Thread: 2011 D4 'Gearbox Fault' warning

Agree 40 is the target. When the gearbox is in R or D with foot on brake is when the temp actually rises. Idling in P doesn’t move the dial.

It is the ZF 8HP that has the different procedure and you need to get above 75degC first to open a thermostat valve, but then wait for it to cool down below 30degC to start the level checking - which is then done between 30-50degC but has more steps involved where you rev the engine at 2000rpm for 30 seconds once above 30degC and also hold it in D, D1, D2, and R for 10 seconds each before then checking the final level.

Whilst 40degC would be the mid point for the correct level the ZF 8HP procedure does not set an exact point like the ZF 6HP as long as you are above 30degC when you start, and still below 50degC by the time you are finished.

With the ZF 6HP26, after an oil change and level check as per the ZF procedure, I still then take it for a drive to get fully hot, then redo the level check procedure starting from cold the next day and rechecking at 40degC. It then may need another top up suggesting the ZF6 procedure probably should add the same “get it hot” step as per the ZF8.

Thanks very much DiscoDB. That's very helpful.

I'm still psyching for the valve body rebuild. More to the point, trying to scratch out a free weekend. I'll be ordering parts tonight. On the shopping list so far are:

(ZF6HP26)
Zip kit (Still a bit unsure whether I need a Gen 1 or Gen 2 kit)
Solenoids
Filter
Gasket
Oil
Separator plate (I've confirmed I need a B plate)
Valve Body to Transmission seals
Mechatronics Case Connector Seal
Anything else?

(Useful link: 6HP26, 6HP26X - ZF by Transmission | Transmissions)

Pretty sure the earlier HP26 takes the Gen 1 ZIP kit, thr later HP28 uses thr Gen2 kit. Flick the team at sonnax an email with the transmission serial number to be extra sure.

Thank Eric

You are correct. I got nervous and checked with Sonnax. They were super fast with a response and definitive answer. I've been a bit busy at work so have been dragging the chain. It'll be mid Sept before I get to it unfortunately.

Sonnax confirmed I need:


Valve Body Separator Plate: Part No. 95740-052 (1068 327 180 is stamped on my valve body and B052 on the plate in my gearbox).
Zip Kit®: Part No. ZF6-6R60-ZIP (For Gen 1 ZF6Hp19/26/32)


They also suggested this link: Sonnax How to Identify Similar Ford & ZF6 Transmissions — Four Features to Check Before You Begin a Rebuild

Thanks again to everyone for the tips.

Committed now. Always the bulk bargain buyer, I went silly with the oil. 20L. The drum may well outlast the car.

You'll be surprised how quick 20l goes, don't forget to flush the front mounted cooler, that takes a good 5-8l on its own....

Yeah a good flush with a drop and refill approach takes three rounds of fluid and uses about 18L when I did it.