ZF 5HP24 AUTO Transmission Workshop Service Repair Manual

All Rights Reserved For Reference Only © 2003 ZF Industries, Inc. - Page 1 ZF 5HP18 Automatic Transmission - Spare Parts Catalog Table of Contents 5HP18 Transmission Overview (North American Applications) Make / Model / Model Year 02 5HP18 Technical Information Torque, Gear Ratio & Weight 02 Transmission Oil Reference Guide 02 5HP18 Lubrications 02 5HP18 Technical Literature 03 5HP18 General Transmission Oil Filling Procedure 03 5HP18 Spare Parts How To Use This Catalog 05 Gearbox Housing Group 06 Oil Supply Group 07 Output Group 08 Converter Group 09 Planetary Drive Groups 10 Clutch Pack Groups 12 Oil Sump Group 19 5HP18 Valve Body Duct Plate Group 20 Valve Housing Groups 22 5HP18 Selective Shims, Snap Rings & Kit Content 5HP18 Selective Shims & Snap Rings 28 5HP18 Kit Content 32 Miscellaneous Quotation / Order Form 37 Notes 38

All Rights Reserved For Reference Only © 2003 ZF Industries, Inc. - Page 2 ZF 5HP18 Automatic Transmission - Spare Parts Catalog 5HP18 Transmission Overview (North American Applications) Make / Model / Model Year Make Model Style Model Year From – Up to Code OE Part # ZF Part # BMW 320i E36 Sedan 1992 – 1995 LW 24 00 1 219 955 1056 000 081 BMW 530i E34 Sedan 1992 – 1993 – 07/93 MG 24 00 1 421 214 1056 000 087 1993 – 1995 07/93 – MN 24 00 1 421 411 1056 000 088 BMW 530i E34 Touring 1992 – 1993 – 07/93 MG 24 00 1 421 214 1056 000 087 1993 – 1995 07/93 – MN 24 00 1 421 411 1056 000 088 BMW M3 E36 Coupe 1993 – 1996 OK 24 00 1 421 946 1056 000 097 BMW M3 3.2 E36 Convertible 1997 – 1999 RE 24 00 2 228 375 1056 000 099 Note: This spare parts catalog includes only transmission specification numbers for North American applications. For all other 5HP18 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). 5HP18 Technical Information Torque, Gear Ratio & Weight Input Torque 1 st Gear 2 nd Gear 3 rd Gear 4 th Gear 5 th Gear Rev Gear Weight (approximate) Oil Capacity (approximate) 310 Nm 3.66 2.00 1.41 1.00 0.74 4.08 ~75 kg (165 lbs.) ~10.5 liter (11.1 quart) Transmission Oil Reference Guide Make Oil Grade Type Plate (color) ZF Part # OE Part # BMW Dexron III Black 1056 000 081 24 00 1 219 955 1056 000 087 24 00 1 421 214 1056 000 088 24 00 1 421 411 BMW ESSO LT 71141 Green 1056 000 097 24 00 1 421 946 1056 000 099 24 00 2 228 375 5HP18 Lubrications Amount ZF Part # Description Where used (1056 000 ___) Notes 20 Liter 0671 090 166 Oil ESSO LT 71141 (Canister) 097/099 205 Liter 0671 090 169 Oil ESSO LT 71141 (Drum) 097/099 Note: For approved Dexron III lubricants, please see the current ZF lubrication list TE-ML 11. ZF Transmission Specification # Vehicle Manufacturer Transmission # Transmission Serial #

All Rights Reserved For Reference Only © 2003 ZF Industries, Inc. - Page 3 ZF 5HP18 Automatic Transmission - Spare Parts Catalog 5HP18 Technical Information (continued) 5HP18 Technical Literature Language ZF Part # Description Where used (1056 000 ___) Notes English 5HP18FD 5HP18 Functional Description All English 5HP18REP 5HP18 Repair Manual All English AAAAZFS018 5HP18 Wall Chart All English 5HPVBMAN 5-Speed Valve Body Manual All 5HP18 General Transmission Oil Filling Procedure Idle speed should be n eng = 650 … 950 rpm (according to vehicle manufacturer’s directive). Hold each gear for 3 seconds and engage the parking lock. Select R and D and use step shift (manual-winter program) to shift through to 3 rd gear. Shift through gears with engine running at idle speed. Start the engine (large consumers, such as A/C should be switched on). With the engine stopped, add ATF, only use lubricants as to specification (see Page 2), through the fill hole until oil emerges from fill hole. Install Fill Plug (Pos. 90.250). Connect tester to read off transmission oil temperature and engine speed. Position vehicle horizontally on hoist and apply the handbrake. Continues on next page

