Notice: The service procedures found in this section cover the repair
of the components that are serviceable by the dealer under the ZF S6-40
6 Speed Manual Transmission Exchange Program. No repairs of components other
than those outlined in these procedures are allowed. Refer to updated service
information for any revisions to the transmission exchange program. Should
the transmission exchange program be discontinued refer to the Transmission/Transaxle/Transfer
Case Unit Repair Manual (TURM) for overhaul procedures.
The ZF S6-40 is a 6-speed 95 mm manual transmission assembly.
Identify the manual transmission assembly as follows:
| • | Calculate the number of forward gears. |
| • | Measure the distance between the centerline of the mainshaft and
the countershaft. |
The ZF S6-40 6-speed manual transmission assembly has the
following features:
| • | Aluminum transmission case |
| • | Fully synchronized gears |
| • | Internal shift rail mechanism |
| • | Transmission mounted, dual pivot isolated shifter |
| • | Needle bearings under all speed gears |
| • | Solenoid inhibit of 2ND speed and 3RD speed gears |
These features provide a rugged and reliable system that will handle
input torques of up to 610 N·m (450 Ib ft).
The 2ND and 3RD speed gears are inhibited when shifting out of lST speed
gear under the following conditions:
| • | With the coolant temperature above 50°C (122°F) |
| • | When the vehicle speed is between 20 and 29 km/h (12 and
19 mph) |
| • | With the throttle opened 35% or less |
| | This ensures good fuel economy and compliance with federal fuel economy
standards. |
The gear ratios in this transmission offer a wide operating range for
excellent acceleration and fuel economy.
The gear ratios (:1) are as follows:
