BMW 540i 2003-2010

BMW 540i 2003-2010 ZF 6HP Transmission Specifications

Comprehensive technical specifications for the ZF-6HP automatic transmission used in the 2003-2010 BMW 540i. This document covers gear ratios, torque converter details, fluid capacity, shift patterns, and diagnostic codes specific to the ZF-6HP transmission system.

Updated Oct 24, 2023

Overview Specifications

Comprehensive description of the ZF-6HP transmission specifications for the 2003-2010 BMW 540I, including key features, measurements, and technical details.

How to Use

Use the search function to locate specific ZF-6HP transmission specifications by entering keywords such as 'torque capacity', 'gear ratios', or 'fluid capacity'.

Navigate through the documentation sections using the table of contents or by scrolling through the major sections and subsections.

Key Specifications

Gear Ratios

1st: 4.171:1, 6th: 0.691:1

Torque Capacity

440 Nm (325 lb-ft)

Fluid Capacity

9.5 liters (10.0 quarts)

Weight

86 kg (189.6 lbs)

Length

680 mm (26.77 in)

Available Specifications

Transmission Design and Features

Details about the design, construction, and key features of the ZF-6HP transmission.

Transmission Type and Configuration

6-speed automatic transmission
Longitudinal mounting configuration
Electronically controlled hydraulic system
Integrated torque converter with lock-up clutch

Key Design Features

Compact and lightweight aluminum housing
Adaptive shift control for optimized performance
Integrated mechatronic module for precise gear shifts
Sealed for life design with no scheduled fluid changes

Note: The mechatronic module combines the valve body and electronic control unit for enhanced reliability.

Technical Specifications

Detailed technical specifications and measurements for the ZF-6HP transmission.

Gear Ratios

1st gear: 4.171:1
2nd gear: 2.340:1
3rd gear: 1.521:1
4th gear: 1.143:1
5th gear: 0.867:1
6th gear: 0.691:1
Reverse gear: 3.403:1

Torque and Power Handling

Maximum torque capacity: 440 Nm (325 lb-ft)
Engine power compatibility: Up to 245 kW (330 hp)
Designed for V8 engines in the BMW 540I
Optimized for smooth power delivery and fuel efficiency

Fluid and Maintenance Specifications

Information about transmission fluid requirements and maintenance guidelines.

Transmission Fluid Specifications

Recommended fluid: ZF Lifeguard 6
Fluid capacity: 9.5 liters (10.0 quarts)
Fluid type: Fully synthetic ATF
Operating temperature range: -40°C to 150°C (-40°F to 302°F)

Maintenance Guidelines

No scheduled fluid changes under normal conditions
Fluid level check recommended every 60,000 miles
Use only ZF-approved fluids for optimal performance
Inspect for leaks and damage during routine service

Note: Fluid changes may be required under severe driving conditions.

Dimensions and Weight

Physical dimensions and weight specifications of the ZF-6HP transmission.

Physical Dimensions

Length: 680 mm (26.77 in)
Width: 450 mm (17.72 in)
Height: 350 mm (13.78 in)
Bellhousing bolt pattern: Specific to BMW V8 engines

Weight

Dry weight: 86 kg (189.6 lbs)
Weight with fluid: 92 kg (202.8 lbs)
Lightweight design for improved vehicle dynamics

Search Specifications

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Transmission Specifications

General information

Transmission Type: 6-speed automatic

Manufacturer: ZF Friedrichshafen AG

Model: 6HP19/6HP21/6HP26

Application: 2003-2010 BMW 540i

Part Number: 24 11 7 561 123

Fluid Type: BMW ATF LT 71141

Dimensions And Weight

Length: 680 mm

Width: 450 mm

Height: 350 mm

Weight: 85 kg (dry)

