Langbahn Team – Weltmeisterschaft

ZF 6HP transmission

6HP
Automatic Transmission 6HP 26 cutaway
Overview
ManufacturerZF Friedrichshafen
Production2000–2014
Model years2000–2014
Body and chassis
Class6-Speed Longitudinal Automatic Transmission
RelatedFord 6R
GM 6L
Aisin AWTF-80 SC
MB 7G-Tronic
Chronology
PredecessorZF 5HP
SuccessorZF 8HP

6HP is ZF Friedrichshafen AG's trademark name for its 6-speed automatic transmission models (6-speed transmission with Hydraulic converter and Planetary gearsets) for longitudinal engine applications, designed and built by ZF's subsidiary in Saarbrücken. Released as the 6HP 26 in 2000, it was the first 6-speed automatic transmission in a production passenger car. Other variations of the first generation 6HP in addition to the 6HP 26, were 6HP19, and 6HP 32 having lower and higher torque capacity, respectively. In 2007, the second generation of the 6HP series was introduced, with models 6HP 21 and 6HP 28. A 6HP 34 was planned, but never went into production.[1]

It uses a Lepelletier gear mechanism,[2] an epicyclic/planetary gearset, which can provide more gear ratios with significantly fewer components. This means the 6HP 26 is actually lighter than its five-speed 5HP predecessors.

The 6HP is the first transmission to use this 6-speed gearset concept.

The last 6HP automatic transmission was produced by the Saarbrücken plant in March 2014 after 7,050,232 units were produced.[3][4] The ZF plant in Shanghai continued to produce the 6HP for the Chinese market.[3]

The Ford 6R, GM 6L, and Aisin AWTF-80 SC transmissions are based on the same globally patented gearset concept. The AWTF-80 SC is the only one for transverse engine installation.

Gear Ratios[a]
Gear
Model
R 1 2 3 4 5 6 Total
Span
Span
Center
Avg.
Step
Compo-
nents
2000: 1st Generation 3
Gearsets
2
Brakes
3
Clutches
6HP 26[b] · 6HP 19 · 6HP 32 −3.403 4.171 2.340 1.521 1.143 0.867 0.691 6.035 1.698 1.433
2007: 2nd Generation
6HP 28 · 6HP 21 · 6HP 34 −3.403 4.171 2.340 1.521 1.143 0.867 0.691 6.035 1.698 1.433
Other Manufacturer
Aisin AWTF-80 SC · 2005 −3.394 4.148 2.370 1.556 1.155 0.859 0.686 6.049 1.687 1.433
Ford 6R 60 · 6R 80 · 2005 −3.403 4.171 2.340 1.521 1.143 0.867 0.691 6.035 1.698 1.433
Ford 6R 140 · 2005 −3.128 3.974 2.318 1.516 1.149 0.858 0.674 5.899 1.636 1.426
GM 6L 45 · 6L 50 · 2006 −3.200 4.065 2.371 1.551 1.157 0.853 0.674 6.035 1.655 1.433
GM 6L 80 · 6L 90 · 2005 −3.064 4.027 2.364 1.532 1.152 0.852 0.667 6.040 1.638 1.433
  1. ^ Differences in gear ratios have a measurable, direct impact on vehicle dynamics, performance, waste emissions as well as fuel mileage
  2. ^ first transmission to use this 6-speed gearset concept

Specifications

Layout (Gearset Concept) Progress

The main objective in replacing the predecessor model was to improve vehicle fuel economy with extra speeds and a wider gear span to allow the engine speed level to be lowered (downspeeding). The layout brings the ability to shift in a non-sequential manner – going from gear 6 to gear 2 in extreme situations simply by changing one shift element (actuating clutch E and releasing brake A).

Progress Quality

In order to increase the number of ratios, ZF has abandoned the conventional design method of limiting themselves to pure in-line epicyclic gearing and extended it to a combination with parallel epicyclic gearing. This was only possible thanks to computer-aided design and has resulted in a globally patent for this gearset concept. The 6HP is the first transmission designed according to this new paradigm. After gaining additional gear ratios only with additional components, this time the number of components has to decrease while the number of ratios still increase. The progress is reflected in a much better ratio of the number of gears to the number of components used compared to existing layouts.

