6hp26 transmission / transfer box failure

**rar110** · 2nd July 2015, 09:41 PM

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** · 2nd July 2015, 10:13 PM

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** · 3rd July 2015, 05:06 AM

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

**carlschmid2002** · 3rd July 2015, 05:15 AM

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** · 3rd July 2015, 05:32 AM

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** · 3rd July 2015, 06:59 AM

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** · 3rd July 2015, 08:05 AM

Bugger RAR.

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

Is the car at home?

**rar110** · 3rd July 2015, 10:19 AM

Originally Posted by harlie

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** · 3rd July 2015, 09:35 PM

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** · 4th July 2015, 06:35 AM

Originally Posted by 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

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.

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