ZF 63 A User manual

ZF 63 A
ZF 63
ZF 80 A
ZF 80-1 A
ZF 80 A NEW VERSION
ZF 80-1 A NEW VERSION
ZF 85 A
NOVEMBER 2005
cod.
310.01.0054h
Repair Manual
and
Spare arts List

TABLE OF CONTENTS
INTRODUCTION. . ................................... 3
1. MAJOR COMPONENTS. . .......................... 5
1.1 TRANSMISSION SET-UP . .......................5
1.2 CLEANERS AND SEALANTS . . . ..................6
1.3 MEASURING TOOLS . ...........................6
1.4 STANDARD TOOLS AND FIXTURE . ..............6
2. SPECIAL TOOLS . . ............................... 7
3. DISASSEMBLY ................................... 9
INTRODUCTION....................................9
3.1 FLUID FILTER . . ................................9
3.1.1 Remove f uid fi ter . . . .......................9
3.1.2 Suction of transmission f uid . . . ..............9
3.1.3 Suction of transmission f uid on
ZF 80 A, ZF 80-1 A and ZF 85 A . ..............9
3.2 DIPSTICK . . .................................. 10
3.3 BREATHER VALVE. . . ......................... 10
3.4 OUTPUT FLANGE............................. 10
3.5 CONTROL BLOCK . . . ......................... 11
3.5.1 Neutra Safety Switch ..................... 11
3.5.2 Neutra Safety Switch Check . . . ............ 11
3.6 HOUSING . . .................................. 12
3.6.1 Transmission housing ha ves. . . ............ 12
3.6.2 Shafts and gears ......................... 12
3.6.3 Radia shaft sea s ......................... 12
3.6.4 F uid in et pipe . . ......................... 13
3.7 TAPERED ROLLER BEARINGS. ................ 14
3.7.1 Outer races of tapered ro er bearing . ....... 14
3.7.2 Inner races of tapered ro er bearings ....... 14
3.8 CLUTCH PACK . .............................. 15
3.8.1 Remova of the c utch discs ................ 15
4. ASSEMBLY...................................... 17
INTRODUCTION.................................. 17
4.1 INPUT SHAFT . . .............................. 17
4.1.1 Mount discs into reversing c utch ........... 17
4.1.2 Insta need e bearings and gear............ 18
4.1.3 Assemb e butting rings .................... 18
4.1.4 Mounting inner races of tapered
ro er bearings. . . ......................... 18
4.1.5 Assemb e piston rings ..................... 18
4.2 INTERMEDIATE SHAFT. . . ..................... 19
4.2.1 Mounting inner races of tapered
ro er bearings. . . ......................... 19
4.3 OUTPUT SHAFT .............................. 19
4.3.1 Mounting inner race of tapered
ro er bearing............................. 19
4.4 PREASSEMBLY OF HOUSING ..................20
4.4.1 Assemb y of outer races
(tapered ro er bearings) . ...................20
4.4.2 Insta ation of f uid suction pipe and baff e. . . . 20
4.4.3 Assemb ing input shaft sea . . . ..............21
4.4.4 Mounting the breather fi ter . . . ..............21
4.5 MEASURING THE BEARING CLEARANCE/
ADJUSTING THE PRETENSION OF BEARINGS . . 22
4.5.1 Genera . . . ................................22
4.5.2 Mounting outer races of tapered ro er
bearings into housing . . . ...................22
4.5.3 Inserting gear set into housing ..............22
4.5.4 Measuring bearing c earance on input
shaft . ....................................23
4.5.5 Measuring bearing c earance at
intermediate shaft . . .......................23
4.5.6 Measuring the bearing c earance on the
output shaft...............................23
4.5.7 Adjusting the pretension/c earance of
bearings. . ................................24
4.5.8 Fina assemb y of the housing ..............24
4.6 CONTROL BLOCK . . ...........................25
4.6.1 Mounting the contro b ock . . . ..............25
4.7 FLUID FILTER . ................................25
4.7.1 Mounting the f uid fi ter . ...................25
4.8 OUTPUT FLANGE . . ...........................25
4.9 MAKING THE TRANSMISSION
READY FOR OPERATION . . . ...................26
4.9.1 Fi ing up with transmission F uid . ..........26
4.9.2 Check f uid eve . . . .......................26
5. ADJUSTMENT DATA . . ...........................27
5.1 SHIFTING PRESSURE . . .......................27
5.2 LUBE OIL DELIVERY RATE. . ...................27
6. HYDRAULIC DIAGRAM. ...........................28
7. TIGHTENING TORQUES...........................29
8. FUNCTION TEST . ................................3
9. TROUBLESHOOTING . . ...........................31
1 . AUTOMATIC TRANSMISSION FLUID ..............36
11. SPARE PARTS LIST
ZF63A - ZF63 - ZF8 A - ZF8 -1A...............39
Preface . . .........................................39
Name p ate . . . ....................................39
FIG. 1 ZF 63 A. ....................................40
FIG. 1 ZF 63 . . ....................................42
FIG. 1 ZF 80 A - ZF 80-1 A . . .......................44
1
Repair Manua and Spare Parts List Tab e of contents