Innovative Strength Analysis
With
Asessment
Output:
Gear
Ratios
Innovation
Elasticity[a]
Δ Output : Δ Input
Input: Main Components
Total Gearsets Brakes Clutches
6HP
Ref. Object

Topic[a]



Δ Number
Relative Δ Δ Output

·
Δ Input
6HP
5HP 24/30[b]
6[c]
5[c]
Progress[a] 8
9
3[d]
3
2
3
3
3
Δ Number 1 -1 0 -1 0
Relative Δ 0.200
−1.800[a]
·
−0.111
0.000
−0.333
0.000
6HP
5HP 18/19[b]
6[c]
5[c]
Progress[a] 8
10
3[d]
3[d]
2
3
3
4
Δ Number 1 -2 0 -1 -1
Relative Δ 0.200
−1.000[a]
·
−0.200
0.000
−0.333
−0.250
6HP
3-Speed[e]
6[c]
3[c]
Market Position[a] 8
7
3[d]
2
2
3
3
2
Δ Number 3 1 1 -1 1
Relative Δ 1.000
7.000[a]
·
0.143
0.500
−0.333
0.500
  1. ^ a b c d e f g h Innovation Elasticity Classifies Progress And Market Position
    • Automobile manufacturers drive forward technical developments primarily in order to remain competitive or to achieve or defend technological leadership. This technical progress has therefore always been subject to economic constraints
    • Only innovations whose relative additional benefit is greater than the relative additional resource input, i.e. whose economic elasticity is greater than 1, are considered for realization
    • The required innovation elasticity of an automobile manufacturer depends on its expected return on investment. The basic assumption that the relative additional benefit must be at least twice as high as the relative additional resource input helps with orientation
      • negative, if the output increases and the input decreases, is perfect
      • 2 or above is good
      • 1 or above is acceptable (red)
      • below this is unsatisfactory (bold)
  2. ^ a b Direct Predecessor
    • To reflect the progress of the specific model change
  3. ^ a b c d e f plus 1 reverse gear
  4. ^ a b c d of which 2 gearsets are combined as a compound Ravigneaux gearset
  5. ^ Reference Standard (Benchmark)
    • 3-speed transmissions with torque converters have established the modern market for automatic transmissions and thus made it possible in the first place, as this design proved to be a particularly successful compromise between cost and performance
    • It became the archetype and dominated the world market for around 3 decades, setting the standard for automatic transmissions. It was only when fuel consumption became the focus of interest that this design reached its limits, which is why it has now completely disappeared from the market
    • What has remained is the orientation that it offers as a reference standard (point of reference, benchmark) for this market for determining progressiveness and thus the market position of all other, later designs
    • All transmission variants consist of 7 main components
    • Typical examples are

Layout Quality

The ratios of the 6 gears are nicely evenly distributed in all versions. Exceptions are the large step from 1st to 2nd gear and the almost geometric steps from 3rd to 4th to 5th gear. They cannot be eliminated without affecting all other gears. As the large step is shifted due to the large span to a lower speed range than with conventional gearboxes, it is less significant. As the gear steps are smaller overall due to the additional gear(s), the geometric gear steps are still smaller than the corresponding gear steps of conventional gearboxes. Overall, therefore, the weaknesses are not overly significant. As the selected gearset concept saves up to 2 components compared to 5-speed transmissions, the advantages clearly outweigh the disadvantages.

It has a torque converter lock-up for all 6 forward gears, which can be fully disengage when stationary, largely closing the fuel efficiency gap between vehicles with automatic and manual transmissions.

In a Lepelletier gearset, a conventional planetary gearset and a composite Ravigneaux gearset are combined to reduce both the size and weight as well as the manufacturing costs. Like all transmissions realized with Lepelletier transmissions, the 6HP also dispenses with the use of the direct gear ratio and is thus one of the very few automatic transmission concepts without such a ratio.

