ZF HP-500 2009 Parts Catalog – Factory Assembly Data for 5-Speed Automatic

Description

If you’re tearing down a ZF HP-500, you need the right part numbers – not some third-party list that’s missing the updated seals or gets the clutch count wrong. I’ve seen guys order a whole valve body because a generic catalog showed the wrong revision. That’s wasted money and a week of downtime. This ZF HP-500 2009 Parts Catalog is the OEM document from ZF Friedrichshafen, 59 pages, dated 20 January 2009. It’s what the factory uses to order parts for the 5 HP-500 transmission. No abbreviations, no “similar to” numbers – straight from the source.

Ratios, Pressures, and Oil Capacity – Page 2 Tells All

Page 2 of this catalog lists every critical spec for the HP-500. First gear ratio 3.43, top gear 0.83, reverse 4.84. Main pressure with converter open is 18 bar, closed 10 bar. Oil capacity 20 dm³ (that’s about 21 quarts). The manual also gives the cleaness scale numbers and the ZFN 5015 specification for internal cleanliness. If you’re swapping a converter or rebuilding the valve body, those pressures are your baseline. Don’t trust a generic table – use the factory numbers.

What Oil Does This Transmission Take?

The technical cover page specifies oil grade permissible acc. to TE-ML14. That’s ZF’s own lubricant list. For the HP-500, you need a fluid that meets TE-ML 14. Don’t guess with Dexron or some universal “multi-vehicle” stuff. The catalog also lists the oil sump design as deep, drain connections prepared left+right. Oil fill tube height is 192 mm with coding K01. That matters when you’re measuring level.

7 Critical Specs from the Technical Cover Page

This catalog doesn’t waste space. The technical cover (pages 1–2) crams in 7 specs you need before ordering parts: operating voltage 12V, maximum brake torque 1100 Nm, output flange type HA yoke 1710, converter designation W360 with TPC 210 Nm, converter characteristic μ 2.43, and the ZFN 916 conservation spec. If you’re rebuilding a unit for a fire truck or bus, those numbers prevent buying the wrong output shaft.

Get the Correct Part Numbers – Avoid Returns

Every drawing referenced in the catalog has a separate part number: 4139.000.101 for attachment parts, 4139.003.307 for the gearbox itself, 4139.103.023 for the output, 4139.106.218 for shift control, 4139.110.019 (no description given), 4139.147.135 for heat exchanger, 4139.601.106 for the automatic transmission assembly. Plus archived documents for test and assembly instructions (000000118324, 000000118325). You can cross-ref those numbers directly with ZF. No aftermarket cross-list that swaps a bearing for a bushing.

OEM Documentation vs Aftermarket: Why It Matters

I’ve had parts catalogs from third-party publishers that list the wrong seal size for a HP-500 rear cover. The OEM document is the only one that shows the exact material numbers and revision amendments. This catalog includes amendment numbers on every page. It’s marked “For information only, not subject to amendment service” – that means it’s a static snapshot of the original. No risk of outdated data being mixed in with a later update. Use it, and you order what actually fits.

Now, if you work on multiple ZF transmissions, you might also need parts lists for other models. Check out the ZF 16S151 ECOSPLIT III & 16S151 R 2007 Parts Catalog for heavy-duty truck boxes. Or the ZF 16S221 ECOSPLIT III 1316 2007 Parts Catalog OEM Specs for the 16-speed family. For the 2521 series, see the ZF 16 S 2521 TO 2010 Parts Catalog – OEM Factory Specs.

For context on how ZF transmissions evolved, read the Automotive Industry Overview on Wikipedia. And remember – operating voltage is 12V; if your battery is weak, the shift solenoid might not pull in correctly. Check your Automotive Battery condition before blaming the valve body.

FAQ – Common Questions About This Parts Catalog

Does this catalog include exploded diagrams?

No. This is a parts catalog – it lists part numbers, quantities, and references to drawings (e.g., 4139.000.101). You get the numbers, not the illustrations. For assembly diagrams, you need the service manual.

What transmission models are covered?

Only the ZF 5 HP-500, material number 4139.003.362. Not the HP-600 or earlier 4 HP models. Check the material number on the transmission data plate before ordering.

Can I use this for rebuilding?

It helps with ordering, but rebuilding requires torque specs and tolerances, which this catalog doesn’t contain. Get the factory service manual for assembly procedures.

Why is the oil capacity given in dm³ not quarts?

ZF uses metric. 20 dm³ = 20 liters = about 21.1 US quarts. Use the exact fill height (192 mm) to avoid under- or overfilling.

Stop guessing with aftermarket junk. Access the Factory Manual for your HP-500 today and get the correct part numbers, ratios, and specs – all from the original ZF document.