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Repair Manual and Spare Parts List
4.1.2 Install needle bearings and gear
Input spline side
Install needle bearing (item 1, fig. 1-2) onto shaft.
.
Slide spacer (item 3, fig. 1-2) where required.
.
Align splines on clutch discs previously installed
.
and install gear (item 2, fig. 1-2).
Make sure clutch gear is fully installed, engaging all
clutch discs.
Control block side
Repeat same procedure of input sline.
.
Spacer is only in ZF 80 A and ZF 80-1 A.
4.1.3 Assemble butting rings
NOTE
Make sure thrust washer is fully pressed on and
.
gear is free to rotate.
Thrust washer must not be bent.
.
Position shaft assembly on suitable holding fixture.
Using a tube with a bore dia. of 35 mm (1.38 inch) in
and a plastic hammer gently drive thrust washer in po-
sition. (item 1, Fig. 1-3). Repeat same procedure on op-
posite side.
4.1.4 Mounting inner races of tapered roller
bearings
Heat inner race of tapered roller bearing (item 1, Fig. 1-
4) to approx. 120 ë(248 ëF) and push onto input shaft.
After cooling down, press bearing carefully against but-
ton ring (item 2, Fig. 1-4) by means of a sleeve and a
manual press or a copper brass punch.
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CAUTION
Handle heated tapered roller bearing inner race only
with special gloves!
NOTE
For pressing, apply sleeve to inner race but not to
rollers.
4.1.5 Assemble shims, support shims and
retaining ring (ZF 85 A)
Place the shims (item 1, Fig. 1-5).
.
Install the washer (item 2, Fig. 1-5).
.
Put the retaining ring (item 3, Fig. 1-5) in the groove
.
of the input shaft using a plier.
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WARNING!
Correct the shim thickness:
.
check that there is no slack between washer and
the retaining ring.
Maximum permissible clearance should be 0.05
.
mm.
Use a feeler gauge to check it.
18
ZF 63 A (Ratio= 2.7 only)
ZF 80 A - ZF 80-1 A - ZF 85 A
2
1
3
120 ˚ C
248 ˚ F
FIG. 1 - 4
2
1
Section 4
ZF 63 A (no Ratio= 2.7)
ZF 63
2
1
FIG. 1 - 2
1
D
FIG. 1 - 3
1
2
3
FIG. 1 - 5
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