How-to-Guides

Useful tips for mechanics

Practices worth knowing

Hands-on instructions for your workshop

ZF Aftermarket provides you with practical tips on professionally replacing car parts, inspecting them for potential damage and reinstalling them. Our technical experts have collected a comprehensive set of tips for detecting replicas and plagiarism and everything for the professional service in terms of safe vehicle part replacement.

Our guide to everything that workshops should consider. To make the best of our products – in your workshop, for your clients.

How-to-Guides Overview

Find the instructions you need – quick

Below you will find all useful tips available for workshops.

You can filter the results by clicking on one of the product category boxes. There may be more tips available than initially depicted. Just click on "More results" to find further instructions on your topic.

Mechanic checks a vehicle in a workshop while looking at a tablet

Products

Safe driving in winter

In view of the fact that the braking distance of cars is ten times longer on slippery roads, ZF Aftermarket emphasises the importance of a conscientious winter check of your car.

Brake

Information on the correct Installation of brake pads

TRW brake pads are manufactured to correspond to the original parts and are supplied to our customers with the suitable installation accessories.

Brake

Superkit – the easiest way to repair drum brakes

Despite the increasing number of vehicles with disc brakes on the rear axle, drum brakes remain a fixed component of vehicle engineering.

Brake

Electric Park Brake (EPB) - emergency release

This article discusses a problem that only rarely occurs on mechanical versions – when the brake fails to release.

Brake

Brake judder

The ongoing development in the automotive industry has resulted in increased requirements for braking systems in vehicles.

Brake

Original vs counterfeit – quality characteristics of the Electric Park Brake (EPB)

When it comes to comfort and safety, electric park brakes offer several crucial advantages over conventional hand brakes with cable actuation.

Brake

Replacing the brake disc on an HCV

A step-by-step how-to-guide

Brake

Fault tracing on the brake booster

So is the brake booster defective or is it not?

Brake

How to change brake pads - with EPB

This how to guide shows and describes how to change the brake pads when a car is fitted with TRW electric park brake (EPB).

Brake

How to change the caliper - with EPB

This how to guide shows and describes how to change the caliper when a car is fitted with TRW electric park brake (EPB).

Brake

How to replace a brake drum with bearing (superkit)

A step-by-step useful tip for workshops

Brake

How to replace a brake hose

Whether or not a brake hose is worn or damaged as shown, TRW recommends that hoses should be changed every 50,000 km or after five years at the latest.

Brake

How to measure the boiling point of brake fluid using YWB214

The YWB214 brake fluid tester is specifically designed to measure the wet boiling point of brake fluid in situ on the vehicle.

Brake

How to change the brake fluid reservoir on a VW Passat

A step-by-step useful tip for workshops

Brake

How to diagnose a fault when a car presents an ABS fault light

When a car is presenting an ABS fault light, start by plugging in your diagnostic service tool, select the ABS system and the correct vehicle make and / or model and read for any fault codes.

Brake

Pre-filled brake calipers from TRW

As with any closed hydraulic system, the safe functioning of a vehicle braking system depends on it being free from air.

Brake

Replacing the brake caliper on a HCV disc brake

Our practical advice manual shows and describes how to replace a TRW replacement caliper on an HCV.

Brake

Essential guide to park brake systems

There are three types of park brake systems: Conventional (manual) Park Brake, Electric Cable Puller and Electric Park Brake (EPB).

Brake

Changing Brake Pads on an HCV Disc Brake

Changing brake pads on an HCV disc brake does not present any major challenges for trained mechanics, who should be the only ones carrying out this task. There are still a few fundamental things to take into account.

Brake

Frequently asked questions about brakes

Here we answer frequently asked questions of our users.

Steering

Frequently asked questions about steering

Here we answer frequently asked questions of our users.

Brake

Active Pad Retraction (APR)

CO2 emissions as well as minimizing noises in the increasingly growing number of electric vehicles in the future are matters of urgency concerning vehicle manufacturers.

Brake

Dissembling a blocked brake drum

A sudden locking of the rear axle while driving is one of the most dangerous defects that can occur in a vehicle.

Brake

Measuring the residual slip torque on a front axle disc brake

This how-to guide addresses this issue and tries to find the cause by measuring the residual slip torque of the front axle brake system.

Brake

Electric parking brakes on rolling test bench

Electric systems such as electric parking brakes present workshops with ever increasing challenges for diagnosis and repair.

Brake

Checking and replacing handbrake cables

Unlike brake pads or brake discs, handbrake cables are not exposed to high mechanical stress, but are still subject to a certain amount of wear.

Brake

Pre-filled brake calipers including carrier

TRW offers pre-filled brake calipers including pre-installed carrier for specific vehicles.

Steering

Assembly of Belt Pulleys and Adapter Flanges

Despite the ever growing proportion of electrical steering systems, there are still new vehicles and older models that have conventional power steering.

Steering

Correct Mounting of Bellows

Despite the introduction of an increasing number of electronic components, the causes for mistakes leading to damage on the steering are still the same.

