GENERAL WORKING INSTRUCTIONS
During all operations, pay attention to cleanliness and skilled working.
Therefore, Transmissions, removed from the vehicle, must be cleaned prior to open them
We assume that the Special Tools, specified by ZF, will be used.
The Special Tools have a 10-digh Subject-No. and are available from ZF-Passau.
After the disassembly, all components must be cleaned, especially corners, cavities and recesses of housing
and covers.
The old selling compound must be carefully removed.
Check lubricating holes, grooves and pipes for free passage. They must be free of residues, foreign material
or protective compounds.
The latter refers expecially to new parts.
Parts which have been inevitably damaged in a disassembly operation, must be generally replaced by new
ones, e.g.: rotary seal rings, O-Rings, U-Section rings, cap boots, protective caps etc..
Components such as roller bearings, thrust washers, synchronizing parts etc. which are subject to normal
wear in automotive operation, must be checked by the skilled Serviceman.
He will decide if the parts can be reused.
For the heating of bearings etc., hot plates, rod healers or heating furnaces must be used.
Never heat parts directly with the flame. An auxiliary solution would be to immerse the bearing in a vessel
filled with oil, which is then heated with the flame.
In this way, damage to the bearings could be avoided.
Ball bearings, covers, flanges and parts like that must be heated to about 90° to 100° C.
Hot-mounted parts must be reset after cooling in order to assure a proper contact.
Before pressing shafts, bearings etc. in position, both parts must be lubricated.
During the reassembly, all specified adjustment values, testing specifications and torque limits must be
respected.
After the repair, ZF-Units are filled up with oil.
The procedure and the permitted oil qualities can be taken from the Operator's Manual, resp. from the
Lubrication Instructions and the corresponding List of Lubricants.
The Lists of Lubricants are available at all ZF-Service Stations.
After the oil filling, the oil level plugs and oil drain plugs must be tightened to the specified torque limits.
SPC000007 Transmission and Torque Converter
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