6hp26 transmission / transfer box failure

[rar110]

5L40 tranny owners you are not alone.

OK, as some might have noticed, I had a total failure with my tdv8 tranny nearly 4 weeks ago. It went wiz and all drive stopped.

The advice is that the output shaft on the 6 speed zf is stripped at the transfer box end, and the receiving drive gear on the transfer box is stripped or near so.

This has occurred on a 08MY L322 with 240,000km, so Im not shocked about something like this happening. It was a bargain tdv8 L322 and my plan from the beginning was to put a bit of money aside each year for a catastrophic failure of some kind. Based on the experience of others I was hoping it would last at least another 50,000km. However, it has happened earlier than I had planned for.

I am looking at a bill of $7-8000. So any advice would be appreciated.

[Laurie]

Pete
When it let go, did metal go through the megatronics unit and the T/C ?How is the internals of the transfer box ?
I know this won't help but didn't RRPhil put out a warning about ZF's not having anti-seize compound on the output shaft put on in the factory.

" It's just that we've had a couple of instances on here of 6HP26's failing because the output shaft hadn't apparently been coated with anti-seize grease at the factory and the spline into the transfer box had subsequently failed/worn away through fretting corrosion"

If this is the case I would at least try to get a deal out of ZF in Sydney. I remember one other member saying he got ZF Sydney ? to do a rebuild and got a good deal, hopefully someone might remember who it was.

Laurie

[Blade74]

What year models did they not use the anti seize?
Sorry to hear that rar110.

[carlschmid2002]

If you are near a major city contact ZF as I believe they are doing a deal at the moment for a complete rebuild for $4000. There is something about t in the D3/4/RRS section. I don't have time to search for it now. Don't know if that includes your shaft etc.

[rar110]

Thanks for the replies. Yes Laurie as RRPhil suggested the failure is due to spline wear as no lubrication in this join. Same issue occurred on the LT85 and early R380 gearboxes.

Graeme had his D4 box rebuilt by ZF. They are continuing with that same deal for a full transmission rebuild including output shaft $4400 incl GST. They told me most 6HP26s get to about 180,000km, although they have seen them get to 700,000. ZF advised that at 240,000 km the stator bush and TC are likely to be worn.

I also need at least a transfer box input gear. Although at 240,000 km other components like bearings are likely to be worn. I might try to pick up a newer transfer box from a 10MY facelift wreck with a lot less km.

[Laurie]

Pete
Phil can source parts for you in the UK if you don't do any good here, good luck with the rebuild !

Laurie

[harlie]

Bugger RAR.

I had this issue with my 300tdi disco many moons ago....

Is the car at home?

[rar110]

Bugger RAR. I had this issue with my 300tdi disco many moons ago.... Is the car at home?

Yes, I had it happen to me years ago on a 1986 110. The splines were huge on that output shaft.

It's down at Ormiston.

[Laurie]

Pete
The MY10 models had a second generation 6HP26 that had a higher torque rating hence the 6HP28. If cheap to upgrade by ZF; it would be good mod espically with a upgraded T/C.
T/C's in the 6HP series usally seem to be the first thing that goes, again cost is the factor !

Laurie

[rar110]

Pete The MY10 models had a second generation 6HP26 that had a higher torque rating hence the 6HP28. If cheap to upgrade by ZF; it would be good mod espically with a upgraded T/C. T/C's in the 6HP series usally seem to be the first thing that goes, again cost is the factor ! Laurie

Thanks Laurie.

I was thinking the same as that's what Graeme got when ZF refurbed his D4 box. The 6hp28 version seem to have a torque spec that better matches the motor output. I asked ZF about doing this upgrade to my tranny a couple of weeks ago. They didn't seem too confident it was possible on the earlier 6hp26 box, which doesn't make any sense to me. They said the parts for the 6hp28 were for a box with different electronics. I assume he was talking dual canbus.

[RR44TDV8]

5L40 tranny owners you are not alone.

OK, as some might have noticed, I had a total failure with my tdv8 tranny nearly 4 weeks ago. It went wiz and all drive stopped.

The advice is that the output shaft on the 6 speed zf is stripped at the transfer box end, and the receiving drive gear on the transfer box is stripped or near so.

This has occurred on a 08MY L322 with 240,000km, so Im not shocked about something like this happening. It was a bargain tdv8 L322 and my plan from the beginning was to put a bit of money aside each year for a catastrophic failure of some kind. Based on the experience of others I was hoping it would last at least another 50,000km. However, it has happened earlier than I had planned for.

I am looking at a bill of $7-8000. So any advice would be appreciated.

Sorry to hear Pete.......hope it works out ok?

[rar110]

Ta Grant I might actually be lucky in finding a solution.

The tranny would let go some stage with the km. The turbos/egrs are another risk area for me to plan for. I got it cheap with these risks in mind. Unfortunately it happened earlier than anticipated. Better it occurred near Brisbane than near Karumba. It's still the best vehicle I've driven in. No regrets at this stage.

