheet 1 All Intermediate Plate 1 All / Intermediate Sheet 1 All / Counters. Screw M6x15 5 All / Piston Ring 2 All * Available in kit / Piston 1 All / Compression Spring 1 All / Sleeve 1 All / Screw Plug M22x1.5 1 All * Available in kit / Breather 1 All / O-Ring 1 All * Available in kit / Locking Washer 1 All Gasket 1 All * Available in kit Torx Screw M6x35 9 All Torx Screw M5x50 1 All Screw Plug M14x1.5 1 All * Available in kit Breather Cover 1 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 12

15 5HP24 Spare Parts Output Group 009/013/014/015/024/ Extension 1 026/027/ Extension 1 005/016/021/ Extension 1 029/ / Extension 1 005/016/021/ Extension Extension 1 029/ / Ball Bearing 1 029/ Ball Bearing 1 009/013/014/015/024/ 026/027/ /009/013/014/015/ 016/021/022/024/026/ 027/ / Retaining Ring 1 All (except 032) / Shaft Seal 1 All (except 032) * Available in kit /013/014/015/024/ Output Flange 1 026/027/ Output Flange 1 005/016/021/ Adapter 1 029/ O-Ring 1 029/ Protecting Cap 1 029/034 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 13

16 5HP24 Spare Parts Output Group (continued) Retaining Ring 1 029/ Slotted Nut M45x /009/013/014/015/ 016/021/022/024/026/ 027/ Cover / Cover / Axial Needle Bearing / Shaft Seal O-Ring 1 All * Available in kit /013/014/015/024/ Hexagon Screw M8x /027/ Hexagon Screw M8x /016/021/ Torx Screw M8x / Torx Screw M6x Hexagon Screw M8x /013/014/015/024/ 026/027/ See Page 35 Output Shim 1 All (except 032) Selective Shim See Page 35 Output Shim Selective Shim O-Ring Snap Ring All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 14

17 5HP24 Spare Parts Converter Group 009/013/014/015/024/ Converter Bell 1 026/027/ Converter Bell 1 005/016/021/022/ Converter Bell Converter Bell Torque Converter L / Torque Converter P / Torque Converter Q /013/ Torque Converter J / Torque Converter K Torque Converter N Torque Converter L Torque Converter F / Torque Converter L Hexagon Screw M10x35 6 All Hexagon Screw M10x90 14 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 15

18 5HP24 Spare Parts Parking Lock Group Parking Lock Wheel 1 All (except 032) Parking Lock Wheel All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 16

19 5HP24 Spare Parts Brake Group Snap Ring 1 All Axial Needle Bearing 1 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 17

20 5HP24 Spare Parts Planetary Drive Groups Planet Carrier 1 All Planet Carrier 1 All Ring Gear 1 All Snap Ring 1 All Ring Gear 1 All Snap Ring 1 All Sun Gear 1 All Axial Needle Bearing 1 All Ring Gear 1 All Snap Ring 1 All O-Ring 1 All * Available in kit Disc Carrier 1 All Bearing Set 1 All Sun Gear 1 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 18

21 5HP24 Spare Parts Planetary Drive Groups (continued) Planet Carrier 1 All (except 032) Planet Carrier All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 19

22 5HP24 Spare Parts Clutch Pack Groups Input Shaft 1 All O-Ring 1 All * Available in kit Piston 1 005/009/013/014/015/ Piston 1 016/ /022/026/027/028/ 029/032/ O-Ring 1 All * Available in kit O-Ring 1 All * Available in kit Cup Spring Cup Spring 2 005/009/013/014/015/ 016/ /022/026/027/028/ 029/032/ Oil Dam 1 All O-Ring 1 All * Available in kit Snap Ring 1 All Undulated Spring Undulated Spring 1 005/009/013/014/015/ 016/ /022/026/027/028/ 029/032/ Steel Plate A 6 005/009 * Available in kit Steel Plate A 6 All (except 005/009) * Available in kit Friction Plate A 6 005/009 * Available in kit Friction Plate A 6 All (except 005/009) * Available in kit * Available in kit * Available in kit End Plate 1 All See Page 36 Clutch A Snap Ring 1 All Selective Snap Ring All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 20

