ZF Repair Manual: ZF63IV, ZF80IV, ZF80-1IV
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Repair Manual and Spare Parts List
Section 4: Assembly
5.6 Measuring the bearing clearance on the
output shaft
a) Mounting the output flange
Drive parallel pins (item 1, Fig. 5-6a) into output flange
(item 2, Fig. 5-6a)
Screw output flange with socket head bolts (item 3,
Fig. 5-6a) on output shaft
Tightening torque: 32 Nm (23.6) ZF 63 IV: 100 Nm
(73.8 ft.lb.) ZF80IV - ZF80-1IV
b) Turn output shaft repeatedly to permit bearings to
seat
c) Mount dial gauge support securely onto housing, and
"0" indication gauge
d) Place dial gauge onto bolt head
e) Lift output shaft carefully, using two screwdrivers, and
record measurement.
NOTE
This step should be done very carefully to obtain the
actual bearing clearance.
f) Carry out steps "b" and "e" for several times
g) The bearing clearance measured plus the pretension
required in section 5.1 will determine the required
thickness of shims.
NOTE
Round off the determined shim thickness to 0.05 mm
(0.001968 in.)
h) Unscrew bolt with washer and dial gauge with sup-
port.
5.7 Adjusting the pretension of bearings
When the thickness of shims has been determined, the
transmission must be disassembled again.
a) Unscrew output flange (see Fig. 5.6a)
b) Using a adequate drift punch, drive the parallel pins
(item 1, Fig. 5-7a) with slight blows out of the housing
c) Loosen hex bolts (item 2 and 3) with lockwashers
(item 4, Fig. 5-7a) and remove input side of housing
(item 5, Fig. 5-7a)
d) Remove gears from the housing (Fig. 5-7b)
e) Pull outer races of bearings out of the "drive" housing
half using the extracting unit or heat the half of the
housing in an oven to approx. 120ëC (248ëF) and re-
move the outer races of bearings together with shims.
|
WARNING
|
Handle heated housing half and outer race only with
protective gloves!
NOTE.
Make sure to keep the shims with each outer race and
not mix them together.
3
2
1
FIG. 5-6a
FIG. 5-6b
1
4
2
3
FIG. 5-7a
FIG. 5-7b