thectsc mechatronic replacement

7/24/2019 Thectsc Mechatronic Replacement

1/22

1

Our mechatronic units have the following components included.* Mechatronic units for vehicles with plastic oil pan include a new oil pan, sealing sleeve andmechatronic seal adapter.

* Mechatronic units for vehicles with steel oil pan include a new filter, sealing sleeve and

mechatronic seal adapter, the oil pan gasket needs to be ordered separately.

Mechatronic Replacement Hints

Our mechatronic units


2/22

2

Note

-Secure vehicleagainst rolling,secure wheels withwheel chocks.-Drain transmissionfluid andremove thetransmission oil pan.

-Unlock anddisconnect thevehicle connectorfrom thetransmission.

-Pull thesealingsleeve lockingmechanism tothe unlockedposition.

Thelockingtabislocatedonthe bottom ofthemechatronicbelow

the sealingsleeve.

-Remove thesealing sleeve.

Locking

mechanism

Sealing

sleeve


Removingharness andsleeve


3/22

3

-On E-shiftapplications only(vehicles withemergency releasecable).

Useawiretieormechanicswireandsecuretheemergencyrelease

leverinasl ightbackwardposi tionas shown.

Park emergency

releaselever

MV2Solenoid

Note

During removal andhandlingof themechatronic applyspecial carenot tobump, dropor

rough handletheunitespeciallyintheareaofMV2solenoid.

Note

Bymoving theemergency releaselever backward,the

transmissionisnolongerinthepark posi tion.Secure

againstrolling, applyparking brakeand secure wheels

withchocks .


Securethe emergencyrelease lever


4/22

4

Releaseand remove thescrews 1 through 10 or 1 through 13 as shown inthe schematicbelow to

removethe mechatronic.

Note

During removal andhandlingof themechatronic applyspecial carenot tobump, dropor

rough handletheunit.Thepressureactuatorandsolenoidsareeasi lydamagedandcan

causeerratic operationoreven result in transmissiondamage.


Removingthe mechatronic


5/22

5

Note

Adapter height X on6HP19 & 21= 15.4mm 0.1 mm

Adapter height X on6HP26 & 28 & 32 = 14.4 mm 0.1mm

- The6HP19-21andthe6HP26-28-32adapters are

di fferentin theirheight.Check theheightoftheadapterwithout theseals installed.

- Removethemechatronicadapterfrom thetransmission

housingandreplace i twi ththe newone thatcamewiththe mechatronic. Usetransmission fluidtocoat

theadapter seals.


Adapterreplacement


6/22

6

-Wheninstal lingthereplacementmechatronic makesurethepark cyl inderrodonE-shi ftor

themanual valveon M-shiftis properlyengaged beforeinstalling anyof themechatronicmountingbolts.

E -shi ft M-shi ft


Park cylinderrod orselector valvealignment

Note

Ifthescrews wereinstal led withoutthepark cyl inderor manualvalveinplace,donot

forcethe components inplace, irreversibledamage will occur.Remove all mechatronicmountingscrews and startfrom thebeginning.

MechatronicReplacementHints


7/22

7

Note

Usehandtools donotusepower toolsforscrewinstal lation.Impropertorque ofthe

mechatronic mountingscrews will causeerratic transmissionoperation.

Firstinstall andturns crew 1and4 alternatelyuntil seatedtheninstall all otherscrews until they

makecontact withthe mechatronic. Afterall screws are installed,tightenscrews in

order 1 through 10 or 1 through 13 as showninthe schematicbelow.

Torquefor screws is 8NM 0.8Nm.


Installingthe mechatronicmounting bolts



8/22

8

Locking

mechanism

Locatingtab

2.5to

3.0mm

- Unlock thesealing sleeve lockingmechanism andinstall thesealing sleevewith thelocating tab

properlyaligned withthe mechatronic.Use transmission fluidto lubricatethe sealsfor

installation.After thesleeve is properlyseated, pushthe lockingmechanism tothe locked

position.Install thevehicle connectorplug andcheck thatthe sleeveis properlyseated. The

gap x shouldbe between 2.5 to3.0mm.

n ew s le ev e o ld s le ev e

Note

p

Sleeveinstallation


Oil pantorque sequence


9/22

9

- Install theoi l panandattachal l screws unti l theyjustmakecontactwiththeoi l pan.Afteral l screws

areinstalled, tightenscrews inorder 1 through 24 or 1 through 21 asshown in theschematic below.

