Zf6hp26 Six Speed Autmatic Transmission

[Gadgetman]

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.

[Polyal]

um we know all this...lol

Talk about regurgitation.

[Bryan2013]

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?

[Professor Farnsworth]

12 year thread mine, nice work. Ring your local wreckers or look on eBay.

[BFIIGhiaZF6]

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

[EWT]

Curiosity question here.
Is it possible to transplant a new 8 speed ZF into our Falcons?

[vztrt]

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).

[malazn mafia]

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.

[malazn mafia]

Originally Posted by EWT

Curiosity question here.
Is it possible to transplant a new 8 speed ZF into our Falcons?

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.

[Bossxr8]

Originally Posted by EWT

Curiosity question here.
Is it possible to transplant a new 8 speed ZF into our Falcons?

There would be no way to control it.