Gear Ratios
With Assessment[a] Planetary Gearset: Teeth[b]
Lepelletier gear mechanism
Count Total[c]
Center[d]
Avg.[e]
Simple Ravigneaux
Manufacturer
Model
Version
First Delivery
S1[f]
R1[g]
S2[h]
R2[i]
S3[j]
R3[k]
Brakes
Clutches
Ratio
Span
Gear
Step[l]
Gear
Ratio
R
1
2
3
4
5
6
Step[l] [m] [n]
Δ Step[o][p]
Shaft
Speed
Δ Shaft
Speed[q]
2000: 1st Generation
ZF 6HP 26[r]
ZF 6HP 19[r]
ZF 6HP 32[r]
600 N⋅m (443 lb⋅ft)
400 N⋅m (295 lb⋅ft)[s]
750 N⋅m (553 lb⋅ft)[5]
2000 (all)
37
71
31
38
38
85
2
3
6.0354
1.6977
1.4327[l]
Gear
Ratio
−3.4025[m]
4.1708
2.3397[n]
1.5211
1.1428[p][q]
0.8672
0.6911
Step 0.8158[m] 1.0000 1.7826[n] 1.5382 1.3311 1.3178 1.2549
Δ Step[o] 1.1589 1.1559 1.0101[p] 1.0502
Speed -1.2258 1.0000 1.7826 2.7419 3.6497 4.8096 6.0354
Δ Speed 1.2258 1.0000 0.7826 0.9593 0.9078[q] 1.1599 1.2258
2007: 2nd Generation
ZF 6HP 28[r]
ZF 6HP 21[r]
ZF 6HP 34[r]
600 N⋅m (443 lb⋅ft)
450 N⋅m (332 lb⋅ft)[t]
750 N⋅m (553 lb⋅ft)[u]
2007 · (all)
37
71
31
38
38
85
2
3
6.0354
1.6977
1.4327[l]
Ratio −3.4025[m] 4.1708 2.3397[n] 1.5211 1.1428[p][q] 0.8672 0.6911
Other Manufacturer
Aisin
AWTF-80 SC
450 N⋅m (332 lb⋅ft)[6]
2005
50
90
36
44
44
96
2
3
6.0494
1.6865
1.4333[l]
Gear
Ratio
−3.3939[m]
4.1481
2.3704[n]
1.5556
1.1546[p]
0.8593
0.6857[q]
Step 0.8182[m] 1.0000 1.7500[n] 1.5238 1.3472 1.3436 1.2532
Δ Step[o] 1.1484 1.1311 1.0027[p] 1.0722
Speed -1.2222 1.0000 1.7500 2.6667 3.5926 4.8272 6.0494
Δ Speed 1.2222 1.0000 0.7500 0.9167 0.9259 1.2346 1.2222[q]
Ford
6R 60 · 6R 80
600 N⋅m (443 lb⋅ft) · 2005
800 N⋅m (590 lb⋅ft) · 2005
37
71
31
38
38
85
2
3
6.0354
1.6977
1.4327[l]
Ratio −3.4025[m] 4.1708 2.3397[n] 1.5211 1.1428[p][q] 0.8672 0.6911
Ford
6R 140
1,400 N⋅m (1,033 lb⋅ft)
2005
49
95
37
47
47
97
2
3
5.8993
1.6361
1.4261[l]
Gear
Ratio
−3.1283[m]
3.9738
2.3181[n][p]
1.5158
1.1492[p][q]
0.8585
0.6736
Step 0.7872[m] 1.0000 1.7143[n] 1.5293 1.3190 1.3389 1.2744
Δ Step[o] 1.1210[p] 1.1594 0.9854[p] 1.0504
Speed -1.2703 1.0000 1.7143 2.6216 3.4580 4.6290 5.8993
Δ Speed 1.2703 1.0000 0.7143 0.9073 0.8364[q] 1.1710 1.2703
GM
6L 45 · 6L 50
500 N⋅m (369 lb⋅ft) · 2006 49
89
37
47
47
97
2
3
6.0346
1.6548
1.4326[l]
Gear
Ratio
−3.2001[m]
4.0650
2.3712[n][p]
1.5506
1.1567[p][q]
0.8532
0.6736
Step 0.7872[m] 1.0000 1.7143[n] 1.5293 1.3406 1.3557 1.2662
Δ Step[o] 1.1210[p] 1.1408 0.9889[p] 1.0703
Speed -1.2703 1.0000 1.7143 2.6216 3.5144 4.7643 6.0346
Δ Speed 1.2703 1.0000 0.7143 0.9073 0.8928[q] 1.2499 1.2703
GM
6L 80 · 6L 90
800 N⋅m (590 lb⋅ft) · 2005 50
94
35
46
46
92
2
3
6.0401
1.6384
1.4329[l]
Gear
Ratio
−3.0638[m]
4.0267
2.3635[n][p]
1.5319
1.1522[p][q]
0.8521
0.6667
Step 0.7609[m] 1.0000 1.7037[n] 1.5429 1.3296 1.3522 1.2781
Δ Step[o] 1.1043[p] 1.1604 0.9832[p] 1.0580
Speed -1.3143 1.0000 1.7037 2.6286 3.4948 4.7258 6.0401
Δ Speed 1.3143 1.0000 0.7037 0.9249 0.8662[q] 1.2310 1.3143
Ratio
R & Even
Ratio
Odd
Algebra And Actuated Shift Elements
Brake A[v]
Brake B[w]
Clutch C[x]
Clutch D[y]
Clutch E[z]
ZF
5HP 18[aa]
310 N⋅m (229 lb⋅ft) · 1990 32
76
38[ab]
34
34
98
3
4
4.9363
1.6495
1.4906[l]
Gear
Ratio
−4.0960[m]
3.6648
1.9990[n]
1.4067[l][p][q]
1.0000
0.7424
Step 1.1176[m] 1.0000 1.8333[n] 1.4211[l] 1.4067 1.3469
Δ Step[o] 1.2901 1.0102[p] 1.0444
Speed -0.8947 1.0000 1.8333 2.6053 3.6648 4.9363
Δ Speed 0.8947 1.0000 0.8333 0.7719[q] 1.0596 1.2715
  1. ^ The 6HP-transmission is the first one to use the Lepelletier gear mechanism
  2. ^ Layout
    • Input and output are on opposite sides
    • Planetary gearset 1 is on the input (turbine) side
    • Input shafts are R1 and, if actuated, C2/C3 (the combined carrier of the compound Ravigneaux gearset 2 and 3)
    • Output shaft is R3 (ring gear of gearset 3: outer Ravigneaux gearset)
  3. ^ Total Ratio Span (Total Ratio Spread · Total Gear Ratio)
    • A wider span enables the
      • downspeeding when driving outside the city limits
      • increase the climbing ability
        • when driving over mountain passes or off-road