FIG. 2 ZF 63 A .................................... 46
FIG. 2 ZF 63 . .................................... 50
FIG. 2 ZF 80 A - ZF 80-1 A. . ....................... 52
FIG. 3 Mechanica se ector va ve
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . . ..... 56
FIG. 4 O d e ectric se ector va ve with proportiona va ves
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . . ..... 58
FIG. 5 ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . . ..... 60
FIG. 6 O d e ectric se ector va ve ON/OFF 12V, 26 bar
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . . ..... 62
FIG. 7 New e ectric se ector va ve ON/OFF 12V - 26 bar
New e ectric se ector va ve ON/OFF 24V - 26 bar
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . ..... 64
FIG. 8 New e ectric se ector va ve ON/OFF 12V - 26 bar
with tro ing va ve
New e ectric se ector va ve ON/OFF 24V - 26 bar
with tro ing va ve
ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A . . ..... 66
ZF 63 A - ZF 63 KIT COMPONENTS . . . .............. 68
ZF 80 A - ZF 80-1 A KIT COMPONENTS .............. 69
12. SPARE PARTS LIST ZF 8 A - ZF 8 -1 A
NEW VERSION . ................................ 71
Preface . . ........................................ 71
Name p ate . . . .................................... 71
FIG. 1 ZF 80 A - ZF 80-1 A . . . ....................... 72
FIG. 2 ZF 80 A - ZF 80-1 A . . . ....................... 74
FIG. 3 Mechanica se ector va ve
ZF 80 A - ZF 80-1 A . . . ....................... 78
FIG. 4 O d e ectric se ector va ve ON/OFF 12V, 26 bar
ZF 80 A - ZF 80-1 A . . . ....................... 80
FIG. 5 New e ectric se ector va ve ON/OFF 12V - 26 bar
New e ectric se ector va ve ON/OFF 24V - 26 bar
ZF 80 A - ZF 80-1 A . . . ....................... 82
FIG. 6 New e ectric se ector va ve ON/OFF 12V - 26 bar
with tro ing va ve
New e ectric se ector va ve ON/OFF 24V - 26 bar
with tro ing va ve
ZF 80 A - ZF 80-1 A . . . ....................... 84
KIT COMPONENTS ZF 80 A - ZF 80-1 A .............. 86
13. SPARE PARTS LIST ZF 85 A . . ................... 87
Preface .......................................... 87
Name p ate. . ..................................... 87
FIG. 1 ZF 85 A . . . ................................. 88
FIG. 2 ZF 85 A . . . ................................. 90
FIG. 3 Mechanica se ector va ve
ZF85A.................................... 92
FIG. 4 E ectric se ector va ve ON/OFF 12V - 26 bar
E ectric se ector va ve ON/OFF 24V - 26 bar
ZF85A.................................... 94
FIG. 5 E ectric se ector va ve ON/OFF 12V - 26 bar
with tro ing va ve
E ectric se ector va ve ON/OFF 24V - 26 bar
with tro ing va ve
ZF85A.................................... 96
KIT COMPONENTS ZF 85 A ........................ 98
2
Repair Manua and Spare Parts List Tab e of contents

