Gearbox Teardown & Refurbish - 6HP28A61

[RS_BROKE]

just a quick update i have been busy with other stuff, not the best time to be fixing a gearbox when your in the middle of opening a new business
waiting on a t27 to take the oil pump off and i have also snapped one of the sump bolts typical me anyone got any ideas on removing it.

[cammmy]

Two options, one is to get a nut on there and weld it. The other is to use a left hand drill bit slightly smaller than the thread size. Don't use a screw extractor. I find them more likely to break and then you are screwed, as they are hardened.

If you go the drill route. Make sure it's a left hand bit, use cutting oil and go fairly slow. As you remove material from the fastener, it will relieve the pressure and often the bit will end up winding it out. Just be careful to keep it centred and not hit the threads.

[Jim Haseltine]

+1 on the left hand bits. I used a set to remove a sheared exhaust manifold stud in situ. Even though it was the most forward of the righthand bank it wasn't easy as I had to use a flexible drive and couldn't apply any pressure - and the studs are A2 stainless so very hard. Once I'd cut a shallow hole the stud loosened enough to wind out with the grip from a square section extractor using my fingers.

[RS_BROKE]

Double oil seal looks good

That double oil seal is probably responsible for most 6HP problems. It's a no-brainer to replace it, but watch out, there are two different sizes / heights.

Nick

Yes it will be replaced as the rubber goes brittle

[RS_BROKE]

Two options, one is to get a nut on there and weld it. The other is to use a left hand drill bit slightly smaller than the thread size. Don't use a screw extractor. I find them more likely to break and then you are screwed, as they are hardened.

If you go the drill route. Make sure it's a left hand bit, use cutting oil and go fairly slow. As you remove material from the fastener, it will relieve the pressure and often the bit will end up winding it out. Just be careful to keep it centred and not hit the threads.

Thanks lads, don’t have a welder so will look at a set of left hand bits and extractor il get pic up of the bolt

[ATinOf]

These do look scored inside and the top

They look clean, I suspect no trouble there

[ATinOf]

Double oil seal looks good

That double oil seal is probably responsible for most 6HP problems. It's a no-brainer to replace it, but watch out, there are two different sizes / heights.

Nick

There is only one double oil seal size, common to both 6HP26 and 6HP28, don-t be mis-led

[RS_BROKE]

Double oil seal looks good

That double oil seal is probably responsible for most 6HP problems. It's a no-brainer to replace it, but watch out, there are two different sizes / heights.

Nick

There is only one double oil seal size, common to both 6HP26 and 6HP28, don-t be mis-led

second this i have double checked on a 26

[welwynnick]

There's too much misinformation on the net already, and the last thing I want to do is make it worse. To the best of my knowledge, there are two ZF 6HP mechatronic double seals:

ZF 0501 215 718 which is used on 6HP26, 28 & 32 (typically used on V8/10/12's)

ZF 0501 215 783 which is used on 6HP19 & 21 (typically used on 4/6's)

I'm not sure what the differences are, but I believe one is thicker than the other, and they're not interchangeable. So I just wanted to say make sure you don't use the 6HP19/21 seal on the RS6.

Happy New Year!

Nick

[ATinOf]

We all need to stick to the correct terminology to stop this misinformation spreading (me included!)

The double seal that is only one common size is the output shaft double seal, described at this post
viewtopic.php?f=47&t=129779&start=15#p894628

The 'Bridge Seal' which is mistakenly called a double seal just to confuse everyone, and even I did it in my earlier posts, is the one that comes in 2 sizes, different heights, discussed at this post;
viewtopic.php?f=47&t=129779&start=90#p894721

I will now reprimand myself and go and update that original post to declare it as a bridge seal (doh)

Happy new year guys

[welwynnick]

Ever wary of the frustrating befuddlement often attributable to terminological inexactitudes - I agree. Bridge seal it is!

[RS_BROKE]

the terminology is not the easiest i call the final drive running to the front diff a propshaft ha ha

[ATinOf]

Does anyone know what these two are for front diff? Next to the oil coolers

If that's where I think it is it could be the pressure test points. Plugged normally. Hard to tell from the image

[ATinOf]

Completely unrelated but worth noting, due to the number of images I have up on PhotoBucket they think I'm hosting so want to charge me - not that Im going to, but they wont let me upload any more images without paying ;(. I need a new image hosting service me thinks.....

[ATinOf]

the terminology is not the easiest i call the final drive running to the front diff a propshaft ha ha

Well, it is a shaft, and it helps to propel the car - so who is going to argue with that