ZF 5HP transmission explained

5HP 18 · 5HP 30 · 5HP 24
Production:	1991–2008
Model Years:	1991–2008
Manufacturer:	ZF Friedrichshafen
Class:	5-Speed Longitudinal Automatic Transmission
Predecessor:	ZF 4HP Transmission Family
Successor:	ZF 6HP Transmission

5HP is ZF Friedrichshafen AG's trademark name for its five-speed automatic transmission models (5-speed transmission with Hydraulic converter and Planetary gearsets) for longitudinal engine applications, designed and built by ZF's subsidiary in Saarbrücken.

Specifications

Final Conventionally Designed Gearbox

With planetary gearboxes, the number of gears can be increased conventionally by adding additional gear sets as well as brakes and clutches, or conceptually by switching from serial to parallel power flow. The conceptual way requires a computer-aided design.

The 5HP is the last transmission family with serial power flow. To provide more gears, components were added. This makes these transmissions larger, heavier and even more expensive to manufacture. As the presence of ten main components (together with brakes and clutches) in the Ravigneaux gearbox types shows, this meant the end of the conventional gearbox design. The all new Lepelletier gearset concept of the later 6HP-family, requiring only eight main components for six gears, reflects the progress that this new paradigm represented.

1990: 5HP 18 · 1997: 5HP 19 · Ravigneaux Planetary Gearset Types

Gear Teeth and Ratios		Planetary Gearset: Teeth			Count	Total	Avg.
		Ravigneaux		Simple
Model	Version First Delivery	{S _{1}} {R _{1}}	{S _{2}} {R _{2}}	{S _{3}} {R _{3}}	Brakes Clutches	Ratio Span	Gear Step
Gear n	R	1	2	3	4	5	6
Step i _{n-1} /i _{n}	- R : 1		1 : 2	2 : 3	3 : 4	4 : 5	5 : 6
5HP 18	310Nm 1990	38 34	34 98	32 76	3 4
Ratio i _{n}	- \tfrac{ 1323 }{ 323 }	\tfrac{ 1323 }{ 361 }	\tfrac{ 7938 }{ 3971 }	\tfrac{ 294 }{ 209 }	1.0000 \tfrac{ 1 }{ 1 }	\tfrac{ 49 }{ 66 }
Step	1.1176		1.8333	1.4211	1.4067	1.3469
5HP 19	325Nm 1997	38 34	34 98	32 76	3 4
Ratio i _{n}					1.0000
Step	1.1176		1.8333	1.4211	1.4067	1.3469
Ratio R & Even	- \tfrac{R _{2} (S _{3+} R _{3)}} {S _{2} R _{3}}	\tfrac{R _{2} (S _{1+} R _{1)} (S _{3+} R _{3)}} {S _{1} R _{3} (S _{2+} R _{2)}}			\tfrac{ 1 } { 1 }
Ratio Odd	\tfrac{R _{1} R _{2} (S _{3+} R _{3)}} {S _{1} S _{2} R _{3}}		\tfrac{R _{2} (S _{1+} R _{1)}} {S _{1} (S _{2+} R _{2)}}		\tfrac{R _{2}} {S _{2+} R _{2}}
6HP	600Nm 2000	31 38	38 85	37 71	2 3	6.0354	1.4327
Ratio i _{n}	- 3.4025	4.1708	2.3397	1.5211	1.1428	0.8672	0.6911
Step	0.8158		1.7826	1.5382	1.3311	1.3178	1.2549

