ZF 6HP transmission

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Template:Short description Template:Infobox automobile

6HP is ZF Friedrichshafen AG's trademark name for its 6-speed automatic transmission models (6-speed transmission with Hydraulic converter and Planetary gearsets) for longitudinal engine applications, designed and built by ZF's subsidiary in Saarbrücken. Released as the 6HP 26 in 2000, it was the first 6-speed automatic transmission in a production passenger car. Other variations of the first generation 6HP in addition to the 6HP 26, were 6HP19, and 6HP 32 having lower and higher torque capacity, respectively. In 2007, the second generation of the 6HP series was introduced, with models 6HP 21 and 6HP 28. A 6HP 34 was planned, but never went into production.[1]

It uses a Lepelletier gear mechanism,[2] an epicyclic/planetary gearset, which can provide more gear ratios with significantly fewer components. This means the 6HP 26 is actually lighter than its five-speed 5HP predecessors.

The 6HP is the first transmission to use this 6-speed gearset concept.

The last 6HP automatic transmission was produced by the Saarbrücken plant in March 2014 after 7,050,232 units were produced.[3][4] The ZF plant in Shanghai continued to produce the 6HP for the Chinese market.[3]

The Ford 6R, GM 6L, and Aisin AWTF-80 SC transmissions are based on the same globally patented gearset concept. The AWTF-80 SC is the only one for transverse engine installation.

Gear RatiosTemplate:Efn
Template:Diagonal split header R 1 2 3 4 5 6 Total
Span
Span
Center
Avg.
Step
Compo-
nents
2000: 1st Generation 3
Gearsets
2
Brakes
3
Clutches
6HP 26Template:Efn · 6HP 19 · 6HP 32 Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round
2007: 2nd Generation
6HP 28 · 6HP 21 · 6HP 34 Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round
Other Manufacturer
Aisin AWTF-80 SC · 2005 Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round
Ford 6R 60 · 6R 80 · 2005 Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round
Ford 6R 140 · 2005 Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round
GM 6L 45 · 6L 50 · 2006 Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round
GM 6L 80 · 6L 90 · 2005 Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round Template:Round
Template:Notelist

Specifications

Progress Gearset Concept

Main Objectives

The main objective in replacing the predecessor model was to improve vehicle fuel economy with extra speeds and a wider gear span to allow the engine speed level to be lowered (downspeeding). The layout brings the ability to shift in a non-sequential manner – going from gear 6 to gear 2 in extreme situations simply by changing one shift element (actuating clutch E and releasing brake A).

Extent

In order to increase the number of ratios, ZF has abandoned the conventional design method of limiting themselves to pure in-line epicyclic gearing and extended it to a combination with parallel epicyclic gearing. This was only possible thanks to computer-aided design and has resulted in a globally patent for this gearset concept. The 6HP is the first transmission designed according to this new paradigm. After gaining additional gear ratios only with additional components, this time the number of components has to decrease while the number of ratios still increase. The progress is reflected in a much better ratio of the number of gears to the number of components used compared to existing layouts.

Innovation Strength Analysis
With
Asessment
Output:
Gear
Ratios
Innovation
ElasticityTemplate:Efn
Δ Output : Δ Input
Input: Main Components
Total Gearsets Brakes Clutches
6HP
Ref. Object
nO1
nO2
TopicTemplate:Efn nI=nG+
nB+nC
nG1
nG2
nB1
nB2
nC1
nC2
Δ Number nO1nO2 nI1nI2 nG1nG2 nB1nB2 nC1nC2
Relative Δ Δ Output
nO1nO2nO2
nO1nO2nO2:nI1nI2nI2
=nO1nO2nO2·nI2nI1nI2
Δ Input
nI1nI2nI2
nG1nG2nG2 nB1nB2nB2 nC1nC2nC2
6HP
5HP 24/30Template:Efn
6Template:Efn
5Template:Efn
ProgressTemplate:Efn 8
9
3Template:Efn
3
2
3
3
3
Δ Number 1 -1 0 -1 0
Relative Δ Template:Round
15
Template:RoundTemplate:Efn
15:19=15·91=95
Template:Round
19
Template:Round
03
Template:Round
13
Template:Round
03
6HP
5HP 18/19Template:Efn
6Template:Efn
5Template:Efn
ProgressTemplate:Efn 8
10
3Template:Efn
3Template:Efn
2
3
3
4
Δ Number 1 -2 0 -1 -1
Relative Δ Template:Round
15
Template:RoundTemplate:Efn
15:15=15·51=11
Template:Round
15
Template:Round
03
Template:Round
13
Template:Round
14
6HP
3-SpeedTemplate:Efn
6Template:Efn
3Template:Efn
Market PositionTemplate:Efn 8
7
3Template:Efn
2
2
3
3
2
Δ Number 3 1 1 -1 1
Relative Δ Template:Round
11
Template:RoundTemplate:Efn
11:17=11·71=71
Template:Round
17
Template:Round
12
Template:Round
13
Template:Round
12
Template:Notelist

