FG MK1 - XR6 Turbo Automatic Transmission removal (ZFHP26)

[Puffwagon]

I use a reasonably large brass wire wheel for the sump, it is a bit softer and only removes the silicone, not the metal. The smaller ones are less bendy and eat into stuff more.

[greasemonkey]

OKAY. RAN INTO A PROBLEM (auto mechanics, who would have thought).

So the last two weeks I've made really good progress.

 

I managed to put the trans back and bolt it to the engine. I now am up to bolting the torque converter to the flexplate/driveplate.

 

So I get my socket bar and rotate clockwise but nothing happens. The engine is locked. It will not rotate.

What have I done? Do I need to take the transmission off again? Is the torque converter stuck?

The torque converter was pushed onto the input shaft. I rotated it before installing the trans, just to see it would rotate.

Frustrating as hell! Any help would get me out of this hole I think. Thanks guys. Sorry to hear Puff about your engine also.

 

How my flex plate and torque converter sit currently

[Puffwagon]

The converter isn't in properly and is jammed on the trans pump inner gear. Usually when you do that and bolt the trans fully in, it will snap the tabs off the gear. Trans out, converter out, inspect the gear.

Edited 05/11/24 10:02 PM by Puffwagon

[greasemonkey]

I asked this question and someone told me this is a possibility. I can get the pump gears and oil pump housing for the ZF for around $650. I asked the shop if they carry this often and he said not really because they usually never break. So at least I know I can get one.

 

This video explains a tear down well on a ZF. Not the 26 but ZF19.

I would only touch the oil pump and remove if I can do it with hand tools and put it back in without damaging anything else.

Is it as straight forward as this (up to the oil pump removal).

 

[Puffwagon]

You'll find out everything you need to know from that youtube channel, he has several zf6 disassembly videos. If you forget the order of parts, ask a question. I can direct you to several places that show an exploded diagram or other assembly processes.

[xr6tForMe]

Is this something where new parts should be used, or they are reliable/dont wear out, so reusing second hand parts would be ok?

[Puffwagon]

You could pull a pump assy out of a na trans and use that.

[greasemonkey]

12 hours ago, xr6tForMe said:

Is this something where new parts should be used, or they are reliable/dont wear out, so reusing second hand parts would be ok?

I thought about that. If the gears were in good condition then it wouldn't be an issue I guess. You'd have to buy the N/A box most likely which could cost more than the price of a new oil pump for the ZF26 trans.

 

I got the gearbox off today. You get quicker after your first time. Still take more time putting it back together again.

When I got the gearbox off, the converter was still in on 3rd notch. I could rotate it by hand with resistance easily. I took the trans out and took a photo

 

On the oil pump, I still have the two black tabs which slot onto the torque converter shaft. They aren't broken off. Should I be checking the inside of the torque converter shaft as well as the oil pump???? I read on internet land you can damage the torque converter but I can't see any damage.

The engine turns over fine so definitely things weren't aligned properly somehow.

Also need to work out how I can create something that will give mechanical advantage to lift up a 100kg gearbox. Otherwise I'll be taking it apart on the garage floor. I can fit under their okay as I'm not a big person but its not the greatest obviously.

[Puffwagon]

The tabs were what was preventing the engine spinning, as the converter was pushing them into the back of the pump. The might not be completely snapped off but there is a good chance they are still farked, also the back of the pump might have dents or scratches in it now which is no bueno.  As for the converter being in the trans properly, I would reevaluate how you checked it, this exact scenario has been played out by thousands of people before and the symptoms and outcomes are all the same.

[greasemonkey]

I'm taking the oil pump out of the trans. Is it possible easily to visually inspect the oil pump once out and removed from the gearbox?

When I removed the trans, the torque converter came out with the box and was on the 3rd spline. When I pulled the torque converter off, I had to get it off the same way as when I first pulled off the gearbox. That was going from the furthers notch spline, to the first. The torque converter also was spinning by hand with normal resistance. 
 

Thanks for the ZF material you posted earlier. It is making the process much easier (along with Gary Ferarro - transmission youtube star).

I'll post pictures up when its out.

Edited 09/11/24 02:57 AM by greasemonkey