23 5HP24 Spare Parts Clutch Pack Groups (continued) Cylinder B 1 All Piston 1 All O-Ring 1 All * Available in kit O-Ring 1 All * Available in kit Sealing Ring 1 All * Available in kit Cup Spring 1 All Fixing Washer 1 All Snap Ring 1 All Undulated Spring 1 005/009/013/014/015/ Undulated Spring 1 016/ /022/026/027/028/ 029/032/ Steel Plate B 6 005/009 * Available in kit Steel Plate B 6 All (except 005/009) * Available in kit Friction Plate B 6 005/009 * Available in kit Friction Plate B 6 All (except 005/009) * Available in kit End Plate B 1 005/009 * Available in kit End Plate B 1 All (except 005/009) * Available in kit See Page 36 Clutch B Snap Ring 1 All Selective Snap Ring Piston Ring 2 All * Available in kit Axial Needle Bearing 1 All Intermediate Shaft 1 All Axial Needle Bearing 1 All Disc Carrier 1 All Disc Carrier 1 All Snap Ring 1 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 21

24 5HP24 Spare Parts Clutch Pack Groups (continued) Cylinder D 1 005/ Cylinder D Cylinder D 1 013/015/016/ Cylinder D Cylinder D Cylinder D / Cylinder D Cylinder D Cylinder D 1 021/022/026/027/029/ /009/013/015/016/ /022/026/027/029/ Cylinder D Cylinder D / Fitting Key 2 All / Piston 1 All (except 034) Piston / O-Ring 1 All * Available in kit / O-Ring 1 All * Available in kit All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 22

25 5HP24 Spare Parts Clutch Pack Groups (continued) / Cup Spring 1 All / Snap Ring 1 All / Undulated Spring Undulated Spring 1 005/009/013/014/015/ 016/ /022/026/027/028/ 029/032/ / Steel Plate D 4 005/009 * Available in kit Steel Plate D 3 014/028 * Available in kit Steel Plate D 4 013/015/016/021/022/ 024/026/027/029/032 * Available in kit Steel Plate D * Available in kit / Friction Plate D 4 005/009 * Available in kit Friction Plate D 3 014/028 * Available in kit Friction Plate D 4 013/015/016/021/022/ 024/026/027/029/032 * Available in kit Friction Plate D * Available in kit / End Plate D 1 005/009 * Available in kit / End Plate D 1 013/014/015/016/021/ 022/024/026/027/028/ 029/032/034 * Available in kit /220 See Page 36 Clutch D Snap Ring 1 All Selective Snap Ring All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 23

26 5HP24 Spare Parts Clutch Pack Groups (continued) Piston 1 All O-Ring 1 All * Available in kit O-Ring 1 All * Available in kit Cup Spring 1 All Split Ring 1 All Undulated Spring 1 021/022/026/027/028/ 029/032/ Steel Plate E 5 005/009 * Available in kit Steel Plate E 4 014/028 * Available in kit Steel Plate E 5 013/015/016/021/022/ 024/026/027/029/032/ 034 * Available in kit Friction Plate E 5 005/009 * Available in kit Friction Plate E 4 014/028 * Available in kit Friction Plate E 5 013/015/016/021/022/ 024/026/027/029/032/ 034 * Available in kit End Plate E 1 005/009 * Available in kit End Plate E 1 All (except 005/009) * Available in kit See Page 36 Clutch E Snap Ring 1 All Selective Snap Ring Support Bush 1 All O-Ring 1 All * Available in kit O-Ring 1 All * Available in kit All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 24

27 5HP24 Spare Parts Clutch Pack Groups (continued) Cylinder C 1 005/ Cylinder C 1 013/014/015/016/ Cylinder C 1 021/022/026/027/028/ 029/032/ / Cylinder C 1 All / Piston 1 All / O-Ring 1 All * Available in kit / O-Ring 1 All * Available in kit / Cup Spring 1 All / Split Ring 1 All / Undulated Spring Undulated Spring 1 005/009/013/014/015/ 016/ /022/026/027/028/ 029/032/ / Steel Plate C 4 005/009 * Available in kit Steel Plate C 4 All (except 005/009) * Available in kit / Friction Plate C 4 005/009 * Available in kit Friction Plate C 4 All (except 005/009) * Available in kit / End Plate C 1 005/009 * Available in kit End Plate C 1 All (except 005/009) * Available in kit /210 See Page 36 Clutch C Snap Ring 1 All Selective Snap Ring Sun Gear Shaft 1 All / Sun Gear Shaft 1 All / O-Ring 2 All * Available in kit / Sealing Ring 2 All * Available in kit All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 25

