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 ZF5HP24a gearbox teardown - Pic heavy View next topic
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jockthedog
Experienced


Car: S4-B5.3
Power: C5-RS6Plus
Torque: in' hell!
Engine code: 0xFA

Joined: 14 Mar 2011
Posts: 3132

Location: Moonbase Alpha

PostPosted: Tue Apr 26, 2016 9:28 pm  Reply with quoteBack to top

I'll remind you of that if I end up bringing the track car.

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Noggymike
Veteran


Car: 2002 B5 RS4
Power: 430 bhp
Torque: Whatever
Engine code: BHP

Joined: 07 Oct 2012
Posts: 12209

Location: In front of you, lol'ing

PostPosted: Tue Apr 26, 2016 10:03 pm Reply with quoteBack to top

jockthedog wrote:
I'll remind you of that if I end up bringing the track car.


 

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AutomaticTransmission
Brand New, Welcome :)



Joined: 30 Jan 2016
Posts: 10

Location: Preston

PostPosted: Thu May 12, 2016 7:55 am Reply with quoteBack to top

[quote="jockthedog:692313"]Now onto the next bit - the gear tower.

To lift the oil pump out of the bell housing again 'requires' a special lifting tool.
Here's how to make one:

Take two tiny bolts, about M4 I think. Just too large to fit in the little holes on the outer shaft you see in the housing, and grind away te tips so that they do fit.

IMG_0298 by jockthedog, on Flickr
IMG_0299 by jockthedog, on Flickr

Then insert those into the two holes and arrange a puller to press down on the inner shaft and pull the outer shaft upwards. This releases the seal on the oil pump making it easy to pull out.

IMG_0300 by jockthedog, on Flickr
IMG_0302 by jockthedog, on Flickr
IMG_0303 by jockthedog, on Flickr


In fact when I pulled the pump out, because the wee bolts catch on the tip of the internal shaft, I also pulled the top set of clutchs and brakes, 'tower II', out of the box....

IMG_0304 by jockthedog, on Flickr

IMG_0305 by jockthedog, on Flickr



This is what you should see inside the box now...

IMG_0324 by jockthedog, on Flickr

There is a giant snap ring inside the casing, holding the next bit in.
Trying to lift this next part - the D/E Brake drum and (heavy!) planetary gearsets - out was going to be tricky and again a special tool is available.

I made my own by using a small bearing puller inside the shaft, which has a nice lip inside it.

The correct tool attaches thru all of the the planetary gear carriers below the D-E drum but I wasn't bothered about that - this will make it tricky to reinstall so i will likely make another tool to do that job, when I get to it.
This way I get the D-E drum and planetary gears I and II, in one go.

Here's my lifting tool:
Slide hammer shaft with an internal bearing puller attached. Works a treat!

IMG_0327 by jockthedog, on Flickr

IMG_0329 by jockthedog, on Flickr

IMG_0332 by jockthedog, on Flickr



Throw our twopennyworth in to say save yourself time on making removal tools.
The pump is only held by the dryness of the O ring. So use gravity to your advantage and lay the box on its back, use a screwdriver to ease the B clutch drum forward from the centre support & it`ll pop out.
Also don`t try pulling the geartrain and centre support upwards with that puller against the bushing - again with gearbox on its back grasp the shaft with your hand and use gravity instead of fighting it. The whole lot will pull out with a quick yank.
Any questions just ask
www.automaticgearboxrepairs.com

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Last edited by AutomaticTransmission on Thu May 12, 2016 8:09 am; edited 3 times in total
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AutomaticTransmission
Brand New, Welcome :)



Joined: 30 Jan 2016
Posts: 10

Location: Preston

PostPosted: Thu May 12, 2016 8:00 am Reply with quoteBack to top

jockthedog wrote:
I've been busy over the xmas hols and again this weekend to start putting the box back together.



As you can see I've made my own 'lifting device' from a slide hammer. Simples!



Quote:
I then used an internal bearing puller and the slide hammer shaft again, to lower this all down on top of the sun gear which is sticking up at the bottom of the box.
This proved a little tricky as the lower part can slip down, out of the E clutch and so the D/E unit needs pressure downwards to stop this and keep everything together.
Plus you need to rotate the shaft to get the bottom sun gear engaged.
Not easy with only one pair of hands!

I needed to knock the D/E unit downwards with a handy length of wood, to get the snap ring in place above it, which holds all of this tight in the box.
In fact the manual says that the snap ring may need tapped into its groove with a hammer - it is tapered towards its outer edge, to allow this.


And that's what I've done so far. Shouldn't be more than a couple of hours left in this job, I'm hoping.

Still looking for a guinea pig to try this box in their car!


Before you lower assembly in use the sun shaft from the C clutch to centralise everything, carefully remove shaft and use a simple 2 piece bearing clamp th hold everything in place - then lower it all in by hand

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jockthedog
Experienced


Car: S4-B5.3
Power: C5-RS6Plus
Torque: in' hell!
Engine code: 0xFA

Joined: 14 Mar 2011
Posts: 3132

Location: Moonbase Alpha

PostPosted: Sat May 14, 2016 9:20 am Reply with quoteBack to top

All very welcome advice to a noob. Thanks!

I did figure out the oil pump just needed a good tug - the manual is a bit OTT with lifting gear etc!

Never dawned on me to use a clamp.

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