Tools / supplies (minimum)
- Shop manual for the exact ZF transmission model (torque, shim list, clearances, special-tool numbers).
- Full metric hand tool set (sockets, ratchets, extensions, hex/torx/allen).
- Torque wrench (0–200+ Nm range).
- Hydraulic press (1–20 ton) with parallel plates and appropriate support adapters.
- Bearing pullers / slide hammers and adapters.
- Snap‑ring / circlip pliers (internal & external).
- Planetary gear puller / carrier puller or carrier support tool (ZF special tool or equivalent).
- Sun‑gear removal tool (ZF special tool / extractor).
- Hub/drift / driver set and seal installer set.
- Heat source (induction heater or propane torch) and cold source (freezer/ice) for interference fits.
- Dial indicator with magnetic base (for backlash/endplay checks).
- Feeler gauges / plastigauge (if required for thrust/clearance checks).
- Punches, brass drift, soft hammer.
- Clean parts tray, lint‑free rags, solvent parts wash.
- Safety gear: eye protection, gloves, steel‑toe boots, hearing protection.
- Transmission jack or engine hoist and cradle.
- New transmission fluid, filter, pan gasket, RTV (as required).
- OE or ZF planetary gear kit (planet gears, planet shafts/pins, bearings, bushings, thrust washers, snap‑rings, circlips, sun gear if required, ring gear if required), new bolts and lockplate if specified, seals/o‑rings.

Safety precautions
- Work on a flat level surface, block wheels, and chock vehicle if transmission remains in vehicle.
- Disconnect battery before starting.
- Use a transmission jack to support the gearbox when removing/installing; do not rely on a hoist only.
- Drain the fluid into a container; dispose per regulations.
- Wear eye protection and gloves. Keep fingers clear of press and puller pinch points.
- Use proper lifting techniques and get help for heavy components (torque converter, case halves).
- Keep the work area clean and organized; keep small parts in labeled trays.

High‑level procedure (step‑by‑step)
Note: This is a generic ZF-style planetary replacement procedure. Follow the exact procedure and torque values in the ZF service manual for your model.

1) Preparation and removal
- Drain ATF, remove pan and filter to reduce fluid volume. Remove any electrical connections, linkages, cooler lines, and ancillary components blocking removal.
- Remove torque converter (with engine supported or torque converter locked per manual) and unbolt transmission from the engine. Use a trans jack/cradle to lower transmission.
- Place transmission on a workbench/case support rated for its weight.

2) External disassembly to access planetary section
- Remove bellhousing bolts, front cover/input housing and pump if required by model.
- Remove valve body / control body if necessary to gain access to drum assemblies. Label and bag valves/springs and keep fasteners in order.
- Remove output housing/extension housing bolts and separate housings to expose planetary carriers and clutches.

3) Identify and document
- Before removing the planetary assembly, photograph and mark the orientation of carriers, sun gear, ring gear, and clutch drums. Count and label any shims or spacers and note their order.

4) Remove clutch drums / output members
- Remove clutch pistons and steels/plates as necessary. Use safe storage for frictions.
- Unbolt and remove the carrier drum(s) that retain the planet set. Some ZF units use snap rings that must be removed first.

5) Extract planetary carrier
- Use the ZF carrier puller or adapter plate to support the carrier and extract the carrier assembly from the case. If retained by circlips, remove them with circlip pliers first.
- If the planet carrier is pressed in or tight, use a puller to push the carrier off the shaft. Support the case to prevent deformation.

6) Disassemble planetary carrier (planet removal)
- Secure the carrier in a vise with soft jaws or on press plates.
- Remove the retaining ring or lock pin for the planet pins (some models use roll pins, pins with circlips, or bolted shafts).
- Use a hydraulic press or drift to push planet pins out. If planet gear bushes/bearings are a shrink fit, heat the carrier lightly or freeze the planet pin to help extraction.
- Remove planet gears and needle bearings/races. Collect rollers/needles carefully; replace all bearings/races — do not reuse needle bearing strips.

How to use specific tools:
- Snap‑ring pliers: compress internal/external circlips fully and remove; verify orientation on reassembly.
- Hydraulic press: use matched plates to push pins/shafts straight; support the carrier evenly to avoid distortion. Use a short travel, check alignment frequently. Press bearings off using an adapter against the inner race only.
- Bearing puller: install jaws behind bearing race or use a two‑ or three‑arm puller; operate slowly to avoid breaking gear teeth.
- Heat / freezer: heat the carrier around a pressed bearing evenly to ~120–150°C (follow bearing heating safety) or chill the gear assembly to shrink, then press to separate interference fits.
- Sun gear extractor: engage into the sun gear splines and extract straight; protect splines with a drift if necessary.

