SERVICE MANUAL AND SPARE PARTS LIST

S E R V I C E M A N U A L A N D S P A R E P A R T S L I S TS E R V I C E M A N U A L A N D S P A R E P A R T S L I S T

Cod. 310.01.0052f

RE

PA

I RM A N U A L

ZF 3 M (HBW 35)ZF 5 M (HBW 50)ZF 10 M (HBW 100)ZF 12 M (HBW 125) / HBW 10ZF 15 M (HBW 150)ZF 15 MA (HBW 150 A)ZF 15 MIV (HBW 150 V)ZF 25 M (HBW 250)ZF 25 MAZF 30 M

Manual and Spare Parts List ZF M line

3

This ZF M manual has been preparedfor all those who have to do with ZF-HURTH Marine reversing gearbox unitsof the ZF M line, including models ZF 3M, ZF 5 M, ZF 10 M, ZF 12 M, ZF 15 M,ZF 15 MA, ZF 25 M, ZF 25 MA, ZF 30 M,ZF 15 MIV, in particular for- power plant suppliers- shipyards- craft owners

The ZF M manual is intended as an aidfor handling ZF M transmissions and willanswer all questions that may arise indaily operation and in connection with theinstallation and repair of ZF M transmis-sions.

This manual contains:

- Technical description of the gearboxunits and a number of important tech-nical data;

- Instructions for proper installation of thegearbox in the craft;

- Explanatory notes on correct operationand maintenance;

- Detailed description of all disassemblyand reassembly procedures (withdrawings);

- Troubleshooting table with possiblecauses of trouble and the required re-medial action;

- Spare parts list with stock numbers ofall sparte parts;

- Explosion-View drawings showingeach part with the reference numeralsused in the text.

No problems will be encountered in han-dling, installing and operating the ZF Mgearbox if the instructions in this manualare followed. Should a repair be neces-sary, a qualified technician will have nodifficulty in doing the repair work in ac-cordance with the detailed instructionsgiven on the following pages.

In addition, ZF M Service Stations (dis-tributors and dealers) are available forany repairs and for supplying the spareparts required. The manufacturer will al-ways be glad to name the Service Sta-tion nearest to your location.

All transmission units are covered by aworldwide guarantee given by the manu-facturer. The manufacturer’s warrantywill be subject to the condition that:- the instructions in this manual are

strictly observed in handling thetransmission.

- no work is performed by persons notauthorized by ZF-HURTH Marine.

- no changes or alterations of any kindare made on the transmission.

Failure to observe these points willinvalide all and any warranty claims.

Caution: never start doing any work onthe transmission unless and until theengine and the propeller have come toa complete standstill.


4

Table of contents

1. Description1.1 Brief description1.2 Technical data and main

dimensions1.2.1 ZF 3 M boat reversing

gearbox unit1.2.2 ZF 5 M boat reversing




gearbox unit1.2.6 ZF 15 MA boat reversing

gearbox unit1.2.7 ZF 15 MIV boat reversing


gearbox unit1.2.9 ZF 25 MA boat reversing

gearbox unit1.2.10 Accessories1.2.11 Tools1.2.12 Ident. No.1.3 Gear casing1.4 Gear set1.5 Multiple-disc clutch and clutch

operation1.6 Shaft bearings1.7 Shaft seals1,8 Lubrication1.9 Cooling unit

2. Installation2.1 Delivery condition2.2 Transport2.3 Removal of preservative2.4 Painting the gearbox2.5 Connection of gearbox

with engine2.6 Connection of gearbox

with propeller2.7 Suspension of engine-

gearbox assembly in the boat2.8 Position of gearbox in

the boat2.9 Operation of gearbox2.10 Cooling unit2.11 Engine-gearbox compartment

3. Operation3.1 General information3.2 Initial operation3.3 Operating temperature3.4 Operation of gearbox3.5 Sailing or moving in tow3.6 Lay-up periods3.7 Preparation for re-use

4. Maintenance4.1 Transmission oil4.2 Oil quantity4.3 Oil level checks4.4 Oil change4.5 Checking the shift cable

and linkage4.6 Cooling unit4.7 Automatic transmission fluiid

List of recommended fluids

5. Disassembly5.1 Removing the cooling unit5.2 Removing and disassembling

the actuating lever cover plate5.3 Removing the bearing shields5.4 Separating the gearbox

sections and removing theinput and output shafts

5.5 Removing the shifting fork5.6 Removing the intermediate gear5.7 Disassembling the input shaft5.8 Disassembling the output shaft5.9 Disassembling the quill shaft

6. Reassembly6.1 General information6.2 Pre-assembling the intermediate

gear shaft in the gearbox sectionwithout opening

6.3 Pre-assembling the shifting forkin the gearbox section withopening

6.4 Pre-assembling the actuatinglever cover plate

6.5 Pre-assembling the gears6.6 Measuring the pre-assembled

gears to determine settingvalue «a»

6.7 Pre-assembling the bearingshields

6.8 Pre-assembling the actuatingmembers

6.9 Reassembling the input shaft6.10 Reassembling the output shaft6.11 Reassembling the quill shaft6.12 Final assembly of gearbox6.13 Measuring the gear sets of

input shaft and output shaft6.14 Mounting the actuating lever

cover plate6.15 Mounting the cooling unit

7. Procedure to adjust the shiftinglever cover

8. Troubleshooting

9. Spare parts list

10. Drawings (Explosion view)


5

1. Description

1.1 Brief description

ZF-HURTH Marine boat reversing gear-box units of the ZF M line are servo-au-tomatically controlled helical gear trans-missions developed for use in pleasurecraft and commercial craft. The servo-operated multiple-disc clutchrequires only minimum effort for shifting,making the ZF M transmission suitablefor single-lever remote control via a rodlinkage or shift cable.

In emergency situations the ZF M per-mits direct reversing at engine speedabove idle rpm.

The torque capacity of the clutch is ex-actly rated, preventing shock loads fromexceeding a predetermined value to en-sure maximum protection of the engineand thus providing the effect of a safetyclutch.

The transmission units are characterizedby low weight and small overall dimen-sions. The gearbox castings are madeof a high-strength, corrosion-resistantaluminium alloy, chromized for improvedseawater resistance and optimumadhesion of paint.

A choice of gear ratios, a high efficiencyrating and low-noise operation are otherprominent features of the ZF M gearboxunits.

The transmissions are immersion-lubri-cated. Maintenance is restricted to oillevel checks (see «Maintenance», chap-ter 4).

The shafts are supported by heavy-dutytaper roller bearings and the gearbox isdesigned to take the axial propeller thrust(for permissible values see «Technicaldata», item 1.2).

Transmission sizes are available forright-hand (RH) and left-hand (LH)rotation of the input shaft, the directionof rotation being specified as seen by anobserver facing the input shaft.In gear lever positions A, the engine shaftand the propeller shaft rotate in oppo-site directions, in position B in the samedirection (Fig. 1).On model ZF 15 MIV, the directions ofrotation are the other way round (Fig. 2).

Engine manufacturers should note thatthe direction of rotation refers to an ob-server facing the flywheel, so that left-hand rotation of the engine correspondsto right-hand rotation of the gearbox in-put shaft.

Fig. 1

Fig. 2


6

1.2.1 ZF 3 M

Power diagramBased on engine power B to DIN 6270;shock factorK = 1.25 to applied, if engine has 1 cylinderK = 1.20 for 2 cylindersK = 1.15 for 3 cylinders

Transmission input speed (rpm)

Transmission power input

Technical data ZF 3 M-2 R ZF 3 M-3 R

Shifting position «A» ratio 2.05:1 2.72:1

Shifting position «B» ratio 1.86:1 2.15:1

Input torque max. Nm (ft lb) 40 (29,5) 30 (22,1)

Power input max. kW (hp) 15 (20)

Input speed max. rpm 5000

Propeller thrust max. N (lb) 1000 (225)

Weight without fluid kg (lb) 8 (17.7)

Fluid quantity liter 0.3

Fluid grade Automatic-Transmission-Fluid (ATF)


7

All dimensions in mm

Fig. 3 ZF 3 M

54


8

1.2.2 ZF 5 M

Power diagram for Pleasure Craft DutyBased on engine power B to DIN 6270;shock factorK = 1.25 to applied, if engine has 1 cylinderK = 1.20 for 2 cylindersK = 1.15 for 3 cylinders


ZF 5 M 2.045 1.864 0.0066 0.0088 18 25 20 27 20 27 5000 8 18 B/W2.722 2.150 0.0047 0.0063 13 18 14 19 17 23 5000 Max input power 15 kW

MODEL RATIO POWER / RPM INPUT POWER CAPACITY MAX WEIGHT BELL HSGS.

«A» Pos «B»Pos kW hp kW hp kW hp kW hp RPM kg lb AND NOTES

2800 rpm 3000 rpm 3600 rpm

«A» POS = continuous running position (normally AHEAD).«B» POS = reverse position.B/W = Borg Warner adaptor.Note = For all «M» (Mechanical) transmission reduce power capacity by the following schock factors: 1 cylinder engine ÷ 1.25, 2 cylinder engine ÷ 1.20,3 cylinder engine ÷ 1.15.


9

Fig. 4 ZF 5 M


54


10

** Max. 95 Nm (70 ft lb) admissible for main travelling direction with gearlever set to «B»

1.2.3 ZF 10 M




1,8



2800 rpm 3000 rpm 3600 rpm

ZF 10 M 1.482 1.864 0.0109 0.0146 30 41 33 44 38 51 5000 9.5 21 SAE 4, 5, B/W1.792 1.864 Max input power 38 kW.2.045 1.864 0.0095 0.0128 27 36 29 38 34 46 5000 Ratio 1.482 «B» Pos.2.722 2.150 0.0068 0.0091 19 26 20 27 25 33 5000 max torque 95 Nm. Ratio

1.792 «B» Pos. maxtorque 95 Nm.



11

Fig. 5 ZF 10 M


54


12

1.2.4 ZF 12 M

Power diagram for pleasure craftBased on engine power B to DIN 6270;shock factor K = 1.25 to applied,if engine has fewer than 4 cylinders.



ZF 12 M 2.136 1.955 0.0131 0.0176 37 49 39 53 47 63 5000 13 29 SAE 4, 5, B/W2.632 1.955 0.0111 0.0149 31 42 33 45 40 54 5000 Max input power 55 kW



2800 rpm 3000 rpm 3600 rpm



13

Fig. 6 ZF 12 M

Model without mounting flange

a) Clockwise rotation b) Oil dipstick and filler screw 17 mm c) M 8/12 deep, holes same on both sides d) Oil drain plug 17 mm widthacross flats e) Spline profile similar B 10 x 23 x 29 DIN 5464 f) Minimum lever travel

Model with mounting flangeAll dimensions in mm


14

** Max. 120 Nm (88.5 ft lb) admissible for main travelling directionwith gear lever set to «B»

1.2.5 ZF 15 M






2800 rpm 3000 rpm 3600 rpm

ZF 15 M 1.556 1.955 0.0152 0.0204 43 57 46 61 55 73 5000 13 29 SAE 4, 5, B/W, Yanmar JH1.875 1.955 Max input power 55 kW.

Ratio 1.556 «B» Pos.max torque 120 Nm.Ratio 1.875 «B» Pos. max torque 120 Nm.



15

Fig. 7 ZF 15 M



16

** Max. 120 Nm (88.5 ft lb) admissible for main travelling directionwith gear lever set to «B»

1.2.6 ZF 15 MA


Gearbox input speed (1/min)




2800 rpm 3000 rpm 3600 rpm

ZF 15 MA 1.875 1.955 0.0152 0.0204 43 57 46 61 55 73 5000 13 29 SAE 4, 5, B/W, Yanmar JH2.136 1.955 0.0131 0.0176 37 49 39 53 47 63 5000 Max input power 55 kW.

8 degrees 2.632 1.955 0.0111 0.0149 31 42 33 45 40 54 5000 Ratio 1.875 «B» Pos.max torque 120 Nm.Ratio 2.136 «B» Pos. max torque 120 Nm.



17

Fig. 8 ZF 15 MA

Model without mounting flange

a) Clockwise rotation b) Oil dipstick and filler screw 17 mm c) M 8/12 deep, holes same on both sides d) Oil drain plug 17 mm width across flats e) Spline profilesimilar B 10 x 23 x 29 DIN 5464 f) Minimum lever travel g) Support for control cable h) full profile

Model with mounting flangeAll dimensions in mm


18

* Max. 120 Nm (88.5 ft lb) admissible for main travelling direction withgear lever set to «B».

** Max 45 kW for main travelling direction with gear lever set to «B».

1.2.7 ZF 15 MIV






2800 rpm 3000 rpm 3600 rpm

ZF 15 MIV 2.134 2.224 0.0152 0.0204 43 57 46 61 55 73 5000 20 44 SAE 4, 5, B/W, Yanmar JH2.718 2.224 0.0111 0.0149 31 42 33 45 40 54 5000 Max input power 55 kW.

8 degrees 2.995 2.224 5000 Ratio 2.134 «B» Pos.max torque 120 Nm.



19

Fig. 9 ZF 15 MIV


20

** Max. 230 Nm (170 ft lb) admissible for main travelling direction with gear lever set to «B»

1.2.8 ZF 25 M



Transmission power inputkW

90

80

70

60

50

40

30

20

151 2 3 4 5 6x103

30

40

50

60

70

80

100

120

hp



2800 rpm 3000 rpm 3600 rpm

ZF 25 M 1.880 2.095 0.0262 0.0351 73 98 79 105 80 107 5000 18 40 SAE 4, 5, B/W, Yanmar JH2.273 2.095 0.0216 0.0289 60 81 65 87 78 104 5000 Max input power 80 kW.2.737 2.722 0.0177 0.0237 50 66 53 71 64 85 5000 Ratio 1.880 «B» Pos.

max torque 230 Nm.



21

Fig. 10 ZF 25 M


22

1.2.9 ZF 25 MA

** Max. 169 Nm (125 ft lb) admissible for main travelling direction with gear lever set to «B»



Transmission power inputkW

90

80

70

60

50

40

30

20

151 2 3 4 5 6x103

30

40

50

60

70

80

100

120

hp



2800 rpm 3000 rpm 3600 rpm

ZF 25 MA 2.227 2.737 0.0215 0.0288 60 81 64 86 77 104 5000 18 40 SAE 4, 5, B/W, Yanmar JH2.737 2.737 0.0177 0.0237 50 66 53 71 64 85 5000 Max input power 80 kW.

