ZF Repair Manual: ZF63IV, ZF80IV, ZF80-1IV
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Repair Manual and Spare Parts List
Section 4: Assembly
5.8Final assembly of the housing
a) Heat input side of the housing in an oven to approx.
120ëC (248 ëF).
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WARNING
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Handle heated housing only with protective gloves!
b) Insert the required shims for proper pretension into
bearings bore under bearing outer race
c) Insert outer races of bearings. When the housing half
has reached ambiet temperature, drive outer races of
bearings up to the stop, using a copper punch
d) Insert gears again
e) Fill space between seal and dust lips of shaft seal
rings with a high quality bearing grease.
f) Apply a thin coat of Loctite 518 on mating face of "in-
put" housing half and join both housing halves
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WARNING
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The necessary time for a complete polymerization is
5 hours: we recommend therefore to clean carefully
the mating surfaces with Loctite 7063 cleaner before
applying the Loctite 518 and wait the requested time
before the spi test.
g) Drive parallel pins into housing to align housing
halves, before tightening.
h) Apply Loctite 242 or 262 on to mounting bolts (item1
Fig. 5-5a) and torque them to 40 Nm (30 ft lb)
i) Check pretension of bearings accord-ing to sections
5.4, 5.5 and 5.7
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CAUTION
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There must be no measurable bearing clearance.
j) Only for transmission size i=2.0 and i=2.5
ZF63IV. Press radial shaft seal (item 1, Fig. 4-3b) with
a suitable pipe into the "drive" housing half.
NOTE
The sealing lip on the radial shaft seal show to the in-
side of the housing. The radial shaft seal must be so
adjusted that the sealing lip does not bear on the for-
mer running point of the shaft.
k) Mount the output flange again. (see chapter 5.6).
6. CONTROL BLOCK
6.1Mounting the control block
New piston rings (item 1, Fig. 6-1) have already been as-
sembled according to section 1.6.
a) Insert key (item 2, Fig. 6-1) into groove of shaft
b) Place new gasket (item 3, Fig. 6-1) onto control block
c)
Key slot in pump-drive wheel should be aligned Fig. 6-1
d) Slide control block carefully on input shaft
e) Push lock washers (item 4, Fig. 6-1) on socket head
bolts (item 5, Fig. 6-1) and provide screw threads each
with a drop of Loctite 242 or 262
f) Screw control block tight. Tightening torque of
screws: 18 Nm (13 ft.lb.)
4
2
5
1
3
FIG. 6-1