ZF Repair Manual: ZF45C, 63C, 88C
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Repair Manual and Spare Parts List ZF 45C / 63C / 88C
Syptom
Possibly cause
Remedy
6. Shifting pressure
6.1 Fluid filter clogged
Clean or replace fine filter
too low
6.2 Fluid level in transmission
Top-up with fluid; in case
too low.
of fluid loss check transmission,
cooler and pipelines
for leakage and remedy
same; also refer to 10.
through 13.
6.3 Fluid pump is worn out
Replace cover
containing fluid pump
6.4 Spring in shifting pressure
Replace control valve
relief valve is broken
6.5 Piston rings on input
Replace piston rings. In case
shaft are faulty
of wear due to faulty piston
rings replace housing cover
as well
6.6 O-rings in clutch
Disassemble transmission,
are faulty
replace clutch O-rings
7. No shifting pressure
7.1 Direction of engine rotation
Rotate pump assy. of 180
°
available
does not agree with
arrow on transmission
7.2 No fluid in the transmission
Refill with fluid
7.3 Fine filter is dirty
Clean or replace fine filter
7.4 Fluid level in transmission
Top-up with fluid. In case of
is too low
loss of fluid check transmission,
cooler and pipelines
for leakage and remedy
same, also refer to 10.
through 13.
7.5 Fluid pump worn out
Replace pump cover and pump
7.6 Fitting key in input shaft
Remove control block.
for fluid pump drive is
Replace fitting key, replace
broken
any other faulty parts
8. Excessive fluid
8.1 Fluid cooler is too small
Use a larger fluid cooler
temperature
8.2 Excessive fluid in transmission
Remove excessive fluid
8.3 Fluid cooler is dirty on
Detach coolant water lines
water side
and clean fluid cooler
on water side
8.4 Worn fluid pump in
Replace cover
transmission
taining fluid pump
8.5 Faulty piston rings in
Replace piston rings.
input shaft
8.6 Clutch is slipping
Refer to 3.
8.7 Clutch does not open
Dismount transmission and
completely due to worn
coupling, replace all faulty
disc support
parts
8.8 With fluid cooler in bypass
Correct bypass pipeline
and unfavorable
arrangement of pipelines
too little coolant waterflows
through bypass to
cooler
9. Water in the fluid,
9.1 Fluid cooler faulty
Repair leakage at cooler or
fluid looks milky
replace cooler. Change
transmission fluid
9.2 High water level in
Remedy cause for water
engine compartment,
level in engine compartment
water entering through
change transmission fluid.
output shaft seal or
breather.
10. Fluid leakage at
10.1 Breather clogged with paint or dirt
Remove paint or dirt from breather
output shaft
10.2 Shaft seal faulty
Disassemble transmission, replace seal.