ZF 63 - Page 3

TABLE OF CONTENTS
INTRODUCTION. . ................................... 3
1. MAJOR COMPONENTS. . .......................... 5
1.1 TRANSMISSION SET-UP . .......................5
1.2 CLEANERS AND SEALANTS . . . ..................6
1.3 MEASURING TOOLS . ...........................6
1.4 STANDARD TOOLS AND FIXTURE . ..............6
2. SPECIAL TOOLS . . ............................... 7
3. DISASSEMBLY ................................... 9
INTRODUCTION....................................9
3.1 FLUID FILTER . . ................................9
3.1.1 Remove fluid filter . . . .......................9
3.1.2 Suction of transmission fluid . . . ..............9
3.1.3 Suction of transmission fluid on
ZF 80 A, ZF 80-1 A and ZF 85 A . ..............9
3.2 DIPSTICK . . .................................. 10
3.3 BREATHER VALVE. . . ......................... 10
3.4 OUTPUT FLANGE............................. 10
3.5 CONTROL BLOCK . . . ......................... 11
3.5.1 Neutral Safety Switch ..................... 11
3.5.2 Neutral Safety Switch Check . . . ............ 11
3.6 HOUSING . . .................................. 12
3.6.1 Transmission housing halves. . . ............ 12
3.6.2 Shafts and gears ......................... 12
3.6.3 Radial shaft seals ......................... 12
3.6.4 Fluid inlet pipe . . ......................... 13
3.7 TAPERED ROLLER BEARINGS. ................ 14
3.7.1 Outer races of tapered roller bearing . ....... 14
3.7.2 Inner races of tapered roller bearings ....... 14
3.8 CLUTCH PACK . .............................. 15
3.8.1 Removal of the clutch discs ................ 15
4. ASSEMBLY...................................... 17
INTRODUCTION.................................. 17
4.1 INPUT SHAFT . . .............................. 17
4.1.1 Mount discs into reversing clutch ........... 17
4.1.2 Install needle bearings and gear............ 18
4.1.3 Assemble butting rings .................... 18
4.1.4 Mounting inner races of tapered
roller bearings. . . ......................... 18
4.1.5 Assemble shims, support shims and
retaining ring............................. 18
4.1.5 Assemble piston rings ..................... 19
4.2 INTERMEDIATE SHAFT. . . ..................... 19
4.2.1 Mounting inner races of tapered
roller bearings. . . ......................... 19
4.3 OUTPUT SHAFT .............................. 19
4.3.1 Mounting inner race of tapered
roller bearing............................. 19
4.4 PREASSEMBLY OF HOUSING ..................20
4.4.1 Assembly of outer races
(tapered roller bearings) . ...................20
4.4.2 Installation of fluid suction pipe and baffle. . . . 20
4.4.3 Assembling input shaft seal. . . ..............21
4.4.4 Mounting the breather filter . . . ..............21
4.5 MEASURING THE BEARING CLEARANCE/
ADJUSTING THE PRETENSION OF BEARINGS . . 22
4.5.1 General. . . ................................22
4.5.2 Mounting outer races of tapered roller
bearings into housing . . . ...................22
4.5.3 Inserting gear set into housing ..............22
4.5.4 Measuring bearing clearance on input
shaft . ....................................23
4.5.5 Measuring bearing clearance at
intermediate shaft . . .......................23
4.5.6 Measuring the bearing clearance on the
output shaft...............................23
4.5.7 Adjusting the pretension/clearance of
bearings. . ................................24
4.5.8 Final assembly of the housing ..............24
4.6 CONTROL BLOCK . . ...........................25
4.6.1 Mounting the control block . . . ..............25
4.7 FLUID FILTER . ................................25
4.7.1 Mounting the fluid filter . ...................25
4.8 OUTPUT FLANGE . . ...........................25
4.9 MAKING THE TRANSMISSION
READY FOR OPERATION . . . ...................26
4.9.1 Filling up with transmission Fluid . ..........26
4.9.2 Check fluid level . . . .......................26
5. ADJUSTMENT DATA . . ...........................27
5.1 SHIFTING PRESSURE . . .......................27
5.2 LUBE OIL DELIVERY RATE. . ...................27
6. HYDRAULIC DIAGRAM. ...........................28
7. TIGHTENING TORQUES...........................29
8. FUNCTION TEST . ................................30
9. TROUBLESHOOTING . . ...........................31
10. AUTOMATIC TRANSMISSION FLUID ..............36
11. SPARE PARTS LIST
ZF63A - ZF63 - ZF80A - ZF80-1A...............39
Preface . . .........................................39
Name plate . . . ....................................39
FIG. 1 ZF 63 A. ....................................40
FIG. 1 ZF 63 . . ....................................42
FIG. 1 ZF 80 A - ZF 80-1 A . . .......................44
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Repair Manual and Spare Parts List Table of contents