How to Identify Similar Ford & ZF6 Transmissions — Four Features to Check Before You Begin a Rebuild

The Ford 6R60, 6R75, 6R80 and 6R100, and ZF6HP19/26/32 (Gen. 1) and ZF6HP21/28/34 (Gen. 2) valve bodies are all very similar at first glance — one of those situations where you could say they’re all just a “horse of a different color.” However, the slight differences that can be overlooked may get you in trouble during a rebuild. Following are some key identifying features that can help your rebuilds go more smoothly.

Review Casting Designs
There are two basic casting designs — either an electronic “E-shift” or mechanical “M-shift”. The ZF family can have either an E- or M-shift, while all Ford designs use the M-shift. The E-shift castings have a distinct notch that houses an extra solenoid (Figure 1）。所有福特铸件都有“Fomoco”或“福特”铸造到表面上，所有ZF铸件都有一个以1068开始的铸造号码。图1还显示了一些有助于区分FORD 6R60,6R75，首先设计6R80和ZF6HP Gen的关键特征。1铸件和第二代ZF应用。

Figure 1 — ZF & Ford E‐Shift & M‐Shift Casting Identification

6R80经历了四种不同的设计变化。有关识别三个后者（'10 -later）6R80铸件的帮助，参考Figure 2。存在各种通道改变，并除去D2调节阀孔以加入低​​二极管。

图2 - 6R80和6R100铸造识别

图表中Figure 3provides casting numbers for both upper and lower sections of the valve body as well as other unit identifiers. The 6R100 transmission came out in 2017 and is a heavy-duty version of the 6R80. The ’15-later 6R80 valve body without stop/start design is also used in the 6R100.

Check Solenoid Color, Location & Numbering
一种nother important differentiator on these valve bodies is what solenoids are used. For the ZF6HP first generation, the EDS solenoid connector colors were blue and yellow. Be cautious about just identifying units by connector color though, as these tend to change with heat to green and tan. The second generation ZF6HP kept the blue and yellow connector EDS solenoids for most locations, but changed to orange connectors at the EDS1 and EDS2 locations (图4.）。Ford initially used a combination of brown and black solenoid connectors (Figure 5). In 2010 Ford changed to cream colored solenoids on the ’10-later 6R80s, which also have band numbers between 1 and 5 to indicate flow rate. It is important during a rebuild to make sure that a solenoid of the same band number is put back into the same bore, as this will aid in shift adaptation.

图4 - EDS电磁阀连接器

验证分隔板代码
分离器板是至关重要的识别和学习h to your original casting, as worm tracks and passages vary considerably by application. ZF has continued to use the silicon beaded gasket designs, which should be replaced due to delamination issues anytime the valve body is worked on. They have an A/B code identification for easy reference. The early Ford applications also used the silicon beaded gasket design, which has an E510F plate code. Later design Ford units moved to bonded gaskets. The chart in Figure 6 provides a quick reference for the different variants that have been identified to date.

Measure Pressure Regulator Valve Components
这些阀体中的任何一个初级磨损区域是压力调节阀和套筒。基本设计通过几代ZF和早期和晚期福特应用程序保持不变。然而，如果在错误的应用中不匹配，则存在一些小直径和长度差异可能会导致适合和压力问题。建议测量图7所示的位置，以验证正确的OE或替换部分是否适合在重建期间适用于适当的应用程序。

Figure 7 — Pressure Regulator Valve & Sleeve Identification

虽然这些各种阀门已经围绕了一段时间，但它们继续被ZF和Ford更新，因此始终关注在任何大修期间的小细节将有助于第一次进行。

Maura Stafford是一个Sonnax产品线管理器，用于传输组件和再制造阀体。她是一个成员Sonnax TASC Force(Technical Automotive Specialties Committee), a group of recognized industry technical specialists, transmission rebuilders and Sonnax Transmission Company technicians.