28 5HP24 Spare Parts Clutch Pack Groups (continued) Cylinder F 1 All Needle Sleeve 1 All Snap Ring 1 All Piston 1 All Cup Spring 1 All Split Ring 1 All Spring Clutch Disc 1 All Steel Plate F 6 005/009 * Available in kit Steel Plate F 6 All (except 005/009) * Available in kit Friction Plate F 6 005/009 * Available in kit Friction Plate F 6 All (except 005/009) * Available in kit End Plate F 1 005/009 * Available in kit End Plate F 1 All (except 005/009) * Available in kit See Page 37 Clutch F Snap Ring 1 All Selective Snap Ring Free Wheel 1 All / Free Wheel Ring 1 All / Free Wheel 1 All / Free Wheel Ring 1 All / Fixing Washer 1 All / Snap Ring 1 All Snap Ring 1 All O-Ring 1 All * Available in kit Counters. Screw M8x24 12 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 26

29 5HP24 Valve Body Duct Plate Group Duct Plate 1 All Valve Orifice D=1.0 1 All Valve Orifice D=2.2 1 All Valve Orifice D=1.4 1 All Valve Orifice D=1.5 1 All Valve Orifice D=1.2 1 All Rubber Part 1 All * Available in kit Piston 1 All * Available in kit Valve Orifice D=1.0 1 All Valve Orifice D=1.4 1 All Valve Orifice D=1.0 1 All Valve 1 021/022/026/027/028/ 029/032/ Ball 1 All Screen 1 All Valve 1 All Gasket 1 All * Available in kit Intermediate Sheet Intermediate Sheet Ledge 1 All Torx Screw M5x22 4 All Ledge 1 All Torx Screw M5x22 3 All Speed Sensor 1 All Bracket 1 All Torx Screw M5x12 1 All Intermediate Sheet Intermediate Sheet 1 005/009/013/014/015/ 016/ /022/026/027/028/ 029/032/ /009/013/014/015/ 016/ /022/026/027/028/ 029/032/ Cylindrical Pin 1 All Torx Screw M5x40 10 All Guide Sheet 2 All Spring Washer 2 All Torx Screw M5x55 2 All Torx Screw M5x55 10 All Wiring Harness 1 All / O-Ring 2 All * Available in kit Retaining Clamp 1 All Cable Terminal 1 All Filter 1 All Torx Screw M6x60 17 All Torx Screw M6x30 5 All Filter 1 All * Available in kit 5HP24FK O-Ring 1 All Torx Screw M5x14 2 All Speed Sensor 1 All * Available in kit * Available in kit 5HP24FK All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 27

30 5HP24 Valve Body Duct Plate Group (continued) Bracket 1 All Torx Screw M6x15 1 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 28

31 5HP24 Valve Body Valve Housing Groups Valve Housing Valve Housing 1 All (except 014) Selector Shift Valve 1 All Piston Piston 1 All (except 014) Compression Spring 1 All (except 014) Compression Spring Piston 1 All Compression Spring 1 All Piston 1 All Compression Spring 1 All Piston 1 All Stop Plate 1 All Piston 1 All Compression Spring 1 All Sealing Cap 1 All Support Plate 1 All Piston 1 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 29

32 5HP24 Valve Body Valve Housing Groups (continued) Compression Spring Compression Spring Valve Spool 1 All Compression Spring 1 All Valve Spool 1 All Compression Spring 1 All Piston 1 All Compression Spring 1 All Piston 1 All Compression Spring 1 All Piston 1 All Compression Spring 1 All Cover 1 All Torx Screw M5x12 5 All Cover 1 All Torx Screw M5x12 4 All Cover 1 All Torx Screw M5x12 2 All 005/009/013/014/015/ 016/ /022/026/027/028/ 029/032/034 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 30

