ZF Repair Manual: ZF63A, ZF63, ZF80A, ZF80-1A

6. CONTROL BLOCK

6.1Mounting the control block

NOTE

Piston rings (item 1, Fig. 6-1) have to be replaced, if

thickness is less than 2.39 mm (0.094in).

a) Insert key (item 2, Fig. 6-1) into groove of shaft.

b) Place new seal (item 3, Fig. 6-1) onto control block.

c) Align key and slot in rotor pump.

d) Slide control block carefully on input shaft.

e) Insert 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 243.

f) Tight control block bolts. Tightening torque:

18 Nm (14 ft.lb.).

FIG. 6-1

7. FLUID FILTER

7.1Mounting the fluid filter

Wet O-rings (item 1 and 2, Fig. 7-1) with some ATF

fluid and mount them.

Install filter element (item 3, Fig. 7-1) into the trans-

mission.

Lock cover (item 4 Fig. 7-1) to the transmission using

an allen wrench. Tightening torque: min. 5 Nm - max

8 Nm (min. 4 ft.lb. - max 6 ft.lb.)

FIG. 7-1

8. OUTPUT FLANGE

Provide spline (X) of output shaft with a thin coat of Loc-

tite 245 and sealing lip (Z) of shaft seal with a thin coat of

ATF fluid. (Fig. 8-1)

Fit output flange (item 1, Fig. 8-1).

Provide O-ring (item 2, Fig. 8-1) with ATF fluid and insert

into output flange.

Tight output flange down on output shaft with bolt (item

3, Fig 8-1) and washer (4).

Tightening torque:

ZF63A - ZF63: 100 Nm (74 ft.lb.)

ZF80A - ZF80-1 A: 180 Nm (133 ft.lb.)

FIG. 8-1

Repair Manual and Spare Parts List

Section 4: Assembly