ZF Repair Manual: ZF25A, ZF25, ZF45A, ZF45-1
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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................ 10
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................ 12
3.6 HOUSING . ................................... 12
3.6.1 Transmission housing halves................ 12
3.6.2 Shafts and gears .......................... 12
3.6.3 Radial shaft seals.......................... 13
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. . . 19
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.............................. 20
4.3.1
Mounting inner race of tapered roller bearing ....20
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
4.4.2.1 Installation of fluid suction pipe ........ 20
4.4.2.2 Installation of baffle. . ................. 21
4.4.3 Assembling input shaft seal rings............ 21
4.4.4 Mounting the breather filter ................. 22
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 . ........ 23
4.5.3 Inserting gear set into housing ...............23
4.5.4 Measuring bearing clearance on input shaft . . . 23
4.5.5 Measuring bearing clearance at
intermediate shaft . . ........................24
4.5.6 Measuring the bearing clearance on
the output shaft ............................24
4.5.7 Adjusting the pretension/clearance of
bearings. . .................................25
4.5.8 Final assembly of the housing. ...............26
4.6 CONTROL BLOCK . ............................26
4.6.1 Mounting the control block...................26
4.7 FLUID FILTER .................................27
4.7.1 Mounting the fluid filter. . ....................27
4.8 OUTPUT FLANGE . ............................27
4.9 MAKING THE TRANSMISSION
READY FOR OPERATION . . ....................28
4.9.1 Filling up with transmission Fluid . . ...........28
4.9.2 Check fluid level............................28
5. ADJUSTMENT DATA
.............................29
5.1 SHIFITNG PRESSURE . ........................29
5.2 LUBE OIL DELIVERY RATE. ....................29
6. HYDRAULIC DIAGRAM
............................30
7. TIGHTENING TORQUES
...........................31
8. FUNCTION TEST
.................................32
9. TROUBLESHOOTING
.............................33
10. AUTOMATIC TRANSMISSION FLUID
..............38
11. SPARE PARTS LIST
.............................41
PREFACE ........................................41
NAME PLATE .....................................41
Fig. 1 ZF25 A .....................................42
Fig. 1 ZF25 . . .....................................44
Fig. 1 ZF45 A .....................................46
Fig. 1 ZF45-1 .....................................48
Fig. 2 ZF25 A .....................................50
Fig. 2 ZF25 . . .....................................52
Fig. 2 ZF45 A .....................................54
Fig. 2 ZF45 -1 .....................................58
Fig. 3 Mechanical selector valve ....................62
Fig. 4 Old electric selector valve with
proportional valves...........................64
Fig. 5 Old electric selector valve with
proportional valves...........................66
Fig. 6 Old electric selector valve on/off
12V, 26 bar .................................68
Fig. 7 New electric selector valve on/off
12Vand24V-26bar........................70
Fig. 8 New electric selector valve on/off
12V and 24V - 26 bar with throlling valve. ......72
Kit components (ZF 25 A - ZF 25). ....................74
Kit components (ZF 45 A) ...........................75
Kit components (ZF 45-1) ...........................76
Repair Manual and Spare Parts List
Table of contents
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