Auto trans fail from heat...keep them cool and they dont really fail that often.
That's not the only failure mode.
Auto trans also fail when too much energy is dumped into the clutches on shifts. There are a number of factors affecting how much energy they have to absorb on a shift. Engine power is one of them, obviously. But also the speed of the shift. Trans are programmed with a certain time period built into the shifts, when the clutches are allowed to slip, in order to make shifts softer. This is another way that a bigger engine will destroy an auto trans. It can be fixed with higher energy clutches, which it sounds like that's what in the 4HP24. It can also be fixed by firming up the shifts. Less slip, less energy dumped into them.
Overheating the oil will make this situation worse, but overcooling it won't help if you're really overdoing it.
They also fail from even the smallest bit of water getting in.
ZF's are some of the best auto box's there are.
Pfft! From what I read when looking at repairing mine, the American auto trans repair industry does not share your enthusiasm.
http://www.transtec.com/rebuilder_news/3rd_q94r-n.pdf
Overall length is increased not the case length. The difference is in the bell housing to accommodate a larger torque converter. The oil pump and other internals are different but case length is unchanged.
Ok, I'll buy that. Sounds like the clutch diameter increased too, however? From the above link:
It sure surprises me that the “huge” - 3.94"
O.D. - friction will burn so easily. This friction is the main
thing ZF changed when they came up with their “heavy
duty” 4HP24. The frictions on that one are 4.92".
Apparently, the European Wizards finally realized that
they needed something bigger than motorcycle-sized
frictions to handle a 12-cylinder engine.