8 degrees Ratio 2.227 «B» Pos.max torque 169 Nm.



23

Fig. 11 ZF 25 MA

a) Clockwise rotation b) Oil dipstick and filler screw 17 mm c) M 10/15 deep, holes same on both sides d) Oil drain plug 17 mm widthacross flats e) SAE 26 teeth - DP 20/40 - 30° - Flat Root - Class t6 - f) Minimum lever travel

B

75


24

1.2.10 Accessories

Resilient Coupling for ZF 3 M - ZF 5 M - ZF 10 M Ident-No. 254 750 - 3306 316 001

Resilient Coupling for ZF 25 M - ZF 25 MA Ident-No. 256 526 - 3307 316 001

Resilient Coupling for ZF 10 M - ZF 12 M - ZF 15 M - ZF 15 MA - ZF 15 MIV Ident-No. 254 762 - 3306 316 003

splineA 10 x 23 x 29

DIN 5464

max. torque 100 Nmmax. axial misalignment 0.25 mm

friction factor 4–10 Nm


DIN 5464



splineSAE 20/40

26 Z




25

1.2.10 Accessories

Resilient Coupling for ZF 25 M / 25 MA Ident-No. 223 557 - 3307 316 003

Resilient Coupling PERKINS for ZF 10 M - ZF 12 M - ZF 15 M - ZF 15 MA - ZF 15 MIV Ident-No. 288 240 - 3306 316 002

Resilient Coupling PERKINS for ZF 25 M / 25 MA Ident-No. 288 238 - 3307 316 002

splineSAE 20/40

26 Z

splineSAE 20/40

26 Z

Bolt circle 142,6

Bolt circle 142,6


DIN 5464

max. torque 450 Nm

max. torque 200 Nm

max. torque 200 Nm


26

1.2.10 Accessories

Adapter flange for ZF 3 M - ZF 5 M - ZF 10 M - ZF 12 M - ZF 15 M - ZF 15 MA Ident-No. 344 544 - 3306 116 001 (kit)

Adapter flange ZF 25 M - ZF 25 MA Ident-No. 345 964 - 3307 116 001 (kit)

Adapter flange ZF 15 MIV Ident-No. 345 965 - 3306 116 004 (kit)

Bolt circle 235+0.1

Bolt circle 235+0.1

Bolt circle 235+0.1


27

1.2.10 Accessories

Cooler for ZF 10 M - ZF 12 M - ZF 15M - ZF 15 MA - ZF 15 MIV - ZF 25 M - ZF 25 MA Ident-No. 326 742 - 3306 107 001

M8 x DIN 931-8.8 vcad (4x)tightening torque 14 Nm

(when mounting on transmission)

1.2.11 Tools

Tool to adjust the shifing lever cover on ZF 10 M - ZF 12 M - ZF 15M - ZF 15 MA - ZF 25 M - ZF 25 MA(See Service Bulletin No. 007/03)

BRACKET P/N 20.4039.02

EXTENSION SECTION P/N 20.4039.03

377 755 - 0636 010 575

442 372 - 0630 302 090


28

Model prop. turns draw. no. Id. no. weightanti engine

ZF 3 M 2,05:1 487926 3302 002 001 8 kg2,72:1 487927 3302 002 002 8 kg

Housing adapter Kit 344544 3306 116 001Damper plate up to 100 Nm 254750 3306 316 001

ZF 5 M 2,05:1 388817 3303 002 001 8 kg2,72:1 459413 3303 002 002 8 kg

Housing adapter Kit 344544 3306 116 001Damper plate up to 100 Nm 254750 3306 316 001

ZF 10 M 1,48:1 407345 3304 002 003 9,5 kg1,79:1 407346 3304 002 004 9,5 kg2,05:1 - 3304 002 0102,72:1 467329 3304 002 005 9,5 kg

Housing adapter Kit 344544 3306 116 001Housing adapter Kit SAE 5 500013 3306 116 002Oil cooler Kit 326742 3306 107 001Damper plate up to 100 Nm 254750 3306 316 001Damper plate up to 200 Nm 254762 3306 316 003Damper plate PERKINS up to 200 Nm 288240 3306 316 002

ZF 12 M 2,14:1 407205 3305 002 001 13 kg2,63:1 407206 3305 002 002 13 kg

Housing adapter Kit 344544 3306 116 001Housing adapter Kit SAE 5 500013 3306 116 002Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 254762 3306 316 003Damper plate PERKINS up to 200 Nm 288240 3306 316 002

ZF 15 M 1,56:1 407208 3306 002 003 13 kg1,88:1 407207 3306 002 004 13 kg


ZF 15 MA 2,0:1 407461 3306 001 004 13 kg2,14:1 - 3306 001 003 13 kg2,5:1 407462 3306 001 005 13 kg


ZF 15 MIV 2,13:1 407377 3306 003 001 20 kg2,72:1 439386 3306 003 003 20 kg2,99:1 407378 3306 003 002 20 kg


ZF 25 M 1,88:1 408089 3307 002 001 18 kg2,27:1 - 3307 002 007 18 kg2,74:1 408090 3307 002 002 18 kg

Housing adapter Kit 345964 3307 116 001Housing adapter Kit SAE5 - 3315 116 001Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 256526 3307 316 001Damper plate PERKINS up to 200 Nm 288238 3307 316 002Damper plate up to 450 Nm 223557 3307 316 003

ZF 25 MA 2,23:1 - 3307 001 005 18 kg2,74:1 - 3307 001 006 18 kg

Housing adapter Kit 345964 3307 116 001Housing adapter Kit SAE5 - 3315 116 001Oil cooler Kit 326742 3306 107 001Damper plate up to 200 Nm 256526 3307 316 001Damper plate PERKINS up to 200 Nm 288238 3307 316 002Damper plate up to 450 Nm 223557 3307 316 003

1.2.12 Gearboxes and accessories


29

1.3 Gear Casing

The oil-tight gearbox housing is made ofa corrosion-resistant aluminium alloychromized for added protection from cor-rosion. The gear casing is divided in avertical plane into two equal halves.Cooling fins ensure good heat dissipa-tion and mechanical rigidity.

The oil filter screw with dipstick and theoil drain plug are screwed into the gearcasing. The filler screw is provided witha breather hole.

The actuating lever, actuating cam andcover plate are a pre-assembled unit fit-ted laterally to the gearbox unit.

Holes (see «Main dimensions» item 1.2pos. c) are provided for bolting the trans-mission to a flywheel housing or anadapter flange.

1.4 Gear set

The transmission is equipped with casehardened helical gears made of forgedlow-carbon alloy steel and case hard-ened spiral bevel gears (V drive). Thedrive shaft with the drive gears are anintegral unit.

The splined input shaft connecting thetransmission with the engine is hardenedas well.

The driven shaft (propeller side) of thetransmission, with the exception of theZF15 MIV model, is fitted with an inte-grally forged coupling flange.

The servo-automatic clutch system gov-erns the direction of rotation of the inputshaft, and ZF M transmission units areavailable for clockwise:(RH = right hand) or counterclockwise(LH = left hand) rotation.

Fig. 11

45 44 48 51 52 57 60 59 65

36

66

Power flowin lever position

Output

AB

1.5 Multiple-disc clutch and clutch operation - power train

The engine torque is applied to the inputshaft (36) in the specified direction ofrotation and, in shifting position A (seeMain Dimensions item 1.2), via gear (44),the frictionally engaged clutch discs (51and 52) to the external disc carrier (57)and from there via the guide sleeve (59)to the output shaft (66).

In shifting position B, the torque is trans-mitted from the input shaft (36) via inter-mediate gear (26), gear (65), clutch discs(51 and 52) to the external disc carrier(57), the guide sleeve (59) and the out-put shaft (66).

Function

The transmission uses a positivelydriven, mechanically operatedmultipledisc clutch system mounted onthe output shaft.

The thrust force required for obtainingpositive frictional engagement betweenthe clutch discs is provided by a servo-automatic system.

This essentially comprises a number ofballs which, by the rotary movement ofthe external disc carrier, are urgedagainst inclined surfaces provided inpockets between the guide sleeve andthe external disc carrier and in this wayexert axial pressure. The thrust forceand, as a result, the transmittable fric-tion torque are thus proportional to theinput torque applied.Due to the cup springs (48) supportingthe clutch disc stack and a limitation ofthe range of axial travel of the externaldisc carrier (57), the thrust force will notexceed a predetermined value.

The actuating sleeve (60) is held in themiddle position by spring-loaded pins. Toinitiate the shifting operation, the actuat-ing sleeve (60) needs merely be dis-placed axially by the shifting fork until thearresting force has been overcome. Thenthe actuating sleeve (60) is moved auto-matically by the spring-loaded pins, whilethe external disc carrier which follows thismovement, is rotated by frictional forcesexerted by the clutch discs, and the shift-ing operation is completed servo-auto-matically as described above.

Input


30

1.6 Shaft bearings

Both the input and the output shafts arecarried in amply dimensioned taper rollerbearings.

The propeller thrust can be absorbed bythe bearings (for permissible values see«Technical data», item 1.2).

The intermediate gear and the movablegears are carried in sturdy needle rollerbearings.

1.7 Shaft seals

External sealing of the input and outputshafts is provided by radial sealing rings.The running surfaces on the shafts arecasehardened.

1.8 Lubrication

The transmissions are immersion-lubri-cated. The bearings are generously sup-plied with splash oil.

1.9 Cooling unit

Transmissions intended for use at highambient temperatures and for continu-ous operation at high power (especiallywhen shifting position B is used for themain direction of movement of the craft),must be supplied with a cooling unit (seeitem 2.10).

2. Installation

2.1 Delivery condition

HURTH ZF M gearbox units leave thefactory in fully assembled condition. Forsafety reasons, the gearbox is not filledwith oil for shipment. The actuating le-ver is mounted on the actuating shaft.On request, the gearbox is delivered withthe cooling unit (see item 2.10) andflange (see item 1.2) fitted, as well asthe previous damper plate between en-gine and gearbox.The multi-spline shaft is provided with anoil film and protected by a plastic cap.The bright surfaces of the coupling flangeon the output side are coated with ananticorrosive agent for shipment andstorage. The casing is chromized andthus resistant to seawater.

Fig. 12

(0.1 mm = 0.004 inches)

Before leaving the factory, each trans-mission is subjected to a test run withthe prescribed ATF oil. The residual oilremaining in the transmission after drain-ing acts as a preservative and providesreliable protection against corrosion forat least 1 year if the units are properlystored.

2.2 Transport

Care should be taken when transportingthe gearbox or the engine-gearbox as-sembly to prevent undue shocks andimpacts. This applies particulary to theinput and output shafts.

2.3 Removal of preservative

Use a suitable solvent for removing theanticorrosive agent, but never use em-ery cloth or paper, because this coulddamage the sealing surface and void thewarranty.

It is advisable, especially after long peri-ods of storage, to flush the transmissionwith the prescribed oil and remove re-sidual oil.

2.4 Painting the gearbox

Always cover the running surfaces andsealing lips of the radial sealing rings onboth shafts before painting. Make cer-tain that the breather hole on the oil fillerscrew is not covered by paint. The iden-tification plates should remain clearly leg-ible.

2.5 Connecting the gearbox with engine

Fit a recommended damping plate be-tween the engine and the transmissionto compensate for minor alignment er-rors and protect the input shaft from ex-ternal forces and loads.

If the flywheel housing of the engine isof suitable design, the gearbox unitshould be directly bolted to the housingby means of the holes provided in thegearbox.Make certain to use bolts with the rightappropriate length (see «Main dimen-sions», item 1.2) and thighten them tothe correct torque, M8 =14 Nm (10 ft lb),M10 = 28 Nm (20 ft lb)using LOCTITE 242 or 262

An adapter flange and a damper plateare available on request for each gear-box unit (see «Main dimensions», item1.2.10).

The radial and axial runout values shownin the drawing Fig. 12 should never beexceeded between the engine and trans-mission.

The input shaft end is provided with amulti-spline or involute spline profile (see«Main dimensions», item 1.2).


31

2.6 Connection of gearbox with propeller

We recommend a flexible connectionbetween the gearbox and the propellershaft, when the engine is flexiblymounted, in order to compensate forangular deflections. The installation of aspecial propeller thrust bearing is notrequired, since the propeller thrust willbe taken by the transmission bearing,provided the value specified under«Technical data», item 1.2, is not ex-ceeded. However, the output shaftshould be protected from additionalloads. Special care should be taken toprevent torsional vibration. When usinga universal joint shaft, make certain toobserve the manufacturer’s instructions.

2.7 Suspension of engine–gearbox assembly in the boat

Special care should be taken to protectthe gearbox from detrimental stressesand loads when the engine-transmissionassembly is not elastically suspended inthe boat or craft.

The gearbox should be conveniently ac-cessible for maintenance. If the oil drainplug of the gearbox is not accessible, theoil will have to be sucked off.

2.8 Position of gearboxin the boat

The inclination of the gearbox unit in thedirection of the shafts should not exceedan installation angle of 20 degrees (seeFig.13) and 15° for ZF 15 MIV.

2.9 Operation of gearbox

The gearbox is suitable for single leverremote control. Upon loosening the re-taining screw (7), the actuating lever (6)can be moved to any position requiredfor the control elements (cable or rod link-age). (Fig. 14).

IMPORTANTMake certain that the lever does not con-tact the actuating lever cover plate (9):the minimum distance between lever andcover must be 0.5 mm.

The control cable should be perpendicu-lar to the actuating lever in the neutralposition of the lever.The zero position of the operating leveron the control console must coincide withthe zero position of the actuating leveron the gearbox.

The shifting travel, as measured at thepivot point of the actuating lever, be-tween the neutral position and end posi-tions A and B must be at least 35 mm forthe outer and 30 mm for the inner pivotpoint.A larger amount of lever travel is in noway detrimental.

IMPORTANTHowever, if the lever travel is shorter,proper gear engagement mightbeimpeded which, in turn, would meanpremature wear, excessive heat genera-tion and resulting damage.

The position of the cover plate under-neath the actuating lever is factory-ad-justed to ensure equal lever travel fromneutral position A and B.

IMPORTANTIf this cover is removed in exceptionalcases, proceed as described under item6.14 of this manual.

