ZF 5HP19 Transmission Master Rebuild Kit, BMW Audi VW

A master rebuild kit for the ZF 5HP19 five-speed automatic, the longitudinal unit behind a long list of late-90s and 2000s European cars. Listed fitment includes 1995-on BMW 3 and 5 Series (323i, 325i, 330i, 525i from 2000-2007), 1996-2007 Audi A4 and S4, 1997-2005 A6, 1997-2000 A8 3.7L, 1998-2012 VW Passat and 2006-2008 Porsche Cayman 2.7 and 3.4.

The kit covers the soft parts for a full overhaul: friction clutch material, gaskets, seals and O-rings. On the 5HP19 the usual reasons to go inside are harsh or delayed engagement, slipping in 4th and 5th, and flares on the 2-3 shift once the clutch packs and piston seals wear. Worn seals also let the unit bleed pressure, which shows up as slow shifts when hot.

Bench notes: measure clutch pack clearances on reassembly rather than trusting stack height, soak new frictions in fluid before installing, and replace the mechatronic/valve body seals while the unit is apart. Refill with the ZF-approved ATF for your application and check level hot at the fill plug, then run a transmission adaptation reset with a scan tool.

Confirm your transmission tag reads 5HP19 before ordering; the 5HP18 and 5HP24 look similar from the outside but do not share this kit.