Quality Gearset Concept

The ratios of the 6 gears are nicely evenly distributed in all versions. Exceptions are the large step from 1st to 2nd gear and the almost geometric steps from 3rd to 4th to 5th gear. They cannot be eliminated without affecting all other gears. As the large step is shifted due to the large span to a lower speed range than with conventional gearboxes, it is less significant. As the gear steps are smaller overall due to the additional gear(s), the geometric gear steps are still smaller than the corresponding gear steps of conventional gearboxes. Overall, therefore, the weaknesses are not overly significant. As the selected gearset concept saves up to 2 components compared to 5-speed transmissions, the advantages clearly outweigh the disadvantages.

It has a torque converter lock-up for all 6 forward gears, which can be fully disengage when stationary, largely closing the fuel efficiency gap between vehicles with automatic and manual transmissions.

In a Lepelletier gearset, a conventional planetary gearset and a composite Ravigneaux gearset are combined to reduce both the size and weight as well as the manufacturing costs. Like all transmissions realized with Lepelletier transmissions, the 6HP also dispenses with the use of the direct gear ratio and is thus one of the very few automatic transmission concepts without such a ratio.

Gear Ratios
With AssessmentTemplate:Efn Planetary Gearset: TeethTemplate:Efn
Lepelletier gear mechanism
Count TotalTemplate:Efn
CenterTemplate:Efn
Avg.Template:Efn
Simple Ravigneaux
Manufacturer
Model
Version
First Delivery
S1Template:Efn
R1Template:Efn
S2Template:Efn
R2Template:Efn
S3Template:Efn
R3Template:Efn
Brakes
Clutches
Ratio
Span
Gear
StepTemplate:Efn
Gear
Ratio
R
iR
1
i1
2
i2
3
i3
4
i4
5
i5
6
i6
StepTemplate:Efn iRi1Template:Efn i1i1 i1i2Template:Efn i2i3 i3i4 i4i5 i5i6
Δ StepTemplate:EfnTemplate:Efn i1i2:i2i3 i2i3:i3i4 i3i4:i4i5 i4i5:i5i6
Shaft
Speed
i1iR i1i1 i1i2 i1i3 i1i4 i1i5 i1i6
Δ Shaft
SpeedTemplate:Efn
0i1iR i1i10 i1i2i1i1 i1i3i1i2 i1i4i1i3 i1i5i1i4 i1i6i1i5
2000: 1st Generation
ZF 6HP 26Template:Efn
ZF 6HP 19Template:Efn
ZF 6HP 32Template:Efn
Template:Convert
Template:ConvertTemplate:Efn
Template:Convert[5]
2000 (all)
37
71
31
38
38
85
2
3
Template:Round
Template:Round
Template:RoundTemplate:Efn
Gear
Ratio
Template:Font color Template:Round
9,1802,201
Template:Font color Template:Round
10871
Template:Font color Template:Round
4,5905,293
Template:Round
85123
Step Template:Font colorTemplate:Efn 1.0000 Template:Font color 1.5382 Template:Font color 1.3178 1.2549
Δ StepTemplate:Efn 1.1589 1.1559 Template:Font colorTemplate:Efn 1.0502
Speed Template:Font color 1.0000 1.7826 2.7419 Template:Font color 4.8096 6.0354
Δ Speed Template:Font color 1.0000 0.7826 0.9593 Template:Font colorTemplate:Efn 1.1599 1.2258
2007: 2nd Generation
ZF 6HP 28Template:Efn
ZF 6HP 21Template:Efn
ZF 6HP 34Template:Efn
Template:Convert
Template:ConvertTemplate:Efn
Template:ConvertTemplate:Efn
2007 (all)
37
71
31
38
38
85
2
3
Template:Round
Template:Round
Template:RoundTemplate:Efn
Ratio Template:Font color Template:Round Template:Font color Template:Round Template:Font color Template:Round Template:Round
Other Manufacturer
Aisin
AWTF-80 SC
Template:Convert[6]
2005
50
90
36
44
44
96
2
3
Template:Round
Template:Round
Template:RoundTemplate:Efn
Gear
Ratio
Template:Font color Template:Round
11227
Template:Font color Template:Round
149
Template:Font color Template:Round
336391
Template:Font color