INTRODUCTION
This manua gives specific instructions for the proper repair on
ZF 63 - ZF 63 A - ZF 80 A - ZF 80-1 A - ZF 85 A transmissions.
P ease fo ow the procedures carefu y to insure qua ity service.
ZF HURTH MARINE recommends to read the manua comp ete y
before starting with repairs, as some of the procedures described
are rather comp ex.
A ong with standard too s, ZF HURTH MARINE recommends the
use of specia too s, necessary to perform repairs correct y. The
specia too s are avai ab e through your oca ZF HURTH MARINE
dea er.
This manua is based on the technica information at the time of
printing. The manua has been checked carefu y in order to avoid
errors. However ZF HURTH MARINE is not iab e for any misrepre-
sentations, errors of description or omissions.
Modifications on future manua s may be introduced without prior
notice.
3
Repair Manua and Spare Parts List Introduction

4

1. MAJOR COMPONENTS
1.1 TRANSMISSION SET-UP
The main components of the ZF Marine Transmissions are:
ITEM DESCRIPTION ITEM DESCRIPTION
1
Two-piece a uminum die cast
2
Gears
1.1
Oi fi ter
2.1
Input shaft with reversing c utch pack assemb y
1.2
Oi dipstick
2.2
Intermediate shaft
1.3
Breather va ve
2.3
Output shaft
1.4
Oi drain p ug (ZF 80A, ZF 80-1A, ZF 85A)
3
Contro b ock
5
Repair Manua and Spare Parts List Section 1
1
1.2
1.3
1.1
1.4
3
2.1
2.3
2.2
2

1.2 CLEANERS AND SEALANTS
6
Repair Manual and Spare Parts List Section 1
For cleaning:
Cold cleaner such as benzene, thrichloroethane or Loc-
tite fast cleaner N
o 7063
| WARNING |
Keep detergents away from yo r skin, do not drink
and do not inhale their vapors! Always wear protec-
tive gloves and safety glasses!
Note accident prevention r les!
For assembly:
. Loctite 243 medium-hard for securing oil plug on
ZF 80 A - ZF 80-1 A - ZF 85 A
. Loctite 245 for securing output flange on spline
. Loctite 518 for housing surfaces
. Loctite 574 for outer diameter sealing rings
. Grease: Staburags NBU 30, Klueber Co for radial
shaft seals
. ATF FLUID:
3 8 litres (1 0 US gallons) for ZF 63
4 0 litres (1 05 US gallons) for ZF 63 A
5 5 litres (1 5 US gallons) for ZF 80 A - ZF 80-1 A
5 5 litres (1 5 US gallons) for ZF 85 A
1.3. MEASURING TOOLS
MICROMETER
Measuring gauge from 0-25 mm (0-1 0 in )
Accurancy of reading 1/100 mm (0 0004 in )
DIAL INDICATOR GAUGE WITH ARM-TYPE
SUPPORT
DIAL GAUGE INCREMENTS
DIAL FACE CAN BE TURNED
TO ZERO POSITION
ACCURACY OF READING:
SMALL HAND 1 mm (.03937 in)
LARGE HAND
1/100 mm (.0004 in)
MEASURING DEPTH
APPROX. 11 mm (.433 in)
FEELER GAUGE
1.4. STANDARD TOOLS AND FIXTURE
WRENCH for hexagon bolts (8 - 17 - 19 - 22 mm) (7/8")
ALLEN WRENCH (6 mm)
HEXAGON SOCKET WRENCH (6 - 8 - 17 - 19 mm)
TORQUE WRENCH
adjustable up to 180 Nm (152 ft lb )
PLASTIC HAMMER (1000 g) and sturdy screwdriver
EXTRACTOR minimum diameter 130 m
PLIER