        • or when towing a trailer
  4. ^ Ratio Span's Center
    • The center indicates the speed level of the transmission
    • Together with the final drive ratio
    • it gives the shaft speed level of the vehicle
  5. ^ Average Gear Step
    • With decreasing step width
      • the gears connect better to each other
      • shifting comfort increases
  6. ^ Sun 1: sun gear of gearset 1
  7. ^ Ring 1: ring gear of gearset 1
  8. ^ Sun 2: sun gear of gearset 2: inner Ravigneaux gearset
  9. ^ Ring 2: ring gear of gearset 2: inner Ravigneaux gearset
  10. ^ Sun 3: sun gear of gearset 3: outer Ravigneaux gearset
  11. ^ Ring 3: ring gear of gearset 3: outer Ravigneaux gearset
  12. ^ a b c d e f g h i j k l Standard 50:50
    — 50 % Is Above And 50 % Is Below The Average Gear Step —
    • With steadily decreasing gear steps (yellow highlighted line Step)
    • and a particularly large step from 1st to 2nd gear
      • the lower half of the gear steps (between the small gears; rounded down, here the first 2) is always larger
      • and the upper half of the gear steps (between the large gears; rounded up, here the last 3) is always smaller
    • than the average gear step (cell highlighted yellow two rows above on the far right)
    • lower half: smaller gear steps are a waste of possible ratios (red bold)
    • upper half: larger gear steps are unsatisfactory (red bold)
  13. ^ a b c d e f g h i j k l m n o Standard R:1
    — Reverse And 1st Gear Have The Same Ratio —
    • The ideal reverse gear has the same transmission ratio as 1st gear
      • no impairment when maneuvering
      • especially when towing a trailer
      • a torque converter can only partially compensate for this deficiency
    • Plus 11.11 % minus 10 % compared to 1st gear is good
    • Plus 25 % minus 20 % is acceptable (red)
    • Above this is unsatisfactory (bold)
  14. ^ a b c d e f g h i j k l m n o Standard 1:2
    — Gear Step 1st To 2nd Gear As Small As Possible —
    • With continuously decreasing gear steps (yellow marked line Step)
    • the largest gear step is the one from 1st to 2nd gear, which
      • for a good speed connection and
      • a smooth gear shift
    • must be as small as possible
      • A gear ratio of up to 1.6667:1 (5:3) is good
      • Up to 1.7500:1 (7:4) is acceptable (red)
      • Above is unsatisfactory (bold)
  15. ^ a b c d e f g From large to small gears (from right to left)
  16. ^ a b c d e f g h i j k l m n o p q r s t u Standard STEP
    — From Large To Small Gears: Steady And Progressive Increase In Gear Steps —
    • Gear steps should
      • increase: Δ Step (first green highlighted line Δ Step) is always greater than 1
      • As progressive as possible: Δ Step is always greater than the previous step
    • Not progressively increasing is acceptable (red)
    • Not increasing is unsatisfactory (bold)
  17. ^ a b c d e f g h i j k l m n o Standard SPEED
    — From Small To Large Gears: Steady Increase In Shaft Speed Difference —
    • Shaft speed differences should
      • increase: Δ Shaft Speed (second line marked in green Δ (Shaft) Speed) is always greater than the previous one
    • 1 difference smaller than the previous one is acceptable (red)
    • 2 consecutive ones are a waste of possible ratios (bold)
  18. ^ a b c d e f for Rear-wheel drive cars
  19. ^ 400 N⋅m (295 lbf⋅ft) or 400 N⋅m (295 lbf⋅ft)
  20. ^ produced in the PRC,[4] alternatively known as 6HP 19tu and 6HP 19z
  21. ^ planned, but never went into production[1]
  22. ^ Blocks R2 and S3
  23. ^ Blocks C2 (carrier 2) and C3 (carrier 3)
  24. ^ Couples C1 (carrier 1) and S2
  25. ^ Couples C1 (carrier 1) with R2 and S3
  26. ^ Couples R1 with C2 (carrier 2) and C3 (carrier 3)
  27. ^ no Lepelletier gear mechanism is applied · shown here to reflect the progress the Lepelletier gear mechanism means
  28. ^ inner and outer sun gear of the compound Ravigneaux planetary gearset are inverted

