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). All Ford castings have “FoMoCo” or “Ford” cast into the surface, and all ZF castings have a casting number beginning with 1068. Figure 1 also shows some key features that help distinguish between Ford 6R60, 6R75, first design 6R80 and ZF6HP Gen. 1 castings and the second generation ZF applications.

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

The 6R80 has gone through four different design changes. For help in identifying the three latter (’10-later) 6R80 castings, reference Figure 2. There were various passage changes, and the D2 regulator valve bore was removed to coincide with the addition of the low diode.

Figure 2 — 6R80 & 6R100 Casting Identification

The chart in Figure 3 provides 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
Another 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 (Figure 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.

Figure 4 — EDS Solenoid Connectors

Verify Separator Plate Codes
Separator plates are critical to identify and match 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
One of the primary wear areas in any of these valve bodies is the pressure regulator valve and sleeve. The basic design has remained the same through both generations of ZF and early and late Ford applications. However, there are some small diameter and length differences that can cause fit and pressure issues if mismatched into the wrong application. It is recommended to measure the locations shown in Figure 7 to verify that the correct OE or replacement part is fit into the appropriate application during rebuild.

Figure 7 — Pressure Regulator Valve & Sleeve Identification

While these various valve bodies have been around awhile, they continue to be updated by ZF and Ford, so always paying attention to the little details during any overhaul will help make it right the first time.

Maura Stafford is a Sonnax product line manager for transmission components and remanufactured valve bodies. She is a member of the Sonnax TASC Force (Technical Automotive Specialties Committee), a group of recognized industry technical specialists, transmission rebuilders and Sonnax Transmission Company technicians.