I finished the rebuild on the A6, had the unit "dyno-tested" at Autosports in Zeeland, Michigan. Pretty cheap insurance, cost 2-hrs labor to test it (140.00) ,well worth the cost and piece of mind that came with it. If something had been wrong, they could have addressed it on the spot and the dyno would have pointed them right to the problem.
Using a PDF creator I added a great deal of additional information to the original ZF manual I converted. I added hints, "special tool" alternatives, photos, traps to avoid, extra pages of parts list and national suppliers. I think it will be real handy to someone considering a rebuild on their own. The manual increased from the original 202 pages to over 270.
It was a long and difficult rebuild, there was a couple seals I simply could not replace, without a press. I think I can make the PDF available without getting into trouble with ZF. Let me know if you want a copy. It's still pretty rough and needs editing, but still usefull.
Jackson

 

This is exactly what I have been looking for. Are you selling copy of ZF manual, they are hard to find also parts are not easy to look up. Can you give some sources you used. Greatly appreciate any help.

 

Its been almost two years, have you made the PDF available for us. I'm looking all around for these information. thanks

 

I have the PDF on disc. It is nearly 300 pages. It can not be "downloaded" as it is too large. I have been sending to a physical address, for those folks who want it.

 

How big the file size would be? couple hundreds MB wouldn't be too large for downloading. And how much u would like charge? thanks.

 

I would also be interested is it is for the GAG model.
I was looking to purchase this from ZF themselves. If you want it to go through you, simply load it onto an FTP server and charge.

 

It's for a ZF5HP24A. If you have this transmission,....it's relevant.

 

https://sizablesend.com/

 

yes I have the trans from the 2003 RS6 5hp24A.
One problem I am having is removing the pump behind the torque convertor. Any suggestions?

 

Yes, you have found the larger torix head bolts that go around the pump,...but there are also 2 smaller bolts that you will also need to remove (8-total bolts,..I think). These smaller bolts are also located on the front of the pump housing. If you have removed all the bolts, the only thing holding in the pump housing,...is the O-ring that seals the pump housing to the transmission housing. It is pretty tight.
There's also two bolts behind those two black plastic plugs.