Maximizing Mobility Uptime: ZF showcases pioneering innovations for the Now & Next

Philippe Colpron, Head of ZF Aftermarket, explains why the division focuses on driving innovation and sustainability across all our product lines: “We are committed to providing our customers with the highest quality solutions while also contributing to a sustainable future. Our extensive portfolio of high-quality components enhances the longevity and reliability of vehicles. At the same time, our specialists provide expert support and services for our partners, ensuring that any issues are efficiently resolved, maximising uptime together. This is one example of how we create sustainable value in our ecosystem.“

For more safety and greater comfort on the road: ADAS Solutions and Calibration Equipment for Passenger Cars

ZF is a global market leader for ADAS, producing over 10 million cameras per year. Now, the Group’s aftermarket division makes not only ADAS OE technology available to the IAM but also the right equipment and knowledge to handle these advanced systems. Early 2025, the ZF Smart Camera will be available for popular applications including the Nissan Leaf, Nissan Qashqai, Peugeot 3008 and Citroen C3, bringing OE innovation and precision into the aftermarket. This high-performance mono front camera detects the environment in front of the vehicle, providing high-resolution pictures for object recognition to enable functions like Automatic Emergency Braking (AEB), Lane Keep Assist System (LKA), and Adaptive Cruise Control (ACC).

To complement ZF’s ADAS offering for the IAM, the business also presents ADAS calibration equipment as part of the new ZF [pro]Diagnostics portfolio. ZF [pro]Diagnostics offers remote diagnostics capabilities, access to advanced technical information, as well as comprehensive solutions for both static and dynamic ADAS calibration, suitable for multi-brand passenger cars and commercial vehicles.

The ZF [pro]Diagnostics ADAS calibration equipment comes with the latest digital technology standard which enables workshops to handle precise sensor calibration in a convenient way without a need to change physical calibration targets. In addition, ZF Aftermarket offers new ADAS training courses for its workshop partners to provide them with first-hand OE expertise to best prepare them for working with ADAS systems.

Markus Wittig, Head of Business Line Passenger Cars, explains why workshops need to become experts in ADAS: “We will expand the ADAS product line further in 2025 because these systems are witnessing unprecedented growth due to an increasing customer awareness of safety and assistance features as well as rising regulatory requirements. Since such a system must always operate reliably to ensure the desired level of safety, it must be precisely calibrated. We support our partners with comprehensive expertise and practical assistance in solving specific problems while providing access to the corresponding products in OE quality.”

Maintain – Repair – Replace: ZF Aftermarket’s Electric Powertrain Approach for Passenger Cars

At Automechanika, ZF also spotlights its lifecycle solution approach for the electric powertrain and the strategy "Maintain – Repair – Replace".

With its extended portfolio of ZF Lifeguard eFluid and ZF Lifeguard Hybrid, ZF Aftermarket recently doubled its range for EVs and HEVs, taking care that more than 50% of electrified vehicles in Europe can be maintained accordingly. Thanks to ZF Aftermarket's complete packages for transmission oil changes, workshops receive the necessary spare parts set from a single supplier to ensure smooth replacement. In the field of repair, ZF's aftermarket division has recently launched its first repair kits — now ZF is continuously expanding its range, with more kits for various car models to follow, including for example for the Lotus Eletre which visitors of ZF's booth can see on the show floor in Frankfurt. The last pillar is Replace: Thanks to its decades of remanufacturing expertise, ZF has developed a technical concept for remanufacturing of electric axle drives such as the eVD2, which visitors to the Automechanika can see at the ZF stand.

“With our Maintain – Repair – Replace offering we aim to ensure that customers enjoy longer-lasting, high-performance electric vehicles with maximized Uptime and lower total cost of ownership,” comments Markus Wittig.

Sustaining leadership position by expansion of the portfolio for Electric and Combustion vehicles in the Passenger Car segment

ZF Aftermarket’s aim is to provide customers with the best possible support for the technologies of today and tomorrow to increase their uptime. ZF has further increased its product coverage in the field of e-mobility − from fluids, suspension and damping to steering, brakes and rubber-metal parts.

A completely new addition in the portfolio for electric vehicles is TRW NOxidation, a newly developed special brake assembly paste for the requirements of brake systems in modern vehicles. TRW NOxidation grease tackles the persistent problem of stiff brake rust and corroded brake discs, ensuring that customers enjoy quieter rides and safer brake systems.

ZF Aftermarket’s portfolio of up to 1,000 braking references for electric vehicles is being constantly expanded. For example, 90% of the Top 10 Electric Vehicles in Europe are being covered with ZF brake pads, while a coverage of more than 86% have already been achieved with the steering & suspension portfolio across Lemförder and TRW. At the same time, the company continues to work on broadening and deepening its range for vehicles with conventional drive systems. In braking, ZF offers over 20 different product groups for efficient and reliable repair of brake systems. The TRW product range in Europe covers up to 95% of the car park, and as much as 97% for brake pads. In the area of shock absorbers, 85% of vehicles are covered by OE-quality SACHS components And ZF does not stop adding completely new products to its range, such as the SACHS Air Struts which are premiering at Automechanika.