Step Template:Font colorTemplate:Efn 1.0000 Template:Font color 1.5238 Template:Font color 1.3436 1.2532
Δ StepTemplate:Efn 1.1484 1.1311 Template:Font colorTemplate:Efn 1.0722
Speed Template:Font color 1.0000 1.7500 2.6667 3.5926 4.8272 Template:Font color
Δ Speed Template:Font color 1.0000 0.7500 0.9167 0.9259 1.2346 Template:Font colorTemplate:Efn
Ford
6R 60 · 6R 80
Template:Convert
Template:Convert
2005 (all)
37
71
31
38
38
85
2
3
Template:Round
Template:Round
Template:RoundTemplate:Efn
Ratio Template:Font color Template:Round Template:Font color Template:Round Template:Font color Template:Round Template:Round
Ford
6R 140
Template:Convert
2005
49
95
37
47
47
97
2
3
Template:Round
Template:Round
Template:RoundTemplate:Efn
Gear
Ratio
Template:Font color Template:Round
13,9683,515
Template:Font color Template:Round
14495
Template:Font color Template:Round
13,96816,271
Template:Round
97144
Step Template:Font colorTemplate:Efn 1.0000 Template:Font colorTemplate:Efn 1.5293 Template:Font color 1.3389 1.2744
Δ StepTemplate:Efn Template:Font colorTemplate:Efn 1.1594 Template:Font colorTemplate:Efn 1.0504
Speed Template:Font color 1.0000 1.7143 2.6216 Template:Font color 4.6290 5.8993
Δ Speed Template:Font color 1.0000 0.7143 0.9073 Template:Font colorTemplate:Efn 1.1710 1.2703
GM
6L 45 · 6L 50
Template:Convert
2006
49
89
37
47
47
97
2
3
Template:Round
Template:Round
Template:RoundTemplate:Efn
Gear
Ratio
Template:Font color Template:Round
13,3863,293
Template:Font color Template:Round
13889
Template:Font color Template:Round
13,38615,689
Template:Round
97144
Step Template:Font colorTemplate:Efn 1.0000 Template:Font colorTemplate:Efn 1.5293 Template:Font color 1.3557 1.2662
Δ StepTemplate:Efn Template:Font colorTemplate:Efn 1.1408 Template:Font colorTemplate:Efn 1.0703
Speed Template:Font color 1.0000 1.7143 2.6216 Template:Font color 4.7643 6.0346
Δ Speed Template:Font color 1.0000 0.7143 0.9073 Template:Font colorTemplate:Efn 1.2499 1.2703
GM
6L 80 · 6L 90
Template:Convert
2005
50
94
35
46
46
92
2
3
Template:Round
Template:Round
Template:RoundTemplate:Efn
Gear
Ratio
Template:Font color Template:Round
6,6241,645
Template:Font color Template:Round
7247
Template:Font color Template:Round
144169
Template:Round
23
Step Template:Font colorTemplate:Efn 1.0000 Template:Font colorTemplate:Efn 1.5429 Template:Font color 1.3522 1.2781
Δ StepTemplate:Efn Template:Font colorTemplate:Efn 1.1604 Template:Font colorTemplate:Efn 1.0580
Speed Template:Font color 1.0000 1.7037 2.6286 Template:Font color 4.7258 6.0401
Δ Speed Template:Font color 1.0000 0.7037 0.9249 Template:Font colorTemplate:Efn 1.2310 1.3143
Ratio
R & Even
R3(S1+R1)R1S3 R3(S1+R1)(S2+R2)R1S2(S3+R3) R2R3(S1+R1)R2R3(S1+R1)S1S2S3 R3S3+R3
Ratio
Odd
R2R3(S1+R1)R1S2S3 S1+R1R1 R3(S1+R1)R3(S1+R1)+S1S3
Algebra And Actuated Shift Elements
Brake ATemplate:Efn
Brake BTemplate:Efn
Clutch CTemplate:Efn
Clutch DTemplate:Efn
Clutch ETemplate:Efn
ZF
5HP 18Template:Efn
Template:Convert
1990
32
76
38Template:Efn
34
34
98
3
4
Template:Round
Template:Round
Template:Font color
Gear
Ratio
Template:Font color Template:Round
1,323361
Template:Font color Template:Font color Template:Round
11
Template:Round
4966
Step Template:Font colorTemplate:Efn 1.0000 Template:Font color Template:Font colorTemplate:Efn 1.4067 1.3469
Δ StepTemplate:Efn 1.2901 Template:Font colorTemplate:Efn 1.0444
Speed Template:Font color 1.0000 1.8333 Template:Font color 3.6648 4.9363
Δ Speed Template:Font color 1.0000 0.8333 Template:Font colorTemplate:Efn 1.0596 1.2715
Template:Notelist