2. SPECIAL TOOLS
It is assumed that a standard too s, such as, torque
wrenches, open-end wrenches, a en keys and extrac-
tors, are avai ab e.
A fixtures for pressing parts in or out shou d be used in
conjunction with a hydrau ic or manua press.
EXTRACTOR
Tapered ro er bearing inner races
Basic Unit P/N 978.25.0017.0 (454421)
ADAPTER for basic unit 978.25.0017.0 (454421).
For bearing input shaft - sp ine side.
- P/N 978.25.0018.0 (469686) ZF 63 A - ZF 63
- P/N 978.35.0019.0 (500465) ZF 80 A - ZF 80-1 A -
ZF 85 A
D
EXTRACTOR SPLIT RING
Input shaft. Taper ro er bearing inner race - contro
b ock side. P/N 224.836.009 (456170)
EXTRACTOR Tapered ro er bearing outer races basic
unit P/N 978.25.0021.0 (454422)
ADAPTER FOR
BASIC UNIT 454422
50
AB
BASIC UNIT
LEGS KIT (composed of three legs)
P/N 978.25.0006.0 (477776)
Part number ZF 63
ZF 63 A
ZF 8 A
ZF 8 -1 A ZF 85 A
978.25.0009.0 (477853) ll
978.25.0011.0 (477854) lll
978.25.0012.0 (477856) l
978.25.0013.0 (477857) l
978.35.0016.0 (477895) ll
CLAMPING RING for measuring the bearing c earance
input shaft P/N 219.354.3 (618582)
LEVER
CLAMPING SCREW
INPUT SHAFT
DIAL INDICATOR
MANDREL
For disassemb y and assemb y
Shaft sea - input side : P/N 224.836.005 (454425)
Shaft sea - output side:
- P/N 224.836.006 (454426) ZF 63 A - ZF 63
- P/N 978.35.0005.0 (500449) ZF 80 A - ZF 80-1 A -
ZF 85 A
For assemb ing input shaft sea on the input sp ine side
Bushing P/N 20.0012.01 to insert input shaft sea
On y for mode s: ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
Mandre P/N 20.0012.02 to assemb e input shaft sea
On y for mode s: ZF 63 A - ZF 63 - ZF 80 A - ZF 80-1 A
Mandre P/N 20.1072.01 to assemb e input shaft sea
On y for mode : ZF 85 A
7
Repair Manua and Spare Parts List Section 2

SHIM
To determinate the correct pre oad of the tapered ro er
bearings.
- P/N 20.1005.00 ZF 63 A
- P/N 20.1018.00 ZF 63
- P/N 20.1016.00 - ZF80 A - ZF 80-1 A - ZF 85 A
SPECIAL HEX HEAD BOLT WITH BEARING
for measuring the bearing c earance intermediate shaft
P/N. 224.836.008 (458105)
PUNCH
for assemb y Sea - suction pipe
- P/N 20.1021.00 ZF 80 A - ZF 80-1 A - ZF 85 A
- P/N 20.1029.00 ZF 63 A - ZF 63
CENTRE SQUARE PUNCH To position the oi suction
pipe into housing P/N 20.1041.00
8
Repair Manua and Spare Parts List Section 2

3. DISASSEMBLY
9
Repair Manua and Spare Parts List Section 3
FIG. 1 - 1
1
2
3
FIG. 1 - 2
INTRODUCTION
C ean the transmission thorough y on the outside be-
fore disassemb y.
The repair area shou d be c ean and we ighted.
ZF HURTH MARINE recommends using a swive ing
stand for aiding in assemb y and disassemb y.
3.1 FLUID FILTER
3.1.1 Remove fluid filter
Turn the screw that fixes the oi fi ter cover in a counter-
c ockwise direction and remove the fi ter from its hous-
ing (item 1, fig. 1-1). Use a 6 mm A en wrench.
Pu fi ter e ement off (item 2, fig.1-1).
Check O-rings (item 3 and 4, fig. 1-1) for wear, rep ace if
necessary.
3.1.2 Suction of transmission fluid
Push hose of suction pump (item 1, Fig. 1-2) through
the suction pipe (item 2, Fig. 1-2) down to the bottom
of the housing and suck the f uid off.
3.1.3 Suction of transmission fluid on
ZF 8 A, ZF 8 -1 A and ZF 85 A
Remove the p ug (item 3, Fig. 1-2) and et the oi f ow
from the proper ho e.
+|
IMPORTANT |
The used oil and the oil filter are to be handled as
special waste that pollute the environment.
For the safe disposal of used oil and filter, take all
the measures required by the relevant local rules
and legislation.
Swiveling stand ZF
Output - half side up
Swiveling stand ZF
Input - half side up
13
4
2

