ZF Aftermarket: Professionals in Transmission Repair for Commercial Vehicles

Thanks to the rapid development of automobile technologies, present-day gearboxes are notable for high efficiency and reliability. However, drivers often ignore operation rules and disregard timely maintenance services, thereby imposing additional loads on the most important car components (engine, gearbox) and causing their wear-out or even damage.

To avoid time-devouring and expensive repairs, especially in the field of commercial vehicles (CV), it is extremely important to provide accurate diagnostics and efficient repair solutions. ZF Aftermarket is specialized in top-quality repair services for both ZF and non-ZF transmissions for CVs. Gearbox repair experts from ZF can guarantee excellent services thanks to advanced diagnosis and repair approaches using original spare parts.

Learn more about repair services from ZF Aftermarket

Nowadays, there is a wide range of gearboxes of different types and designs available on the market. When referring to CV gearbox repairs, independent repair shops can seek guidance from ZF Aftermarket – no matter whether they are dealing with manual, automatic or automated gearboxes. Repair specialists of ZF Aftermarket Service really know what it takes to properly fix almost all common CV gearboxes provided by well-known manufacturers. ZF uses only top-quality OE spare parts for repair services.

Under normal conditions of use, CV gearboxes can function properly for 700-800 thousand kilometers, equivalent to a service life of twelve or fifteen years. However, ill-timed maintenance services and mistakes in gear shifting can lead to premature wear of gearbox components. The structural complexity of the gearbox elements makes a comprehensive diagnosis and repair process a must. It is important to understand that numerous signs that seem to refer to gearbox failure can be misleading and in reality may point to problems in elements which interact with the gearbox. The ZF Aftermarket technicians claim that it is necessary to make sure that the problem lies in the gearbox itself before performing any repair procedures.

When it comes to gearbox repair ZF Aftermarket sticks to the following plan of action: diagnostics, cleaning, assessment, dismantling, rebuilding or replacement of worn elements as necessary.

• Diagnostics

An accurate diagnostics procedure is based on using reliable tools and correctly interpreting all vehicle info received in the process of diagnostics. ZF specialists have at their disposal advanced diagnostic tools that ensure efficient systematic faultfinding. The ZF Testman diagnostic tool is intended for testing ZF products with electronic control (mainly driveline solutions). Unlike other diagnostic units, this tool can be applied for testing of already dismantled gearboxes.

ZF Testman diagnostic tool in action

• Cleaning

After the source of malfunction is positively identified, it is necessary to clean the gearbox. Thanks to sandblast cleaning, any deposits and traces of dirt are accurately eliminated.

• Disassembly

The next step is to inspect the gearbox internals. For this purpose, the gearbox is fully disassembled and each separate element is carefully inspected. The torque converter is removed, washed and rebuilt.

• Repair and testing

ZF Aftermarket's technicians have solid experience, skills, and advanced equipment to perform the gearbox repair and replacement with 100 % quality. This ranges from replacement of worn gearbox elements to complete assembly of a rebuilt unit that meets the highest quality standards. After all repair procedures, all gearbox units are tested on the ZF test bench. The ATF is heated to 75°C to simulate the operating temperature and pressure conditions. Therefore, repair technologies and methods offered by ZF experts often turn out to be a reliable reference point for individual repair shops.

After assembly, the gearbox is filled with fresh ATF. ZF has designed a special test stand for accurate air-tightness and performance testing of its gearboxes. After these tests, the gearbox software is reset so that the repair shop can re-enter the vehicle data and update the original software after mounting of the gearbox. Lastly, the rebuilt gearbox installed in the car is exposed to the final performance test.