Gearbox Teardown & Refurbish - 6HP28A61

[RS_BROKE]

I’ve got proper torx se but this is external I just put a 9mm socket and it came off thanks anyway

TX-sockets

Thanks I need to get set

[RS_BROKE]

They are the female torx set you need for that if anyone wants to know but a 9mm socket works fine

[RS_BROKE]

Above I said the mechatronic unit wouldn’t come out as I thought it was catching on selector I was wrong it was just stupid me left one bolt

[RS_BROKE]

As At said make sure not to scratch the mating surfaces I used some bubble wrap.

[RS_BROKE]

Hmm the oil that was left after lifting the mechatronic out looks black and burnt clutches?
Next up clutches out then we will see!

[RS_BROKE]

Double oil seal looks good

[RS_BROKE]

These do look scored inside and the top

[RS_BROKE]

These are all different sizes, this is starting from the opposite side to the front diff

[RS_BROKE]

I used a little pick to get the rubber tubes out like the ones you use for oil filter seals works fine just be careful no to scratch the bores!

[RS_BROKE]

My valve body seal number is also ao63

[ATinOf]

Finally got the oil coolers off by making a t30 fit in a t25

Some of the ZF torx fittings are T27, thats prob why you stripped a few - not a common size but you can get them, I'd recommend the impact versions as they tend to last a bit longer

I did point this out I think in one of my posts, maybe I missed it, it was a bit of an epically long post!

[ATinOf]

Transfer case magnet
The bearing in the transfer case seems to have lot of play when the output shaft is out maybe this is normal maybe At can comment on this.

Some play in that thrust bearing is normal with nothing pushing it together, did you check the axial play in the output shaft with a DTI before the strip down? The output shaft axial clearance is taken up by that round selective washer that nearly fell out in your prior post, dont lose it !!

[welwynnick]

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

[RS_BROKE]

Finally got the oil coolers off by making a t30 fit in a t25

Some of the ZF torx fittings are T27, thats prob why you stripped a few - not a common size but you can get them, I'd recommend the impact versions as they tend to last a bit longer

I did point this out I think in one of my posts, maybe I missed it, it was a bit of an epically long post!

im waiting on a t27 now for the oil pump

[RS_BROKE]

Transfer case magnet
The bearing in the transfer case seems to have lot of play when the output shaft is out maybe this is normal maybe At can comment on this.

Some play in that thrust bearing is normal with nothing pushing it together, did you check the axial play in the output shaft with a DTI before the strip down? The output shaft axial clearance is taken up by that round selective washer that nearly fell out in your prior post, dont lose it !!

yes we did it was 0,2xx i have it written somewhere cant remember the exact reading, yes still have the washer, i have looked at another gearbox that we have sitting around which is also a zf6 quattro once taken off as the shaft is not there to "support sit in there"