All Rights Reserved For Reference Only © 2003 ZF Industries, Inc. - Page 4 ZF 5HP18 Automatic Transmission - Spare Parts Catalog 5HP18 Technical Information (continued) 5HP18 General Transmission Oil Filling Procedure (continued) Continues from previous page Oil emerges at oil temperature below 95ºF (35ºC). NO YES Allow time for excess oil to drip then install Fill Plug (Pos. 90.250). Torque Fill Plug to 100Nm (see also Repair Manual). Oil temperature must not exceed 122ºF (50ºC). Wait until oil temperature reaches 104ºF ±18ºF (40ºC ±10ºC). Add ATF, only use lubricants as to specification (see Page 2), through the fill hole until oil emerges from fill hole. Oil level in transmission is below minimum. Oil temperature should be between 86º…95ºF (30º…35ºC). NO YES Shift through gears with engine at idle speed. Depending on value allow oil to cool down or warm up. Remove fill plug (Pos. 90.250) on housing. Hold each gear for 3 seconds and engage the parking lock. Select R and D and use step shift (manual- winter program) to shift through to 3 rd gear. Fill Plug

All Rights Reserved For Reference Only © 2003 ZF Industries, Inc. - Page 5 ZF 5HP18 Automatic Transmission - Spare Parts Catalog 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 www.zf-group.com. 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 01.010 is either a spare part or an assembly. A position number like 01.010/110 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 (Where used (10__ 000 ___)) 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 (Notes) gives more information about the spare part (e.g. included in a kit). Example: Pos # ZF Part # Description Qty Where used (1056 000 ___) Notes 01.010 1056 201 084 Gearbox Housing 1 087/088 1056 201 087 Gearbox Housing 1 081 01.010/110 1056 301 174 Gearbox Housing 1 087/088 1056 301 175 Gearbox Housing 1 081 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 ZF 5HP18 Automatic Transmission - Spare Parts Catalog 5HP18 Spare Parts - Gearbox Housing Group Pos # ZF Part # Description Qty Where used (1056 000 ___) Notes 01.010 1056 201 084 Gearbox Housing 1 087/088 1056 201 087 Gearbox Housing 1 081 1056 201 088 Gearbox Housing 1 099 1056 201 090 Gearbox Housing 1 097 01.010/110 1056 301 174 Gearbox Housing 1 087/088 1056 301 175 Gearbox Housing 1 081 1056 301 181 Gearbox Housing 1 099 1056 301 182 Gearbox Housing 1 097 01.010/120 0631 306 045 Cylindrical Pin M6x16 1 All 01.010/130 1055 206 013 Detent Spring 1 All 01.010/150 0736 101 240 Torx Screw M6x13 2 All 01.010/160 1056 306 021 Selector Shaft 1 All 01.010/170 1055 206 012 Detent Disc 1 All 01.010/180 0501 320 396 Clamping Sleeve 1 All 01.010/200 0734 319 623 Shaft Seal 1 All * Available in kit 1056 298 062 01.010/240 0501 318 572 Screw Plug M10x1 1 All * Available in kit 1056 298 062 01.010/250 0631 306 123 Cylindrical Pin 1 081/097/099 01.020 1056 324 018 Pin 1 All 01.030 1056 324 011 Pawl 1 All 01.040 1056 324 005 Leg Spring 1 All 01.050 1056 224 014 Connecting Bar 1 All 01.060 1056 324 016 Guiding Plate 1 All 01.070 1056 324 019 Cover Sheet 1 All 01.080 0736 101 318 Torx Screw M6x20 4 All 01.090 0636 308 015 Screw Plug M12x1.5 1 All * Available in kit 1056 298 062 Note: Parts marked with * are only available in kits.