When installing the gearbox, make cer-tain that shifting is not impeded by re-stricted movability of the cable, by un-suitably positioned guide sheaves, toosmall bending radius, etc.

Fig. 13

20°

➞

➞

Clamping screw (7) tobe tightened to torqueof 20 Nm

Minimum shifting movementfor actuating lever (6)

Do not remove coverplate (9) or loosen screws

Oil drain plugOil dipstick and oil filler screw17 mm width across flats

Min. distance ofactuating lever 0.5 mm

Fig. 14


32

2.10 Cooling unit

The arrangement of the cooling unit forthe ZF 10 M, ZF 12 M, ZF 15 M, ZF 15MA, ZF 15 MIV, ZF 25 M and 25 MA (nocooling is required for ZF 3 M and 5 M)can be seen from Fig.15.

The table below shows the maximumpower output in continuous operation (le-ver position A and B) usable without cool-ing. When these values are exceeded,a cooling unit is required.

The cooling unit should be connected tothe fresh-water pressure line (externalcircuit) of the engine in accordance withFig.16. The minimum volume of flow is10 ltr/min. Retrofitting of the cooling unitinvolves no problems (see item 6.15).

2.11 Engine-gearbox compartment

Care should be taken that the enginegearbox compartment is properly venti-lated.

Fig. 15

10 liters/min2.6 gal/min

Fig. 16

Max. engine power usable without cooling

Lever position ZF 3 M ZF 10 M ZF 12 M ZF 15 MIV ZF 25 MZF 5 M ZF 15 M ZF 25 MA

ZF 15 MA A no cooling no cooling 40 kW 25 kW 40 kW

54 hp 34 hp 54 hp B no cooling 25 kW 25 kW 20 kW always with

34 hp 34 hp 34 hp cooling unit


33

Correct readings up to 20°inclination in direction of shafts(15° for ZF 15 MIV)

3. Operation

3.1 General information

All ZF M boat reversing gearbox unitsare test-run on a test stand at the fac-tory prior to delivery.

For safety reasons, the oil is drainedbefore shipment.

3.2 Initial operation

Fill the gearbox with oil (ATF), (see 4.7or recommended fluids). The oil levelshould be up to the index mark on thedipstick (see fig. 17).

To check the oil level, just insert the dip-stick, do not screw in. Retighten the hexscrew with the dipstick after the oil levelcheck. Do not forget sealing ring.

3.3 Operating temperature

Normal operating temperature of thetransmission oil should be in the rangeof 50°C (122°F) to 80°C (176°F). Max.permissible ATF temperature of 100°C(212°F) may only be reached for a shorttime.

3.4 Operation of gearbox

The zero position of the operating leveron the control console must coincide withthe zero position of the actuating leveron the transmission. Shifting is initiatedby a cable or rod linkage via the shiftinglever and an actuating cam. The

completition of the gear changing opera-tion is servo-automatically controlled.Gear changing should be smooth, not tooslow, and continuous (without interrup-tion). Direct changes from forward to re-verse are permissible, since the multi-ple-disc clutch permits gear changing athigh rpm, including sudden reversing attop speeds in the event of danger.

3.5 Sailing or moving in tow

Rotation of the propeller while the boatis sailing, being towed, or anchored in ariver, as well as operation of the enginewith the propeller stopped (for chargingthe battery), will have no detrimental ef-fects on the gearbox.

IMPORTANTWhen the boat is sailing (enginestopped), the gear lever must be in zeropos-ition. Never put the gear lever in thepos-ition corresponding to the directionof travel of the boat.

Locking the propeller shaft by an addit-ional brake is not required: use the gearlever position opposite your direction oftravel for this purpose.

3.6 Lay-up periods

If the transmission is not used for peri-ods of more than 1 year it should be com-pletely filled with oil of the same gradeto prevent corrosion. Protect the inputshaft and the output flange by means ofan anticorrosive coating if required.

3.7 Preparation for re-useSee item 2.3

4. Maintenance

4.1 Transmission oil

To ensure trouble-free operation of theclutch only use Automatic TransmissionFluid (ATF).

4.2 Oil quantity

ZF 3 M 0.30 ltr 0.32 qtsZF 5 M 0.30 ltr 0.32 qtsZF 10 M 0,35 ltr 0.37 qtsZF 12 M 0.56 ltr 0.59 qtsZF 15 M 0.56 ltr 0.59 qtsZF 15 MA 0.47 ltr 0.50 qtsZF 15 MIV 1.00 ltr 1.06 qtsZF 25 M 0.75 ltr 0.79 qtsZF 25 MA 0.75 ltr 0.79 qts

min. 0.90 ltr min. 0.95 qtsZF 30 Mmax. 1.10 ltr max. 1.17 qts

Use the index mark on the dipstick as areference (see item 3.2)

4.3 Oil level checks

Check the oil level in the gearbox aboutonce a month. Correct oil level: indexmark on dipstick (see item 3.2). Alwaysuse the same oil grade when topping up.Don’t overfill the gearbox. This will cre-ate higher operating temperatures.

4.4 Oil change

Change the oil the first time after about25 hours of operation, then at intervalsof at least 1 year.

4.5 Checking the control cable linkage

The control cable or rod linkage should bechecked at shorter time intervals. Checkthe zero position of the operating lever (onthe control console) and of the shifting le-ver (on the gearbox) on this occasion. Theminimum lever travel from the neutral po-sition to operating positions (0-A = 0-B)should be 35 mm (1.38 in) for the outerand 30 mm (1.18 in) for the inner pivotpoint. Make certain that these minimumvalues are safely reached. Check the ca-ble for easy movability (see item 2.9).

4.6 Cooling

If the transmission is equipped with acooling unit, drain the cooling waterbefore long periods of non-use whentemperature is below freezing point.

Fig. 17


34

4.7 Automatic Transmission FluidList of recommended fluidsFor ZF-HURTH ZF M Marine Transmissions Automatic Transmission Fluid (ATF) must to be used as lubricant.

ADDINOL MINERALÖL GMBH, KRUMPA/D ADDINOL ATF D IIDADDINOL MINERALÖL GMBH, KRUMPA/D ADDINOL ATF D IIIAGIP PETROLI SPA, ROM/I AGIP ATF II DAGIP PETROLI SPA, ROM/I AGIP ATF D 309AGIP PETROLI SPA, ROM/I AGIP ATF PLUSAGIP PETROLI SPA, ROM/I AGIP DEXRON IIIAGIP SCHMIERTECHNIK, WÜRZBURG/D AUTOL GETRIEBEÖL ATF-DAGIP SCHMIERTECHNIK, WÜRZBURG/D AUTOL GETRIEBEÖL ATF III DARAL LUBRICANTS GMBH, BOCHUM/D ARAL GETRIEBEÖL ATF 22ARAL LUBRICANTS GMBH, BOCHUM/D ARAL GETR.ÖL ATF 55 F-30589AVIA MINERALÖL-AG, MÜNCHEN/D AVIA FLUID ATF 86BLASER SWISSLUBE, HASLE-RÜEGSAU/CH BLASOL 229BP OIL DEUTSCHLAND, HAMBURG/D FRONTOL UNIVERSAL-ATF 100BP OIL INTERNATIONAL, LONDON/GB AUTRAN DX IIBP OIL INTERNATIONAL, LONDON/GB AUTRAN MBXBP OIL INTERNATIONAL, LONDON/GB AUTRAN DX III (F-30370)BP OIL INTERNATIONAL, LONDON/GB AUTRAN DX III (F-30381)BUCHER+CIE AG, LANGENTHAL/CH MOTOREX ATF SUPER D-22656BUCHER+CIE AG, LANGENTHAL/CH MOTOREX ATF DEXRON III MCCALPAM GMBH, ASCHAFFENBURG/D PAMATIC FLUID 289CALPAM GMBH, ASCHAFFENBURG/D CALPAMATIC FLUID III FCALTEX PETROLEUM CORP., LONDON/GB CALTEX ATF-HDACALTEX PETROLEUM CORP., LONDON/GB CALTEX ATF-HDMCALTEX PETROLEUM CORP., LONDON/GB CALTEX TEXAMATIC 1278CALTEX PETROLEUM CORP., LONDON/GB CALTEX TEXAMATIC 7045CALTEX PETROLEUM CORP., LONDON/GB CALTEX TEXAMATIC 1205ACASTROL LTD, SWINDON/GB CASTROL TQ-D (22765)CASTROL LTD, SWINDON/GB CASTROL TQ DEXRON III F-30520CASTROL LTD, SWINDON/GB CASTROL TRANSMAX S (F-30319)CASTROL LTD, SWINDON/GB CASTROL TRANSMAX T (F-30359)CASTROL LTD, SWINDON/GB CASTROL TQ-D (21289)CASTROL LTD, SWINDON/GB CASTROL ATF 21293CEPSA, MADRID/E CEPSA ATF-70CHEVRON PRODUCTS CO., RICHMOND/USA CHEVRON ATF F-30108CITGO PETROLEUM CORP., TULSA/USA CITGO ATF DEXRON III F-30167C.J.DIEDERICHS SÖHNE, WUPPERTAL/D CIDISOL-HYDR.-FLUID DEXRON IIDDE OLIEBRON B.V., ZWIJNDRECHT/NL ATF DMMDE OLIEBRON B.V., ZWIJNDRECHT/NL ATF 289DEA MINERALÖL AG, HAMBURG/D DEAMATICDEA MINERALÖL AG, HAMBURG/D DEAFLUID 4011DEA MINERALÖL AG, HAMBURG/D DEAFLUID 3003DEUTSCHE SHELL AG, HAMBURG/D MAC ATF D-21666DUCKHAMS OIL, BROMLEY/GB UNIMATICELF LUBRIFIANTS, PARIS/F TRANSANTAR DF2ELF LUBRIFIANTS, PARIS/F ANTAR 22329ELF LUBRIFIANTS, PARIS/F ELFMATIC G2 22329ELF LUBRIFIANTS, PARIS/F HUILE RENAULT DIESEL STARMATICELF LUBRIFIANTS, PARIS/F ELFMATIC G3ELF LUBRIFIANTS, PARIS/F TRANSANTAR DF3ELLER-MONTAN-COMP., DUISBURG/D ELLMO-AUTOMATIK-FLUID 22233ENGEN PETROLEUM, CAPE TOWN/ZA ENGEN ATF 22DERTOIL SA, MADRID/E TRANSMISIONES AUTOMATICAS D2ESSO AG, HAMBURG/D ESSO ATF D (21611)ESSO AG, HAMBURG/D ESSO ATF F-30320ESSO AG, HAMBURG/D ESSO ATF D (21065)FIAT LUBRIFICANTI, VILLASTELLONE/I TUTELA GI/AFINA EUROPE SA, BRÜSSEL/B FINAMATIC II-DFUCHS LUBRICANTS (UK), DERBY/GB SILKTRAN MP-ATFFUCHS LUBRICANTS (UK), DERBY/GB SILKTRAN PSV ATFFUCHS MINERALÖLWERKE, MANNHEIM/D TITAN ATF 4000GINOUVES GEORGES SA, LA FARLEDE/F YORK LT 785GULF OIL (GB) LTD, CHELTENHAM/GB UNIFLUIDGULF OIL (GB) LTD, CHELTENHAM/GB ATF 2HANDELSMIJ NOVIOL B.V., NIJMEGEN/NL KENDALL ATF DEXRON IIDHOMBERG GMBH+CO KG, WUPPERTAL/D HOMBERG-GETRIEBE-FLUID DIGOL FRANCE, PARIS/F IGOL ATF 420INA RAFINERIJA ZAGREB/CROATIA INA-ATF SUPERITALIANA PETROLI, GENOVA/I TRANSMISSION FLUID DXJAPAN ENERGY CORP., TOKYO/JAPAN JOMO ATF KKÄPPLER K., STUTTGART/D SELECTOL FLUID GETR.ÖL IID 23KLÖCKNER ENERGIEHANDEL GMBH, KÖLN/D DEUTZ OEL ATF-DKROON OIL BV, ALMELO/NL ATF DEXRON IIDKROON OIL BV, ALMELO/NL ALMIROL ATFKUWAIT PETROLEUM, HOOGVLIET/NL Q8 AUTO 15KUWAIT PETROLEUM, HOOGVLIET/NL Q8 AUTO 14 (IID-21677)KUWAIT PETROLEUM, HOOGVLIET/NL Q8 AUTO 14 (IID)

