TD5 Trans Upgrade

[Hamish71]

From my understanding, my TD5 D2a auto, has a ZF 4HP22 in it? http://www.zf.com/sso/content/media/import/zf_belgien/zf_belgien_nv-sa/03_diensten/werkplaats___garage/Overview_gearbox_cars.pdf

I intend increasing power and torque via intercooler, VNT, and tune. I have read sporadically around the forum that the ZF has it's limits in terms of power, and particularly torque.

What are those limits? and why?
What could be done in terms of "beefing up" the transmission to cope with more power/torque?

Any recommended trans shops in Melbourne to do the work?

Thanks in advance.

[Pedro_The_Swift]

The 22 will cope with a bit extra,,
you can add bits from the 24 to cope with lots extra,

ZF themselves do exchange,,

AFAIK george130 has the baddest box on here,,

[Hamish71]

I made an enquiry with A&B Automtive Remanufacturing here in Melbourne. They told me that adding 4HP24 parts would make the box longer, and therefore need new shafts etc. And that the cost would be about $3500.

He also said the torque limit for a 22 was about 350nm, and the 24 about 450nm.

Does all that sound right?

[Slunnie]

hmmmm lot my reply - stupid NextG.

Anyway, the nutshell of what I typed was:

22 rated to 380Nm, the 24 rated to 480Nm
Definately get a bigger high pressure ATF cooler lock up runs line pressure at about 120psi.

24 in 22 parts are the 3rd and 4th gear clutches, 1st and 2nd wont fit. There are a lot more parts that make the difference between the 22 and 24, many of them are mechanical. If you do this, I'd be very interested in the conversion.

A&B are meant to be the benchmark in Aus for ZF. I understand they also have a professional relationship with the ZF factory in Germany with aspects such as training staff etc.

[Hamish71]

hmmmm lot my reply - stupid NextG.

Anyway, the nutshell of what I typed was:

22 rated to 380Nm, the 24 rated to 480Nm
Definately get a bigger high pressure ATF cooler lock up runs line pressure at about 120psi.

24 in 22 parts are the 3rd and 4th gear clutches, 1st and 2nd wont fit. There are a lot more parts that make the difference between the 22 and 24, many of them are mechanical. If you do this, I'd be very interested in the conversion.

A&B are meant to be the benchmark in Aus for ZF. I understand they also have a professional relationship with the ZF factory in Germany with aspects such as training staff etc.

Slunnie...didnt quite understand this bit "
Definately get a bigger high pressure ATF cooler lock up runs line pressure at about 120psi."

[Slunnie]

When you start pushing more power through the 22 it will run hot. Once you have run it hot it triggers a sequence where the auto will slowly die as the various parts fracture, spread and continue to damage. If you are going to put more power through the auto, even if it is spec'd up to 24 in the parts that can be, you will need extra cooling to cope. The 4.6V8 had a larger cooler than the TD5/4.0V8. Keep in mind the TD5 will put a lot lot more torque through the box than the V8.

The cooler that you run will need to be a high pressure cooler, not a normal ATF cooler. The normal ones only run fairly low pressure eg 15-20psi and just have regular push on fitting with hose clamps. The ZF 4HP22EH runs about 120psi and will blow those fittings apart. You need to use one that is rated to those pressures and runs proper Pirtek type pressure multi-barbed fittings etc.

[sniegy]

Bill Rolfe is the owner of A&B auto transmission, he is also a Rangie owner (or used to be & loves the LR brand).
Bill has invested a lot of money in his MAGNIFICENT workshop in Dandenong.
There is a refurb/building section that is under a vacuum & you can eat off the floor.
It has to be this way & ZF themselves have inspected the shop & were very happy.
ZF also have stringent guidelines to adhere to & Bill has acheived this also.

I would have no hesitation in recommending what Bill says as he is very knowlegable in his field & been playing with these transmissions for many many years.