8 controlled stages — from diagnosis to final testing
ZF transmission remanufacturing is not limited to replacing the failed component. Every transmission passes through a complete process of diagnosis, overhaul and final testing.
The eight remanufacturing stages
Details of the eight stages
Every unit follows a controlled process. Select a stage to view the full technical scope.
1Diagnosis with ZF Testman Pro
Before the transmission is removed, we carry out electronic diagnostics with ZF Testman Pro — the specialist diagnostic tool for ZF systems.
We analyse stored fault codes, operating parameters and transmission behaviour to identify the original cause of the problem.
2Identification and initial inspection
The transmission is identified by its type, Part List Number and serial number. We also check its external condition, any leaks and the condition of the oil.
3Complete disassembly
The transmission is completely disassembled. We do not limit the work to the component that caused the failure — all major mechanical, hydraulic and electronic assemblies are disassembled down to the last bolt and inspected individually.
4Washing and cleaning
The housing and internal components are thoroughly cleaned to remove oil, friction material residue, deposits and metal particles.
Thoroughly cleaned components are essential for an accurate inspection.
5Component inspection and measurement
Every component undergoes a visual inspection and, where necessary, precision measurement.
Depending on the transmission type, we inspect gears, shafts, planetary gearsets, clutches, bearings, bushings, the oil pump, hydraulic system, valve body, mechatronics and the Intarder.
Components that do not meet the required technical tolerances are replaced.
6Overhaul and component replacement
Worn components and all parts that do not meet the technical requirements are replaced.
Seals, O-rings, oil seals, friction discs and the other components scheduled for replacement during the overhaul are replaced with parts that meet ZF specifications.
The main assemblies are overhauled separately before final assembly.
7Assembly according to ZF specifications
The transmission is assembled in accordance with the technical documentation for the relevant model.
All specified tolerances, clearances, preloads, assembly sequences and tightening torques are followed during assembly.
8Final testing
After the overhaul, the transmission undergoes a functional inspection and, where applicable, a test-bench test.
We check correct operation, the absence of leaks, gear shifting, pressures, clutches, the torque converter, the Intarder and the electronic systems.
Only after successfully passing the final checks is the transmission considered ready to return to service.
A complete process, not just a repair
Our goal is not only to correct the specific failure, but also to identify its cause and restore the complete functionality of the transmission. This reduces the risk of subsequent failures and supports high reliability and operational safety.
Every fully remanufactured transmission is returned to the customer with 0 km after the overhaul — the start of a new operating cycle following its complete restoration.
What we inspect
Gears, shafts, planetary gearsets, bearings, bushings and clutches.
Oil pump, hydraulic circuits, valve body, pressures and signs of contamination.
Stored fault codes, operating parameters, mechatronics and electronic control functions.
Torque converter, Intarder and the components relevant to the transmission application.
Send the correct identification details
Accurate identification helps ATS assess the unit, select the correct technical approach and avoid assumptions based only on the vehicle model.
- Part List Number
- Serial Number
- Transmission type or model
- Vehicle or machine application
- Symptoms and available diagnostic information
The same transmission family can have different specifications, control systems and service requirements depending on the application and production version. Accurate identification is the starting point for a reliable technical assessment.
Technical questions about the remanufacturing process
Why should diagnosis be carried out before the transmission is removed?
Electronic diagnosis can capture stored fault codes, operating parameters and system behaviour while the transmission is still connected to the vehicle or machine. This information can help distinguish an internal transmission fault from a problem in the external control system, wiring, a sensor or the specific application.
Why does ATS inspect the complete transmission instead of replacing only the failed component?
A failed component may be the result of contamination, incorrect pressure, wear in a related assembly or an electronic control problem. Complete disassembly and inspection help identify related damage and reduce the risk of returning a unit with an unresolved root cause.
Which information should a workshop send for a reliable first assessment?
Send the Part List Number, Serial Number, transmission type, vehicle or machine application, fault symptoms and any available diagnostic information. Photographs of the identification plate and the unit can also help ATS determine the correct technical approach.
Does every remanufactured transmission undergo a test-bench test?
Every unit undergoes a final functional inspection. A test-bench test is performed where applicable for the transmission type and the available test procedure. ATS confirms the relevant scope during the technical assessment.
Need technical support for a ZF transmission?
Send ATS the data listed in the table above: Part List Number, Serial Number, the transmission type or model, the vehicle or machine application, as well as the symptoms and available diagnostic information. We will help determine the correct diagnostic and service approach for your unit.