KUWAIT PETROLEUM, HOOGVLIET/NL Q8 AUTO 14 (IID-21883)LEPRINCE+SIVEKE GMBH, HERFORD/D LEPRINXOL FLUID CNLIQUI MOLY / MEGUIN, ULM/D ATF IIELIQUI MOLY / MEGUIN, ULM/D MEGOL ATF IIDLUBRICATION ENGIN., FORT WORTH/USA AUTOMATIC TRANSMISSION FLUIDMAURAN SA, ODARS/F INTER OIL INTER MATIC ATF D2MIN.ÖL-RAFFIN. DOLLBERGEN, UETZE/D PENNASOL FLUID-GETR.ÖL TYP PCNMOBIL OIL, WEDEL/D MOBIL ATF 220 D20104 / D21685MOBIL OIL, WEDEL/D MOBIL ATF F-30107MOBIL OIL, WEDEL/D MOBIL ATF 220 D21412 / D22187MOBIL SEKIYU KABUS.KAISHA, TOKYO/J MOBIL ATF 220Y (D-21412)MOL HUNGARIAN OIL, KOMARON/H CARRIER ATFMORRIS LUBRICANTS, SHREWSBURY/GB LIQUIMATIC DIINAFTEC, ALGIER/DZ TASSILIANANHAI SUPERIOR LUB-OIL, CHINA NANHAI ATF (D2)NIS-RAFINERIJA NAFTE BEOGRAD/YU GALAX MATIC DACOEST G. MIN.ÖLWERK, FREUDENSTADT/D ATF T 4011OMEX PETROLEUM PTY, BELLEVUE/AUS OMEX ATF DEXRON IIOMV AG, SCHWECHAT/A OMV ATF D II (D22427)OMV AG, SCHWECHAT/A OMV ATF III (F-30580)OPTIMOL ÖLWERKE, HAMBURG/D OPTIMOL ATF T 4011OSWALD KLUTH, BARGFELD-STEGEN/D UNIVERSAL ATF-DPAKELO MOTOR OIL, SAN BONIFACIO/I MULTIPURPOSE TRANSM. FLUID IIDPANOLIN AG, MADETSWIL/CH PANOLIN ATF MULTI 21996PANOLIN AG, MADETSWIL/CH PANOLIN ATF DEXRON IIIPARS OIL CO., TEHRAN/IR PARS ENTEGHAL-E AUTOMATIC OILPAZ LUBRICANTS&CHEMICALS, HAIFA/IL PAZBO EZFPENNZOIL PRODUCT COMP., HOUSTON/USA PENNZOIL ATF F-30110PETRO-CANADA, MISSISSAUGA/CDN DEXRON III/MERC.ATF (F-30395)PETROL OFISI A.S., BAKANLIKLAR/TR PETROL OFISI ATF IIPETROLEX, KWIDZYN/PL VECO MATIC IIDPRINZ-SCHULTE, FRECHEN/D AERO-LINE ATF-2PRINZ-SCHULTE, FRECHEN/D AERO-LINE ATF-DREPSOL DISTRIBUCION SA, MADRID/E REPSOL MATIC ATFS.A.E.L, ALCOBENDAS/E GULF ATF DII D-22233SASOL OIL, RANDBURG/ZA SASOL ATF DXIISCHMIERSTOFFRAFFINERIE SALZBERGEN/D WINTERSHALL ATF DSHELL ASEOL AG, BERN/CH ASEOL ATF DB UNIVERSALSHELL INTERNATIONAL, LONDON/GB SHELL DONAX TA (D-21666)SHELL INTERNATIONAL, LONDON/GB SHELL DONAX TG (F-30358)SLOVNAFT JS CO, BRATISLAVA/SLO MADIT AUTOMATICSONOL ISRAEL LTD, HAIFA/IL DEXRON 2 DSOPROGRASA SA, MADRID/E SOPRAL 164STATOIL STAVANGER/N TRANSWAY DX III (F-30373)STATOIL STAVANGER/N TRANSWAY DX IISTL TECNOL, ESCALQUENS/F TECNOL TECMATIC D2SUN OIL COMPANY, AARTSELAAR/B SUNAMATIC 149SUN OIL COMPANY, AARTSELAAR/B SUNAMATIC 153SUOMEN PETROOLI OY, HAMINA/SF TEBOIL FLUID E (F-30301)SUOMEN PETROOLI OY, HAMINA/SF TEBOIL FLUID DSVENSKA STATOIL AB, NYNÄSHAMN/S TRANSWAY DX III (F-30373)TAMOIL LUBES, GENEVA/CH TAMOIL ATF II DTEXACO LUBRICANTS COMP., BEACON/USA ATF MERCON / DEXRON IIITEXACO SERVICES LTD, BRÜSSEL/B TEXAMATIC 7045TEXACO SERVICES LTD, BRÜSSEL/B TEXAMATIC 4261TEXACO SERVICES LTD, BRÜSSEL/B TEXAMATIC 7080TEXACO SERVICES LTD, BRÜSSEL/B TEXTRAN PSMTEXACO SERVICES LTD, BRÜSSEL/B TEXAMATIC 4011TEXACO SERVICES LTD, BRÜSSEL/B TEXAMATIC 4291TEXACO SERVICES LTD, BRÜSSEL/B TEXAMATIC 9226TOTAL RAFFINAGE DISTR., PARIS/F TOTAL FLUIDE ATXTOTAL RAFFINAGE DISTR., PARIS/F TOTAL FLUIDE IIDTOTAL RAFFINAGE DISTR., PARIS/F TOTAL FLUIDE AT 42TOTAL SOUTH AFRICA, JOHANNESBURG/ZA TOTAL FLUIDE ATDTURBOTANK BÖSCHE+BÖDEKER, BREMEN/D TURBO UNIV. ATF MERCON 4011UFANEFTECHIM REFINERY, UFA/RUS UFALUB ATFUNIL DEUTSCHLAND GMBH, BREMEN/D UNIL MATIC CN T 4011VALVOLINE INC., LEXINGTON/USA VALVOLINE MULTI-PURPOSE ATFVALVOLINE INTERNAT., DORDRECHT/NL VALVOLINE ATF TYPE DVEBA OEL AG, GELSENKIRCHEN/D MOVARA ATF-GETRIEBEÖL DIIDVEEDOL INTERNATIONAL, SWINDON/GB VEEDOL ATF-M (22764)VEEDOL INTERNATIONAL, SWINDON/GB VEEDOL ATF DEXRON III F-30521VEEDOL INTERNATIONAL, SWINDON/GB VEEDOL UNITRANS S PLUSYACCO SA, ST PIERRE-LES-ELBEUF/F YACCO ATF DZELLER+GMELIN GMBH&CO, EISLINGEN/D DIVINOL FLUID 666


35

5. Disassembly

Note: fold out illustration sheets 1 and 2or (for ZF 15 MIV) sheets 3 and 4 (ex-ploded views) for reference.

5.1 Removing the cooling unit(if present)

Unscrew 4 hex head screws M8x50 andtake off unit (see illustration under item6.14.2).

5.2 Removing and disassembling theactuating lever cover plate

5.2.1 Always set actuating lever to neu-tral position.

5.2.2 Remove hex nuts (22) from coverplate (9), using 13 mm spanner (wrench),and take off spring washers (4).

5.2.3 Remove cover plate assembly (12),lever (6) and actuating cam (11).

5.2.4 Remove screw (7) from lever (6).Pull off lever (6). Remove actuating cam(11) and needle bearing (70) only inmodels ZF 12 M - 15 M - 25 M - 30 M.Remove actuating cam sealing ring (8).

5.3 Removing the bearing shields

5.3.1 Remove hex head screw (5) frombearing shields (2) and (3), using 13 mmspanner (wrench), and take off springwashers (4).

5.3.2 Remove cover (3) and bearingshield (2) on input shaft (36) together withseals (28).

5.4 Separating the gearbox sections andremoving the input and output shafts

5.4.1 Remove hex nuts (22) from gear-box (1), using 13 mm spanner (wrench),take off spring washers (4) and removescrews (21).

5.4.2 Separate the two halves of gear-box (1) by light hammer blows on the oilfiller screw and oil drain plug (19 and 20).

5.4.3 Remove shims (37, 38, 39, 40)from the input and output shafts and keepseparately. For proper reassembly it isadvisable to note down the thickness andlocation of each of the shims to obtainthe correct bearing play.If none of the parts (2, 3, 32, 33, 36) onthe input shaft and of the parts (2, 3, 34,35, 43, 46, 47, 59) of the output shaftare replaced, the shims can be re-usedin the same positions. When any of theseparts are replaced, the dimensions of thegear set relative to the casing have tobe measured anew and suitable shimshave to be installed.

5.5. Removing the shifting fork (15)

5.5.1 Remove screw plug (17) (not nec-essary in ZF 3 M - 5 M since there is noplug but only a O-ring).

5.5.2 Pull actuating shaft (16) out of thehole in the half housing.

5.5.3 Remove shifting fork (15).

5.6 Removing the intermediate gear (26)

5.6.1 Heat gearbox section with interme-diate gear to a temperature of approx.80°C (176 F); in ZF 3 M - 5 M only, firstremove the retaining ring (23).

5.6.2 Knock pin (24) out of its bearing bylight hammer blows, using a driving pinof suitable size.

5.6.3 Remove intermediate gear (26),retaining plates (25) and roller cage (27).

5.7 Disassembling the input shaft (36)

5.7.1 Remove outer bearing races (32).

5.7.2 In the event of bearing damage,cautiously drive inner races (33) off theinput shaft (36) with a punch (away fromgear).


36

5.8 Disassembling the outputshaft (66)

5.8.1 Mount support rail on a vice withthe pins pointing upwards (not on ZF 15MIV).

5.8.2 Place output shaft (66) verticallyon the support rail with the flange sidedown.

5.8.3 Remove screw (41) spacer (42)and outer bearing race (34).Only in models ZF 3 M - 5 M removealso shims (68) and in model ZF 15 MAspacer (68).

42

5.8.4 Place side of gear (65) adjacent toshaft flange against a suitable support(a divided flange or two brackets of suit-able section) and use pin of suitable sizeto press off the output shaft.Do not place the support neither againstthe gear's (65) teeth nor against the fric-tion washer (43). But place it as shownon the drawing below.

The parts removed from the upside ofthe shaft are not interchangeable with theparts removed from the flange side. Keepseparately.

5.8.5 Remove keys (67) from the outputshaft and keep in a separate place (1key for ZF 3 M and 5 M, 2 keys for ZF 10M, 12 M, 15 M, 15 MA, and 4 keys forZF 25 M, 25 MA and ZF 30 M).

Fig. 18

Fig. 19

41

34 68

65

6543


37

5.8.6 Put off shims (53, 54, 55, 56),spacer (47) and needle bearing (45) fromthe output shaft.

5.8.7 Attach divided flange to face sideof bearing shield (2) and pull off thrustwasher (43), inner race (46) and taperroller bearing (34, 35) with shield. On ZF15 MIV only pull off taper roller bearing(34, 35).

5.8.8 Remove internal and externalclutch discs from gears (44) and (65).

5.8.9 Dismantling the gearsCompress cup springs (48) (only oneeach side for ZF 3 M - 5 M) by means ofdismantling tool. Remove circlip (50) andtake off thrust plate (49).

5.8.10 Dismantling the actuating mem-bers.Detach springs (64), watching for balls (58).

5.8.11 Remove disc carrier (57).

5.8.12 Place actuating sleeve (60) on aplane surface and press out guide sleeve(59). Watch for detent pins and springsjumping off the guide sleeve. It will beadvisible to wrap a rag around the actu-ating sleeve (60) and the guide sleeve(59) to catch any parts that might jumpoff.

5.9 Disassembling the quill shaft (ZF 15MIV).

Note: see drawing page 38.

5.9.1 Remove grooved ring nut (83) bymeans of socket spanner and take offring (34) with sealing ring (31).

5.9.2 Place divided flange against faceside of bevel gear (80) and force bevelgear (80) spacer ring (76) and bearing(74) off quill shaft.

5.9.3 Remove key (81) and spacer ring (76).

5.9.4 Force off bearing (74) by means ofdivided flange.

Fig. 20

47

46

43

44 - 65

49

50

53 - 5455 - 56

45

34 - 35

2

Fig. 21

Fig. 22

64

575863

626160595857

48


38

6. Reassembly

Note: fold out illustration sheets 1 and 2(exploded views) for reference. For ZF15 MIV use illustration sheets 3 and 4.

6.1 General information

The following points should be observedwhen reassembling the gearbox:

- Clean all parts thoroughly, especiallysealing surfaces, inspect for wear,damage and cracks, and replace if re-quired.

- Check shifting fork (15) for wear. Thecontact surfaces of this fork are pro-vided with amolybdenum coating.Should this coating be worn away atany point, replace the shifting fork. Maxwear on guiding surfaces 0.2 mm(0.008 in) on each side.

- Thrust rings (43) require replacementif wear exceeds 0.25 mm (0.0098 in).

- Internal discs (51) have a sinteredmetal coating of 0.3 mm (0.012 in) oneach side. If the surface structure (af-ter clean-ing) shows indications ofwear, replace the discs.

- Apply thin coat of oil to antifriction bear-ings before installation.

0.5 ±0.2 mm

not for ZF 3 M - 5 M - 10 M

6.2 Assembling the intermediategear shaft in gearbox section

side cooler

6.2.1 Insert retaining plate (25).

IMPORTANT:Note that the bevelled corners of retain-ing plates (25) have to be placed in differ-ent positions (see illustration on sheet 1).

6.2.2 Insert needle cage (27) into inter-mediate gear (26) and place completeassembly with retaining plate (25).

6.2.3 Insert second retaining plate (25).Not for ZF 3 M - 5 M.

6.2.4 Fit O-ring (23) to intermediate gearshaft (24)* and drive it into gearboxsection by knocking slightly on a drivepin.

* on ZF 3 M - 5 M insert intermediate gearshaft with seeger 23 and Loctite 574.

* on ZF 25 M - 25 MA and ZF 30 M, in-sert intermediate gear shaft (24) with-out O-ring (23) and close bore in gear-box section with sealing compound bypressing in a plug (23) with Loctite 574.(see illustration on sheet 1).

* on ZF 15 MIV insert intermediate shaft(24) and stop it in its place by knock-ing with a driver pin on the edge of thehole of the housing. Close the outsiderhole in the housing by pressing in plug(23) with Loctite 574.

6.3 Assembling the shifting fork ingearbox section side shifting cover

6.3.1 Insert shifting fork (15) into gear-box section (1) side the actuating leverin such a way that the long arm of thefork points downwards.

6.3.2 Insert shifting rod (16) throughbores in gearbox and shifting fork.

6.3.3 Fit screw plug (17) to gearbox,making certain that the clearance be-tween shifting rod (16) and screw plug(17) is min. 0.5 mm (0.02 in).Seal screw plug with Loctite 242 (ZF 3M - 5 M only O-Ring).

6.3.4 Check shifting fork for easymovability.

6.4 Pre-assembling the actuatinglever cover plate

Use punch tool to press sealing ring (8)into cover plate (9). Spread antifrictionbearing grease between sealing lips.

6.4.1 Insert actuating cam assembly (11)into cover plate (9).

6.4.2 Fit actuating lever (6).

IMPORTANT:Clearance between actuating lever andcover plate 0.5 mm (0.02 in).

6.4.3 Clamp actuating lever by meansof retaining screw (7), using a 13 mmspanner (wrench). Screw in with torqueof 20 Nm.

Fig. 23

8 11

70

6

7

Punch ToolFig. 24

8

9


39

6.5 Pre-assembling the gears (65) and(44) with cup springs (48) and clutchdiscs (51 and 52)

IMPORTANT:If previously disassembled parts areused, make certain that only mating andassociated parts are reassembled.

6.5.1 Join two cup springs (48) (only onecup spring for ZF 3 M - 5 M) face to face(external diameters in contact) and placethem on the centering collar of gears (65)and (44).

6.5.2 Place thrust ring (49) on cupsprings.

6.5.3 Place circlip (50) on gear hub anduse mounting tool and press to fit circlipinto groove on hub. Don't presscompletely the cup springs and be surethat the tool presses at least on threepoints on the thrust washer (49).

6.5.4 Attach clutch discs (51 and 52), firstinternal disc (51), then alternatively ex-ternal disc (52), internal disc (51), etc.