3.2 DIPSTICK
Unscrew dipstick (item 1, Fig. 2-1) (counterc ockwise)
and pu out of housing. Rep ace O-Ring if present
(check parts ist section 11).
3.3 BREATHER VALVE
Unscrew breather va ve (item 1, Fig. 3-1). Wash va ve
in a detergent, et dry and dip in oi , then et oi drip off.
3.4 OUTPUT FLANGE
Lock output f ange in swive frame.
Unscrew hex head bo t (item 1, Fig. 4-1).
Remove disc (item 2, Fig. 4-1) and O-ring (item 3, Fig. 4-
1).
Screw hex bo t (item 1, Fig. 4-1) in again.
P ace extractor on the transmission and pu output
f ange (item 1, Fig. 4-2) off.
10
Repair Manua and Spare Parts List Section 3
1
FIG. 2 - 1
1
FIG. 3 - 1
1
2
3
4
FIG. 4 - 1
1
FIG. 4 - 2

3.5 CONTROL BLOCK
Unscrew a en head bo ts (item 1, Fig. 5-1)
Pu contro b ock (item 2, Fig. 5-1) together with sea
(item 3, Fig. 5-1) off the input shaft.
Remove key (item 4, Fig. 5-1) from input shaft (item 5,
Fig. 5-1).
3.5.1 Neutral Safety Switch
Unscrew neutra safety switch (item 1, Fig. 5-2).
Note: Use 7/8 inch wrench for hex bo ts.
To reassemb e switch:
tightening torque: 25 Nm (18.5 ft. b.)
3.5.2 Neutral Safety Switch Check
To check for proper operation of the switch perform one
of the fo owing tests:
A: Ohm meter
Connect the ohm meter eads to the termina connec-
tion of the switch.
With the pin (item 1a Fig. 5-3) extended you shou d get
a reading, indicating a good switch.
Compressing the pin (item 1b Fig. 5-3) you shou d have
«O» reading,
B: 12 volt light
Connect the neutra safety switch with a ight in series
to a 12 vo t battery. The switch is good when the ight
goes out when the center pin (item 1b Fig. 5-3) is com-
pressed.
11
Repair Manua and Spare Parts List Section 3
1
23
4
FIG. 5 - 1
1
FIG. 5 - 2
1a
1b
FIG. 5 - 3
Battery 12 V DC Lamp 8.4 A
Neutral
position
Battery 12 V DC Lamp 8.4 A
AorB
position

3.6 HOUSING
3.6.1 Transmission housing halves
Using an adequate drift punch, top the ocating pins
(item 1, Fig. 6-1a and 6-1b) out of the housing.
Loosen and remove a hex head bo ts and ock
washers (item 2 and 3, Fig. 6-1b). Using a p astic ham-
mer s ight y top the sp it ine of the case ha ves to break
the sea . Then remove the input side of the housing.
3.6.2 Shafts and gears
Take the gear set out of the housing
. Intermediate shaft (item 2, Fig. 6-2).
. Input shaft (item 1, Fig. 6-2).
. Output shaft (item 3, Fig. 6-2).
Check a gears, bearings and three piston rings on the
input shaft (item 4, Fig. 6-2) for signs of wear or fai ure.
If any of the gears are damaged or showing signs of ex-
cessive wear ZF HURTH MARINE recommends rep a-
cing the comp ete gear set.
When tapered ro er bearings on the input shaft need to
be rep aced, the butting rings and need e bearings
shou d a so be rep aced. To check for correct c utch op-
eration, rotate the gears on the input shaft. If it is hard
to turn the gears, the c utch is probab y damaged.
3.6.3 Radial shaft seals
Input shaft seal
Using a sea mandre inside the housing top the input
shaft sea out.
Discard sea and rep ace with a new one. (Fig. 6-3a).
12
Repair Manua and Spare Parts List Section 3
1
FIG. 6 - 1a
1
32
FIG. 6 - 1b
2
1
4
3
FIG. 6 - 2
FIG. 6 - 3a