Steering

Function Principle of Electro-Hydraulic Power Steering

EHPS (electrohydraulic power steering) is an electrically assisted power steering system from TRW which combines the advantages of electronically controlled, demand-based steering with robust hydraulic actuation.

Steering

Electro-hydraulic noise emission

Electrically powered hydraulic steering (EPHS) is an intermediate technology on the path to fully electric steering (EPS – electrically powered steering).

Steering

Installing Electric Steering Columns, Gearboxes and Electro-hydraulic Power Steering Pumps

This practical advice will help you to allocate the required measures to the different components.

Steering

Installation kit EPHS steering JKR104 – VW Polo

ZF Aftermarket offers a complete installation kit for electrohydraulic steering for a range of vehicles from the VW Group (Seat, Skoda, VW).

Steering

Remove and Refit an EPHS Steering Pump

Our step-by-step guide on how to remove and refit an EPHS Steering Pump.

Steering

Replace the Rear Track Control Arm

Our step-by-step guide on how to replace the rear track control arm.

Steering

Replace a Steering Pump on a Ford Focus

Our step-by-step guide on how to replace a steering pump on a Ford Focus.

Steering

Replace a Steering Rack on a BMW 3 Series

Our step-by-step guide on how to replace a steering rack on a BMW 3 series.

Steering

Replace a Steering Rack on a Volkswagen Passat

Our step-by-step guide on how to replace a steering rack on a Volkswagen Passat.

Clutch

Automatic Clutch Cables – resetting before Installation

Automatic clutch cables are equipped with a safety device to prevent unlocking of the adjustment mechanism of the cable.

Suspension

How to re-programme the valves in direct TPMS systems

The TRW easycheck TPMS function can used to re-programme the valves in direct TPMS systems.

Suspension

How to change the shock absorbers on a VW Golf 4

Our step-by-step guide on how to change the shock absorbers on a VW Golf 4.

How to change the rear shock absorbers on a VW Golf 4

Suspension

How to change the rear shock absorber on a VW Golf 4

Our step-by-step guide on how to change the rear shock absorber on a VW Golf 4.

Suspension

How to change a suspension strut mount

Our step-by-step guide on how to change a suspension strut mount.

Suspension

Diagnosing faulty ball joints

The checking and testing of ball joints is a difficult thing to do. This tip will give your technicians a good basis on how to test these parts.

Suspension

Multi-link suspensions – more comfort through more arms

Multi-link suspensions have largely replaced conventional wishbone suspensions. The modern design offers increased driving dynamics as well as substantial added comfort.

Suspension

Information on Multi-Link Suspension Systems

The basic elements in a multi-link suspension are two pairs of upper control arms (front and rear), two pairs of lower control arms, stub axle, stabilizer, connecting rods, shock absorbers and springs.

Suspension

TRW Rubber Bushes

Rubber bushes are installed in the suspension. They improve handling during steering and braking, which is particularly important on uneven road surfaces.

Clutch

Checking clutch disks

The clutch disk is the component that makes the connection in the center of the clutch. It is a compact, very complicated component which is subjected to heavy loads.

Steering

Recognize damages to the car chassis and steering system

Careless driving and dirt accumulation significantly increase the risk of wear on safety-relevant chassis and steering components. Workshops need to pay attention to typical indications of defects and remedy damages as required.

Torsional damper with multistage damping

Clutch

Defective torsional dampers

Torsional dampers perform an important function in the clutch: Models with multi-stage damping effect are used to reduce vibrations in the driveline.

Clutch

Bleeding clutch actuations

Even though the electrification of vehicle components is progressing inexorably - the electric power steering system just being one example - especially three components continue to be actuated hydraulically

Clutch

Calibrating ConAct

The Concentric Clutch Actuation System, abbreviated ConAct, is an electronically controlled pneumatic clutch actuation system for commercial vehicles.

Clutch

Checking the vehicle electrical systems and cleaning the electric contact surfaces

Rough engine running and noises when starting or switching off the engine are in some cases too quickly associated with a possible dual-mass flywheel (DMF) defect.

Clutch

Clutch replacement

As the link between the engine and transmission, the clutch is responsible for transferring the engine's torque to the road.

Clutch

Clutch doesn’t disengage

Frequent causes why the clutch doesn’t disengage correctly include faults in the release system (clutch release bearing, slave cylinder, clutch lever), a jammed pilot bearing, or non-compliance with important installation requirements.

Clutch

Grabbing clutch - causes and damage evaluation

When alternating torques occur in the slip phase (e.g., due to friction value fluctuations) and causes vibration of the driveline, this is called clutch grab.

Clutch

Replacing the slave cylinder

Correctly replacing the slave cylinder prevents seal and clutch damage. It should be replaced whenever the clutch is replaced.

Clutch

Checking the DMF

The wrong diagnosis is often a defective dual-mass flywheel. Therefore, checking the dual-mass flywheel should always start with excluding other causes in the area of the flywheel first.