Fluid Capacity: 9.5 liters

Gear Ratios

1st Gear: 4.171:1

2nd Gear: 2.340:1

3rd Gear: 1.521:1

4th Gear: 1.143:1

5th Gear: 0.867:1

6th Gear: 0.691:1

Reverse Gear: 3.403:1

Torque Capacity

Maximum input Torque: 450 Nm

Maximum Output Torque: 600 Nm

Torque Converter Stall Torque: 2.2:1

Operational Parameters

Maximum Engine Speed: 7000 rpm

Maximum Transmission Temperature: 120°C

Shift Response Time: 150 ms

Adaptive Shift Control: Yes

Fluid Specifications

Fluid Type: BMW ATF LT 71141

Fluid Change interval: 60,000 miles or 60 months

Fluid Temperature Range: -40°C to 150°C

Fluid Pressure: 4.5 bar

Maintenance Specifications

Filter Replacement interval: 60,000 miles or 60 months

Seal inspection Interval: 100,000 miles or 120 months

Torque Converter inspection Interval: 100,000 miles or 120 months

Fluid Level Check interval: 30,000 miles or 36 months

Diagnostic Specifications

Diagnostic Tool: BMW ISTA/D

Fault Code Readout: Yes

Adaptive Reset Procedure: Required after fluid change

Sensor Monitoring

Input speed sensor
Output speed sensor
Transmission fluid temperature sensor

Safety information

High Temperature Warning: 120°C

Fluid Leak inspection: Regularly check for leaks

Emergency Shift Procedure: Manual shift override available

Related Components

Torque Converter: Part Number: 24 41 7 561 124
Stall Speed: 2200 rpm

Mechatronic Unit: Part Number: 24 31 7 561 125
Solenoid Valves: 8
Pressure Regulation: Electro-hydraulic

Output Flange: Part Number: 24 21 7 561 126
Material: Steel
Spline Count: 32

Service Information Service

Detailed service requirements and schedules for the ZF 6HP transmission

30,000 miles

36 months

Check transmission fluid level
Inspect for fluid leaks
Check transmission mounts

Ensure fluid level is within specified range

60,000 miles

60 months

Replace transmission fluid
Replace transmission filter
Perform adaptive reset procedure

Use only BMW ATF LT 71141 fluid

100,000 miles

120 months

Inspect torque converter
Inspect seals and gaskets
Perform full diagnostic scan

Replace any worn or damaged components

Common Questions

Find answers to common questions about torque specifications

What is the torque capacity of the ZF 6HP transmission in the 2003-2010 BMW 540i?

The ZF 6HP transmission used in the 2003-2010 BMW 540i has a torque capacity of up to 600 Nm (442 lb-ft). This makes it suitable for the 4.4L V8 engine, which produces up to 333 horsepower and 450 Nm (332 lb-ft) of torque.

What type of transmission fluid is recommended for the ZF 6HP transmission?

The ZF 6HP transmission requires ZF Lifeguard 6 transmission fluid or an equivalent fluid meeting ZF TE-ML 14B specifications. The fluid capacity is approximately 9.5 liters (10 quarts) when performing a complete fluid exchange.

How often should the transmission fluid be changed in the ZF 6HP transmission?

BMW recommends changing the transmission fluid and filter every 60,000 to 100,000 miles (96,000 to 160,000 km) under normal driving conditions. Severe driving conditions, such as frequent towing or stop-and-go traffic, may require more frequent service intervals.

What are common symptoms of a failing ZF 6HP transmission?

Common symptoms include harsh or delayed shifting, slipping gears, transmission fluid leaks, and warning lights such as the 'Transmission Fault' or 'Check Engine' light. These issues may indicate worn clutch packs, solenoid failures, or low fluid levels.

Can the ZF 6HP transmission be reprogrammed or updated?

Yes, the ZF 6HP transmission can be reprogrammed using BMW-specific diagnostic tools such as ISTA/D or INPA. Software updates can improve shift quality, adapt to new components, and address known issues. Always use official BMW software for updates.

Factory Service Resources

Access official service manuals, technical documents, and repair guides. These resources provide detailed procedures, specifications, and diagrams directly from the manufacturer.

ZF 6HP Transmission Technical Manual

Coming Soon

Official technical documentation from ZF covering service procedures, specifications, and troubleshooting for the 6HP transmission.

BMW 540i Service Manual

Coming Soon

Comprehensive service manual for the 2003-2010 BMW 540i, including transmission maintenance and repair procedures.

ZF Lifeguard 6 Fluid Specifications

Coming Soon

Detailed information on ZF Lifeguard 6 transmission fluid, including compatibility and usage guidelines.

BMW ISTA/D Diagnostic Software Guide

Coming Soon

Step-by-step guide for using BMW ISTA/D software to diagnose and reprogram the ZF 6HP transmission.

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Technical Information

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