BMW ZF 5-HP-19 By Bob Cherrnay Technical Editor ‘The ZF 5-HP-19 series transmission (See Figure 1) is manufactured in Germany by ZF. The 5-HP-19 is an electronically controlled five-speed automatic transmission with a converter clutch. Two planetary gearsets, one Ravigneaux gearset and one standard planetary gearset on the output side, four rotating multiple-disc clutches, three multiple-disc brake clutches and one sprag clutch (freewheel) are used to provide the five forward speeds and reverse. This unit is found in: BMW ‘97-current, 3 Series E46, 5 Series 39, 7 Series, E38 ‘Audi ’95-current, Ad, A8 Audi ’97-current, A6 Porsche Boxster 1996-1997 ‘VW Passat ’96 - current. In Figure 2, we have provided a clutch and brake- clutch application chart for the 5-HP-19. oe ZF 5-HP-19 Clutch and Brake-Clutch Application Chart A Cc D Clutch G Clutch B Clutch Clutch E ciutch / eiutch F Clutch © f 1 A B c pd |tow | £ F G | Gear | Conv Range _| Clutch | Clutch | Clutch | Clutch | Sprag | Clutch | Clutch | Clutch | Ratio| Clutch| Park On Reverse| On On On 4.08 ‘On. D-ist On Hold. On 3.66. D-2nd On On On 1.99 D-3rd On On On 1.40 * D-4th ‘On ‘On ‘On 1 cm g D-5th On ‘On [On ozs [= 4 Same as above; Automatic Shift Ist thru 4th; 5th gear is inhibited. : 3 above; Automatic Shift 1st thru 3rd; 4th and 5th gears are inhibited. * 2 Same as above thy nd; 3rd, 4th and 5th gears *Converter clutch may be On or Off depending on vehicle speed and throttle position.ZF 5-HP-19 Solenoid Application Chart MV1 MV 2 MV3 EDS 1 EDS 2 EDS 3 EDS 4 id] Solenoid| Solenoid | Solenoid | Solenoid| Solenoid| Solenoid ‘On * ‘on rn = On On ** * On On ** * ‘On On rr . = D-ard ‘On rr = oe D-4th “= ae D-Sth = ¥ = oe Failsafe (4th)| Off Off Off Off Off off Off ‘Solenoid Chart Legend On [MV 1, MV 2and MV 3 solenoids are energized by the Electronic Transmission Control unit and have two functions. They are Open or Closed. Energized (On), there is pressure in circuit, ® | MV 3is turned ON if reverse is selected at a high vehicle speed, to inhibit reverse engagement. ++ | EDS 1 is used for line-pressure control only and operates from 0 to 0.8 amps. When the solenoid is OFF (0. amps), pressure is high. EDS 1 pressure is lowered as the solenoid is modulated by the control unit. + [EDS 2, EDS 3 and EDS 4 solenoids are also pulse modulated but are exactly the opposite of EDS 1 solenoid. When these solenoids are ON, oil pressure in the hydraulic circuit is high, and when they are OFF, pressure in the hydraulic circuit is low. [Solenoid OFF (hydraulic pressure low), then Solenoid ON (hydraulic pressure high). [Solenoid ON briefly (hydraulic pressure high), then Solenoid OFF (hydraulic pressure low). The pressure acts briefly on regulator valves to cushion clutch application at |EDS 4 Solenoid is used for torque-converter-clutch apply and release only and depends on throttle [position and vehicle speed as to its application. Solenoid and Sensor Resistance Chart ® Case Connector | Control Unit Connector | Resistance Solenoid | Pin Numbers Pin Numbers In Ohms - ot MV1 8 and 12 30 and 52 30-34Q. MV 2 9 and 12 33 and 52, 30-34Q MV3 4and 12 32 and 52 30-34Q. EDS 1 2and 12 Sand 52 5.2-6.8Q. EDS 2 3 and 12 Tand 52 6.2-7.8Q. — EDS 3 Zand 12, 29 and 52 6.2-7.8Q2 | EDS 4 1 and 12 Aand 52 6.2-7.8Q. TOT 13 and 14 21 and 22 70000 at 25°C OSS land 10 14 and 42 292-3580 TSS Sand 6 44 and 16 292-3580eo ZF 5-HP-19 Internal Wire Schematic Output-Speed ‘Sensor MV 1 Solenoid €Ds-1 EDS-2 Solenoid Solenoid Turbine-Speed Sensor EDS-4 Solenoid View Looking Into Case Connector Purple Purple Purple ECU Connector Output Sensor