Output shaft seal
Using a mandre punch top the output f ange sea out
from the other side of the housing. Discard sea and re-
p ace with a new one. (Fig. 6-3b).
3.6.4 Fluid inlet pipe
Rep acing the sea :
ZF 63 A - ZF 63 (Fig. 6-4a)
. Remove baff e p ate (item 2).
. Remove suction pipe (item 3).
. Drive out sea (item 1).
ZF 8 A - ZF 8 -1 A - ZF 85 A (Fig. 6-4b)
. Remove suction pipe (item 2).
. Drive out sea (item 1).
13
Repair Manua and Spare Parts List Section 3
FIG. 6 - 3b
12
3
3
OLD VERSION NEW VERSION
FIG. 6 - 4a
1
2
FIG. 6 - 4b

3.7 TAPERED ROLLER BEARINGS
Check for failed bearings or excessive bearing wear.
3.7.1 Outer races of tapered roller beari g
Remove the outer races out of the housing halves by
means of the special tool (Fig. 7-1 or by heating the
housing halves in an oven to approx. 120 ëC (248 F :
Put the housing in the oven upside down, so the outer
races will fall down.
| WARNING |
Use protective gloves whe ha dli g the heated
housi g a d outer races.
+|
IMPORTANT |
Regard locatio of shims u der each outer race for
correct positio duri g reassembli g.
Shims are located u der outer races of the cover
o ly.
3.7.2 I er races of tapered roller beari gs
NOTE
. I put shaft - spli e side
. The extractor (Fig. 7-2a) is required for pulli g
the i er races off.
For extracti g the i er races proceed as follows:
. Screw in adapter onto the puller (item 1 .
. Place adapter onto the roller cage.
. Tighten collar to rollers by means of cap nut (item
2 .
. Screw spindle (item 3 against shaft and pull bear-
ing evenly and carefully off.
| WARNING |
Improper use of the extractor whe removi g the
races, could cause damage to the race or slip off.
I put shaft - Co trol block side
The inner race and the gear on the control block side
can be removed by using the split ring and a standard
hydraulic press (fig. 7-2b .
I put shaft - Co trol block side ZF 85 A
. Remove the retaining ring (item 1, Fig. 7-2c using
a plier.
. Scrap the retaining ring.
. Remove the washer (item 2, Fig. 7-2c .
. Remove the shims (item 3, Fig. 7-2c .
14
Repair Manual and Spare Parts List Section 3
FIG. 7 - 1
3
2
1
INPUT SPLINE SIDE CONTROL BLOCK SIDE
FIG. 7 - 2a FIG. 7 - 2b
12
3
FIG. 7 - 2c

3.8 CLUTCH PACK
3.8.1 Removal of the clutch discs
Control block side (Fig. 8-1a)
ZF 63 A - ZF 63
. Remove thrust washer (1) off using two screwdri-
vers.
. Take off gear (2) and, need e bearings (3).
. Remova of pressure p ate.
Press snap ring (5) against periphery of pressure
p ate (4) by means of screwdrivers. Extract them to-
gether. The discs (6) can now be removed from the
c utch housing.
Control block side (Fig. 8-1b)
ZF 8 A - ZF 8 -1 A
. Remove thrust washer (1) off using screwdrivers.
. Take off gear (2), need e bearings (3), and spacer
(7).
. Remova of pressure p ate.
Press snap ring (5) against periphery of pressure
p ate (4) by means of screwdrivers. Extract them to-
gether. The discs (6) can now be removed from
c utch housing.
Control block side (Fig. 8-1c)
ZF 85 A
. Remove thrust washer (1) off using two screwdri-
vers.
. Take off gear (2) and need e bearing (3).
. Remova of pressure p ate.
Press snap ring (5) against periphery of pressure
p ate (4) by means of screwdrivers. Extract them to-
gether. The discs (6) can now be removed from the
c utch housing.
15
Repair Manua and Spare Parts List Section 3
4
5
2
1
6
3
FIG. 8 - 1a
4
7
2
1
3
6
5
FIG. 8 - 1b
4
5
2
1
6
3
FIG. 8 - 1c