1992: 5HP 30 · 1996: 5HP 24 · Simpson Planetary Gearset Types

Gear Teeth and Ratios		Planetary Gearset: Teeth			Count	Total	Avg.
		Simpson		Simple
Model	Version First Delivery	S _{1} R _{1}	S _{2} R _{2}	S _{3} R _{3}	Brakes Clutches	Ratio Span	Gear Step
Gear n	R	1	2	3	4	5	6
Step i _{n-1} /i _{n}	- R : 1		1 : 2	2 : 3	3 : 4	4 : 5	5 : 6
5HP 30	560Nm 1992	40 100	32 108	38 97	3 3
Ratio i _{n}	- \tfrac{ 70 }{ 19 }	\tfrac{ 135 }{ 38 }	\tfrac{ 175 }{ 78 }	\tfrac{ 275 }{ 178 }	1.0000 \tfrac{ 1 }{ 1 }	\tfrac{ 70 }{ 89 }
Step	1.0370		1.5835	1.4522	1.5449	1.2714
5HP 24	440Nm 1996	36 93	32 100	35 90	3 3
Ratio i _{n}	- \tfrac{ 86 }{ 21 }	\tfrac{ 25 }{ 7 }	\tfrac{ 11 }{ 5 }	\tfrac{ 161 }{ 107 }	1.0000 \tfrac{ 1 }{ 1 }	\tfrac{ 86 }{ 107 }
Step	1.1467		1.6234	1.4621	1.5047	1.2442
Ratio R & Even	- \tfrac{S _{2} (S _{1+} R _{1)(S} _{3+} R _{3)}{S} _{1} R _{2} S _{3}}		\tfrac{(S _{2+} R _{2)(S} _{3+} R _{3)}{S} _{2} R _{3+} S _{3(S} _{2+} R _{2)}}		\tfrac{ 1 }{ 1 }
Ratio Odd		\tfrac{S _{3+} R _{3}{S} _{3}}	\tfrac{(S _{1} (S _{2+} R _{2)+} R _{1} S _{2)(S} _{3+} R _{3)}{S} _{2} (S _{1+} R _{1)} (S _{3+} R _{3)+} S _{1} R _{2} S _{3}}		\tfrac{S _{2} (S _{1+} R _{1)(S} _{3+} R _{3)}{S} _{2} (S _{1+} R _{1)} (S _{3+} R _{3)+} S _{1} R _{2} S _{3}}
6HP	600Nm 2000	31 38	38 85	37 71	2 3	6.0354	1.4327
Ratio i _{n}	- 3.4025	4.1708	2.3397	1.5211	1.1428	0.8672	0.6911
Step	0.8158		1.7826	1.5382	1.3311	1.3178	1.2549

Applications

1990: 5HP 18 · 1997: 5HP 19 · Ravigneaux Planetary Gearset Types

5HP 18

• Introduced in MY 1991 on the BMW E36 320i/325i and E34 5 Series.
• Input torque maximum is 310Nm
• Weight: ~75kg (165lb)
• Oil capacity: ~10.5l

Applications^[1]

• 1992–1993 BMW E32 — 730i M60B30
• 1992–1995 BMW E34 — 525i M50B25TÜ
• 1992–1995 BMW E34 — 530i M60B30
• 1992–1995 BMW E34 — 525tds M51D25
• 1995–2000 BMW E38 — 725tds M51D25
• 1994–1996 BMW E38 — 730I M60B30
• 1993–1996 BMW E36 — M3 S50B30US
• 1995–1999 BMW E36 — 328i M52B28 - BMW Part No A5S 310Z
• 1996–1998 BMW E38 — 728i/iL M52B28
• 1997–1999 BMW E36 — M3 3.2 S52B32
• 1995–1999 BMW E39 — 523i M52B25
• 1995–1999 BMW E39 — 528i M52B28
• 1995–1999 BMW E39 — 525tds M51D25
• 1991–1999 BMW E36 — 320i

5HP 19

• Introduced in 1996, it has been used in a variety of cars from Audi, BMW, Porsche, and Volkswagen Passenger Cars.
• Input torque maximum is 300Nm
• Weight: ~79kg (174lb)
• Oil capacity: ~9.2l

Applications^[1]

BMW — longitudinal engine, rear wheel drive

• 2001–2003 BMW E46 — 330Ci M54B30
• 2001–2003 BMW E46 — 330i M54B30
• 2000–2003 BMW E46 — 320i M52TUB20/ M54B22
• 2000– BMW E46 — 323Ci M52TUB25
• 2000– BMW E46 — 323i M52TUB25
• 2000– BMW E46 — 328i M52TUB28
• 2000– BMW E38 — 728i M52TUB28
• 2001–2003 BMW E46 — 325Ci M54B25
• 2001–2003 BMW E46 — 325i M54B25
• 1999–2002 BMW E39 — 520i M52TUB20
• 1999–2002 BMW E39 — 523i M52TUB25
• 1999–2002 BMW E39 — 528i M52TUB28
• 2001–2003 BMW E39 — 525i M54B25
• 2001–2003 BMW E39 — 530i M54B30
• 2002–2005 BMW E85 — Z4 (M54 engine)

