April 2005 Archives - Transmission Digest
April 2005 Issue

In This Issue
The ZF-5HP-24: Preliminary Information

Identification Guide to BorgWarner Transfer Cases

One of the most time-consuming and annoying problems associated with manual-transmission and transfer-case repair is unit identification. It is difficult to diagnose, buy parts or remanufactured units, and create a correct estimate for the customer when you cannot identify which unit you are working on. All units leave the factory well marked with decals, metal ID tags or both, but through use, weather and previous repairs, many of these ID devices become illegible or non-existent.

A Case of Mistaken Identity, Part 2: Impossible?

It is important that you identify the problem immediately. Do not road-test the vehicle to check out the forward speeds if you are having a problem with reverse. The reduction band must be anchored to the case by the anchor stud to prevent rotation. If you try to drive the vehicle without the stud in place, the band will rotate, wedging itself between the drum and case. This will prevent the drum from rotating and will burn the clutches that try to apply for a given gear. If the clutches lose their service ability, then the transmission must be removed.

Exploring the Globally Diverse JF506E

In today’s global economy, manufacturers of all types of goods are looking into joint ventures with other global partners. In the past the transmission industry has had dealings in this global marketplace. Ford and GM have been using and continue to use ZF Industries to provide medium-duty manual transmissions for its pickup trucks. ZF automatic transmissions are now finding their way into a growing number of non-German vehicles.

Warranty Insurance Is Supposed to Protect YOU

There was a time when selling transmission overhauls was a simple matter. Most shops offered one service at one price. If the customer approved it, the job was carried out. The problem with that one service was that many times it didn’t suit the needs of either the customer or the shop. If a customer wanted more than a 12-month/12,000-mile warranty he was out of luck. If the shop needed a way to make an overhaul more profitable it had a hard time finding one. So customer choices and shop profits were limited.

Going Bald

Curve-recognition programs in BMW’s 3, 5 and 7 series with bald tires can make your head go even balder. The purpose of this strategy is to prevent shift business during turns for driver pleasability. Recently we had a call where a shop was distraught over a 530i with a 5HP18 that had no upshifts to 4th or 5th under light to medium throttle and no upshift to 3rd under heavy throttle. Much was done and replaced to remedy this complaint when all along it was one tire being a different size from the other three.