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Foley Engines ZF 45 C - Toyota, Repair Manual

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Foley Engines ZF 45 C - Toyota Repair Manual Download Page 1

R E P A I R   M A N U A L   A N D   S P A R E   P A R T S   L I S T

R E P A I R   M A N U A L   A N D   S P A R E   P A R T S   L I S T

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ZF 45 C

version 10; 001

ZF 45 C - Walter

version 002

ZF 45 C - Toyota

version 11; 003

ZF 63 C

version 07; 001

ZF 88 C

version 001

Cod.

310.01.0056d

FOLEY ENGINES
 1-800-233-6539

Summary of Contents for ZF 45 C - Toyota

Page 1: ...S T R E P A I R M A N U A L A N D S P A R E P A R T S L I S T R E P A I R M A N U A L ZF 45 C version 10 001 ZF 45 C Walter version 002 ZF 45 C Toyota version 11 003 ZF 63 C version 07 001 ZF 88 C ver...

Page 2: ......

Page 3: ...ASSEMBLY 12 Introduction 12 1 Input shaft 12 2 Housing assembly 15 3 Complementary operations 18 4 Oil pump 21 SECTION V PLAY ADJUSTMENT 22 1 Reverse clutch clearance 22 2 Forward clutch clearance 23...

Page 4: ...on the technical information at the time of printing The manual has been checked carefully in order to avoid errors However ZF HURTH MARINE is not liable for any misrepresentations errors of descript...

Page 5: ...id list chap IX 3 MEASURING TOOLS Dial indicator gauge with arm type support Range 0 1 0 25 mm in 0 0005 0 01 mm increments Caliper Range 0 6 0 150 mm in 0 0005 0 01 mm increments 1 2 tool bar working...

Page 6: ...4 P N 978 45 0023 0 Mandrel Control valve oil seal Id No 500495 P N 978 45 0024 0 Mandrel Input shaft rollers bearing Id No 500496 P N 978 45 0025 0 Mandrel Forward clutch circlip Id No 500497 P N 978...

Page 7: ...n as removed SECTION III DISASSEMBLY PREPARATION INTRODUCTION Clean the transmission thoroughly on the outside before disassembly The repair area should be clean and well lighted ZF HURTH MARINE recom...

Page 8: ...35 2 8 Remove reverse clutch first outer disc 63 2 9 Remove springs 58 2 4 Using pliers remove the key 28 from shaft NOTE Take note of the position of the key 2 5 Screw off bolts 7 8 and washers 10 2...

Page 9: ...one 2 14 Remove flange using appropriate puller WARNING see type page 3 2 15 With a soft hammer disassemble the output shaft Driving it out from the housing 2 10 Remove inner disc 62 outer disc 63 in...

Page 10: ...d of shaft disassemble it from the clutch housing This operation will damage the bearing Use a press with distance 200 mm 8 inches min force 2000 kg 4400 lbs 3 5 Remove piston rings 40 from the input...

Page 11: ...ch has to be discarded and replaced with a new one 4 7 Introduce air with tool P N 500501 to push out the piston 51 The piston can also be removed by gently tapping on the outer diameter of the housin...

Page 12: ...Rings 33 57 if disassembled 4 12 Remove the stop screw 17 and position screw 18 the two washers 13 the spring 20 and the ball 21 4 13 Remove the neutral safety switch 15 the plugs 12 14 spacer 16 ball...

Page 13: ...ikingwithasofthammerremoveneedlebearing 41 Only if bearing is defective To do it properly support the cover allowing room for the needle bearing to come out bottom side Stick a screw driver punch into...

Page 14: ...her SECTION IV ASSEMBLY INTRODUCTION A well lighted work area that is free from dirt and chips will facilitate the work considerably ZF HURTH MARINE recommends to use a swivelling stand described in t...

Page 15: ...d with ATF 1 7 With tool p n 500498 and a suitable support press the ball bearing 43 into the ring gear support 47 1 8 Insert the circlip 48 WARNING Be sure that snap ring has been properly seated che...

Page 16: ...opposite positions 1 14 Insert shims 75 76 between circlip 48 and thrust washer 42 NOTE To set correct play see item 3 pag 24 1 9 Press the forward clutch housing 47 on the input shaft 37 1 10 Install...

Page 17: ...ditional baffles 30 31 and pin spacer 32 2 3 With special tool P N 500496 install needle bearing 41 into the cover 35 2 4 Install O Rings 33 into the cover 35 1 15 WithtollP N 500499andasuitablesuppor...

Page 18: ...Install onto cover 35 ball 21 spring 20 and guide spring 18 together with sealing washer 13 Guide spring 18 tightening torque 12 Nm 8 9 lb ft Turn slowly spool valve 24 to centre groove to ball 21 NOT...

Page 19: ...g ring 23 using the special tool P N 500495 and a plastic hammer NOTE Check the correct position of sealing ring 23 2 16 Install the lever 25 with bolt 11 washer 10 and nut 9 NOTE Tigthen bolt 11 to 2...

Page 20: ...tool P N 500494 3 2 Assemble the output shaft by pressing the shaft into the housing NOTE Coat output shaft with grease prior to assembly As a precaution support the inner race of the bearing Neutral...

Page 21: ...sc 63 must have the four grooves in connection with the four housing studs The last outer disc isconsequentlyinstalledupside downcomparedtothefirst ones 3 10 Coat sealing ring 39 with grease for ex PO...

Page 22: ...m to 18Nm 13 3 lb ft torque Tighten the screws evenly to avoid binding the housing on the shaft 3 13 Install the output flange 66 NOTE Use LOCTITE 245 on the spline between output shaft and output fla...

