4.5.6 Measuring the bearing clearance on
the output shaft
a) Mounting the output flange.
Drive parallel pins (item 1, Fig. 5-6a) into output
flange (item 2, Fig. 5-6a).
Screw output flange with socket head bolts (item 3,
Fig. 5-6a) on output shaft.
Tightening torque:
32 Nm (23.6) ZF 63 IV;
100 Nm (73.8 ft.lb.) ZF 80 IV - ZF 80-1 IV - ZF 85 IV.
b) Turn output shaft repeatedly to permit bearings to
seat.
c) Mount dialgauge support securely onto housing,
and "0" indication gauge.
d) Place dial gauge onto bolt head.
e) Lift output shaft carefully, using two screwdrivers,
and record measurement (Fig. 5-6b).
NOTE
This step should be done very carefully to obtain the
actual bearing clearance.
f) Carry out steps "b" and "e" for severaltimes.
g) The bearing clearance measured plus the preten-
sion required in section 5.1 will determine the re-
quired thickness of shims.
NOTE
Round off the determined shim thickness to 0.05
mm (0.001968 in.).
h) Unscrew bolt with washer and dial gauge with sup-
port.
4.5.7 Adjusting the pretension clearance
of bearings
When the thickness of shims has been determined, the
transmission must be disassembled again.
a) Unscrew output flange (see Fig. 5.6a).
b) Using a adequate drift punch, drive the parallel pins
(item 1, Fig. 5-7a) with slight blows out of the hous-
ing.
c) Loosen hex bolts with lockwashers (items 2 and 3,
Fig. 5-7a) and remove input side of housing (item
4, Fig. 5-7a).
d) Remove gears from the housing (Fig. 5-7b).
25
Repair Manualand Spare Parts List
Section 4
3
2
1
FIG. 5 - 6a
FIG. 5 - 6b
1
4
2
3
FIG. 5 - 7a
FIG. 5 - 7b