Thetighteningt orquefor screws ona plasticoil panis 10 Nm 1.0Nm.

Thetighteningt orquefor screws ona steel oil panis12Nm 1.0 Nm.(steel pannot pictured)

6HP19-6HP21

Oil pan

6HP26-6hp28-6HP32

Oil pan

6HP19

6HP21

6HP26

6HP28

6HP32

Oil pantorque sequence


Emergencyrelease cableadjustment


10/22

10

-E-shi ftvehicles only,removethetiestraporwire thatheldthe emergencypark

releaselever inthe backwards positionand adjustcable asfollows.

Withthe emergencycable released the

clearance X indicatedabovemustbe

adjustedto 1.0to2.0mm.

Thecableshouldnottouchtheleveratany

time,eveni fthe leveris movedback and

forth.Ifthecabledoes comeincontact thencheck fora bentleveror abentcablebracket.


Programming


11/22

11

-If themechatronic was notpreviously programmedwith vehicle specificsoftware thenthis must

beperformedatthis time.Operatingthevehicleinfai lsafemodemaycausetransmission

damage.If onsiteprogramming tools arenot availablethen thevehiclemustbe transported

toa vehiclespecific dealerfor programming.

Note

Thetransmission does notcontain transmissionfluid andthereforeshould onlybe

transportedon a flatbedtow truck.


ZF transmissionLifeguardFluid


12/22

12

LifeguardFluid6 S671090255all 6HP19,all 6HP19X exceptfor AudiQ7,all 6HP21, 6HP21X, 6HP26, 6HP26X,all 6HP26A61(2) exceptvehicleswi thAudiW12-engine

all 6HP28, 6HP28X, 6HP28A61,all 6HP32, 6HP32A (2), 6HP32X

LifeguardFluid6+ S6710902816HP26A61(2)for vehicleswithAudi W12-engine

LifeguardFluid8 AA00601304all 6HP19A (2)

6HP19X for AudiQ7

all 6HP28AF (2)

Notes on transmissionfluid

Useof ANY transmissionfluid otherthan ZFLifeguardFluidcancause transmissionslippage, harsh shifting,noise, lock-up

clutchcycling and reduced servicelife.

(2) differential require different oil, see TE-ML11 for specifications.

Transmissions fluidlevelchecking.


Fluidlevel procedures


13/22

13

Thetransmission fluidtemperature mustbe between30C and35Cbefore checkingcan begin.

Usetest equipmentto determinethe trans temperature.

Thevehicle mustbe level withengine running atidle speedand airconditioningt urnedon.

Steponthe brakes fi rmly, applyparkingbrakefullyandshi fttoD andR,brieflypausingineach

positionbefore shiftingback tothePark position.

Withthe enginerunningat idle speedand the selectorin Park position, remove thefiller plug.

Monitorthetransmissiontemperature,i fasmal l stream ofoi l runsoutat40C,thefluidlevel is

correct.

Ifnooi l runs out whenthefi l lerplugis removed,thefluidlevel istoolow andoi l needs tobe

added until itoverflows.

Withengine running,install theoil fillerplug andtighten toproper torque.

Addingfluidafter repairs.

WiththeenginestoppedandthetransmissioninPark posi tion,removethe oi l fi l lerplug.Add

transmissionfluid until asmall stream ofoil runsout.

Insertthefi l lerplugandtightenbyhand.Starttheengine.

Withthe enginerunning, removethe oil fillerplug andadd transmissionfluid until asmall stream

ofoil runsout. Insertthe filler plug and tightenbyhand.

FollowtheTransmission fluidlevel checkingprocedure describedin section Transmission

fluid levelchecking above.

Notes on fluidlevel andaddingprocedure.