33 5HP24 Valve Body Valve Housing Groups (continued) Valve Housing 1 All Damper Piston 1 All Compression Spring Compression Spring Piston 1 All Compression Spring 1 All Gear Shift Slide 1 All Compression Spring 1 All Piston 1 All Compression Spring 1 All Piston 1 All Compression Spring 1 All Piston 1 All Compression Spring 1 All Piston 1 All Bush 1 All 005/009/013/014/015/ 016/ /022/026/027/028/ 029/032/034 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 31

34 5HP24 Valve Body Valve Housing Groups (continued) Piston 1 All Compression Spring 1 All Damper Piston 1 All Compression Spring 1 All Cover 1 All Torx Screw M5x12 10 All Solenoid Valve 3 All Pressure Regulator Pressure Regulator / O-Ring / O-Ring Pressure Regulator 4 All / O-Ring 1 All Fixing Plate 1 All Torx Screw M5x12 9 All * Available in kit * Available in kit /009/013/014/015/ * Available in kit / /022/026/027/028/ * Available in kit /032/ /022/026/027/028/ * Available in kit /032/ /009/013/014/015/ * Available in kit /024 * Available in kit * Available in kit * Available in kit * Available in kit * Available in kit * Available in kit All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 32

35 5HP24 Valve Body Valve Housing Groups (continued) Valve Housing Valve Housing Valve Housing Piston 1 All Compression Spring Compression Spring 1 005/009/013/014/015/ 016/ /022/026/027/028/ 029/ /009/013/014/015/ 016/ /022/026/027/028/ 029/032/ Piston 1 All Compression Spring 1 All Valve Spool 1 All Compression Spring 1 All Piston Piston 1 All (except 034) Compression Spring 1 All Valve Spool 1 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 33

36 5HP24 Valve Body Valve Housing Groups (continued) Compression Spring 1 All Valve Spool 1 All Compression Spring 1 All Piston Piston Piston Compression Spring Compression Spring Piston 1 All Compression Spring 1 All Cover 1 All Torx Screw M5x12 9 All Valve 1 All Compression Spring 1 All 021/022/026/027/028/ 029/ /009/013/014/015/ 016/ /022/026/027/028/ 029/032/ /009/013/014/015/ 016/024 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 34

37 5HP24 Selective Shims & Snap Rings 5HP24 Selective Shim Pos # Select. Parts Description Qty Intermediate Plate Shim 1 All Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A=3.00 5HP24 Selective Shim Pos # Select. Parts Description Qty Output Shim 1 All (except 032) Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A=3.20 5HP24 Selective Shim Pos # Select. Parts Description Qty Output Shim Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A=4.20 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 35

38 5HP24 Selective Shims & Snap Rings (continued) 5HP24 Selective Snap Ring Pos # Select. Parts Description Qty Clutch A Snap Ring 1 All Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A=3.60 5HP24 Selective Snap Ring Pos # Select. Parts Description Qty Clutch B Snap Ring 1 All /220 Clutch D Snap Ring 1 All Clutch E Snap Ring 1 All Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A=4.60 5HP24 Selective Snap Ring Pos # Select. Parts Description Qty /210 Clutch C Snap Ring 1 All Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A=3.40 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 36

39 5HP24 Selective Shims & Snap Rings (continued) 5HP24 Selective Snap Ring Pos # Select. Parts Description Qty Clutch F Snap Ring 1 All Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A=3.80 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 37

