ZF Repair Manual: ZF63A, ZF63, ZF80A, ZF80-1A
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Repair Manual and Spare Parts List
Section 4: Assembly
1
FIG. 5-4
2
1
FIG. 5-5a
FIG. 5-5b
5.4 Measuring bearing clearance on input
shaft
a)
Turn input shaft several times to permit bearings to seat.
b) Fit clamping ring (tool p/n 219.354.3 (618582)) to the
spline of the input shaft (item 1, Fig. 5-4).
c) Adjust to «0», dial indicator to obtain accurate reading.
d) With two levers carefully pry on the clamping ring and
record end play of shaft.
NOTE
This step must be done very carefully to obtain the
actual bearing clearance.
e) Carry out steps, a) and d) several times.
f) The bearing clearance measured plus the pretension
required in section 5.1 determine the required thick-
ness of shims.
5.5 Measuring bearing clearance at
intermediate shaft
a) Unscrew plug (item 1, Fig. 5-5a) from the housing.
b) Screw in special tool (p/n 224.836.008 (458105)) (item
2, Fig. 5-5a) into intermediate shaft hole.
c) Mount dial gauge support securely onto housing.
d) Turn intermediate shaft several times to permit bear-
ings to seat.
e) Adjust the dial indicator needle on top of the bolt head
and «O» to dial indicator (Fig. 5-5b).
f) Screw hexagon nut carefully against housing (inter-
mediate shaft moves up) until bearing clearance is
overcome (Fig. 5-5b).
NOTE
This step should be done very carefully to obtain the
actual bearing clearance.
g) Carry out steps d) and f) several times.
h) The clearance measured plus the pretension required
in section 5.1 determine the required thickness of
shims.
5.6 Measuring the bearing clearance on the
output shaft
a) Insert output flange onto the output shaft and screw in
nut ring.
b) Install bolt and spacer on input shaft.
c)
Turn output shaft repeatedly to permit bearings to seat.
d) Mount dial gauge support securely onto housing.
e) Place dial gauge onto top of the output shaft and ad-
just it to «0» reading.
f) Lift output shaft carefully, using two screwdrivers, and
record measurement (Fig. 5-6).
NOTE
This step should be done very carefully to obtain the
actual bearing clearance.
Carry out steps c) and f) for several times.
The bearing clearance measured plus the pretension re-
quired in section 5.1 will determine the required thick-
ness of shims.
FIG. 5-6