5HP 19FL

Applications^[1]

Volkswagen Group — longitudinal engine transaxle, front-wheel drive

• 1996–2001 Audi A4 (B5) 2.8 V6
• 1997–2003 Audi A4 (B5) 1.8T
• 1997–1999 Audi A8 (D2) 3.7 V8
• 1998–2001 Audi A6 (C5) 2.8 V6
• 1998–2003 Volkswagen Passat GLS 1.8T
• 1998–2003 Volkswagen Passat GLS 2.8 V6
• 1998–2003 Volkswagen Passat GLX 2.8 V6
• 2003– Volkswagen Passat GL 1.8T
• 2004–2005 Volkswagen Passat GLS 2.0 TDI [ZF 1060 030106,<ref>{{cite web|title=ZF Parts Catalog|url=http://www.zf.com/na/content/media/en/united_states/corporate_replacement_parts_1/service_portfolio/passenger_cars/zf_parts_catalog_pdf.pdf|website=zf.com|url-status=bot: unknown|archiveurl=https://web.archive.org/web/20120906084014/http://www.zf.com/na/content/media/en/united_states/corporate_replacement_parts_1/service_portfolio/passenger_cars/zf_parts_catalog_pdf.pdf|archivedate=2012-09-06}}</ref> VW GMR], [A73 Torque Converter]

5HP 19FLA

Applications^[1]

Volkswagen Group — longitudinal engine, transaxle permanent four-wheel drive

• 1996–2001 Audi A4 (B5) 2.8 V6 quattro
• 1997–2001 Audi S4 (B5) 2.7 V6 'biturbo' quattro
• 1997–2005 Audi A4 (B5) and Audi A4 (B6) 1.8 T quattro
• 1998–2001 Audi A6 (C5) 2.8 V6 quattro
• 2000–2003 Audi A6 2.7 V6 biturbo quattro
• 2000–2003 Volkswagen Passat GLS V6 4motion 2.8 V6
• 2000–2003 Volkswagen Passat GLX V6 4motion 2.8 V6
• 2004–2005 Volkswagen Passat GLS 4motion 1.8T
• 2001–2003 Audi allroad quattro 2.7 V6 biturbo
• 2002–2005 Audi A4 (B6) 3.0 V6 quattro
• 2002–2003 Audi A6 (C5) 3.0 V6 quattro
• 2002–2003 Volkswagen Passat 4.0 W8 4motion

1999 (DRN/EKX) transmissions used Induction speed sensors and 2000+ (FAS) transmissions used Hall Effect sensors. These transmissions are mechanically the same, but are not interchangeable.

5HP 19HL

Applications^[1]

Porsche — longitudinal engine rear engine transaxle

• 1998–2003 Porsche 911 Carrera 996 3.4
• 2002–2003 Porsche 911 Targa 996 3.6

5HP 19HLA

Applications^[1]

Porsche — longitudinal engine rear engine transaxle

• 1999–2003 Porsche 911 Carrera 996 3.6
• 1999–2003 Porsche 911 Carrera 4S 996 3.6

Porsche — mid-engine design flat-six engine, 5-speed tiptronic #1060, rear-wheel drive A87.01-xxx, A87.02-xxx, A87.21-xxx, [5HP19FL Valve Body, Solenoids, and Speed Sensor. Different Wiring Harness.] [Speed Sensor/Pulser part # ZF 0501314432]

• 1997-2004 Porsche Boxster 986 2.5 6-cyl
• 1997-2004 Porsche Boxster 986 2.7 6-cyl
• 1997-2004 Porsche Boxster 986 3.2 6-cyl
• 2005–2008 Porsche Boxster 987 2.7 6-cyl
• 2005–2008 Porsche Boxster S 987 3.4 6-cyl
• 2005–2008 Porsche Cayman 987 2.7 6-cyl
• 2005–2008 Porsche Cayman S 987 3.4 6-cyl