40 5HP24 Kit Content 5HP24 Fiber Clutch Kit Friction Plate A 6 005/ Friction Plate B 6 005/ / Friction Plate D 4 005/ Friction Plate E 5 005/ / Friction Plate C 4 005/ Friction Plate F 6 005/009 5HP24 Fiber Clutch Kit Friction Plate A 6 All (except 005/009) Friction Plate B 6 All (except 005/009) / Friction Plate D 5 All (except 005/009) 014/028 use 3 pieces; 013/015/016/021/022/024/026/ 027/029/032 use 4 pieces Friction Plate E 5 All (except 005/009) 014/028 use 4 pieces / Friction Plate C 4 All (except 005/009) Friction Plate F 6 All (except 005/009) 5HP24 Steel Kit Steel Plate A 6 005/ End Plate A 1 005/ Steel Plate B 6 005/ End Plate B 1 005/ / Steel Plate D 4 005/ / End Plate D 1 005/ Steel Plate E 5 005/ End Plate E 1 005/ / Steel Plate C 4 005/ / End Plate C 1 005/ Steel Plate F 6 005/ End Plate F 1 005/009 5HP24 Steel Kit Steel Plate A 6 All (except 005/009) End Plate A 1 All (except 005/009) Steel Plate B 6 All (except 005/009) End Plate B 1 All (except 005/009) Note: Above listed parts are not sold individually. All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 38

41 5HP24 Kit Content (continued) 5HP24 Steel Kit (continued) / Steel Plate D 5 All (except 005/009) 014/028 use 3 pieces; 013/015/016/021/022/024/026/ 027/029/032 use 4 pieces / End Plate D 1 All (except 005/009) Steel Plate E 5 All (except 005/009) 014/028 use 4 pieces End Plate E 1 All (except 005/009) / Steel Plate C 4 All (except 005/009) / End Plate C 1 All (except 005/009) Steel Plate F 6 All (except 005/009) End Plate F 1 All (except 005/009) 5HP24 Overhaul Kit / Shaft Seal 2 All 016/021/022 use 1 piece Screw Plug M12x1.5 1 All Screw Plug M14x1.5 2 All Screw Plug M18x1.5 1 All Sealing Sleeve 2 All Screw Plug M10x1 7 All / Screw Plug 1 All Gasket 1 All / Sealing Ring 1 All / Shaft Seal 1 All O-Ring 1 All / Piston Ring 2 All / Screw Plug M22x1.5 1 All / O-Ring 1 All Gasket 1 All Screw Plug M14x1.5 1 All / Shaft Seal 1 All (except 032) O-Ring 1 All Rubber Part 1 All Early valve body Piston 1 All Late valve body Gasket 1 All / O-Ring 2 All O-Ring 1 All O-Ring 1 All / O-Ring / O-Ring 4 All O-Ring 1 All O-Ring 1 All O-Ring 1 All O-Ring 1 All O-Ring 1 All Note: Above listed parts are not sold individually. 005/009/013/014/015/ 016/024 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 39

42 5HP24 Kit Content (continued) 5HP24 Overhaul Kit (continued) O-Ring 1 All Sealing Ring 1 All Piston Ring 2 All / O-Ring 1 All / O-Ring 1 All O-Ring 1 All O-Ring 1 All O-Ring 1 All O-Ring 1 All / O-Ring 1 All / O-Ring 1 All / O-Ring 2 All / Sealing Ring 2 All O-Ring 1 All 5HP24 Solenoid Kit Solenoid Valve 3 All Pressure Regulator / O-Ring Pressure Regulator 4 All / O-Ring 1 All 021/022/026/027/028/ 029/032/ /022/026/027/028/ 029/032/034 5HP24 Solenoid Kit Solenoid Valve 3 All Pressure Regulator / O-Ring Pressure Regulator 4 All / O-Ring 1 All 005/009/013/014/015/ 016/ /009/013/014/015/ 016/024 5HP24 Filter Kit 5HP24FK / Screw Plug M16x1.5 1 All Gasket 1 All Filter 1 All O-Ring 1 All Note: Above listed parts are not sold individually. All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 40

43 Quotation / Order Form FAX FORM TO YOUR PREFERRED ZF PASSENGER CAR TRANSMISSION DISTRIBUTOR Purchase Order Date: Purchase Order #: Customer Information Company Name: Contact: Street: City, State & Zip: Phone #: Fax #: Customer #: Shipping Information Ship To: Street: Request Date: Attention: City, State & Zip: Ship via: Vehicle Information Make: Model Year: Model: Transmission Spec: Order Information Line Qty Pos. # ZF Part # Description / Cust. Ref. No Signature: Date: All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 41

44 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 42

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46 ZF Industries, Inc. Passenger Car Transmissions Vernon Hills, IL Phone Fax Web Driveline and Chassis Technology 5HP24SPC0203