Imperfections

Problems with this transmission are well known.[citation needed] This transmission locks up the torque converter in all gears, increasing wear. Combined with a sealed transmission pan and "lifetime fluid", some people have experienced catastrophic transmission failure. Owners report shift issues when oil begins breaking down beyond 50K miles, hence shifting issues are common.[citation needed]

There are also problems with the valve block and solenoids[citation needed] When this failure starts to occur, shift quality and speed, torque transfer and even loss of ability to engage gears can occur. These problems led Volkswagen Group to extend the warranty on all of their vehicles equipped with this transmission to 100,000 miles or 10 years.[citation needed]

Applications

First Generation · 2000

6HP 19

  • BMW X3
  • BMW 520i (E60)
  • BMW 528i (E60)
  • BMW 530i, (E60)
  • BMW 630i, (E63)
  • BMW 730i/li, (E65/E66)
  • BMW 318i, 320i, 325i, 328i, 330i, 335i (E9X), pre-LCI
  • BMW 116i, 118i, 120i (E87), pre-LCI, 135i (E82), 118d (E81)
  • BMW Z4 E85 LCI, E86 (All models except Z4 M)
  • Hyundai Genesis Coupe - 2010-2012 3.8L

6HP 19A

The 6HP 19A is a variation of the 6HP 19 for Four-wheel drive applications (Allrad, all wheel).It was used by the Volkswagen Group for some permanent four-wheel drive models.

6HP 26

The 6HP 26 was the initial version and first used by the BMW 7 Series (E65) in 2001. Initially only used by premium brands, it was later available on the 2009 model year V8 Hyundai Genesis.

Several versions of the 6HP 26 are available depending on application and brand: 6HP 26, 6HP 26A and 6HP 26X.

Ford has developed their own versions (Ford 6R 60 and Ford 6R 80) based on the 6HP 26. Therefore, certain Ford vehicles will not be listed.