Page 23: ...nstall onto shaft 37 key 28 driving inner pump gear NOTE Check carefully correct position of key 28 4 2 Install onto input shaft 37 the inner pump gear NOTE Pump gear must be positioned in the way tha...

Page 24: ...te polymerization is 5 hours we recommend therefore to clean carefully the mating surfaces with Loctite 7063 Cleaner before applying the Loctite 518 and wait the requested time before the spin test SE...

Page 25: ...ear 3 Set 0 00 mm of the caliper on the snap ring 3 Take measurement B See fig no V2 For example B 9 66 mm 4 Select proper tickness shims to set the gap R Shims available Shim 0 3 mm p n 3311 301 042...

Page 26: ...n 3311 302 029 plus 5x internal clutch discs p n 3311 302 028 in different points and make the average 3 INPUT SHAFT PLAY Install input shaft assembly in housing assembly Install shims 75 76 spacer 4...

Page 27: ...ing P N 618582 as shown in figure V6 CAUTION Set down to the housing the input shaft and measure with a dial indicator the play I moving the input shaft with the aid of two prybars 4 OUTPUT SHAFT BEAR...

Page 28: ...NOTE Some transmissions may have different oil dipsticks depending on the version A Wheninsertedintothehousinghole itexpandsbyturning the handle in clockwise direction see Fig item A B It is threaded...

Page 29: ...is available Temperature gauge 0 120 C 0 250 F connecting thread 3 8 18NPSF Flow meter 0 35 liters min 0 10 gals min Tests to be carried out 1 Fluid leaks 2 Noise 3 Direction of rotation LH RH 4 Lube...

Page 30: ...0 0 0 1000 2000 3000 4000 5000 Driving Speed rpm Shifting Pressure bar 0 Shifting Pressure psi 50 100 150 200 250 300 350 400 min 45C max 45C ZF 63C Max 23 bar 333 5 p s i at 70 C 160 F and 4000 rpm M...

Page 31: ...very Rate l min 0 Delivery Rate Gallon min 0 53 1 05 1 58 2 11 2 64 3 16 3 69 4 22 4 75 5 28 5 80 6 33 6 86 7 39 7 91 min ZF 88C Max 24 bar 348 p s i at 70 C 160 F and 4000 rpm Min 19 bar 275 5 p s i...

Page 32: ...Drain fluid refill with prescribed i e propeller speed fluid flush transmission too low as compared while engine runs to engine speed in neutral position drain fluid refill transmission 3 2 Fluid cont...

Page 33: ...worn out Replace pump cover and pump 7 6 Fitting key in input shaft Remove control block for fluid pump drive is Replace fitting key replace broken any other faulty parts 8 Excessive fluid 8 1 Fluid...

Page 34: ...alignment between engine and transmission 13 3 Beginning damage of Disassemble transmission bearings in transmission replace bearings concerned e g due to torsional and other faulty parts Find vibrati...

Page 35: ...2329 ELF LUBRIFIANTS PARIS F ELFMATIC G2 22329 HUILE RENAULT DIESEL STARMATIC ELFMATIC G3 TRANSANTAR DF3 ELLER MONTAN COMP ELLMO AUTOMATIK FLUID 22233 DUISBURG D ENGEN PETROLEUM ENGEN ATF 22D CAPE TOW...

Page 36: ...30358 SLOVNAFT JS CO MADIT AUTOMATIC BRATISLAVA SLO SONOL ISRAEL LTD HAIFA IL DEXRON 2 D SOPROGRASA SA MADRID E SOPRAL 164 STATOIL STAVANGER N TRANSWAY DX III F 30373 TRANSWAY DX II MANUFACTURER PROD...

Page 37: ...rts When oredering spare parts please state transmission type serial number item no Part name ident no and qulity of parts required shipment desired Subject to technical modification Transmission rati...

Page 38: ...ring 3312 308 047 500044 1 21 Sfera Ball 0635 460 014 106695 2 22 Sfiato Breather 3311 301 002 442369 1 23 Guarnizione Seal 0634 309 621 500065 1 24 Complessivo cannotto ZF 45 C Spool valve complete Z...

Page 39: ...88 C 3313 302 040 501778 1 52 Guarnizione OR O Ring 0634 304 400 500354 1 53 Guarnizione OR O Ring 0634 304 128 500243 1 54 Molla a tazza Cup spring 3312 302 015 500148 3 55 Anello di sicurezza Retain...

Page 40: ...0634 801 260 1 21 Ball 0635 460 014 2 27 O Ring 0634 304 405 1 28 Pump Key 3311 306 001 1 33 O Ring 0634 306 300 2 39 Piston ring 0634 402 175 3 40 Piston ring 0634 402 118 2 42a Needle bearing 0635...

Page 41: ...seal 3312 301 030 1 10a O Ring 001 105 0374 2 33 O Ring 0634 306 300 2 39 Piston ring 0634 402 175 3 40 Piston ring 0634 402 118 2 52 O Ring 0634 304 400 1 53 O Ring 0634 304 128 1 57 O Ring 0634 304...

Page 42: ...0634 306 300 2 39 Piston ring 0634 402 175 3 40 Piston ring 0634 402 118 2 52 O Ring 0634 304 400 1 53 O Ring 0634 304 128 1 57 O Ring 0634 304 689 1 62 Inner clutch disc Reverse 3311 302 027 2 63 Ou...

Page 43: ...42b 42a 42b 18 13 20 21 15 16 21 14 19 12 35 33 34 10 7 7 10 10a 1 6 10 6 10 7 3 4 5 41 33 24 8 10 23 9 10 25 11 38 29 31 58 30 32 62 64 65 42 22 47 53 52 51 26 54 55 27 73 74 59 60 61 28 40 39 37 45...

Page 44: ...ZF HURTH MARINE www miniato it FOLEY ENGINES 1 800 233 6539...

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