Input spline side (fig. 8-2a)
ZF 63 A (no ratio 2.7) - ZF 63
. Remove thrust washer (1) off using two screwdri-
vers.
. Take off gear (2) and need e bearings (3).
. Remove pressure p ate (5). Press snap ring (4)
against periphery of pressure p ate by means of
screwdrivers. Extract them together. The discs (6)
can now be removed from the c utch housing.
Input spline side (fig. 8-2b)
ZF 8 A - ZF 8 -1 A
ZF 63 A (only ratio 2.7)
ZF 85 A
. Remove thrust washer (1) off using two screwdri-
vers.
. Take off gear (2), need e bearings (3) and spacer
(4).
. Remove pressure p ate (6). Press snap ring (5)
against periphery of pressure p ate by means of
screwdrivers. Extract them together.
The discs (7) can now be removed from the c utch
housing.
16
Repair Manua and Spare Parts List Section 3
5
2
1
3
6
4
FIG. 8 - 2a
6
4
2
1
3
7
5
FIG. 8 - 2b

4. ASSEMBLY
17
Repair Manua and Spare Parts List Section 4
1
2
FIG. 1 - 1a
FIG. 1 - 1b
1
2
FIG. 1 - 1d
2
1
FIG. 1 - 1c
INTRODUCTION
A we - ighted work area that is free from dirt and chips,
wi faci itate the work considerab y.
ZF HURTH MARINE recommends to use a swive ing
stand, described in the disassemb y section to aid in
the assemb y.
Thorough y c ean a mating surfaces from any Loctite
or gasket materia .
| WARNING |
Cleaners and solvents can be toxic and potentially
harmful without proper ventilation.
Use caution when using such c eaners.
A ways wear protective g oves and g asses!
The next assemb y procedure requires the fo owing:
. An e ectric oven or heating amp for heating the
housing ha ves wi be required when mounting
the bearings.
. A hydrau ic or mechanica press
4.1 INPUT SHAFT
4.1.1 Mount discs into reversing clutch
Equip both sides coup ing with new outer disc (item 1,
Fig. 1-1a) and new inner disc (item 2, Fig. 1-1a).
NOTE
. For exact quantity of inner (item 2, Fig. 1-1a) and
outer discs (item 1, Fig. 1-1a), please refer to the
spare parts list at the end of this manual.
. Stagger the position of the notches on the outer
discs as shown in Fig. 1-1b.
Starting with one of the outer discs, bi d up the c utch.
The ugs on the outer discs have to be positioned in ine
with each other as shown in Fig. 1-1b.
Insta snap ring into groove of c utch housing securing
the pressure p ate.
P ace end disc (item 1, Fig. 1-1c) and snap ring (item 2,
Fig. 1-1c) engaging it into c utch housing groove.
Check correct position of end disc (item 1, Fig. 1-1c).
Repeat same procedure on opposite side of c utch
(Fig. 1-1d).

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 pre iously 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 asher is fully pressed on and
gear is free to rotate.
. Thrust asher 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 dri e 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 slee e and a
manual press or a copper brass punch.
| CAUTION |
Handle heated tapered roller bearing inner race only
ith 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 groo e
of the input shaft using a plier.
| WARNING! |
. Correct the shim thickness:
check that there is no slack bet een asher and
the retaining ring.
. Maximum permissible clearance should be 0.05
mm.
Use a feeler gauge to check it.
18
Repair Manual and Spare Parts List Section 4
1
2
2
1
3
FIG. 1 - 2
ZF 63 A (Ratio= 2.7 only)
ZF 80 A - ZF 80-1 A - ZF 85 A
ZF 63 A (no Ratio= 2.7)
ZF 63
D
1
FIG. 1 - 3
120 ˚C
248 ˚F
1
2
FIG. 1 - 4
3
2
1
FIG. 1 - 5