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#1 | ||
FF.Com.Au Hardcore
Join Date: Dec 2004
Location: Melbourne
Posts: 691
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ZF 6HP26 six-speed automatic
The six-speed automatic is a compact and lightweight, high efficiency, high torque capacity transmission with a low first gear, higher top gear and smaller, more graduated steps between each gear. “With a larger spread of ratios, the six-speed transmission offers real-world benefits in the traditionally divergent areas of performance and fuel consumption,” Calibration Supervisor Tim Postgate said. “The low first gear greatly improves launch feel, while the larger and tighter spread of ratios delivers livelier performance, especially at wide open throttle, along with the added benefits of smoother shift quality and reduced fuel consumption. “Gear shifts between the top few gears are often imperceptible, while the smaller steps between 3rd, 4th, 5th and 6th also ensure less ‘busyness’ within the transmission as it determines the right gear. “The end result of the transmission being in the right gear at the right time is both an improvement in vehicle performance and a reduction in fuel consumption.” Improved transmission cooling capability in the six-speed auto, by virtue of a heat exchanger, ensures rapid warm-up of the transmission fluid and a more stable operating temperature. As well as contributing to a reduction in fuel consumption, the improved cooling also enables the maximum towing capacity to be utilised without requiring additional transmission coolers. Gear train The six-speed automatic transmission is based on the Lepelletier gear set, which is constructed by connecting a planetary gear to a Ravigneaux gear – a double planetary gear set commonly used in four-speed automatic transmissions. The sun of the planetary gear is connected to the housing and cannot rotate, while the carrier of the planetary gear is connected by clutches to the large and small sun wheels of the Ravigneaux gear. The input shaft is always connected to the ring of the planetary gear and can be simultaneously connected to the carrier of the Ravigneaux gear using a separate clutch. The output, or driven, shaft is connected to the ring of the Ravigneaux gear. Hardware changes that have been made to the six-speed automatic transmission to suit Falcon and Territory include: · Unique transmission main case · Unique torque converter · New transmission cross member attachment compatible with both ZF six-speed and ION four-speed automatics · Transfer case compatibility for Territory AWD application · Unique output/driveshaft flange Ford has engineered two versions of the six-speed automatic transmission – a standard version with a torque capacity of 450 Newton metres and a performance version with a torque capacity of 600Nm. The performance version features upgraded clutches, with extra plates in the clutch packs, to increase the torque capacity for use with higher torque output engines. Falcon, Fairlane and Territory models using the Barra 190 engine will be fitted with the standard version, while Falcon and Fairlane models using either the Barra 230, Barra 245T or Boss 260 powerplants will be fitted with the higher torque capacity performance version. Software and calibration “The ZF transmission is able to tailor its responses to individual driving styles courtesy of a number of software functions and Driver Recognition features, all designed to deliver increased transmission functionality and performance, and a refined shift quality,” Postgate said. The Sequential Sports Shift feature introduced on BA Falcon continues as a key element of the new six-speed automatic transmission, offering the same style of adaptive and performance automatic modes as well as total manual control through sequential manual shifting. Torque converter clutch lock-up is available in all six forward gears, not just in the top two overdrive gears. When towing heavy loads at low speeds, such as in city driving or through hilly terrain, converter clutch lock-up in all gears assists with better transmission cooling and reduced fuel consumption. Electronic control of all gearshifts in the six-speed automatic transmission is via clutches rather than bands, delivering a more direct and refined shift quality. The internal Transmission Control Module (TCM), which is mounted on the hydraulic control valve assembly, or mechatronics unit, has been matched to the transmission's valve body. The TCM and the valve body are an exact matched pair, with the TCM being calibrated to the specific valve body during assembly, which ensures accuracy of operation and a more refined shift quality. Calibration features of the six-speed automatic transmission include: · Grade Control Logic (Automatic modes) When driving downhill, with sufficient brake pedal pressure, the transmission will downshift to provide increased engine braking. Introduced with the four-speed automatic on Territory, Grade Control Logic operates in an even more refined and subtle manner with the six-speed automatic transmission, as the gap between the gear ratios is smaller and the execution of gear changes is smoother. · Upshift prevention at zero throttle (Automatic modes) When coasting downhill from rest, this feature inhibits upshifts beyond 2nd gear with zero throttle pedal input, to prevent a ‘running away’ feeling. · Emergency downshift (Manual mode) When in manual mode, if the throttle pedal is pushed through the detent to activate the kickdown switch, the transmission will downshift to a lower gear (depending on vehicle speed) to provide acceleration in an emergency situation. The transmission will then revert to full manual control, remaining in the kickdown gear and requiring the driver to input for upshift. Transient rpm limit The transient rpm limit allows the engine to momentarily exceed the prescribed rev limit during upshifting. This enables wide open throttle upshifting of gears to be scheduled at an engine speed closer to the rev limiter than would otherwise be possible. The transient rpm feature allows the engine to exceed 6000 rpm – up to 6250 rpm – while the transmission is completing the gear change, thereby taking full advantage of the high rpm performance of Barra 190 and 245T engines. Driver Recognition