7) Inspect parts and replace
- Mandatory replacement items: all bearings, needle bearing strips, thrust washers, snap rings/circlips, seals, and any deformed or worn gears. Recommended: Planetary gear kit (planets, pins, bushings), sun gear if pitting or spline wear, ring gear if teeth damaged.
- Inspect planet gear teeth, sun gear, ring gear for pitting, scoring, missing teeth, spalling.
- Check planet pin bores and carrier for wear; replace carrier if bores are ovalled or cracked.
- Measure endplay, gear backlash and bearing preloads per manual and replace shims/thrust washers accordingly.

8) Reassembly of planetary carrier
- Clean all parts in solvent and dry.
- Install new needle bearings/races into planet gears/carrier using the press and proper drivers — press on inner race only. Install new bushings if applicable.
- Assemble planet gears onto pins and secure with new pins/retaining rings. Ensure pins are fully seated and circlips are seated in grooves.
- Check free spin of assembled planets; there should be smooth rotation with correct axial play (consult manual).

9) Install carrier back into transmission
- Lubricate bearings and thrust surfaces with ATF or assembly lube.
- Place carrier into case; fit any shims/thrust washers in exact order. Use dial indicator to check ring/sun gear backlash and carrier endplay. Adjust with shims per manual until within spec.
- Fit snap rings or locking plate; ensure they are fully seated (tape or inspect visually).

10) Reassemble remaining components
- Reinstall clutch packs, drums, pistons as removed, replacing friction plates if worn or as specified.
- Replace any seals, O‑rings, and gaskets removed. Replace pan gasket and filter.
- Reinstall valve body, pump, front cover and torque bolts to spec.

11) Refit transmission to vehicle
- Install torque converter (apply recommended procedure for seating and rotate to check pump engagement).
- Bolt transmission to engine, reconnect lines, wiring, cooler hoses, linkages.
- Refill with specified ZF fluid to fill/level per manual; use the correct fluid type.

12) Testing and break‑in
- Start engine with parking brake set, cycle through gears to charge circuit and check for leaks.
- Road test and monitor shifting and temperatures. Check for noise, harshness or slippage.
- Recheck fluid level after warm‑up and after a short break‑in period.

Common pitfalls and how to avoid them
- Not using the correct service manual: torque values, shim sizes, and preload specs differ — always follow ZF manual.
- Reusing bearing/needle strips, snap rings, thrust washers: always replace wear items.
- Incorrect press technique: applying force to wrong race or misaligned press will damage bearings/gears. Always press against the correct race and support the carrier evenly.
- Overheating bearings or gears with torch: heat evenly and only to required temperature; excessive heat damages temper and tolerances.
- Mixing up shims and thrust washers: label and preserve orientation/sequence during disassembly.
- Improper snap ring seating: partially seated snap rings will let carriers walk out under load — verify full engagement with feeler or probe.
- Not checking endplay/backlash: wrong clearances cause noise, premature wear, or immediate failure. Use a dial indicator and correct shim stack.
- Reusing bolts or torque‑to‑yield fasteners: replace where specified and use threadlocker if required.
- Not replacing seals/filters: contaminant inside will kill a rebuild fast.
- Not bench‑testing: if possible, bench‑test the transmission or at least cycle apply pressures to clutches before final fitment.

Replacement parts typically required
- Planetary gear kit: planet gears, shafts/pins, bearings/needle bearings, bushings, thrust washers.
- Snap rings/circlips and lock plates.
- Sun gear or ring gear if wear/damage is present.
- Bearings and races in the carrier, input and output shafts if worn.
- All seals and O‑rings disturbed during disassembly.
- Filters, pan gasket, and fluid.
- Any clutch friction steels/plates if worn.

Final notes (short)
- This job requires a press, pullers, and usually ZF special tools and references. If you lack the specific tools or explicit torque/clearance data for your ZF model, do not attempt the repair. Incorrect assembly leads to rapid gearbox failure. Follow the model’s shop manual for exact values and tool numbers.
rteeqp73

E46 ZF 5HP19 Transmission Rebuild Part 1 BMW 330i 325i DIY So I've had to rebuild my transmission because it was leaking. This is part 1 of probably 3 videos that I will do on the subject.

The World's Best Automatic Transmission - How Autos Became Cool Again How The Best Automatic Transmission Works. ZF's 8-Speed Auto can give modern dual clutch transmissions a run for their money ...

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