Imperfections

Problems with this transmission are well known.Template:Citation needed This transmission locks up the torque converter in all gears, increasing wear. Combined with a sealed transmission pan and "lifetime fluid", some people have experienced catastrophic transmission failure. Owners report shift issues when oil begins breaking down beyond 50K miles, hence shifting issues are common.Template:Citation needed

There are also problems with the valve block and solenoidsTemplate:Citation needed When this failure starts to occur, shift quality and speed, torque transfer and even loss of ability to engage gears can occur. These problems led Volkswagen Group to extend the warranty on all of their vehicles equipped with this transmission to 100,000 miles or 10 years.Template:Citation needed

Template:Notelist

Applications

First Generation · 2000

6HP 19

  • BMW X3
  • BMW 520i (E60)
  • BMW 528i (E60)
  • BMW 530i (E60)
  • BMW 630i (E63)
  • BMW 730i/li (E65/E66)
  • E9X pre-LCI: BMW 318i, 320i, 325i, 328i, 330i, 335i
  • E87 pre-LCI: BMW 116i, 118i, 120i
  • E82: 135i
  • E81: 118d
  • BMW Z4 (E85) LCI
  • BMW Z4 (E86): all models except Z4 M
  • 2010–2012 Hyundai Genesis Coupe 3.8 L

6HP 19A

The 6HP 19A is a variation of the 6HP 19 for Four-wheel drive applications (Allrad, all wheel). It was used by the Volkswagen Group for some permanent four-wheel drive models.

6HP 26

The 6HP 26 was the initial version and first used by the BMW 7 Series (E65) in 2001. Initially only used by premium brands, it was later available on the 2009 model year V8 Hyundai Genesis.

Several versions of the 6HP 26 are available depending on application and brand: 6HP 26, 6HP 26A and 6HP 26X.

Ford has developed their own versions (Ford 6R 60 and Ford 6R 80) based on the 6HP 26. Therefore, certain Ford vehicles will not be listed.

6HP 26A

The 6HP 26A is a variation of the 6HP 26 for Four-wheel drive applications (Allrad, all wheel). It was used by the Volkswagen Group for some permanent four-wheel drive models and packages a TORSEN type center differential, and open front differential into the transmission assembly.

6HP 26X & 6HP 26Z

The 6HP 26X and 6HP 26Z is another variation of the 6HP 26, also for Four-wheel drive applications. This transmission is suitable for 4WDs with a separate transfer box (the "X" stands for external 4WD).

6HP 32

  • BMW E65 LCI: 745d

6HP 32A

The 6HP 32A is a variation of the 6HP 32 for Four-wheel drive applications (Allrad, all wheel).

  • Audi Q7 6.0 L V12 TDI

Second Generation · 2007

6HP 21

  • 2011–2014 Ford Falcon (FG2 turbocharged I4, naturally-aspirated I6, turbocharged I6 and supercharge V8)
  • 2014–2016 Ford Falcon (FG X turbocharged I4, naturally-aspirated I6, turbocharged I6 and supercharged V8)[4]
  • 2014–2016 Ford Territory (SZ II petrol)[14]
  • 2010–2012 BMW 320d LCI (Thailand) with engine N47D20
  • 2011–2013 BMW 335i (E9X)
  • 2013–2015 BMW X1 (E84): xDrive35i
  • 2009 LCI BMW 528i (E60) with engine N52B30AE
  • 2014–Present Maxus G10
  • 2007–2009 BMW 520d (E61) LCI with engine N47D20A

6HP 28

6HP 34

The 6HP 34 was planned for high-output applications. As the successor 8HP was about to be launched and innovations are typically introduced first in the premium segment, the 6HP 34 never went into production.[1]

See also

References

Template:Reflist