Foley Engines ZF 45 C - Toyota, Repair Manual

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Repair Manual and Spare Parts List ZF 45C / 63C / 88C
TABLE OF CONTENTS
Introduction ........................................................... 2
SECTION I: GENERAL DATA .................................... 2
1. Transmission Set-up ....................................... 2
2. Consumable goods ......................................... 3
3. Measuring Tools .............................................. 3
4. Standard Tools and Fixture ............................. 3
SECTION II: SPECIAL TOOLS ................................. 4
SECTION III: DISASSEMBLY PREPARATION ......... 5
Introduction ........................................................... 5
1. Preliminary operation ...................................... 5
2. Housing disassembly ...................................... 5
3. Input shaft ....................................................... 8
4. Forward clutch housing disassembly .............. 9
SECTION IV: 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
3. Input shaft play ................................................. 24
4. Output shaft bearing play ................................. 25
SECTION VI: TIGHTENING TORQUES ................... 26
SECTION VII: FUNCTION TEST .............................. 26
1. Filling up with transmission fluid ..................... 26
2. Check fluid level .............................................. 26
3. Function test ................................................... 27
4. Shifting pressure ZF 45C / 63C / 88C ............. 28
5. Lube oil delivery ZF 45C / 63C / 88C .............. 29
SECTION VIII: TROUBLESHOOTING ...................... 30
SECTION IX: AUTOMATIC TRANSMISSION
FLUID .................................................. 33
SECTION X: SPARE PARTS LIST AND
EXPLOSION DRAWINGS .................... 35