6.6 Measuring the pre-assembledgears (65) and (44) to determinesetting value «a».

If no parts had to be replaced, the previ-ously disassembled shims (53, 54, 55,56) can be re-used in their former ar-rangement and positions without anymeasuring operation.

If measuring is required, proceed as fol-lows:

6.6.1 Place pre-assembled gear (65),and subsequently gear (44) on thrustwasher (43), (end face of hub down-wards, see illustration).

IMPORTANT:On ZF 3 M - 5 M - 10 M there is a stepon the thrust washer (43). Put the sideof the washer with the step against thegear. Be sure that the needle bearinginner race (46) is fitted into it.

6.6.2 Insert needle cage (45), inner race(46) and spacer (47) into bore of gear.

6.6.3 Fit shims (53, 54, 55, 56), as re-quired, until prescribed seeting value «a»is obtained (see illustration).

6.6.4 Shims are available in thicknessesof 0.4 - 0.5 - 0.6 and 0.7 mm.(0.016 - 0.020 - 0.024 and 0.028 in)

Setting value «a»

Type mm inchesZF 3 M 8.0±0.1 0.315±0.004ZF 5 MZF 10 M 13.0±0.1 0.512±0.004HBW 10ZF 12 MZF 15 M 12.4±0.1 0.488±0.004ZF 15 MAZF 15 MIVZF 25 M / 25 MA 16.2±0.1 0.638±0.004ZF 30 M 19.75±0.1 0.778±0.004Old versions(4+3 externalclutch discs)HBW 10(versionsfrom 01 to 08) 13.2±0.1 0.520±0.004HBW 150(versionsfrom 09 to 14)HBW 150 V(versionsfrom 01 to 07)

Fig. 25

50

49

44 - 65

48

Fig. 26

Thrust washer (43)bronze sideupwards

53 - 5455 - 56

50

49

44 - 65

48

4546

47


40

6.7 Pre-assembling the bearingshields (2) for the input and outputshafts

Use a driver tool to press sealing rings(30 - input and 31 - output) into shield (2).

6.8 Pre-assembling the clutchmembers

6.8.1 Fit driving pins (63), springs (61)and detent pins (62) to guide sleeve (59).

6.8.2 Place actuating sleeve (60) onplane press surface.

6.8.3 Place guide sleeve (59) on top ofactuating sleeve (60) with the three driv-ing pins (63) in alignment with the threegrooves in the actuating sleeve. Watchfor correct position of detent pins (62)relative to angular pockets of sleeve.

6.8.4 Press guide sleeve (59) into actu-ating sleeve (60) up to midway position(noticeable click).

6.8.5 Insert balls (58) into ball pocketsof guide sleeve, attach disc carrier (57),turn upside down then fit balls in oppo-site face side and attach second disccarrier (57).

6.8.6 Attach springs (64) with closed partof spring windings pointing outwards.

6.9 Reassembling the input shaft

Preheat inner races (33) of taper rollerbearings to a temperature of 100° C(212F) and, using tubular or punch tool,press races on input shaft (36) on bothsides.

IMPORTANT:Repress after cooling down, so that nogap is left.

Fig. 27

31 - 32

Punch tool

2

Fig. 28

64

58

63

626160595857

Tubular tool

33

36

36

33

Punch tool

Fig. 29 Fig. 30


41

6.10 Reassembling the output shaft

6.10.1 Place pre-assembled bearingshield (item 6.7) with seal (28) on outputshaft (66) (not applicable to ZF 15 MIV).

6.10.2 Attach outer race (34) of taperroller bearing.

6.10.3 Pre-heat inner race (35) of taperroller bearing to a temperature of approx.100°C (212 F) and press on output shaft(66) in hot condition.On ZF 15 MIV press complete bearing(68) on shaft (66).


6.10.4 Fit thrust ring (43) in such a waythat sintered surface (brown colour)faces gear.

6.10.5 Use tubular tool to press on innerrace (46) of needle bearing for gear (65).

6.10.6 Attach needle cages (45) andcompletely pre-assembled gear (65) withclutch discs (51 and 52).

6.10.7 Fit spacer (47) and shims (53, 54,55, 56) to gear (65).

6.10.8 Fit keys (67) to shaft (1 for ZF 3 M,5 M, 2 keys for 10 M, 12 M, 15 M, 15 MA,4 for ZF 25 M - 25 MA and ZF 30 M).

6.10.9 Press pre-assembled actuatingmembers (see item 6.8) on output shaft(66).

IMPORTANT:Align keys radially relative to guidesleeve (59).

Fig. 31

4241

35

66

Fig. 32

Punch tool

66

46

43

28

2

34

35

65

44

46


42

6.10.10 Attach shims (53,54,55, 56) togear (44).

6.10.11 Attach spacer (47) to gear (44).

6.10.12 Use tubular tool to press on in-ner race (46) of needle bearing for gear(44).

6.10.13 Attach pre-assembled gear (44)with needle cage (45) and clutch discs(51 and 52).

Align external discs for proper engage-ment with actuating member.

6.10.14 Attach thrust ring (43) in such away that sintered surface (brown colour)faces gear.

6.10.15 Pre-heat inner race (35) of ta-per roller bearing to a temperature ofapprox. 100°C (212 F) and press it onshaft.


0.2

± 0.

05 m

m

6.10.16 Screw on bolt (41), (supplied withLoctite) and tighten to torque:

ZF 3 M - 5 M 50 Nm 37 ft lbZF 10 M 60 Nm 44 ft lbZF 12 M - 15 M 100 Nm 74 ft lbZF 15 MA - 15 MIV 100 Nm 74 ft lbZF 25 M - 25 MA 120 Nm 89 ft lbZF 30 M 120 Nm 89 ft lb

6.10.17 (ZF 3 M, ZF 5 M only) attachshims (68) to end shaft (66). The gap hasto be 0.2 ± 0.05 mm (0.0079±0.0019 in).

6.10.18 (ZF 15 MA only) attach spacer (68).

6.10.19 Check gears (44) and (65) forfree movability in an axial direction.

6.10.20 Attach outer race (34) of taperroller bearing.

6.11 Reassembling the quill shaftZF 15 MIV

6.11.1 Fit radial sealing ring (31) and clip(84) together with O-ring (86).

6.11.2 First bearing:Press on bearing inner race (74).Fit bearing outer race (75).

6.11.3 Fit spacer ring (76).

6.11.4 Fit key (81).

6.11.5 Press on gear (80).

6.11.6 Fit second spacer ring (76).

6.11.7 Second bearing:Press on inner race (74).Fit outer race (75).

6.11.8 Push on clip (73) together withO-ring (85).

6.11.9 Tighten grooved ring nut (83) to atorque of 95 Nm (70 lbft), using a socketspanner, and then secure by pressing riminto groove in shaft.

6.11.10 Fit radial sealing ring (31) andcup (84) together with O-Ring (86).

Fig. 33

Fig. 34

Fig. 35

41

82

81

75

74

85

73 83

31

86

84

76

80

76

75

74

86

84

31

41

42

35

68


43

6.12 Final assembly of gearbox

6.12.1 Place pre-assembled gearboxsection (1) - (with intermediate gear) -on side wall.

6.12.2 Place pre-assembled output shaft(66) in lower part of gearbox with flangeside towards intermediate gear side (onZF 15 MIV, bevel gear towards interme-diate gear side).

6.12.3 Place pre-assembled input shaft(36) in upper part of gearbox.

6.12.4 (ZF 15 MIV only) Place pre-as-sembled quill shaft (73) in lower part ofgearbox (watching to correct engage-ment of marked teeth).Add shims 78 on quill shaft:1.2 mm on side input shaft and 2.2 mmon side output flange.Add shims (70) on clutch shaft 2 x 0.1mm on side output flange.

6.12.5 (ZF 15 MIV only) Check backlash0.08 to 0.13 mm (0.003 to 0.005 in). Be-tween teeth of bevel gears using a dialindicator in contact with tooth surface.

Side shifting cover

Fig. 36

To correct backlash:Replace shim 78 side output flange witha thicker one to decrease backlash andvice-versa.If the correction is not enough to reachthe correct backlash, modify shimming(70) on clutch shaft side output flangeand repeat procedure.

To correct axial play (quill shaft):Check axial play 0.05 ± 0.02 mm(0.002 ± 0.0008 in).Compensate for difference by insertingshims (78) side input shaft.

6.12.6 Seal with LOCTITE 574 surfaceof pre-assembled gearbox section (1)(with shifting fork) and place uppersection on lower section of gearbox.

6.12.7 Insert screws (21) preferably inthe middle, and screw in low-tight to se-cure the two gearbox sections together.

6.12.8 Use a plastic hammer to align thetwo gearbox section (1) by tapping themgently into position.

6.12.9 Fit bearing shield (2) with gasket(28) to output shaft (66) by means ofspring washers (4) and screws (5), us-ing a 13 mm spanner (wrench).Tighten to torque of 14 Nm (10 ft lb).

6.12.10 Slide pre-assembled bearingshield (2) with gasket (28) over inputshaft and secure by means of springerwasher (4) and screws (5), using a 13mm spanner (wrench).Tighten to torque of 14 Nm (10 ft lb).

6.13 Measuring the gears sets of input shaft and output shaft

(see illustration)

6.13.1 Tap outer races (32) and (34) onoutput and input shafts to eliminate bear-ing play, simultaneously rotating theshafts.

6.13.2 Determine dimension «b» bymeans of depth gauge (see illustration).

Cover centering depthwith seal (28)


44

6.13.3 Measure dimension «c» on cover(3) with gasket (28) installed, using adepth gauge (see illustration). The dif-ference between the two dimensions in-dicates the distance to be filled up withshims (37, 38, 39, 40). Shims are avail-able in thicknesses of 0.1 - 0.15-02.-03.and 0.5 mm.

On ZF 15 MIV, a hole is provided on theoutput side of the housing to permit thismeasuring operation: move shaft viagear (65) by means of a lever throughopening in gearbox (see illustration nextpage).

Cover centeringdepth with gasket (28)

Distance from gear set

Compensate for differenceby inserting shims (37, 38, 39, 40)

Compensatefor differenceby inserting shims(70, 71, 72)

To correct

axial play

To correct

backlash

Compensate

for difference

by inserting shims (78)

Fig. 37

➤

➤

➤

➤

b

c

b

c Cover centering depthwith gasket (28)

Distance from gear set

Compensate for differenceby inserting shims

(37, 38, 39, 40)


45

6.13.4 Insert the required number ofshims into the bearing bores of the gear-box to obtain an axial clearance of theoutput and input shafts of 0.05 ± 0.02mm.

If no parts had to be replaced (see item5.4.4), the previously disassembledshims (37, 38, 39, 40) can be re-used inthe previous arrangement and positions.It will be advisable, however, to checkthe bearing clearance and correct it ifrequired.

6.13.5 Mount the previously measuredcovers (3) on the output and input shaftsby means of spring washers (4) andscrews (5), using a 13 mm spanner(wrench). Tighten to torque of 14 Nm (10ft lb).

6.13.6 Place spring washers (4) under-neath all screws (21) and tighten screwsto a torque of 22 Nm (16 ft lb), using a13 mm spanner (wrench).

6.13.7 Tap output and input shafts lightlyin an axial direction while rotating theshafts, to ensure freedom of movement.

6.13.8 Axial clearance of input and out-put shafts: 0.05 ± 0.02 mm, measuredby means of dial indicator in contact withend face of shaft (see illustration).

6.13.9 Measure axial clearence of quillshaft (on ZF 15 MIV), also with dial indi-cator in contact with end face of the shaft(see illustration).Permissible clearance: 0.05 ± 0.02 mm.

0.05 ± 0.02 mm0.002 ± 0.0008 in

Fig. 38

Fig. 39


46

6.14 Mounting the actuating levercover plate

6.14.1 Place gasket (29) or Loctite 574on pre-assembled cover plate and fit itto gearbox. Watch for proper engage-ment of actuating cam and shifting fork.The cover plate can be mounted whenthe shifting fork is in the middle (=neu-tral) position. It is important to adjust theactuating lever to exactly midway posi-tion in neutral.Screw the cover plate in place in thisposition.The lever travel from 0 to A and from 0to B should be equal. After a lever travelof 28 to 31 mm (1.10 to 1.22 in) the trans-mission should be in gear.If the lever travel from «0» to «A» andfrom «0» to «B» is not equal adjust coverposition by light hammer blows on thecover up to reach the equal travels. Fitspring washer (4) and screw nuts (22).Tighten to a torque of 20 Nm (15 ft lb).If studs (69) need to be replaced, fit themwith Loctite 270 on the housing.

6.14.2 Fit spring washers (4) and screws(5), using a 13 mm spanner (wrench).Tighten to a torque of 14 Nm (10 ft lb).Check actuating lever for proper opera-tion.

6.14.3 Fit oil drain plug (20) with sealingring (18) and oil dipstick (19) with seal-ing ring (18).Tighten to a torque of 20 Nm (15 ft lb).

6.15 Mounting the cooling unit(if provided)

6.15.1 Attach the cooling unit on the sideopposite the cover plate (9). By meansof 4 screws M8x65 and washers (avail-able on kit pag. 23 item 1.2.10).

Fig. 40


47

7. Procedure to adjust the shifting lever cover

New bracket p/n 20.4039.02 to adjust the shifting lever cover (see picture 1).

A) Before mounting the cover clean the mating surfaces and adjust the shifting forkto the neutral position.

B) Apply Loctite 574 (or alternatively 518) on the cover surface and position it withthe lever in neutral (see picture 2).Only for ZF 25 M, 25 MA: Push towards the bottom (see picture 3).

C) Lightly tighten the four nuts.

D) Adjust the cover roughly in the middle.

E) Fit the adjusting bracket p/n 20.4039.02 using only one nut lightly tighten: thecover must be free to move with light hammer taps (see picture 4).

If the shifting lever in neutral has been rotated from the original vertical positionapply on the adjusting bracket the suitable extension section P/N 20.4039.03 (seepicture 5).

F) Move the lever toward the detent A without engaging the clutch and mark theposition; repeat the same for the detent B. If the shifting lever has two holesrefer to the inner hole (see picture 6 and 7).

3ZF 25 M, ZF 25 MA

2

11

4

765


48

G) Engage the clutch, turn back the lever to the engaging point and mark the posi-tion; repeat the same procedure for the other clutch (see picture 8 and 9).