6HP 26A

The 6HP 26A is a variation of the 6HP 26 for Four-wheel drive applications (Allrad, all wheel). It was used by the Volkswagen Group for some permanent four-wheel drive models and packages a TORSEN type center differential, and open front differential into the transmission assembly.

6HP 26X & 6HP 26Z

The 6HP 26X and 6HP 26Z is another variation of the 6HP 26, also for Four-wheel drive applications. This transmission is suitable for 4WDs with a separate transfer box (the "X" stands for external 4WD).

6HP 32

  • BMW E65 745d (LCI)

6HP 32A

The 6HP 32A is a variation of the 6HP 32 for Four-wheel drive applications (Allrad, all wheel).

  • Audi Q7 6.0 V12 TDI
  • Volkswagen Phaeton (5.0 V10 TDI only) (Typ 3D)

Second Generation · 2007

6HP 21

  • 2011–2014 Ford Falcon (FG2 turbocharged I4, naturally-aspirated I6, turbocharged I6 and supercharge V8)
  • 2014–2016 Ford Falcon (FG X turbocharged I4, naturally-aspirated I6, turbocharged I6 and supercharged V8)[4]
  • 2014–2016 Ford Territory (SZ II petrol)[14]
  • 2010–2012 BMW 320d Lci (Thailand) (Engine N47D20)
  • 2011–2013 BMW 335i (E9X)
  • 2013–2015 BMW X1 (E84) xDrive35i
  • 2009 LCI (BMW 528i E60) (Engine: N52B30AE)
  • 2014–Present Maxus G10
  • 2007–2009 LCI (BMW 520d E61) ( Engine: N47D20A)

6HP 28

6HP 34

The 6HP 34 was planned for high-output applications. As the successor 8HP was about to be launched and innovations are typically introduced first in the premium segment, the 6HP 34 never went into production.[1]

See also

References

  1. ^ a b c "ZF 6HP34" (PDF). ZF Friedrichshafen AG. Retrieved 18 September 2009.[permanent dead link]
  2. ^ Riley, Mike (2013-09-01). "Lepelletier Planetary System". Transmission Digest. Archived from the original on 2023-06-21. Retrieved 2023-03-03.
  3. ^ a b "More than Seven Million: ZF Ends Production of Successful 6-Speed Automatic Transmission" (Press release). ZF Friedrichshafen. 31 March 2014. Retrieved 2 August 2016.
  4. ^ a b c d e "Review: Ford FG X Falcon (2014–16)". AustralianCar.Reviews. Retrieved 2 August 2016.
  5. ^ "ZF 6HP26 Transmission" (PDF). Retrieved 2017-02-02.
  6. ^ Kasuya, Satoru; Taniguchi, Takao; Tsukamoto, Kazumasa; Hayabuchi, Masahiro; Nishida, Masaaki; Suzuki, Akitomo; Niki, Hiroshi (2005). "AISIN AW New High Torque Capacity Six-Speed Automatic Transmission for FWD vehicles". SAE Transactions. 114: 1193–1201. ISSN 0096-736X. JSTOR 44725152. Archived from the original on 2020-07-20. Retrieved 2020-07-09.
  7. ^ Markus, Frank (November 2001). "BMW 745i – First Drive Review". Car and Driver. Archived from the original on 18 September 2014.
  8. ^ "2003 model year XK service training technical guide" (PDF). Jaguar Cars North America. 30 September 2002. p. 4. Archived from the original (PDF) on 8 January 2016.
  9. ^ Crawford, Anthony (25 July 2007). "2007 Aston Martin DB9 Coupe Road Test". CarAdvice. Retrieved 13 September 2016.
  10. ^ a b c "Aston Martin Automatic Gearboxes". JT Automatics Ltd. Archived from the original on 25 April 2016.
  11. ^ "Review: Ford BF Falcon (2005–10)". AustralianCar.Reviews. Retrieved 2 August 2016.
  12. ^ "Review: Ford FG Falcon (2008–14)". AustralianCar.Reviews. Retrieved 2 August 2016.
  13. ^ "Review: Ford SY Territory (2005–11)". AustralianCar.Reviews. Retrieved 2 August 2016.
  14. ^ a b "Review: Ford SZ Territory (2011–16)". AustralianCar.Reviews. Retrieved 2 August 2016.