Complete overhaul kit for the ZF 5HP19 five-speed auto in BMW 3 and 5 Series, Audi A4 A6 A8 and VW Passat: frictions, steels, gaskets, seals and o-rings.
If your BMW 325i, 330i or 530i, your Z4, or an Audi A4 or VW Passat with the five-speed automatic is slipping in reverse, flaring on the 2-3 upshift once it is hot, or shifting late and harsh after a long drive, the ZF 5HP19 inside it is usually overdue for a full overhaul. This master rebuild kit carries the wear parts for that job: friction plates, steel plates, the pan and valve body gaskets, lip seals, sealing rings and the o-ring set, so the unit goes back together with fresh clutch packs and new rubber in every hydraulic circuit.
ZF introduced the 5HP19 in the late 1990s as a stronger successor to the 5HP18. It is a Ravigneaux-type five-speed rated around 300 Nm of input torque, and it holds roughly 9.2 liters of fluid in the rear-drive BMW version. Gear changes come from a set of multi-plate clutches and brakes, each applied by a piston that relies on seals and o-rings to hold pressure. Two of those circuits matter most to the complaints buyers describe: the D accumulator cushions reverse engagement and the F accumulator shapes the 2-3 shift. When their cap o-rings harden and flatten with age, apply pressure bleeds off and the clutch slips even if the friction material still has life in it. A master kit addresses both halves of the problem at once: new frictions and steels for the burnt packs, and new seals and o-rings for the leaking circuits.
Start with the fluid. Pull the fill plug, check level at temperature, and compare a sample with our ATF color and smell chart; black fluid and material on the magnet mean the frictions are spent. If the fluid still looks healthy and the only complaint is a hot reverse slip or a hot 2-3 flare, the fix may be smaller. FenderBender reports that hardened D and F accumulator cap o-rings cause exactly those symptoms on BMW, Audi and VW 5HP19 units, and that some cars come back after a rebuild because those caps were missed. Every rebuild should include them. Rule out the solenoids as well: our guide to testing a transmission solenoid with a multimeter covers the resistance checks, and a worn set can be replaced with the ZF 5HP19 seven-piece solenoid kit.
This kit is listed for the ZF 5HP19 and 5HP19FLA: BMW 3 Series and 5 Series, Audi A4, A6 and A8, VW Passat, and the 2006-2008 Porsche Cayman. In practice the BMW 5HP19 applications are the E46 3 Series from about 2000, the E39 5 Series from 1998 to 2004 and the 2002-2005 Z4 with the M54 engine. Many earlier E36 and E39 cars used the 5HP18 instead, which this kit is not listed for. Audi and VW cars use the longitudinal FL and all-wheel-drive FLA versions, and Porsche used HL and HLA versions. Sensor and internal hardware changed through production, so read the ZF tag on the case before ordering, or send us your year and VIN and we will check it. Audi and VW owners can add the 5HP19 filter and pan gasket kit for the 01V.
| Fits | ZF 5HP19 / 5HP19FLA (BMW 3/5 Series, Audi A4/A6/A8, VW Passat, Porsche Cayman) |
| Kit type | Master rebuild: frictions, steels, gaskets, seals, o-rings |
| Transmission | 5-speed automatic, ZF 5HP19 |
| Weight | About 5 lb |
| Ships | From the USA |
Probably not. Most E36 and early E39 cars used the ZF 5HP18, and this kit is listed for the 5HP19. Check the ZF tag on the side of the case, or send us your year and VIN and we will confirm before you order.
It covers the parts involved. A hot reverse slip on the 5HP19 is often caused by hardened o-rings on the D accumulator cap, and the kit includes the o-ring set. If the frictions are burnt as well, the full kit replaces those too.
Most builders also replace the torque converter, since the captive-clutch design is hard to rebuild. Clean the valve body, replace any scored drum, and change the solenoids if they test out of spec. Also flush the cooler and lines.
The rear-drive BMW version holds about 9.2 liters when completely dry. A rebuilt unit with an empty converter needs most of that. Fill to the level spec at the fill plug with the fluid listed on the transmission tag.
No. The 6HP19 is a six-speed with a different gear train, and none of these clutches or gaskets fit it. Our ZF 6HP19 and 6HP26 problems guide covers that later unit.
Yes. Clear the transmission adaptations with a capable scan tool, then drive the car through all gears under light and moderate throttle so the control unit can relearn clutch fill times on the new plates.