Suspension

Changing suspension springs

Together with shocks and suspension strut mounts, suspension springs fulfill important safety and comfort functions. This is why you should regularly inspect the components and replace them in the event of corrosion damage or fractures.

Workshop employee shanging shock absorber on car mounting

Suspension

Changing shock absorbers

The shock absorber, which is also called the vibration damper, is mainly responsible for safety and driving comfort. Find out in this workshop tip when to change shock absorbers, and how to correctly install new ones.

Suspension

Inspecting shock absorbers

Dampers should be tested regularly. That's because reduced performance causes many risks for drivers.

Suspension

Installing shock absorbers

The performance of the shock absorber suspension system directly affects a car’s handling safety and comfort. Improper assembly or accidents, however, can lead to distortion of dampers.

Suspension

Replacing CDC dampers

SACHS Continuous Damping Control (CDC) is one of the most popular ZF products. Early in 2012, the twelve millionth unit for passenger cars rolled off the line at ZF Friedrichshafen AG's Schweinfurt location.

Suspension

Proper disposal of shock absorbers

The proper disposal of shocks is an important topic for ZF. After all, environmental protection is a key corporate objective.

Suspension

Defective shock absorber due to impact damage

Accidents or serious installation errors can cause impact damage to shock absorbers. It is therefore advisable to look for damage to car axles and damper attachments and to carry out professional wheel alignment.

Suspension

Leaking shock absorbers

Apparently leaking shocks often don't indicate a defect, but are absolutely tight and functioning properly.

Clutch

Clutch noise

The clutch makes noises – what can you do? The SACHS workshop tip gives you valuable information on clutch noise and its possible causes and solutions.

Tribocorrosion with non-greased hub spline

Clutch

Greasing the hub spline of clutch disks

Greasing the hub spine ensures that the clutch will continue to function perfectly in the long-term. Read more.

Clutch

Clutch Slipping

The problem of slipping clutches is very wide-ranging.

Clutch

Identifying defective release bearing systems

A large number of malfunctions in commercial vehicles can be traced to the influence of defective release bearing systems.

Steering

Replacing stabilizer mounts

Problems with sway bar bushings, also known as stabilizer bushings, axle stabilizer, stabilizer bar bushings or sway bar link? We give iInstructions on replacing the stabilizer mounts.

Steering

The safety margin of chassis components and steering parts

How to recognize damages in consideration of the safety margin of chassis components and steering parts.

#zfservice

Legal liability for spare parts

When it comes to sSpare parts from a dubious source, product liability law may consider the workshop to be the manufacturer under certain circumstances and, accordingly, the workshop must assume liability.

Steering

Changing a broken stabilizer link

They transmit torsional forces occurring between the body and the chassis to the stabilizer of the particular axle. Depending on the design of the front or rear axle, they form the necessary connection for optimal interplay between wheel guidance and stabilizer.

Steering

The wheel alignment on four-link suspensions

VW Group vehicles belonging to the so-called B5 platform such as the Audi A4, A6, A8, VW Passat, Skoda Superb, Seat Exeo, and others are equipped with four-link suspensions. They are double-wishbone axles that, thanks to the separate link level, improve driving properties significantly.

Suspension

Replacing control arms

Control arms are installed in pairs on the front and rear axle and connect the chassis to the wheels as part of the suspension. Therefore, they have a significant influence on the driving characteristics of the vehicle.

Steering

Changing a defective compression ball joint

The exact work steps for changing the damaged compression ball joint vary from vehicle to vehicle and are specified by the vehicle manufacturer.

Steering

Tie rod replacement

If you feel a bump in the steering when driving over road bumps or curbs, this might be due to worn tie rod ends or broken inner tie rods. Changing the tie rod must be necessary.

Steering

Replace strut mounts

The top fastening of the suspension strut is attached to the chassis via the strut mount – also known as the suspension strut mount. Since the strut mount must have both a damping force and a rotatable mounting for unhindered steering resetting, there are strict requirements for its function and wear resistance.

#zfservice

Checking rubber-to-metal components

How to check rubber-to-metal components and how to change and replace defective rubber-to-metal components. Click here

#zfservice

FAQs concerning product piracy

Information about repercussions of and measures against product piracy and falsified car parts. Read more here.

Service

High Level Transmission Oils

There are effective tools in the race against wear. ZF Aftermarket shows what really matters.

Service

Changing Transmission Oil

Exemplary step-by-step instruction on a hybrid passenger car

How to change the transmission oil on a passenger car

Service

Perform an Oil Change

Do automatic transmissions need oil changes too? Absolutely! It is the only way to maintain a pleasurable drive and premium performance in the long run.

Service

Passenger Car Chassis Check

ZF Aftermarket recommends a pre-vacation vehicle check at the workshop to ensure that passenger car chassis and steering parts undergo regular maintenance.

General note

Our useful tips provide only an overview. The installation instructions and operating instructions provided by the vehicle manufacturer and the warning and safety instructions contained therein must be observed! All work must be performed by a trained professional.

The pictures used and the procedure described in our tips are examples and may vary depending on the vehicle manufacturer and axle design.

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