Will do an update in a month or two.

[Blade74]

How's the box going Rar110

[rar110]

I had a look at the transfer box out. The box where it joins the transmission was coated with fine rust powder, which are the remains of the spline.

Apparently the earlier tdv8 output shafts splines weren't coated with grease and so rust/wear. Given its only attached with about 8 bolts, I'd be slipping it off at 100,000km to at least check and re-coat.

I have a used box lined up. Hopefully it all works. Anyone have the ZF spec numbers for the pre facelift L322 tdv8? The box I bought is from an early (2009) facelift model with ZF spec 1068 020 075.

[Blade74]

What years didn't have the grease?
Is the transmission still ok?

[rar110]

What years didn't have the grease? Is the transmission still ok?

I don't know. Mine certainly didn't have any or sufficient. However it does have 240,000 km. The output shaft needs replacing, which means emptying the box.

It was going great until the failure.

As it seems so easy to do I think it should be recoated as part of a transmission service.

[rar110]

I took a pic of the back of the transmission this morning.

96245

Also the ZF specification numbers on the boxes are the same.

[rar110]

The FFRR is back on the road with a new tranny and transfer box. It feels more responsive now. It's fantastic driving it again.

[Blade74]

Good to hear.

[austeve01]

The FFRR is back on the road with a new tranny and transfer box. It feels more responsive now. It's fantastic driving it again.

Great news Pete

Cheers Steve

[CSBrisie]

Excellent news mate :);)

[Laurie]

Pete
Was it a standard rebuild or did you get some upgrades ? (T/C or clutches )

Laurie

[rar110]

Gday Laurie

the new tranny is a used transmission/transfer box from a 2009 MY10 L322 tdv8, which was the facelift 3.6 with LCD/TFT instrument panel. The wrecker I bought it from claimed the vehicle had only 11,000km. I was naturally sceptical, but took a punt. It turned out the output spline and internals (viewed after mechatronic removed) looked new. So its at least a low km tranny.

The donor tranny has the same ZF part number (displayed on the side) as the old tranny namely 1068 020 075. A catelogue I found indicates most tdv8 3.6 L322s and L320s had a tranny with this part number. Both trannys are marked as 6HP-26. So, apart from the TCM and maybe the valve block, its seems they have identical internals.

So its probably not going to have the higher torque rating of a 6HP-28. However, it will probably have the lead free stator bush issue, so I'll do a tranny service at 50,000km intervals.

[mfrankcombe]

Hi guys,

After nursing a failing tranny for some time I finally had mine rebuilt by ZF Services. The key issue with mine was the bush failures that led to poor clutch pressure on one set of clutch packs apparently. They also replaced the entire mechatronics unit as well. All up cost was $5900. Hopefully now with proper fluid changes the tranny should last a lot longer than 100,000km.

Just out of interest Bruce said that the 3.6L TDv8's have softer bottom big end bearing shells that fail. Have any of you guys heard of this?

Thanks

Mick

[rar110]

Hi guys,



After nursing a failing tranny for some time I finally had mine rebuilt by ZF Services. The key issue with mine was the bush failures that led to poor clutch pressure on one set of clutch packs apparently. They also replaced the entire mechatronics unit as well. All up cost was $5900. Hopefully now with proper fluid changes the tranny should last a lot longer than 100,000km.



Just out of interest Bruce said that the 3.6L TDv8's have softer bottom big end bearing shells that fail. Have any of you guys heard of this?



Thanks



Mick



I've never heard of a bearing failure. Turbos disintegrating and EGR bits falling into the pots causing damage but no bottom end problems. Mines got over 260,000 on it and it's very smooth. I gave it a caning last week on a soft beach at high tide, 30 degree heat, 50 kmh, low range 3000-4000 rpms. The motor and 6HP26 got very warm but never missed a beat.

[Hammer H]

Hi Mick,

What were the symptoms and how long did they last for?
I'm suspicious of mine.

Cheers Paul

[Pedro_The_Swift]

I gave it a caning last week on a soft beach at high tide, 30 degree heat, 50 kmh, low range 3000-4000 rpms. The motor and 6HP26 got very warm but never missed a beat.

any pics of the rooster tails :angel:

[rar110]

any pics of the rooster tails :angel:



Que?

[Graeme]

30 degree heat????

[CSBrisie]

I assume "rooster tails" is the sand coming out behind the wheels....

[BobD]

????



I was thinking the same Graeme. I would not call 30 degrees heat!!

[Graeme]

Tombie knows what heat is - 45 or better but I guess you do too Bob.

[rar110]

Ok I'm soft[emoji1]

[Judo]

I'd rather be soft than living in 45+ degrees. :p

[BobD]

Even Melbourne gets 45 occasionally! The difference is that it will reduce to 20 within the same day whereas where I live will be above 40 for days at a time. Not as bad as Tombie though!

[Tombie]

Heat is nothing. Just have to get acclimated and then it's smooth sailing..