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7/24/2019 Thectsc Mechatronic Replacement
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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
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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
Mechatronic Replacement Hints
Removingharness andsleeve
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-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 .
Mechatronic Replacement Hints
Securethe emergencyrelease lever
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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.
Mechatronic Replacement Hints
Removingthe mechatronic
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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.
Mechatronic Replacement Hints
Adapterreplacement
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-Wheninstal lingthereplacementmechatronic makesurethepark cyl inderrodonE-shi ftor
themanual valveon M-shiftis properlyengaged beforeinstalling anyof themechatronicmountingbolts.
E -shi ft M-shi ft
Mechatronic Replacement Hints
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
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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.
Mechatronic Replacement Hints
Installingthe mechatronicmounting bolts
Mechatronic Replacement Hints
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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
Mechatronic Replacement Hints
Oil pantorque sequence
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- 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
Mechatronic Replacement Hints
Emergencyrelease cableadjustment
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-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.
Mechatronic Replacement Hints
Programming
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-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.
Mechatronic Replacement Hints
ZF transmissionLifeguardFluid
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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.
Mechatronic Replacement Hints
Fluidlevel procedures
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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
Mechatronic Replacement Hints
Fluidlevel procedures
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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.
Mechatronic Replacement Hints
Drainand fillerplug locationfor 6HP19/21withplastic oil pan
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Drainplug M24x1
Innerhexagon 10mm
Tightening torque 8Nm -0.5 Nm
Fillerplug M18x1.5
Innerhexagon 8mm
Tightening torque 35Nm 3.5Nm
Mechatronic Replacement Hints
Drainandfillerpluglocationfor6HP19X/21Xwithplastic oilpan
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Drainplug M24x1
Innerhexagon 10mm
Tightening torque 8Nm -0.5 Nm
Fillerplug M18x1.5
Innerhexagon 8mm
Tightening torque 35Nm 3.5Nm
Mechatronic Replacement Hints
Drainand fillerplug locationfor 6HP26/28/32withplastic oil pan
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Fillerplug M18x1.5
Innerhexagon 8mm
Tightening torque 35Nm 3.5Nm
Drainplug M24x1
Innerhexagon 10mm
Tightening torque 8Nm -0.5 Nm
Mechatronic Replacement Hints
Drainandfillerpluglocationfor6HP26Xwithsteel oil pan
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Fillerplug M30x1.5
Innerhexagon 17mm
Tightening torque 80Nm 8Nm
Drainplug M10x1
Innerhexagon 5mm
Tightening torque 12Nm 1.2Nm
-Inserttheold seal ingsleeveback intothemechatronic,pushthelockingtabintoi ts
lockedposition forcore returnshipping.
Note
Avoidtouching anyelectrical pins topreventESD (electrostatic discharge)damage.
Mechatronic Replacement Hints
CoreReturn
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-Toreceiveful l creditcoreuni tmustbe returnedundamaged.
Packagingrecommendation:
-Use theoriginal shipping boxfor the
mechatronicreturn.
Placethe cardboardinsert upsidedown
i h hi i b
Mechatronic Replacement Hints
CoreReturn
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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..
Mechatronic Replacement Hints
CoreReturn
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-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
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YES
NOYES
NO
YES NO
PINSPUSHEDBACK?
AREYOUABLETOACCESSALLOTHERSYSTEMS?
REPAIRASNECESSARY
TROUBLESHOOTCOMMUNICATIONPATH
TROUBLESHOOTPOWERPATH-FUSES
RECOMMENDMECHATRONICREPLACEMENT
WITHVEHICLECONNECTORDISCONNECTEDANDIGNITIONON, CHECKVOLTAGEASFOLLOWS
ISVOLTAGEBETWEENPINSBATTERYVOLTAGE?PIN13toPIN 14RECORDVOLTAGE
PIN13TO PIN9RECORDVOLTAGEPIN16TO PIN14RECORDVOLTAGE
PIN16TO PIN9RECORDVOLTAGE