A host of advanced features are accessible to the driver as part of the Driver Recognition software with the six-speed automatic transmission. “Driver Recognition matches transmission performance to the current driving style by considering acceleration and deceleration rates, brake and throttle applications, and cornering speed, to ensure the vehicle is in the right gear at the right time without undesired gear shifts,” Postgate said. “The transmission ‘learns’ the driver's style and assigns a theoretical count system to certain driving scenarios to determine the activation point of particular features.” The count system extends from a “base” fuel economy bias (0 counts), through stages such as “sporty” driver (100 counts), up to “enthusiast” (200 counts). The transmission software recognises various performance-based actions, such as rapid acceleration / pullaways, enthusiastic cornering, pushing the accelerator pedal through the detent and moving the shift lever into performance mode, and increases the number of counts accordingly. By moving the shift lever across from adaptive to performance mode, the driver recognition function increases by 100 counts instantly, making the advanced features more accessible. If the transmission had already learnt to 40 counts in adaptive mode, then when the shift lever is pushed across into the performance mode it would become 140 counts. In performance mode, driver recognition can learn from “sporty”, representing 100 counts, up to “enthusiast” (200 counts). Counts can be gathered quickly as increases occur in blocks, while a more graduated, single point decrease in counts occurs when you return to a less sporty driving style. Driver Recognition A host of advanced features are accessible to the driver as part of the Driver Recognition software with the six-speed automatic transmission. “Driver Recognition matches transmission performance to the current driving style by considering acceleration and deceleration rates, brake and throttle applications, and cornering speed, to ensure the vehicle is in the right gear at the right time without undesired gear shifts,” Postgate said. “The transmission ‘learns’ the driver's style and assigns a theoretical count system to certain driving scenarios to determine the activation point of particular features.” The count system extends from a “base” fuel economy bias (0 counts), through stages such as “sporty” driver (100 counts), up to “enthusiast” (200 counts). The transmission software recognises various performance-based actions, such as rapid acceleration / pullaways, enthusiastic cornering, pushing the accelerator pedal through the detent and moving the shift lever into performance mode, and increases the number of counts accordingly. By moving the shift lever across from adaptive to performance mode, the driver recognition function increases by 100 counts instantly, making the advanced features more accessible. If the transmission had already learnt to 40 counts in adaptive mode, then when the shift lever is pushed across into the performance mode it would become 140 counts. In performance mode, driver recognition can learn from “sporty”, representing 100 counts, up to “enthusiast” (200 counts). Counts can be gathered quickly as increases occur in blocks, while a more graduated, single point decrease in counts occurs when you return to a less sporty driving style. All the Driver Recognition features are available on all models fitted with the ZF six-speed transmission, although certain features are more accessible on the sports XR models through a more performance-biased calibration. Enhanced adaptive shift strategy The refinement of Ford's adaptive shift programming that occurred on BA Falcon has been further enhanced on BF Falcon and SY Territory. “The sheer capacity of the ZF transmission to allow for the real-time calculation of a variety of parameters has enabled us to further refine the shift strategy, shift schedules and shift pressures to cover the whole gamut of driving scenarios,” Postgate said. “With corner, grade and load recognition, the transmission is able to adapt its functionality to suit the situation as demanded by the driver.” Adaptive modes include economy, performance, sports, uphill, downhill and towing. The transmission software compares wheel speeds to infer lateral acceleration, as well as longitudinal acceleration versus flat-road acceleration to infer uphill/downhill operation. It then uses this information to assist the driver by inhibiting upshifts or enabling earlier downshifts. When towing, the transmission perceives the load as a hill and employs gear hold logic. At highway speeds, it will cruise in the appropriate gear to account for the load being towed, which could be 4th, 5th or 6th gear, depending on the precise situation. The result is improved vehicle performance and fuel economy, as well as improved engine and transmission efficiency. Accelerator pedal detent and kickdown switch An accelerator pedal detent feature has been introduced on all automatic Falcon and Territory models, which provides physical feedback when accessing the kickdown switch. When the accelerator pedal is pushed through the pedal detent to the floor, the kick-down switch (which is integrated into the accelerator pedal mechanism) activates the kickdown feature. Depending on vehicle speed and the current gear, the kickdown switch will trigger a single or double downshift. However, to prevent potential damage to engine or gearbox, no downshift will occur if the engine speed is already too high to permit a lower gear from being selected. Revised accelerator pedal map The accelerator pedal map has been revised for more refined foot rotation versus engine throttle-plate calibrations, which has improved driveability and resulted in more linear vehicle performance. Remote transmission oil cooler The new remote transmission oil cooler fitted to all automatic I6 Falcon and Territory models is a heat exchanger mounted to the engine block with a three-way coolant thermostat. It serves the dual function of using engine coolant to provide rapid warm-up of the transmission fluid during start-up, as well as improved cooling of the transmission under high load/high temperature operating conditions. “The rapid warm-up feature delivers a significant