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HOWTO: ZF Transmission replacement (TCM)


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This guide explains the steps to replace a ZF transmission and upload you existing calibration to it. This guide requires that the replacement transmission is from the same vehicle. Eg if you have a BF you must source a ZF from another BF. If you have an FG you must source a ZF from another FG.

UPDATE: BF TCMs can be converted to FG and vice versa by sending your TCM to either Brett at Custom Machine Works or Matt at BPR who both operate a mail order service for reprogramming the base operating system. This cannot be done with PCMTEC as it requires a special cable and software package.

https://www.facebook.com/Custom-Machine-Works-856789001022313/

https://www.bulletperformanceracing.com.au/

If you attempt to put a BF ZF in an FG or vice versa you will have to replace the TCM/mechatronics in the box. Although the boxes are identical the real time operating system is not. The real time operating system is not written when you write the TCM hence you will end up with a TCM that is in limp mode if you do not swap it over.

If you do not follow this guide and attempt to write your existing calibration to the vehicle will get a "Vehicle serial does not match" error when attempting to write the old TCM file.

Step 1:

Read the existing old TCM and save it to disk. Ensure you have ticked "TCM" only within the flash read page. If the TCM was erased at any stage you can still do this step, but you will need to use recovery mode and manually select the TCM type from their corresponding dropdowns. For ZF there is only one option, Ford ZF.

Save this read as "Old TCM.tec"

If you no longer have the old TCM you will need to press Calibration Tools -> Create stock file", then press "Create stock file from strategy or catchcode" then enter in the strategy from the old TCM eg 8R29-7J105-PE (this is NOT the hardware number which looks similar) and save this tile as "Old TCM.tec"

Step 2:

Install the new box ensuring the TCM plug is intact with no pins backing out (this is a common fault).

Read the new TCM only by ensuring only TCM is ticked within the flash read page.

Save this as "new TCM.tec"

Step 3:

Open the merge wizard via "Create Stock File/Calibration Merge"

image.png.aee83d3d0e52ae62955e824b2030139f.png

Select "Manually Merge VID/Serial"

image.png.075f182f9202bdba26b59e182cda7584.png

Press "Load File 1" and select "Old TCM.tec"

Press "Load File 2" and select "new TCM.tec"

image.png.4b4e2c7891ee9ce36cfd128828d1311d.png

Next press "Import TCM Serial from File 2"

Press "Save File 1" and save as "New merged TCM.tec"

Now license the file again (will cost 0 credits to license the new TCM file) and write the file to the vehicle.

A guide to replace the PCM can be found here:

 

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  • 8 months later...

Hi Roland,

Are you aware if FG mk1 and MK 2 mechatronics are the same? 

I have to do a box swap for a customer who has a 2014 MK2 turbo and he has a MK1 FG turbo box, the above process would still work or does it need to be MK2 spec also?

Thanks Neil

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The hardware as far as I know is the same but the operating system may not be. You might be able to just change the calibration, if the operating system needs changing you'd need to send it to Custom Machine Works or BPR to have it changed (requires a special cable that uses KLine) 

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7 hours ago, Roland@pcmtec said:

The hardware as far as I know is the same but the operating system may not be. You might be able to just change the calibration, if the operating system needs changing you'd need to send it to Custom Machine Works or BPR to have it changed (requires a special cable that uses KLine) 

Hi Roland, does the PCMtec application have the ability to change the operating system?

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7 hours ago, Roland@pcmtec said:

Not possible, requires KLine which the tactrix doesn't support. 

Thanks for the confirmation that it couldn't be done using PCMtec & a different cable.

I've been advised of a cable & different software that'll work but haven't looked at it any further yet.

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