1992: 5HP 30 · 1996: 5HP 24 · Simpson Planetary Gearset Types

5HP 30

• Introduced in 1992, it was produced through 2003, and has been used in a variety of cars from Aston Martin, Bentley, BMW, and Rolls-Royce.
• Input torque maximum is 560Nm
• Weight: ~109kg (240lb)
• Oil capacity: ~13.5l

Applications^[1]

• 1992–1995 BMW E34 — 540i M60/B40
• 1995–1997 BMW E39 — 540i M62/B44
• 1998–2001 BMW E39 — 540i M62/B44TU
• 1992–1994 BMW E32 — 740i M60/B40
• 1994–1995 BMW E38 — 740i M60/B40
• 1996–1997 BMW E38 — 740i M62/B44
• 1992–1994 BMW E32 — 740iL M60/B40
• 1994–1995 BMW E38 — 740iL M60/B40
• 1996–1997 BMW E38 — 740iL M62/B44
• 1998-2001 BMW E38 — 740d M67/D40
• 1994–2001 BMW E38 — 750iL M73/B54
• 1993–1995 BMW E31 — 840i M60/B40
• 1995–1996 BMW E31 — 840Ci M62/B44
• 1994–1997 BMW E31 — 850Ci M73/B54
• 1998–2003 Rolls-Royce Silver Seraph 5.4 V12
• 1998–2000 Bentley Arnage 4.4 V8
• 1999–2003 Aston Martin DB7 Vantage 6.0 V12
• 1999–2003 Aston Martin DB7 Vantage Volante 6.0 V12

5HP 24

• Introduced in 1996, it has been used in a variety of cars from Audi, BMW, Jaguar, and Land Rover – all with a front mounted longitudinal engine.
• Input torque maximum is 440Nm
• Weight: ~95kg (209lb)
• Oil capacity: ~9.9L

Applications^[1]

• 1996–1997 BMW E31 — 840Ci M62/B44
• 1997–2001 BMW E38 — 735i M62/B35
• 1997–2001 BMW E38 — 735iL M62/B35
• 1997–2001 BMW E38 — 740i M62/B44
• 1997–2001 BMW E38 — 740iL M62/B44
• 1998–2001 BMW E38 — 730d M57
• 1997–2003 BMW E39 — 540i M62/B44
• 2000–2003 BMW E39 — Alpina D10 Bi-turbo
• 1997-2003 Jaguar XJ Sport 3.2 V8
• 1997–2002 Jaguar XK8 V8 4.0L
• 1998–2003 BMW E53 — X5 4.4i
• 1998–2002 Jaguar XJ8 4.0 V8
• 1998–2001 Jaguar XJ8 Vanden Plas 4.0 V8
• 1998–2001 Jaguar XJ8 L 4.0 V8
• 2001–2003 BMW E53 — 4.6is V8
• 2002–2003 BMW Z8 — Alpina 4.8 V8
• 2002–2003 Jaguar XJ Sport 4.0 V8
• 2003–2005 Range Rover (L322) — With BMW M62/B44 engine

5HP 24A

• Four-wheel drive version used in Audi (quattro) and Volkswagen Passenger Cars (4motion) marques of the Volkswagen Group:
• Input torque maximum is 430Nm
• Weight: ~142kg (313lb)
• Oil capacity: ~11L

Applications^[1]

• 1997–2003 Audi A8 (D2) 4.2 V8
• 2001–2002 Audi A8 (D2) 6.0 W12
• 1998–2003 Audi S8 (D2) 4.2 V8
• 1999–2004 Audi A6 (C5) 4.2 V8
• 1999–2004 Audi S6 (C5) 4.2 V8
• 2000–2003 Audi A8L (D2) 4.2 V8
• 2002–2004 Audi RS6 (C5) 4.2 biturbo V8
• 2002–2011 Volkswagen Phaeton (Typ 3D)

See also

• List of ZF transmissions

Notes and References

1. Web site: ZF North America Application Chart (automatic). ZF-Group.com. https://web.archive.org/web/20030912234148/http://www.zf-group.com/pdf/AppChartpasscartrans.pdf . 12 September 2003 . dead.