H) Consider the centre line between the internal marks and measure the distancefrom this line and the centre of the external marks (see picture 10 and 11).

The maximum allowed distance between the centre line and the external marksmust be 24 mm.The maximum difference between the two measurements must be less than 3 mm.

A must always be < 24 mmB must always be < 24 mmA – B < 3 mm

EX.:A = 20 mm, B = 24 mmA – B = 4 mm > 3 mm NOT ALLOWEDA = 21 mm, B = 23 mmA – B = 2 mm < 3 mm OK

If the above conditions are not reached, move the cover toward the opposite direc-tion where the measurement is largest by light hammer taps and repeat the markingoperation.If it is not possible to adjust the cover to maximum 24 mm, the gearbox needs to beexchanged.

I) After the correct adjusting measurement is reached tighten the four nuts with 22Nm (16 lb.ft) torque.

6) Connect the shifting cable to the inner hole (if two holes) of the lever. Ad-just the neutral position of the cable by the middle of the play of the leverin neutral.The control cable should be perpendicular to the actuating lever in neutralposition of the lever.

7) Make sure that the way of the control cable is enough long to move the innerhole of the lever at least 30 mm.

8

9

10

A

11

B


49

8. Troubelshooting

Possible Troubles and Remedies

Kind of trouble Noticeable effect Possible cause RemedyDelay of gear Propeller will start rotating Detach shift cable and operateengagement with several seconds delay gearbox by hand to find whether

or only after increase in malfunctions is caused by gearengine speed. box or cable.

If caused by transmission:

Lever travel 0-A not equal to Adjust cover plate (9) until lever islever travel 0-B. exactly in midway position. Travel

0-A = 0-B = 35 mm/30 mm 1.37 in/1.18 in

Insufficient clearence between Adjust to min. clearanceactuating lever and cover plate (9). of 0.5 mm (0.02 in).

If caused by shift cable:

Shift cable fails to move lever Check total travel of shift cable.through required min. If too short, adjust accordingly.travel 0-A=0-B= 35 mm/30 mm (1.37 in/1.18 in).

Transmission Excessive effort required Insufficient clearance between Detach shift cable and operatefails to move in to move actuating lever. actuating lever and cover plate (9). lever by hand. If lever jams, adjustgear clearance to 0.5 mm (0.02 in).

Guide sheaves for shift cable Check and adjust accordingly.unsuitably positioned: radiustoo small.

Boat fails to Increased operating Use of wrong oil. Use ATF oil and check oil level.attain top temperature.speed specified Boat operated without cooling unit. Install cooling unit.

Transmission operating in upper Use suitable ZF M transmissionlimit range. unit.

Oil leakage Oil leakage visible on Corrosion effects in area of radial Check and correct oil level.transmission unit. sealing ring and shaft; damaged Remove and dismantle transmission

radial sealing rings. remachine shafts, replace radialImproper installation of seal. sealing rings

Misalignment of output flanges. Check alignment to be within0.08 mm (0.003 in) radially.


50

9. Spare Parts List

PrefaceThe spare parts list is only valid for the type and versions of transmission, as shownbelow.You will find the transmission type and version on your transmission name plate.If the type and version indicated differs from that printed in this Manual, the relativeSpare Parts List should be ordered from ZF -HURTH Marine.The indicated dimensions and standards are as such not enough for ordering parts.

When ordering parts, please state:

- transmission type- serial number- item no. part name, ident no. and quantity of parts required.

The spare parts list is referring to the following versions:

Name Plate

The name plate is mounted to the transmission

Transmission type

Transmission version ratioand serial number

Transmission part number

Transmission ratioShifting position «B»

MODEL

SER. N.

P/N.

ZF 10 M

XXXXX

3304 002 004

Production date everyyear a new progressive

letter is assigned

ZF 3 M versions 001; 002 HBW 35 versions 25; 26;

ZF 5 M versions 001; 002 HBW 50 versions 09; 10; 11; 12; 14

ZF 10 M versions 003; 004; 005; 010 HBW 100 versions 14; 15; 16; 17; 20; 21

ZF 12 M versions 001; 002 HBW 125/HBW 10 versions 15; 16

ZF 15 M versions 003; 004 HBW 150 versions 18, 17; 20; 22

ZF 15 MA versions 003; 004; 005 HBW 150 A versions 01; 02

ZF 15 MIV versions 001; 002; 003 HBW 150 V versions 08; 09; 10; 11

ZF 25 M versions 001; 002; 007 HBW 250 versions 13; 16; 17; 18; 19; 20; 22; 23

ZF 25 MA versions 005; 006

ZF 30 M versions 001; 002

iA= 1,79

iB= 1,86LXXXXX

Transmission ratioShifting position «A»


51

1Ho

usin

g as

sy H

BW 5

0 - 2

L «1

1»1

3303

201

001

3259

52

1Ho

usin

g as

sy Z

F 5

M -

2.05

R «0

01»

133

03 2

01 0

0132

5952

1Ho

usin

g as

sy H

BW 5

0 - 2

R «1

2»1

3303

201

001

3259

52

1Ho

usin

g as

sy H

BW 5

0 - 3

R «1

0»1

3303

201

002

3875

32

1Ho

usin

g as

sy Z

F 5

M -

2.72

R «0

02»

133

03 2

01 0

0238

7532

1Ho

usin

g as

sy Z

F 3

M -

2.05

R «0

01»

133

03 2

01 0

0132

5952

1Ho

usin

g as

sy Z

F 3

M -

2.72

R «0

02»

133

03 2

01 0

0238

7532

1Ho

usin

g as

sy Z

F 10

M -

1.48

R «0

03»

133

04 2

01 0

0328

8079

1Ho

usin

g as

sy Z

F 10

M -

1.79

R «0

04»

133

04 2

01 0

0328

8079

1Ho

usin

g as

sy Z

F 10

M -

2.05

R «0

10»

133

04 2

01 0

03-

1Ho

usin

g as

sy Z

F 10

M -

2.72

R «0

05»

133

04 2

01 0

0446

5642

1Ho

usin

g as

sy H

BW 1

00 -

3R «

16»

133

04 2

01 0

0328

8079

1Ho

usin

g as

sy H

BW 1

00 -

2L «

17»

133

04 2

01 0

0328

8079

1Ho

usin

g as

sy H

BW 1

00 -

2,5R

«21

»1

3304

201

004

4656

42

1Ho

usin

g as

sy H

BW 1

0 / Z

F 12

M /

ZF 1

5 M

133

06 2

01 0

0320

6447

1Ho

usin

g as

sy Z

F 15

MA

133

06 2

01 0

0140

7465

1Ho

usin

g as

sy H

BW 2

50 -

2L «

20»

133

07 2

01 0

0334

5517

1Ho

usin

g as

sy H

BW 2

50 -

3L «

19»

133

07 2

01 0

0434

5519

1Ho

usin

g as

sy H

BW 2

50 -

1,5R

«16

»1

3307

201

003

3455

17

1Ho

usin

g as

sy Z

F 25

M -

1.88

R «0

01»

& «

22»

133

07 2

01 0

0334

5517

1Ho

usin

g as

sy Z

F 25

M -

2.27

R «0

07»

133

07 2

01 0

03-

1Ho

usin

g as

sy Z

F 25

M -

2.74

R «0

02»

& «

23»

133

07 2

01 0

0434

5519

1Ho

usin

g as

sy H

BW 2

50 -

3,5R

«13

»1

3307

201

004

3455

19

1Ho

usin

g as

sy Z

F 25

MA

- 2.2

3R «

005»

3307

201

001

-

1Ho

usin

g as

sy Z

F 25

MA

- 2.7

4R «

006»

3307

201

001

-

1Ho

usin

g as

sy Z

F 30

M -

2.7R

«00

1»33

20 2

01 0

01-

1Ho

usin

g as

sy Z

F 30

M -

2.15

R «0

02»

3320

201

001

-

2Be

arin

g sh

ield

inpu

t1

3304

301

012

2887

6833

04 3

01 0

1228

8768

3306

301

010

2064

5033

06 3

01 0

1020

6450

3307

301

008

2742

4833

07 3

01 0

0827

4248

3307

301

008

-

2Be

arin

g sh

ield

out

put

133

04 3

01 0

1128

8787

3304

301

011

2887

8733

06 3

01 0

1020

6450

3306

301

010

2064

5033

07 3

01 0

0827

4248

3307

301

008

2742

4833

07 3

01 0

08-

3Co

ver

133

06 3

01 0

1120

6452

3307

301

009

2742

19

3Co

ver

233

04 3

01 0

1328

8730

3304

301

013

2887

3033

06 3

01 0

1120

6452

3307

301

009

2742

1933

07 3

01 0

09-

3ACo

ver

133

06 3

01 0

0840

7475

3307

301

003

-

4Sp

ring

was

her

3806

30 3

02 0

9044

2372

0630

302

090

4423

72

4Sp

ring

was

her

4006

30 3

02 0

9044

2372

0630

302

090

4423

7206

30 3

02 0

9044

2372

4Sp

ring

was

her

4206

30 3

02 0

9044

2372

4Sp

ring

was

her

4606

30 3

02 0

90-

5He

x he

ad s

crew

(cov

er)

1606

36 0

15 2

8921

5870

0636

015

289

2158

7006

36 0

15 2

8921

5870

0636

015

289

2158

7006

36 0

15 2

8921

5870

0636

015

289

2158

7006

36 0

15 2

89-

6Ac

tuat

ing

leve

r*1

947.

23.0

06.0

119

5062

947.

23.0

06.0

119

5062

947.

23.0

06.0

119

5062

947.

23.0

06.0

119

5062

947.

23.0

06.0

119

5062

6Ac

tuat

ing

leve

r1

3306

308

001

5006

3533

06 3

08 0

0150

0635

3306

308

001

5006

3533

06 3

08 0

0150

0635

3306

308

001

5006

3533

06 3

08 0

0150

0635

3306

308

001

-

* Up

to le

tter «

E» p

rodu

ctio

n da

te (s

ee n

ame

plat

e de

scrip

tion

pag.

50)

ZF 3

M -

ZF 5

MZF

10

MHB

W 10

/ZF 12

M/15

MZF

15

MA

ZF 2

5 M

ZF 2

5 M

AZF

30

M

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

n

Item

NoPa

rt na

me

Num

ber

per

gear

box


52

ZF 3

M -

ZF 5

MZF

10

MHB

W 10

/ZF 12

M/15

MZF

15

MA

ZF 2

5 M

ZF 2

5 M

AZF

30

M

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

n

Item

NoPa

rt na

me

Num

ber

per

gear

box

7He

x he

ad s

crew

(act

uatin

g le

ver)

*1

0636

015

299

1998

0706

36 0

15 2

9919

9807

0636

015

299

1998

0706

36 0

15 2

9919

9807

0636

015

299

1998

07

7He

x he

ad s

crew

(act

uatin

g le

ver)

