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.

brake pads with numbers for manual
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.

superkit
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.

Electric Park Brake (EPB) - Emergency Release
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 judder
Brake

Brake judder

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

Original vs Counterfeit
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.

employee measuring the brake disc
Brake

Replacing the brake disc on an HCV

A step-by-step how-to-guide

booster check
Brake

Fault tracing on the brake booster

So is the brake booster defective or is it not?

epb's
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).

trw calipers in different colors
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).

TRW Superkit
Brake

How to replace a brake drum with bearing (superkit)

A step-by-step useful tip for workshops

brake hose part
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.

trw testing brake fluid
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.

trw brake fluid reservior
Brake

How to change the brake fluid reservoir on a VW Passat

A step-by-step useful tip for workshops

trw sensor check tool
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.

pre-filled brake calipers from trw
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.

Replacing the Brake Caliper on a HCV Disc Brake
Brake

Replacing th Brake Caliper on a HCV Disc Brake

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

essential guide to park brake systems as diagram
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).

Changing brake pads on an HCV disc brake
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.

workshop employee working on brakes
Brake

Frequently asked questions about brakes

Here we answer frequently asked questions of our users.

workshop employee working on steering
Steering

Frequently asked questions about steering

Here we answer frequently asked questions of our users.

Active Pad Retraction (APR)
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.

rusted drum brake
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.

indicator torque wrench in action
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.

VW Passat brake test video
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.

rusted handbrake cable
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 caliper
Brake

Pre-filled brake calipers including carrier

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

steering pumps
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.

damaged rack
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.

ephs steering system diagramm
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 kit
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).

yellow label
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.

TRW installation kit jkr104
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).

EHPS
Steering

Remove and Refit an EPHS Steering Pump

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

Replace rear track control arm
Steering

Replace the Rear Track Control Arm

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

ephs Steering pump
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_Gear
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_Gear_Exchange
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.

Automatic clutch cable GCC102
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.

TPMS valves re-programming
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.

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

cv joint
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.

Multi-link suspensions – more comfort through more arms
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.

Inspecting the suspension system
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.

TRW Bushes on test rig
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.

Checking clutch disks
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.

Defective torsional dampers
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.

Bleeding clutch actuations
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

conact module perspective
Clutch

Calibrating ConAct

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

Corroded contact surface
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 replacement
Clutch

Clutch Replacement

Replacing the clutch of a manual transmission so expertly that the gears can be shifted again perfectly is mere routine for an automotive technician or mechanic.

Lateral runout of the clutch disk
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.

SACHS clutch with slightly oily facings
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 kit
Clutch

Replacing the Slave Cylinder

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

DMF testing tool
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.

Installing shock absorbers in the workshop
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.

Damper testing
Suspension

Inspecting Shock Absorbers

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

Bent piston rod
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. This can severely shorten their service life, and also lead to serious damage to the component.

CDC (Continuous Damping Control)
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.

Clamp the damper with the piston rod
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.

Broken off rod eye
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.

Oil traces on the damper
Suspension

Leaking Shock Absorbers

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

Clutch disk torn off
Clutch

Clutch Noises? Workshop Tips on Possible Causes

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

Tribocorrosion with non-greased hub spline
Clutch

Greasing the hub spline

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

Facings worn down to rivet heads
Clutch

Clutch Slipping

The problem of slipping clutches is very wide-ranging. For example, the clutch of a vehicle may slip only at high speeds. Other drivers complain that their clutch slips when the engine is cold, during starting, when setting off, or in first speed position.

New and worn pitches compared
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.

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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