ZF 5HP24, ZF 5HP24A Repair Manual

Service Manual improves and makes easier operations of installation, dismantling, diagnostics of transmissions ZF. Repair manual encompasses electric circuits, block diagrams, various types of sockets and circuits of accommodation.
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.

Contents of This Repair Manual:
Preliminary information
1. General information
    1.1 Picture of the transmission
    1.2 Diagram of power flow
    1.3 (Previously used for the oil supply diagrams, not currently used)
    1.4 Making adjustments
          1.4.0 Measuring the disc sets (procedure)
          1.4.1 Adjusting clearance of brake F (snap ring)
          1.4.2 Adjusting clearance of brake D (snap ring)
          1.4.3 Adjusting clearance of brake E (snap ring)
          1.4.4 Adjusting clearance of clutch C (snap ring)
          1.4.5 Adjusting clearance of clutch A (snap ring)
          1.4.6 Adjusting clearance of clutch B (snap ring)
          1.4.7 Output play (shim)
          1.4.8 Input play (shim)
          1.4.9 Adjusting switch (detent spring)
    1.5 Tightening torques
    1.6 Transmission test (test bench/vehicle)
    1.7 Special tools
    1.8 Function tests
          1.8.1 Position switch
2. Disassembly
    2.1 Disassembly of the transmission as of the assembly group
    2.2 Brake F with freewheel, 1st gear
    2.3 Output
    2.4 Tower I
          2.4.1 Brake D, E and clutch C
          2.4.2 Planetary drive (III, II and I)
    2.5 Tower II
    2.6 Oil supply
    2.7 Transmission with flow control valve and breather
    2.8 Transmission with selector mechanism and parking lock
3. Assembly
    3.1 Transmission with selector mechanism and parking lock
    3.2 Brake F with freewheel, 1st gear
    3.3 Tower I
          3.3.1 Planetary drive (III, II and I)
          3.3.2 Brake (E and D)
          3.3.3 Assembly, clutch C
    3.4 Output
    3.5 Tower II (input with clutches A and B)
          3.5.1 Clutch A (input)
          3.5.2 Clutch B (input)
    3.6 Oil supply
    3.7 Control unit, oil pan and converter
    (Complete control unit, see parts list, technical cover sheet, position Y02)

The information in this manual is written in such a way that a novice or an inexperienced master could find and apply information to troubleshoot problems.

Features of the Manual
Format: PDF
Language: English
Compatible with all versions of Windows, Mac, Linux, iPhone, iPad, and Android
Workshop Manual contains detailed repair manuals, technical information, operation and maintenance instructions, service manuals, installation instructions, and calibration designed to serves transmissions ZF 5HP24 and 5HP24A. This Manual covers the procedure for repairing the complete transmission.

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