106

36 1

01 7

2744

2377

0636

101

727

4423

7706

36 1

01 7

2744

2377

0636

101

727

4423

7706

36 1

01 7

2744

2377

0636

101

727

4423

7706

36 1

01 7

27-

8Ra

dial

sea

ling

ring

for s

hift

cove

r1

0634

502

009

1068

6406

34 5

02 0

0910

6864

0634

502

009

1068

6406

34 5

02 0

0910

6864

0634

502

009

1068

6406

34 5

02 0

0910

6864

0634

502

009

-

9Co

ver p

late

133

04 3

08 0

0120

6448

3304

308

001

206

448

3306

308

002

3882

4233

06 3

08 0

0238

8242

3306

308

002

3882

4233

06 3

08 0

0238

8242

3306

308

002

-

10Sp

ring

dow

el p

in1

0631

329

032

1045

5906

31 3

29 0

3210

4559

0631

329

032

1045

5906

31 3

29 0

3210

4559

0631

329

032

1045

5906

31 3

29 0

3210

4559

0631

329

032

-

11Ac

tuat

ing

cam

ass

y1

3304

199

006

3043

3233

04 1

99 0

0630

4332

3306

199

008

4072

1133

06 1

99 0

0840

7211

3306

199

008

4072

1133

06 1

99 0

0840

7211

3306

199

008

-

12Sh

ift c

over

ass

embl

y1

3303

108

001

3262

0833

04 1

08 0

0224

8459

3306

108

002

4072

1033

06 1

08 0

0240

7210

3306

108

002

4072

1033

06 1

08 0

0240

7210

3306

108

002

-

15Sh

iftin

g fo

rk a

ssy

133

04 2

08 0

0132

6000

3304

208

001

3260

0033

06 2

08 0

0122

3563

3306

208

001

2235

6333

07 2

08 0

0132

7374

3307

208

001

3273

7433

07 2

08 0

01-

16Ac

tuat

ing

shaf

t1

3303

308

001

3259

6333

06 3

08 0

0420

6484

3306

308

004

2064

8433

06 3

08 0

0420

6484

3307

301

012

2886

7333

07 3

01 0

1228

8673

3 307

301

012

-

17Pl

ug (O

-rin

g fo

r ZF

3 M

- ZF

5 M

)1

0634

306

179

1055

2406

36 3

01 0

4144

2373

0636

301

041

4423

7306

36 3

01 0

4144

2373

0636

301

041

4423

7306

36 3

01 0

4144

2373

0636

301

041

-

18Se

alin

g rin

g2

3306

301

016

3265

7833

06 3

01 0

1632

6578

3306

301

016

3265

7833

06 3

01 0

1632

6578

3306

301

016

3265

7833

06 3

01 0

1632

6578

3306

301

016

-

19Oi

l dip

stic

k/br

eath

er a

ssy

133

04 2

01 0

0628

8729

3304

201

006

2887

2933

06 2

01 0

0520

6929

3306

201

002

4084

5133

07 2

01 0

0527

4217

3307

201

005

2742

1733

07 2

01 0

05-

20Oi

l dra

in p

lug

133

06 3

01 0

1322

8566

3306

301

013

2285

6633

06 3

01 0

1322

8566

3306

301

013

2285

6633

06 3

01 0

1322

8566

3306

301

013

2285

6633

06 3

01 0

13-

21He

x he

ad s

crew

906

36 0

10 3

7621

5869

0636

010

376

2158

69

21He

x he

ad s

crew

1006

36 0

10 3

7621

5869

0636

010

376

2158

6906

36 0

10 5

6327

9058

21He

x he

ad s

crew

806

36 0

10 5

64-

21He

x he

ad s

crew

1206

36 0

10 5

63-

21A

Hex

head

scr

ew1

0636

010

375

3379

82

21B

Hex

head

scr

ew2

0636

010

548

5009

24

22He

x nu

t10

0637

006

157

4557

85

22He

x nu

t11

0637

006

157

4557

85

22He

x nu

t12

0637

006

157

4557

8506

37 0

06 1

5745

5785

22He

x nu

t14

0637

006

157

4557

85

22He

x nu

t12

0637

006

157

4557

85

22He

x nu

t17

0637

006

157

-

23O-

ring

(See

ger Z

F 3 M

- ZF

5 M

/ Pl

ug Z

F 25

M -

ZF 3

0 M

)1

0630

501

012

1048

0706

34 3

06 0

1110

5679

0634

303

118

1055

3006

34 3

03 1

1810

5530

0630

361

039

2853

7506

30 3

61 0

3928

5375

0630

361

039

-

24In

term

edia

te g

ear s

haft

133

03 3

03 0

0232

5962

3304

303

002

2887

4133

06 3

03 0

0220

6470

3306

303

002

2064

7033

07 3

03 0

0127

4225

3307

303

001

2742

2533

20 3

03 0

01-

25Re

tain

ing

plat

e1

3304

303

003

2887

43

25Re

tain

ing

plat

e2

3304

303

003

2887

4333

06 3

03 0

0320

6473

3306

303

003

2064

7333

07 3

03 0

0228

8702

3307

303

002

2887

0233

20 3

03 0

03-

26In

term

edia

te g

ear

133

03 3

03 0

0132

5961

3304

303

001

-33

06 3

03 0

0125

4730

3306

303

001

2547

3033

07 3

03 0

0327

4226

3307

303

003

2742

2633

20 3

03 0

02-

27Ca

ge1

0635

300

526

1065

8906

35 3

00 5

3028

0128

3306

303

007

2158

7833

06 3

03 0

0721

5878

3307

303

004

2222

7333

07 3

03 0

0422

2273

27Ca

ge2

0635

300

114

-

28Ga

sket

cov

er4

3304

301

015

2887

3933

04 3

01 0

1528

8739

3306

301

014

2547

1533

06 3

01 0

1425

4715

3307

301

011

2742

5133

07 3

01 0

1127

4251

3307

301

011

-

29Ga

sket

cov

er p

late

(or L

OCTI

TE 5

74)

133

06 3

01 0

1525

4716

3306

301

015

2547

1633

06 3

01 0

1525

4716

3306

301

015

2547

1633

06 3

01 0

1525

4716

3306

301

015

2547

1633

06 3

01 0

15-

30Ra

dial

sea

ling

ring,

inpu

t (No

HBW

250

«22

-23»

)1

0634

301

830

2801

3506

34 3

01 8

3028

0135

0634

301

833

2158

7506

34 3

01 8

3321

5875

0634

301

832

2842

6006

34 3

01 8

3228

4260

0634

311

025

-

30Ra

dial

sea

ling

ring,

inpu

t (on

ly v

ers.

«22

-23»

)1

0634

311

025

5011

51

31Ra

dial

sea

ling

ring,

out

put (

No H

BW 2

50 «

22-2

3»)

106

34 3

00 3

7110

5153

0634

300

371

1051

5306

34 3

00 4

6610

5159

0634

300

466

1051

5906

34 3

00 4

6610

5159

0634

300

466

1051

5906

34 3

11 0

26-

31Ra

dial

sea

ling

ring,

out

put (

only

ver

s. «

22-2

3»)

106

34 3

11 0

2650

1152

32Ta

pere

d ro

ller b

earin

g, in

put s

haft

206

35 5

01 9

43-

0635

501

943

-06

35 5

01 5

97-

0635

501

597

-06

35 3

70 0

4216

7210

0635

370

042

1672

1006

35 3

70 0

42-

* Up

to le

tter «

E» p

rodu

ctio

n da

te (s

ee n

ame

plat

e de

scrip

tion

pag.

50)


53

ZF 3

M -

ZF 5

MZF

10

MHB

W 10

/ZF 12

M/15

MZF

15

MA

ZF 2

5 M

ZF 2

5 M

AZF

30

M

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

n

Item

NoPa

rt na

me

Num

ber

per

gear

box

34Ta

pere

d ro

ller b

earin

g, o

utpu

t sha

ft2

0635

501

943

-06

35 5

01 9

43-

0635

501

597

-06

35 5

01 5

97-

0635

370

051

-06

35 3

70 0

51-

0635

370

051

-

36In

put s

haft

HBW

50

- 2L

«11»

z =

22/

221

947.

72.0

01.0

332

5970

36In

put s

haft

ZF 5

M -2

.05R

«00

1» Z

1/Z3

=22/

221

3303

302

001

3269

00

36In

put s

haft

HBW

50

2R 1

2 Z=

22/2

21

947.

72.0

01.0

332

5970

36In

put s

haft

HBW

50

3R 1

0 Z=

18/2

01

947.

72.0

01.0

738

7535

36In

put s

haft

ZF 5

M -

2.72

R «0

02»

Z1/Z

3=18

/20

133

03 3

02 0

0245

8163

36In

put s

haft

ZF 3

M -

2.05

R «0

01»

Z1/Z

3=22

/22

133

03 3

02 0

0132

6900

36In

put s

haft

ZF 3

M -

2.72

R «0

02»

Z1/Z

3=18

/20

133

03 3

02 0

0245

8163

36In

put s

haft

ZF 1

0 M

- 1.

48R

«003

» Z1

/Z3=

27/2

21

3304

302

004

3040

59

36In

put s

haft

ZF 1

0 M

- 1.

79R

«004

» Z1

/Z3=

24/2

21

3304

302

005

3056

05

36In

put s

haft

ZF 1

0 M

- 2.

05R

«010

» Z1

/Z3=

22/2

21

3304

302

018

-

36In

put s

haft

ZF 1

0 M

- 2.

72R

«005

» Z1

/Z3=

18/2

01

3304

302

006

4654

65

36In

put s

haft

HBW

100

- 3R

«16

» z

= 18

/22

194

7.62

.001

.06

3040

74

36In

put s

haft

HBW

100

- 2L

«17

» z

= 24

/22

194

7.62

.001

.08

3272

29

36In

put s

haft

HBW

100

- 2,

5R «

21»

z =

19/2

01

3304

302

007

4709

02

36In

put s

haft

HBW

10

- 2L

«21»

z =

22/

221

3306

302

005

2064

60

36In

put s

haft

HBW

10

/ ZF 1

2 M

- 2.

14R

«001

» Z1

/Z3=

22/2

21

3306

302

005

2064

60

36In

put s

haft

ZF 1

2 M

- 2.

63R

«002

» Z1

/Z3=

19/2

21

3306

302

007

3139

52

36In

put s

haft

ZF 1

5 M

- 1.

56R

«003

» Z1

/Z3=

27/2

21

3306

302

006

3040

88

36In

put s

haft

ZF 1

5 M

- 1.

88R

«004

» Z1

/Z3=

24/2

21

3306

302

008

3258

11

36In

put s

haft

HBW

150

- 2,

4R «

20»

z =

18/2

21

3306

302

009

4391

97

36In

put s

haft

HBW

150

- 3R

«22

» z

= 18

/22

133

06 3

02 0

1046

8211

36In

put s

haft

ZF

15 M

A - 2

R «0

04»

Z1/Z

3=24

/22

133

06 3

02 0

0240

7468

36In

put s

haft

ZF 1

5 M

A 2.

14R

«003

» Z=

22/2

21

3306

302

001

-

36In

put s

haft

ZF

15 M

A - 2

.63R

«00

5» Z

1/Z3

=19/

221

3306

302

003

4074

82

36In

put s

haft

HBW

250

- 2L

«20

» z

= 21

/25

194

7.52

.001

.08

3876

84

36In

put s

haft

HBW

250

- 3L

«19

» z

= 18

/19

194

7.52

.001

.06

3445

88

36In

put s

haft

HBW

250

- 1,

5R «

16»

z =

28/2

11

947.

52.0

01.0

430

4081

36In

put s

haft

ZF 2

5 M

- 1.

88R

«001

» &

«22

» Z1

/Z3=

25/2

11

3307

302

004

3258

09

36In

put s

haft

ZF

25 M

- 2.

27R

«007

» Z1

/Z3=

22/2

11

3307

302

005

5014

85

36In

put s

haft

ZF 2

5 M

- 2.

74R

«002

» &

«23

» Z1

/Z3=

19/1

81

3307

302

003

2889

67

36In

put s

haft

HBW

250

- 3,

5R «

13»

z =

16/1

81

947.

52.0

01.0

943

9199

36In

put s

haft

ZF 2

5 M

A 2.

23R

«005

» Z1

/Z3=

22/1

933

07 3

02 0

01-

36In

put s

haft

ZF 2

5 M

A 2.

74R

«006

» Z1

/Z3=

19/1

933

07 3

02 0

02-

36In

put s

haft

ZF 3

0 M

2.7

R «0

01»

Z1/Z

3=23

/22

3320

302

001

-

36In

put s

haft

ZF 3

0 M

2.1

5R «

002»

Z1/

Z3=2

7/22

3320

302

002

-

37Sh

im 0

.1 m

m2

3304

302

011

2887

3133

04 3

02 0

1128

8731

3306

302

011

2064

7433

06 3

02 0

1120

6474

3307

302

006

2742

5233

07 3

02 0

0627

4252

3307

302

006

-

38Sh

im 0

.15

mm

233

04 3

02 0

1228

8732

3304

302

012

2887

3233

06 3

02 0

1220

6475

3306

302

012

2064

7533

07 3

02 0

0727

4253

3307

302

007

2742

5333

07 3

02 0

07-

39Sh

im 0

.30

mm

233

04 3

02 0

1428

8734

3304

302

014

2887

3433

06 3

02 0

1420

6477

3306

302

014

2064

7733

07 3

02 0

0827

4254

3307

302

008

2742

5433

07 3

02 0

08-


54

ZF 3

M -

ZF 5

MZF

10

MHB

W 10

/ZF 12

M/15

MZF

15

MA

ZF 2

5 M

ZF 2

5 M

AZF

30

M

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

n

Item

NoPa

rt na

me

Num

ber

per

gear

box

40Sh

im 0

.50

mm

233

04 3

02 0

1528

8735

3304

302

015

2887

3533

06 3

02 0

1522

8540

3306

302

015

2285

4033

07 3

02 0

0927

4255

3307

302

009

2742

5533

07 3

02 0

09-

41Sc

rew

133

03 3

04 0

1432

0681

3304

304

038

4508

7033

06 3

04 0

5742

0280

3306

304

057

4202

8033

06 3

04 0

5742

0280

3306

304

057

4202

8033

06 3

04 0

57-

42Sp

acer

133

03 3

04 0

0732

5960

3304

304

026

4396

1133

06 3

04 0

2840

7281

3306

304

028

4072

8133

06 3

04 0

2840

7281

3306

304

028

4072

8133

06 3

04 0

28-

43Th

rust

was

her

233

04 3

04 0

1928

8748

3304

304

019

2887

4833

06 3

04 0

2934

4787

3306

304

029

3447

8733

07 3

04 0

2032

7395

3307

304

020

3273

9533

07 3

04 0

20-

44Fo

rwar

d ge

ar H

BW 5

0 - 2

L «1

1» z

= 4

51

3303

304

001

3259

71

44Fo

rwar

d ge

ar Z

F 5

M -

2.05

R «0

01»

Z2=4

51

3303

304

001

3259

71

44Fo

rwar

d ge

ar Z

F 5

M -

2.72

R «0

02»

Z2=4

91

3303

304

002

3259

71

44Fo

rwar

d ge

ar H

BW 5

0 - 2

R «1

2» z

= 4

51

3303

304

001

3259

71

44Fo

rwar

d ge

ar H

BW 5

0 - 3

R «1

0» z

= 4

91

3303

304

002

3259

76

44Fo

rwar

d ge

ar Z

F 3

M -

2.05

R «0

01»

Z2=4

51

3303

304

001

3259

71

44Fo

rwar

d ge

ar Z

F 3

M -

2.72

R «0

02»

Z2=4

91

3303

304

002

3259

76

44Fo

rwar

d ge

ar Z

F 10

M -

1.48

R «0

03»

Z2=4

01

3304

304

007

3040

60

44Fo

rwar

d ge

ar Z

F 10

M -

1.79

R «0

04»

Z2=4

31

3304

304

008

3056

07

44Fo

rwar

d ge

ar Z

F 10

M -

2.05

R «0

10»

Z2=4

51

3304

304

039

-

44Fo

rwar

d ge

ar Z

F 10

M -

2.72

R «0

05»

Z2=4

91

3304

304

006

2874

55

44Fo

rwar

d ge

ar H

BW 1

00 -

3R «

16»

z =

491

3304

304

006

2874

55

44Fo

rwar

d ge

ar H

BW 1

00 -

2L «

17»

z =

431

3304

304

008

3056

07

44Fo

rwar

d ge

ar H

BW 1

00 -

2,5R

«21

» z

= 48

133

04 3

04 0

0947

0903

44Fo

rwar

d ge

ar H

BW 1

0 - 2

L «2

1» z

= 4

71

3306

304

012

4072

18

44Fo

rwar

d ge

ar H

BW 1

0 / Z

F 12

M -2

.14R

«00

1» Z

2=47

133

06 3

04 0

1240

7218

44Fo

rwar

d ge

ar Z

F 12

M -

2.63

R «0

02»

Z2=5

01

3306

304

013

4072

19

44Fo

rwar

d ge

ar Z

F 15

M -

1.56

R «0

03»

Z2=4

21

3306

304

015

4072

21

44Fo

rwar

d ge

ar Z

F 15

M -

1.88

R «0

04»

Z2=4

51

3306

304

014

4072

20

44Fo

rwar

d ge

ar H

BW 1

50 -

2,4R

«20

» z

= 43

133

06 3

04 0

1643

9198

44Fo

rwar

d ge

ar H

BW 1

50 -

3R «

22»

z =

511

3306

304

017

4682

12

44Fo

rwar

d ge

ar Z

F 15

MA

- 1.8

8R «

004»