Useonly ZF LifeguardFluid6orOE approvedtransmission fluid


Fluidlevel procedures


14/22

14

Useonly ZF-LifeguardFluid6orOE approvedtransmission fluid.

Ifthe transmissiontemperature risesabove 50C duringthe fluidlevel checkingprocedure

theresulting oil level will betolow.Let the transmissioncool down and repeatthe fluid

level procedure.

Havetransmissionfluidandasui tableoi l pumpavai lablebeforestartingthefluidlevel

procedure.The transmission fluid temperaturewill risequicklyduringthe checkingprocedure.


Drainand fillerplug locationfor 6HP19/21withplastic oil pan


15/22

15

Drainplug M24x1

Innerhexagon 10mm

Tightening torque 8Nm -0.5 Nm

Fillerplug M18x1.5

Innerhexagon 8mm

Tightening torque 35Nm 3.5Nm


Drainandfillerpluglocationfor6HP19X/21Xwithplastic oilpan


16/22

16

Drainplug M24x1

Innerhexagon 10mm


Fillerplug M18x1.5

Innerhexagon 8mm



Drainand fillerplug locationfor 6HP26/28/32withplastic oil pan


17/22

17

Fillerplug M18x1.5

Innerhexagon 8mm


Drainplug M24x1

Innerhexagon 10mm



Drainandfillerpluglocationfor6HP26Xwithsteel oil pan


18/22

18

Fillerplug M30x1.5

Innerhexagon 17mm

Tightening torque 80Nm 8Nm

Drainplug M10x1

Innerhexagon 5mm


-Inserttheold seal ingsleeveback intothemechatronic,pushthelockingtabintoi ts

lockedposition forcore returnshipping.

Note

Avoidtouching anyelectrical pins topreventESD (electrostatic discharge)damage.


CoreReturn


19/22

19

-Toreceiveful l creditcoreuni tmustbe returnedundamaged.

Packagingrecommendation:

-Use theoriginal shipping boxfor the

mechatronicreturn.

Placethe cardboardinsert upsidedown

i h hi i b


CoreReturn


20/22

20

intothe shipping box.

-Add additional packaging material to

thebottom ofthebox.

-Toreceiveful l credi tcoreuni tmustbe returnedintheoriginal box..

Packagingrecommendation:

-Placethemechatronicintoaplastic bagtopreventoi l

leakage,then setinto shipping box.

Note:Clean upcharges duetoleaking packages will be

deductedfrom thecore credit..


CoreReturn


21/22

21

-Add additional packaging material ontop ofthe

mechatronictoprovidea snugfi tinthe shippingbox.

Note

Donot returntheoi l pan oranyof theseal ingparts thatcame withthe mechatronic.

Note

Packagemechatronic as secureaspossible,damage tothe mechatronicwill

resultindeductionorloss ofyourcorecredi t.

YES NO

CHECKGAPBETWEENHOUSING ANDCONNECTOR

ISTHEGAPX LARGERTHAN3.0mm?

CHECKFORPUSHEDBACKPINSATTHEVEHICLECONNECTOR?

THESLEEVEISNOTPROPERLYSEATEDINTHEMECHATRONIC.REINSTALLPROPERLY.

No Communication- Failsafe

Most commonissuesafter mechatronic replacement


22/22

22

YES

NOYES

NO

YES NO

PINSPUSHEDBACK?

AREYOUABLETOACCESSALLOTHERSYSTEMS?

REPAIRASNECESSARY

TROUBLESHOOTCOMMUNICATIONPATH

TROUBLESHOOTPOWERPATH-FUSES

RECOMMENDMECHATRONICREPLACEMENT

WITHVEHICLECONNECTORDISCONNECTEDANDIGNITIONON, CHECKVOLTAGEASFOLLOWS

ISVOLTAGEBETWEENPINSBATTERYVOLTAGE?PIN13toPIN 14RECORDVOLTAGE

PIN13TO PIN9RECORDVOLTAGEPIN16TO PIN14RECORDVOLTAGE

PIN16TO PIN9RECORDVOLTAGE

thectsc mechatronic replacement

Documents