reduction in friction losses within the transmission, contributing around 1.5 per cent to the overall improvement in fuel economy within the BF program,” Postgate said. “The remote oil cooler also delivers further refinement to shift quality, as well as reduced fuel consumption, due to better control of the operating temperature of the transmission.” New fine-feel shift lever A uniquely styled shift lever has been developed for all Falcon, Fairlane and Territory models fitted with the six-speed automatic transmission. The new, fine-feel shift lever features a steel shaft, leather-look boot, leather inserts around the selector button and LED illumination. “The steel shaft delivers a more precise, engineered feel to the transmission lever, with the increased rigidity providing clean, crisp shifts when accessing manual gear selection in the Sequential Sports Shift mode,” Postgate said. “It also improves the balance of the lever when moving between Drive and the sequential manual shifting positions.” A new leather-look boot replaces the slider used on the four-speed auto, resulting in reduced noise when changing gears as well as improved feel through the shift lever. LEDs with daytime and nighttime illumination of the ‘PRND’ positions have been integrated with the instrument panel and interior lighting strategies. The driver's ability to identify shift lever position and gear selection has been improved, even in low lighting conditions or with the headlights off, through the use of LEDs, which are activated as soon as the driver's door is unlocked. The selector button on the new shift lever must be depressed to move the transmission from Drive to Neutral, which prevents inadvertent selection of Neutral when on the move. Transmission protection for the Neutral to Drive shift is also a feature of the six-speed automatic, limiting torque on engagement if the driver attempts a shift from Neutral to Drive under throttle. Model range The ZF six-speed automatic transmission will be available on high series and performance Falcon variants, as well as all Territory AWD models. The six-speed automatic will be standard on: · Fairmont Ghia · Fairlane Ghia · Fairlane G8 · LTD · Territory TX AWD · Territory TS AWD · Territory Ghia AWD It will also be offered as the automatic transmission option on Falcon XR6 Turbo and XR8 sedans and Utes, while it is specified as mandatory fitment with the optional Barra 230 V8 on Falcon XT and Fairmont. Falcon XR6 sedan is available with a choice of three transmissions: the Tremec T56 sixspeed manual (available from January 2006) fitted as standard, with the option of the improved ION four-speed automatic (at no additional cost) or the new ZF six-speed automatic. |
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#2 | ||
Virtuous Bogan (TM)
![]() Join Date: Jan 2005
Location: TAS
Posts: 27,566
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um we know all this...lol
Talk about regurgitation.
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#3 | ||
Starter Motor
Join Date: Aug 2013
Posts: 3
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Very informative. I am looking to replace my TCM on 2006 territory AWD Ghia SY. Cannot find a replacement :( Would you have any idea where I may find one?
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#4 | ||
Fossil fuel consumer
![]() Join Date: Jul 2005
Location: Mod For: Pub, Bar, Sales Yard, Show 'N Shine, Photoshop, AU to BF, FG to FGX, Territory & Sports Bar
Posts: 17,038
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12 year thread mine, nice work. Ring your local wreckers or look on eBay.
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#5 | ||
George
![]() Join Date: Jun 2015
Location: Glen Waverley, Melbourne
Posts: 7,412
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Thanks Bryan2013, some of us like you have 10yr old cars with a ZF6 and welcome all information about them, I had never read that post before, thankyou
![]() Shall be posting it in my thread, https://www.fordforums.com.au/showthread.php?t=11441275 Good luck getting the TCM for your Terry, as Prof says, wreckers is probably your best bet ![]()
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BFWSM https://www.fordforums.com.au/vbport...articleid=1708 ![]() R/Up 2019 ![]() ![]() PWR Air/Oil Cooler, K&N, Egas elbow, V8 upper F6 lower CAI. 1997 Fairmont EL Ghia Tickford 4L Auto ![]() 1985 Falcon XF GL 4.1L Auto. 1979 Fairmont XD Ghia 4.1L Auto. 1971 Cortina GL Estate 1200cc Manual. Last edited by BFIIGhiaZF6; 05-07-2017 at 05:25 PM. |
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#6 | ||
Regular Member
Join Date: Oct 2011
Posts: 320
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Curiosity question here.
Is it possible to transplant a new 8 speed ZF into our Falcons? |
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#7 | ||
Boss 335
Join Date: Jan 2006
Posts: 4,330
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This I do want to know, would be prepared to fork out huge to experience an 8speed behind a Barra Turbo. Would even rather spend the same money installing an 8-Speed , than fork out and buy a new BMW or kia Stinker... Crazy I know.
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#8 | ||
Peter Car
Join Date: Dec 2004
Location: geelong
Posts: 23,145
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#9 | ||
IWCMOGTVM Club Supporter
Join Date: Sep 2005
Location: Northern Suburbs Melbourne
Posts: 17,798
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Just for reference there isn't a external tcm in petrol models. The ecu does that job.
As for diesel (which isn't a zf but a ford modified one) it's the same unit as a current ranger (well anything with a 6R80).
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Daniel |
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#10 | ||
Boss 335
Join Date: Jan 2006
Posts: 4,330
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An amazing transmission, still remember the sheer amazement at Ford installing this into the Falcon in 2005, it was the stuff of Bentleighs and 7-Series BMWs at the time. It was a welcome change to the BTR transmisions the Falcon had run for decades. It's really sobering to see it turn 17 years old though.
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