ZF Repair Manual: ZF63IV, ZF80IV, ZF80-1IV
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Repair Manual and Spare Parts List
Section 3: Disassembly
6. HOUSING
6.1 Disassemble the transmission housing
halves
Using a adequate drift punch, top the locating pins (item
1, Fig. 6-1a and 6-1b) out of the housing.
Loosen and remove all hex head bolts and lock washers
(item 2 and 3, Fig. 6-1b). Using a plastic hammer slightly
top the split line of the case halves to break the seal.
Then remove the input side of the housing.
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IMPORTANT
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Only transmission type ZF 63 IV, i=2.0 and i=2.5.
First remove radial shaft seal ring (item 4, Fig. 6-1b) to
remove the housing half.
6.2 Removal of shafts and gears
Take the gear set out of the housing
.
intermediate shaft (item 1, Fig. 6-2)
.
input shaft (item 2, Fig. 6-2)
.
output shaft (item 4, Fig. 6-2)
.
reversal shaft (item 3 Fig. 6-2).
Check all gears, bearings and three piston rings on the
input shaft (item 4, Fig. 6-2) for signs of wear or failure.
If any of the gears are damaged or showing signs of ex-
cessive wear ZF-HURTH MARINE recommends repla-
cing the complete gear set.
When taper roller bearings need replacing on the input
shaft, the butting rings (Fig. 1-2, item 3) and needle bear-
ings (Fig. 1-2, item 1) should also be replaced. When re-
placing inner roller bearings use the same manufacturer.
To check for correct clutch operation, rotate the gears on
the input shaft. If it is hard to turn the gears, the clutch is
probably damaged.
6.3 Removal of radial shaft seals
Input shaft seal
Using a seal mandrel inside the housing top the input
shaft seal out. Discard seal and replace with a new seal.
(item 2, Fig. 6-3a).
NOTE
For transmission types ZF63 IV, i=2.0 and i=2.5
(item 2, Fig. 6-3a) the radial shaft seal ring has already
been removed before dismounting the housing half.
1
FIG. 6-1a
1
2
3
4
FIG. 6-1b
1
2
3
4
FIG. 6-2
1
2
FIG. 6-3a