After an overhaul a Volkswagen/Audi vehicle with the ZF 5HP19/FLA transaxle exhibits a no-shift condition. The vehicle may not upshift at all, or it may make a 1-2 shift and then go into a failsafe condition.
One cause may be an incorrect transmission installed into the vehicle, or a mismatch of internal parts. ZF has used two different types of turbine-speed sensors in the 5HP19/FLA – a pulse-generator type and a Hall-effect sensor. It can be difficult to determine which vehicle uses the pulse generator and which uses the Hall-effect sensor.
Use the information provided in figures 1 and 2 to ensure correct transmission application and internal-component installation. Refer to Figure 1 for a listing of vehicles that use the pulse-generator sensor. Figure 1 also provides an illustration of the transmission identification tag.
Refer to Figure 2 for a listing of vehicles that use the Hall-effect sensor.
The pulse generator and Hall-effect sensor are not installed in the same area of the transmission. Refer to Figure 3 for internal-harness layout and connector ID for units using the pulse-generator sensor.
Refer to Figure 4 for internal-harness layout and connector ID for units using the Hall-effect sensor.
Refer to Figure 5 for location and ID of the pulse-generator sensor; refer to Figure 6 for location and ID of the Hall-effect sensor.
Since the sensors are in different areas of the transmission, they naturally would have to use different components in the transmission to generate their signals. The pulse generator will produce a signal using the spider-clutch bell, whereas the Hall-effect sensor uses the forward-clutch drum to produce its signal.
The forward-clutch drum, the spider-clutch bell and the sun gear are different and not interchangeable between transmissions with pulse-generator sensors and those with Hall-effect sensors. The differences between the forward-clutch drum and spider-clutch bell are easy to see.
The sun gears in both units, however, look almost identical. You can use a magnet to determine which sun gear you have. A magnet will be attracted to the sun gear in a unit that uses a pulse generator but not in a unit with the Hall-effect sensor. That is because the Hall-effect sensor reads though the sun gear, picking up its reading from a magnetic band that is attached to the A-clutch drum. The band contains 36 small magnets around the outside of the drum.
Refer to Figure 7 for identification and description of the forward-clutch drum, spider-clutch bell and sun gear used in pulse-generator units.
Refer to Figure 8 for identification and description of the forward-clutch drum, spider-clutch bell and sun gear used in units with Hall-effect sensors.
Type of turbine-speed sensor Pulse generator: ZF part number:
- ZF 5HP19/FLA pulse-generator sensor . . . . . . . . . . . . . . . . . 0501-311-086
- ZF5HP19/FLA A-clutch drum,models002/012/013/056 . . . 1056-370-047
- ZF 5HP19/FLA A-clutch drum, model 018. . . . . . . . . . . . . . . 1056-370-048
- ZF 5HP19/FLA spider-clutch bell. . . . . . . . . . . . . . . . . . . . . . . 1056-232-079
- ZF 5HP19/FLA sun gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 1060-232-097
- ZF 5HP19/FLA internal wire harness. . . . . . . . . . . . . . . . . . 1056-227-046
September 2006 Issue
Volume 23, No. 9
- Volkswagen/Audi: Parts Mismatch
