TABLE OF CONTENTS
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. MAJOR COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 MAJOR TRANSMISSIONS COMPONENTS . . . . . . . . 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 63 IV, ZF 80 IV, ZF 80-1 IV and ZF 85 IV . . . . 9
3.2 REMOVAL DIPSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 REMOVAL BREATHER VALVE . . . . . . . . . . . . . . . . . 10
3.4 OUTPUT FLANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 REMOVAL CONTROL BLOCK . . . . . . . . . . . . . . . . . . 11
3.5.1 NeutralSafety Switch . . . . . . . . . . . . . . . . . . . . . 11
3.5.2 NeutralSafety Switch Check. . . . . . . . . . . . . . . 11
3.6 HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6.1 Disassemble the transmission housing
hal ves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6.2 Removalof shafts and gears. . . . . . . . . . . . . . . 12
3.6.3 Removalof radialshaft seals . . . . . . . . . . . . . . 12
3.6.4 Removal of fluid inlet pipe . . . . . . . . . . . . . . . . . 13
3.7 TAPERED ROLLER BEARINGS. . . . . . . . . . . . . . . . . 14
3.7.1 Disassembling the outer races of
taper roller bearing . . . . . . . . . . . . . . . . . . . . . . 14
3.7.2 Removalof inner races of
taper roller bearings . . . . . . . . . . . . . . . . . . . . . 14
3.8 REVERSING CLUTCH PACK . . . . . . . . . . . . . . . . . . . 15
3.8.1 Removalof 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.5 Assemble piston rings. . . . . . . . . . . . . . . . . . . . . 19
4.2 INTERMEDIATE AND REVERSAL SHAFT . . . . . . . 20
4.2.1 Mounting inner races of tapered
roller bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3 OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3.1 Preparations for assembly . . . . . . . . . . . . . . . . . . 20
4.3.2 Mounting inner race of
tapered roller bearing . . . . . . . . . . . . . . . . . . . . . . 20
4.3.3 Pressing the gear on . . . . . . . . . . . . . . . . . . . . . . 20
4.4 PREASSEMBLY OF HOUSING . . . . . . . . . . . . . . . . . . 21
4.4.1 Assembly of outer races
(tapered roller bearings). . . . . . . . . . . . . . . . . . . . 21
4.4.2 Installation of fluid suction pipe . . . . . . . . . . . . . 21
4.4.3 Assembling input shaft seal . . . . . . . . . . . . . . . . 22
4.4.4 Mounting the breather filter. . . . . . . . . . . . . . . . . 22
4.5 MEASURING THE BEARING CLEARANCE/
ADJUSTING THE PRETENSION OF BEARINGS . 23
4.5.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5.2 Mounting outer races of tapered roller
bearings into housing . . . . . . . . . . . . . . . . . . . . . 23
4.5.3 Inserting gear set into housing . . . . . . . . . . . . . 23
4.5.4 Measuring bearing clearance
on input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.5.5 Measuring bearing clearance at
intermediate and reversalshafts . . . . . . . . . . . 24
4.5.6 Measuring the bearing clearance
on the output shaft . . . . . . . . . . . . . . . . . . . . . . . 25
4.5.7 Adjusting the pretension clearance
of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.5.8 Finalassembly of the housing . . . . . . . . . . . . . 26
4.6 CONTROL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.6.1 Mounting the controlblock . . . . . . . . . . . . . . . . 27
4.7 FLUID FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.7.1 Mounting the fluid filter . . . . . . . . . . . . . . . . . . . . 27
4.8 MAKING THE TRANSMISSION
READY FOR OPERATION . . . . . . . . . . . . . . . . . . . . . 27
4.8.1 Filling up with Transmission Fluid . . . . . . . . . 27
4.8.2 Inserting fluid filter into housing . . . . . . . . . . . 27
4.8.3 Check fluid level. . . . . . . . . . . . . . . . . . . . . . . . . 28
5. ADJUSTMENT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1 SHIFTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1.1 ZF 80-1 IV VERSION - ZF 85 IV . . . . . . . . . . . . . 29
5.1.2 ZF 63 IV - ZF 80 IV VERSION . . . . . . . . . . . . . . . 29
5.1.3 ZF 63 IV INDMAR VERSION. . . . . . . . . . . . . . . 30
5.2 LUBE OIL DELIVERY RATE. . . . . . . . . . . . . . . . . . . . 30
5.2.1 ZF 80-1 IV VERSION - ZF 85 IV . . . . . . . . . . . . . 30
5.2.2 ZF 63 IV - ZF 80 IV VERSION . . . . . . . . . . . . . . . 31
5.2.3 ZF 63 IV INDMAR VERSION. . . . . . . . . . . . . . . 31
6. HYDRAULIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7. TIGHTENING TORQUES. . . . . . . . . . . . . . . . . . . . . . . . . . 33
8. FUNCTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1
Repair Manualand Spare Parts List
Table of contents
All manuals and user guides at all-guides.com
Summary of Contents for ZF 63 IV
Page 2: ...All manuals and user guides at all guides com...
Page 6: ...4 All manuals and user guides at all guides com a l l g u i d e s c o m...
Page 18: ...16 All manuals and user guides at all guides com...
Page 44: ...42 All manuals and user guides at all guides com...
Page 55: ...53 All manuals and user guides at all guides com...
Page 70: ...68 All manuals and user guides at all guides com...
Page 77: ...75 All manuals and user guides at all guides com...
