ZF Repair Manual: ZF63IV, ZF80IV, ZF80-1IV
<< Previous of 78 Next >>Repair Manual and Spare Parts List
Table of contents
1
TABLE OF CONTENTS
INTRODUCTION
......................................3
Section 1: MAJOR COMPONENTS
.....................5
1. MAJOR TRANSMISSION COMPONENTS . ..........5
2. CLEANERS AND SEALANTS......................6
3. MEASURING TOOLS . ............................6
4. STANDARD TOOLS AND FIXTURE . ...............6
Section 2: SPECIAL TOOLS
...........................7
Section 3: DISASSEMBLY
............................9
INTRODUCTION....................................9
1. FLUID FILTER . . .................................9
1.1 Remove fluid filter . ............................9
1.2 Suction of transmission fluid . ...................9
2. DIPSTICK . . ................................... 10
3. BREATHER VALVE............................. 10
4. OUTPUT FLANGE.............................. 10
5. CONTROL BLOCK ............................. 11
5.1 Neutral Safety Switch . . ...................... 11
5.2 Neutral Safety Switch Check. ................. 11
6. HOUSING . . ................................... 12
6.1 Transmission housing halves ................. 12
6.2 Shafts and gears . . .......................... 12
6.3 Radial shaft seals . .......................... 12
6.4 Fluid inlet pipe.............................. 13
7. TAPERED ROLLER BEARINGS. ................. 14
7.1 Outer races of tapered roller bearing . . ........ 14
7.2 Inner races of tapered roller bearings . . ........ 14
8. CLUTCH PACK . ............................... 15
8.1 Removal of the clutch discs. . ................. 15
Section 4: ASSEMBLY
.............................. 17
INTRODUCTION.................................. 17
1. INPUT SHAFT . . ............................... 17
1.1 Mount discs into reversing clutch. ............. 17
1.2 Install needle bearings and gear . ............. 18
1.3 Assemble butting rings. ...................... 18
1.4 Mounting inner races of
tapered roller bearings. ...................... 18
1.5 Assemble piston rings. . ...................... 18
2. INTERMEDIATE AND REVERSAL SHAFT ........ 19
2.1 Mounting inner races of
tapered roller bearings. ...................... 19
3. OUTPUT SHAFT ............................... 19
3.1 Preparation for assembly..................... 19
3.2 Mounting inner race of
tapered roller bearing. . ...................... 19
3.3 Pressing the gear on . . ...................... 19
4. PREASSEMBLY OF HOUSING . ................. 20
4.1 Assembly of outer races
(tapered roller bearings)...................... 20
4.2 Installation of fluid suction pipe
and baffle.................................. 20
4.3 Assembling input shaft seal. . ................. 21
4.4 Mounting the breather filter . . ................. 21
5. MEASURING THE BEARING CLEARANCE/
ADJUSTING THE PRETENSION OF BEARINGS . . 22
5.1 General . ................................... 22
5.2 Mounting outer races of
tapered roller bearings into housing . ...........22
5.3 Inserting gear set into housing. . ...............22
5.4 Measuring bearing clearance on
input shaft . .................................23
5.5 Measuring bearing clearance at
intermediate shaft............................23
5.6 Measuring the bearing clearance on
the output shaft. . ............................24
5.7 Adjusting the pretension of bearings ...........24
5.8 Final assembly of the housing . . ...............25
6. CONTROL BLOCK . . ............................25
6.1 Mounting the control block ....................25
7. FLUID FILTER . .................................26
7.1 Mounting the fluid filter .......................26
8. MAKING THE TRANSMISSION
READY FOR OPERATION.......................26
8.1 Filling up with transmission Fluid...............26
8.2 Inserting fluid filter into housing. ...............26
8.3 Check fluid level . ............................26
Section 5: ADJUSTMENT DATA
......................27
Section 6: HYDRAULIC DIAGRAM
....................29
Section 7: TIGHTENING TORQUES
...................30
Section 8: FUNCTION TEST
.........................31
Section 9: TROUBLESHOOTING
.....................32
Section 10: AUTOMATIC TRANSMISSION FLUID
......37
Section 11: SPARE PARTS LIST
.....................39
PREFACE ........................................39
NAME PLATE .....................................39
Fig. 1 (ZF 63 IV) . . .................................40
Fig. 1 (ZF 80 IV - ZF 80-1 IV)........................42
Fig. 2 (ZF 63 IV) . . .................................44
Fig. 2 (ZF 80 IV - ZF 80-1 IV)........................46
Fig. 3 (ZF 63 IV - ZF 80 IV - ZF 80-1 IV)..............50
Fig. 4 (ZF 63 IV - ZF 80 IV - ZF 80-1 IV)..............52
Fig. 5 (ZF 63 IV - ZF 80 IV - ZF 80-1 IV)..............54
OLD ELECTRIC SELECTOR VALVE
ON/OFF 12V, 26 BAR . . ............................56
NEW ELECTRIC SELECTOR VALVE
ON/OFF 12V, 26 BAR . . ............................58
KIT COMPONENTS (ZF 63 IV) . . ....................60
KIT COMPONENTS (ZF 80 IV - ZF 80-1 IV)...........61
Section 12: SPARE PARTS LIST ZF80IV,
ZF80 -1IV NEW VERSION
...............63
PREFACE ........................................63
NAME PLATE .....................................63
Fig. 1 ZF 80IV - ZF80-1IV (new version). . ...........64
Fig. 2 ZF 80IV - ZF80-1IV (new version). . ...........66
Fig. 3 ZF 80IV - ZF80-1IV (new version). . ...........70
Fig. 4 OLD ELECTRIC SELECTOR
VALVE ON/OFF.......................... 72
Fig. 5 NEW ELECTRIC SELECTOR
VALVE ON/OFF.......................... 74
KIT COMPONENTS ZF80IV - ZF80-1IV
(new version). .....................................77