All Rights Reserved For Reference Only © 2003 ZF Industries, Inc. - Page 7 ZF 5HP18 Automatic Transmission - Spare Parts Catalog 5HP18 Spare Parts - Oil Supply Group Pos # ZF Part # Description Qty Where used (1056 000 ___) Notes 10.010 1056 210 142 Pump 1 All 10.010/150 1043 319 051 Washer 1 All 10.010/160 0750 111 254 Shaft Seal 1 All * Available in kit 1056 298 062 10.010/170 1056 210 143 Valve 1 All 10.060 1056 210 118 Intermediate Plate 1 081 1056 210 119 Intermediate Plate 1 087/088/097/099 10.060/140 0731 201 555 Cylindrical Pin 2 All 10.100 0736 401 051 Counters. Screw M6x18 9 All 10.190 0734 313 006 O-Ring 1 All * Available in kit 1056 298 062 10.200 0734 313 117 O-Ring 1 All * Available in kit 1056 298 062 10.210 1056 310 013 Piston 1 All 10.240 1050 331 021 Cup Spring 1 All 10.270 1043 302 036 Spring Clutch Disc 1 All 10.280 1043 302 092 End Plate C 1 All * Available in kit 1056 298 064 * Available in kit 1056 298 065 10.290 1043 302 021 Steel Plate C 2 081 * Available in kit 1056 298 064 1043 302 021 Steel Plate C 3 087/088/097/099 * Available in kit 1056 298 064 * Available in kit 1056 298 065 10.300 1056 210 053 Friction Plate C 3 081 * Available in kit 1056 298 063 1056 210 053 Friction Plate C 4 087/088/097/099 * Available in kit 1056 298 063 10.330 0301 302 004 End Plate C 1 All * Available in kit 1056 298 064 * Available in kit 1056 298 065 10.340 See Page 28 Clutch C Snap Ring 1 All Selective Snap Ring 10.360 0734 313 064 O-Ring 1 All * Available in kit 1056 298 062 10.370 0750 113 015 Piston Ring 2 All * Available in kit 1056 298 062 10.380 0750 113 029 Piston Ring 1 All * Available in kit 1056 298 062 10.390 1056 210 132 Bearing Set 1 All 10.400 See Page 28 Intermediate Plate Shim 1 All Selective Shim 10.440 0736 101 171 Torx Screw M6x50 9 All 0750 112 076 Usit Ring 9 All * Available in kit 1056 298 062 Note: Parts marked with * are only available in kits.

All Rights Reserved For Reference Only © 2003 ZF Industries, Inc. - Page 8 ZF 5HP18 Automatic Transmission - Spare Parts Catalog 5HP18 Spare Parts – Output Group Pos # ZF Part # Description Qty Where used (1056 000 ___) Notes 14.010 1056 214 006 Extension 1 087/088/097/099 1056 214 029 Extension 1 081 14.010/110 1056 314 044 Extension 1 All 14.010/120 0750 116 119 Ball Bearing 1 All 14.010/130 0630 502 037 Retaining Ring 1 All 14.010/140 0734 319 607 Shaft Seal 1 All * Available in kit 1056 298 062 14.030 1056 214 020 Output Flange 1 081 1060 214 005 Output Flange 1 087/088/097/099 14.040 0737 502 168 Slotted Nut M40x1.5 1 All 14.050 See Page 28 Output Shim 1 All Selective Shim 14.100 0734 313 083 O-Ring 1 All * Available in kit 1056 298 062 14.110 0636 024 009 Hexagon Screw M8x22 7 All Note: Parts marked with * are only available in kits.

All Rights Reserved For Reference Only © 2003 ZF Industries, Inc. - Page 9 ZF 5HP18 Automatic Transmission - Spare Parts Catalog 5HP18 Spare Parts – Converter Group Pos # ZF Part # Description Qty Where used (1056 000 ___) Notes 22.020 4168 023 066 Torque Converter Y12 1 081 4168 026 235 Torque Converter A11 1 087 4168 026 321 Torque Converter E18 1 088 4168 026 349 Torque Converter O21 1 097 4168 026 361 Torque Converter B26 1 099 Note: Parts marked with * are only available in kits.

All Rights Reserved For Reference Only © 2003 ZF Industries, Inc. - Page 10 ZF 5HP18 Automatic Transmission - Spare Parts Catalog 5HP18 Spare Parts – Planetary Drive Groups Pos # ZF Part # Description Qty Where used (1056 000 ___) Notes 32.020 1056 232 105 Bearing Set 1 All 32.040 1056 232 089 Shaft 1 All 32.040/110 1056 232 085 Shaft 1 All 32.040/120 1056 332 037 Ring Gear 1 All 32.040/130 0730 513 330 Snap Ring 1 All 32.060 1056 232 104 Bearing Set 1 All 32.074 1056 232 079 Spider Clutch Bell 1 All 32.080 1056 232 116 Planet Carrier 1 All 32.090 1056 232 045 Sun Gear 1 All 32.100 1050 231 038 Pot 1 All 32.120 1056 232 103 Bearing Set 1 All 32.140 1060 202 001 Sun Gear Shaft 1 All 32.160 1056 232 101 Bearing Set 1 All 32.180 1056 232 071 Intermediate Shaft 1 All 32.200 1056 232 099 Bearing Set 1 All Note: Parts marked with * are only available in kits.

ZF 5HP24 AUTO Transmission Workshop Service Repair Manual

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