The ZF 5HP24 torque converters don’t have anywhere near as bad a reputation as the GM 5L40-E ones used in the 3.0 litre diesel models but, nevertheless, I always get mine remanufactured when I’m doing a rebuild. I’ve never had any problems/complaints with remanufactured units (done by an approved ZF supplier) yet.

Regarding the little coloured orifice discs, I know that the 2.2mm orange one (for the E-brake = 27.024) was a white one at an earlier point so I guess these were continuously in development to give the best shift/engagement feel. Similarly they must have changed the orifice sizes for the 4.6iS as the F-brake exhaust (lower LH side in my diagram) used to use 27.034 which is the black 1.5mm orifice disc and the A-clutch orifice (on the RH side) was 27.040 which is a 1.2mm orifice (translucent purple).

I’m sure you’ve already done this but, just in case, you need to knock out the centre sleeve of the D/E-brake drum to check the O-rings which seal the sleeve for the C-clutch supply for reverse. I’ve attached a couple of pictures below regarding one that I’d repaired in the past. New O-rings are included in the overhaul kit.






Phil