At Automechanika ZF will introduce a range extension of TRW semi-compound brake discs in new designs −a technical solution that offers premium OE-equivalent replacement parts, designed to highest standards for optimum performance. In addition to ZF’s current portfolio of 27 references for BMW models, 18 new references for Mercedes & Land Rover will be available by the end of the year.

A Uniquely Broad Technology Portfolio & Service Solutions that matter for Commercial Vehicles

“We offer customers access to the broadest range of commercial vehicle solutions in key domains like Electrified Mobility, Driving Assistance and Braking Systems as well as Fleet Operations”, underlines Aleksander Rabinovitch, Head of Business Line Commercial Vehicles, ZF Aftermarket. “Our local teams and ZF [pro]Service partners, established across the globe, offer technical support and service wherever needed. Close customer proximity means for us, we are always on site where our customers are.“

For this reason, ZF Aftermarket will now focus on its ZF [pro]Service concept. With more than 3000 workshop partners in over 100 countries on all continents, it stands for unrivalled customer proximity and extensive customer service. “Our workshop concept transforms the unmatched technological knowledge of the world’s leading commercial vehicle supplier into personalized service solutions for every truck, trailer or bus workshop” explains Aleksander Rabinovitch. “We will continue to build on our strengths independently and growing globally our fleet proximity and technical support with ZF {pro]Service.”

ZF Aftermarket has extended its ADAS portfolio for commercial vehicles with the addition of WABCO OnLaneALERT Camera and OnGuard Radar spare parts camera radar & brackets exclusively for DAF and IVECO commercial vehicles. Both systems assist drivers in recognizing and responding to dangerous driving scenarios, and thus actively contribute to greater road safety. Aftermarket workshops can carry out the replacement of these ADAS spare parts professionally with the appropriate diagnostic software.

New Kits for convenient repairs of CV’s Electric Drives for Commercial Vehicles

Twelve new repair kits for ZF’s CeTrax system are also a good example of how ZF Aftermarket combines its broad portfolio with a high level of customer orientation. CeTrax is an all-electric central drive that can be used in different bus applications as well as in delivery trucks. Installed in battery driven vehicles, the system operates with zero local emissions. ZF repair kits include all relevant parts for a quick ordering and an easy as well as safe repair to ensure that workshops save valuable time. With this innovative portfolio, ZF Aftermarket is once again opening up the technological change in the OEM industry for the aftermarket industry.

ZF’s intelligent Trailer Braking Platform ensures greater cost and time efficiency across the complete trailer value chain. In the fourth quarter of 2024, the aftermarket division will launch the standard and premium variants of the new Trailer Electronic Braking System generation “iEBS” that will provide a variety of integrated functions to the market, e.g. Tire Pressure Monitoring. At the same time, the business prepares ZF [pro]Service partners with the relevant technical know-how to realize shorter installation and training times so that they can maximize the uptime of the vehicles.

SACHS Premium Comfort Valve (PCV) shock absorbers for buses and coaches provide a perfect balance between comfort and stability, thanks to ZF’s innovative valve suspension technology. The latest generation of shock absorbers makes the journey more comfortable for passengers, keeps the vehicle stable and reduces noises to a minimum. What is helpful for all types of drive units, becomes even more important for electrified vehicles, where PCV allows a better control of the changed vehicle construction and weight balances. First applications, for example for MAN and Daimler Buses, can already be ordered.

Digitalization in transport as one of the most important levers for making this sector more sustainable and safer

Smart tachographs provide real time insights to fleet managers and offer increased safety and efficiency. Beginning 21 August 2025, vehicles equipped with Smart Tacho 1, or even older analogue or digital tachographs, must be retrofit to a Smart 2 tachograph. From 1 July 2026, tachographs will also be mandatory in commercial vehicles over 2.5 t in cross-border traffic. The new ZF Smart Tachograph captures comprehensive data such as driving and resting times, speed, and location, streamlining data integration for drivers, dispatchers, and customers. The result: Improved operational transparency and simplified adherence to European regulations for commercial vehicles.

ZF Bus Connect is ZF’s digital fleet management solution for city buses and coaches with electric, hybrid or combustion engines. It is designed to help transport companies and bus OEMs to save cost, increase safety and improve bus fleet operations based on data insights and analytics. Its "Vehicle Health" feature has been nominated for the Automechanika Innovation Award in the “Data & Connectivity” category. This feature provides fleet operators with a comprehensive assessment of each vehicle’s condition by consolidating data from diagnostics messages, ZF Health Check data, Tire Pressure Management Systems, and brakes. The intuitive traffic light system helps fleet managers identify and address potential issues proactively, thus improving uptime and operational reliability.

A Commitment to Innovation and Sustainability

Philippe Colpron emphasizes: “Our presence at Automechanika 2024 is all about delivering tangible value to our customers. We are committed to innovation, quality, and sustainability across all our product lines to ensure that our customers can meet the demands of a rapidly evolving market. From advanced diagnostic tools and a further expanded broad portfolio to cutting-edge fleet solutions, we are enabling our partners to enhance vehicle safety, operational efficiency, and service quality. We’re eager to continue working closely with our customers, turning their needs into reality. With maximizing mobility uptime, an essential prerequisite for connecting people, we empower businesses to thrive and make a sustainable impact on the society.”