Z2=

451

3306

304

003

4074

69

44Fo

rwar

d ge

ar Z

F 15

MA

2.14

R «0

03»

Z=47

133

06 3

04 0

01-

44Fo

rwar

d ge

ar Z

F 15

MA

- 2.6

3R «

005»

Z2=

501

3306

304

005

4074

83

44Fo

rwar

d ge

ar H

BW 2

50 -

2L «

20»

z =

471

3307

304

007

3058

13

44Fo

rwar

d ge

ar H

BW 2

50 -

3L «

19»

z =

521

3307

304

010

2889

71

44Fo

rwar

d ge

ar H

BW 2

50 -

1,5R

«16

» z

= 43

194

7.52

.002

.03

3040

83

44Fo

rwar

d ge

ar Z

F 25

M -

1.88

R «0

01»

& «

22»

Z2=4

71

3307

304

007

3058

13

44Fo

rwar

d ge

ar Z

F 25

M -

2.27

R «0

07»

Z2=5

01

3307

304

008

-

44Fo

rwar

d ge

ar Z

F 25

M -

2.74

R «0

02»

& «

23»

Z2=5

21

3307

304

010

2889

71

44Fo

rwar

d ge

ar H

BW 2

50 -

3,5R

«13

» z

= 56

194

7.52

.003

.04

4392

00

44Fo

rwar

d ge

ar Z

F 25

MA

- 2.2

3R «

005»

Z2=

491

3307

304

001

-

44Fo

rwar

d ge

ar Z

F 25

MA

- 2.7

4R «

006»

Z2=

521

3307

304

003

-

44Fo

rwar

d ge

ar Z

F 30

M -

2.7R

«00

1» Z

2=62

133

20 3

04 0

04-

44Fo

rwar

d ge

ar Z

F 30

M -

2.15

R «0

02»

Z2=5

81

3320

304

007

-


55

45Ne

edle

cag

e2

0635

300

411

3206

7833

04 3

04 0

3728

0132

0635

300

148

2011

8706

35 3

00 1

4820

1187

0635

300

148

2011

8706

35 3

00 1

4820

1187

45Ne

edle

cag

e4

0635

300

148

-

46Ne

edle

bea

ring

inne

r rac

e2

3303

304

012

3260

6033

04 3

04 0

2228

8759

3306

304

021

2515

2433

06 3

04 0

2125

1524

3306

304

021

2515

2433

06 3

04 0

2125

1524

46Ne

edle

bea

ring

inne

r rac

e4

3306

304

021

-

47Sp

acer

233

03 3

04 0

1132

6026

3304

304

017

2887

5633

06 3

04 0

2525

0992

3306

304

025

2509

9233

07 3

04 0

1827

4242

3307

304

018

2742

4233

20 3

04 0

06-

48Cu

p sp

ring

233

03 3

04 0

0532

5958

48Cu

p sp

ring

433

04 3

04 0

1830

5537

3306

304

026

3873

9133

06 3

04 0

2638

7391

3307

304

019

3055

3633

07 3

04 0

1930

5536

3307

304

019

-

49Th

rust

ring

/end

dis

c2

3303

304

006

3259

5933

04 3

04 0

1428

8755

3306

304

030

4071

3933

06 3

04 0

3040

7139

3307

304

014

2742

7133

07 3

04 0

1427

4271

3307

304

014

-

50Ci

rclip

206

30 5

03 0

4032

0677

0630

513

059

2801

3106

30 5

02 0

3127

7055

0630

502

031

2770

5506

30 5

02 0

31-

50Ha

lf rin

g4

3306

304

011

3268

3033

06 3

04 0

1132

6830

51In

tern

al c

lutc

h di

sc4

3304

304

040

51In

tern

al c

lutc

h di

sc8

3304

304

040

3306

304

027

4072

3133

06 3

04 0

2740

7231

51In

tern

al c

lutc

h di

sc (o

ld v

ersi

ons)

894

7.42

.017

.01

2889

12

51In

tern

al c

lutc

h di

sc10

3307

304

021

3307

304

021

51In

tern

al c

lutc

h di

sc12

3307

304

021

52Ex

tern

al c

lutc

h di

sc4

3304

304

021

2887

58

52Ex

tern

al c

lutc

h di

sc6

3304

304

021

2887

58

52Ex

tern

al c

lutc

h di

sc8

3306

304

031

4072

3033

06 3

04 0

3140

7230

3307

304

005

2060

2633

07 3

04 0

0520

6026

52Ex

tern

al c

lutc

h di

sc (o

ld v

ersi

on)

694

7.22

.024

.01

1878

72

52Ex

tern

al c

lutc

h di

sc10

3307

304

005

-

53Sh

im 0

.4 m

m2

3304

304

032

2887

6033

04 3

04 0

3228

8760

3306

304

035

1957

1433

06 3

04 0

3519

5714

3306

304

035

1957

1433

06 3

04 0

3519

5714

3306

304

035

-

54Sh

im 0

.5 m

m2

3304

304

033

2887

6133

04 3

04 0

3328

8761

3306

304

036

1957

1533

06 3

04 0

3619

5715

3306

304

036

1957

1533

06 3

04 0

3619

5715

3306

304

036

-

55Sh

im 0

.6 m

m2

3304

304

034

2887

6233

04 3

04 0

3428

8762

3306

304

037

1957

1633

06 3

04 0

3719

5716

3306

304

037

1957

1633

06 3

04 0

3719

5716

3306

304

037

-

56Sh

im 0

.7 m

m2

3304

304

035

2887

6333

04 3

04 0

3528

8763

3306

304

038

1957

1733

06 3

04 0

3819

5717

3306

304

038

1957

1733

06 3

04 0

3819

5717

3306

304

038

-

57Di

sc c

arrie

r2

3303

304

008

3259

6733

04 3

04 0

1628

8713

3306

304

032

4072

3333

06 3

04 0

3240

7233

3307

304

017

3264

8633

07 3

04 0

1732

6486

3320

304

003

-

58Ba

ll6

0635

460

061

2801

3306

35 4

60 0

6128

0133

0635

460

015

1067

0006

35 4

60 0

1510

6700

0635

460

019

1067

3206

35 4

60 0

1910

6732

0635

460

019

-

59Gu

ide

slee

ve1

3303

304

010

4389

6133

04 3

04 0

1543

8960

3306

304

022

4396

0333

06 3

04 0

2243

9603

3307

304

015

2742

4733

07 3

04 0

1527

4247

3320

304

010

-

60Ac

tuat

ing

slee

ve1

3304

304

027

3260

6333

04 3

04 0

2732

6063

3306

304

023

2068

1733

06 3

04 0

2320

6817

3307

304

016

4080

9333

07 3

04 0

1640

8093

3307

304

016

-

61Co

mpr

essi

on s

prin

g (a

ctua

ting

mem

bers

)3

3304

304

023

2875

2533

04 3

04 0

2328

7525

3306

304

006

2874

0133

06 3

04 0

0628

7401

3306

304

006

2874

0133

06 3

04 0

0628

7401

3306

304

006

-

62De

tent

pin

333

04 3

04 0

2428

8766

3304

304

024

2887

6633

06 3

04 0

3318

7840

3306

304

033

1878

4033

06 3

04 0

3318

7840

3306

304

033

1878

4033

06 3

04 0

33-

63Dr

ivin

g pi

n3

3304

304

025

2887

6733

04 3

04 0

2528

8767

3306

304

008

1952

7133

06 3

04 0

0819

5271

3306

304

008

1952

7133

06 3

04 0

0819

5271

3306

304

008

-

64Sp

ring

333

06 3

04 0

2420

6798

3306

304

024

2067

9833

06 3

04 0

2420

6798

3306

304

024

2067

9833

06 3

04 0

2420

6798

3306

304

024

2067

9833

06 3

04 0

24-

65Re

vers

e ge

ar H

BW 5

0 - 2

L «1

1» z

= 4

11

3303

304

003

3259

66

65Re

vers

e ge

ar Z

F 5

M -

2.05

R «0

01»

Z5=4

11

3303

304

003

3259

66

65Re

vers

e ge

ar H

BW 5

0 - 2

R «1

2» z

= 4

11

3303

304

003

3259

66

65Re

vers

e ge

ar H

BW 5

0 - 3

R «1

0» z

= 4

31

3303

304

009

3875

39

65Re

vers

e ge

ar Z

F 5

M -

2.72

R «0

02»

Z5=4

31

3303

304

009

3875

39

65Re

vers

e ge

ar Z

F 3

M -

2.05

R «0

01»

Z5=4

11

3303

304

003

3259

66

65Re

vers

e ge

ar Z

F 3

M -

2.72

R «0

02»

Z5=4

31

3303

304

009

3875

39

ZF 3

M -

ZF 5

MZF

10

MHB

W 10

/ZF 12

M/15

MZF

15

MA

ZF 2

5 M

ZF 2

5 M

AZF

30

M

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

n

Item

NoPa

rt na

me

Num

ber

per

gear

box


56

65Re

vers

e ge

ar Z

F 10

M -

1.48

R «0

03»

Z5=4

11

3304

304

011

2880

84

65Re

vers

e ge

ar Z

F 10

M -

1.79

R «0

04»

Z5=4

11

3304

304

011

2880

84

65Re

vers

e ge

ar Z

F 10

M- 2

.05R

«01

0» Z

5=41

133

04 3

04 0

1128

8084

65Re

vers

e ge

ar Z

F 10

M -

2.72

R «0

05»

Z5=4

31

3304

304

012

4654

66

65Re

vers

e ge

ar H

BW 1

00 -

3R «

16»

z =

411

3304

304

011

2880

84

65Re

vers

e ge

ar H

BW 1

00 2

L «1

7» z

= 4

11

3304

304

011

2880

84

65Re

vers

e ge

ar H

BW 1

00 -

2,5R

«21

» z

= 43

133

04 3

04 0

1246

5466

65Re

vers

e ge

ar H

BW 1

0 / Z

F 12

M /

ZF 1

5 M

Z5=

431

3306

304

018

4072

35

65Re

vers

e ge

ar Z

F 15

MA

Z5=

431

3306

304

004

4074

80

65Re

vers

e ge

ar H

BW 2

50 -

2L «

20»

z =

441

3307

304

009

2742

40

65Re

vers

e ge

ar H

BW 2

50 -

3L «

19»

z =

491

3307

304

006

2889

69

65Re

vers

e ge

ar H

BW 2

50 -

1,5R

«16

» z

= 44

133

07 3

04 0

0927

4240

65Re

vers

e ge

ar Z

F 25

M -

1.88

R «0

01»

& «

22»

Z5=4

41

3307

304

009

2742

40

65Re

vers

e ge

ar Z

F 25

M -

2.27

R «0

07»

Z5=4

41

3307

304

009

2742

40

65Re

vers

e ge

ar Z

F 25

M -

2.74

R «0

02»

& «

23»

Z5=4

91

3307

304

006

2889

69

65Re

vers

e ge

ar H

BW 2

50 -

3,5R

«13

» z

= 49

133

07 3

04 0

0628

8969

65Re

vers

e ge

ar Z

F 25

MA

- 2.2

3R «

005»

Z5=

521

3307

304

002

-

65Re

vers

e ge

ar Z

F 25

MA

- 2.7

4R «

006»

Z5=

521

3307

304

002

-

65Re

vers

e ge

ar Z

F 30

M -

2.7R

«00

1» Z

5=58

133

20 3

04 0

05-

65Re

vers

e ge

ar Z

F 30

M -

2.15

R «0

02»

Z5=5

81

3320

304

005

-

66Ou

tput

sha

ft1

3303

304

004

3259

5733

04 3

04 0

1343

9448

3306

304

019

4072

8033

06 3

04 0

1940

7280

3307

304

011

4080

9233

07 3

04 0

1140

8092

3320

304

011

-

67Ke

y1

0631

501

634

2801

3006

31 5

01 6

3428

0130

67Ke

y2

3306

304

007

1878

4133

06 3

04 0

0718

7841

67Ke

y4

3307

304

004

2061

2133

07 3

04 0

0420

6121

3307

304

004

-

68a

Shim

0.1

mm

106

30 0

04 1

77-

68b

Shim

0.2

mm

106

30 0

00 2

5733

7665

68c

Shim

0.5

mm

106

30 0

04 1

7933

7664

68d

Shim

1.0

mm

106

30 0

04 1

8033

7662

69St

ud4

0636

610

232

3963

3006

36 6

10 2

3239

6330

0636

610

232

3963

3006

36 6

10 2

3239

6330

0636

610

232

3963

3006

36 6

10 2

3239

6330

0636

610

232

-

70Ne

edle

bea

ring

for s

hift

cove

r2

0635

303

056

2686

2006

35 3

03 0

56 2

6862

006

35 3

03 0

5626

8620

0635

303

056

2686

2006

35 3

03 0

56-

72Nu

t (ac

tuat

ing

leve

r)1

0637

006

157

4557

8506

37 0

06 1

5745

5785

0637

006

157

4557

8506

37 0

06 1

5745

5785

0637

006

157

4557

8506

37 0

06 1

5745

5785

0637

006

157

-

73Sp

acer

ZF

15 M

A - Z

F 25

MA

133

06 3

01 0

0740

7474

3307

301

004

-

74Na

me

plat

e1

3306

301

005

-33

06 3

01 0

05-

3306

301

005

-33

06 3

01 0

05-

3306

301

005

-33

06 3

01 0

05-

3306

301

005

-

75Oi

l nam

e pl

ate

133

04 3

01 0

16-

3304

301

016

-33

04 3

01 0

16-

3304

301

016

-33

04 3

01 0

16-

3304

301

016

-33

04 3

01 0

16-

ZF 3

M -

ZF 5

MZF

10

MHB

W 10

/ZF 12

M/15

MZF

15

MA

ZF 2

5 M

ZF 2

5 M

AZF

30

M

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

nPa

rt No

Old

p/n

Part

NoOl

d p/

nPa

rt na

me

Num

ber

per

gear

box

Item

No


57

1 Housing assy 1 3306 201 004 3447682 Cover 1 3306 301 010 2064503 Cover 1 3306 301 023 3263694 Spring washer 39 0630 302 090 4423725 Hex screw 8 0636 015 289 2158706 Actuating lever * 1 947.23.006.01 1950626 Actuating lever 1 3306 308 001 5006357 Hex. head screw * 1 0636 015 299 1998077 Hex. head screw (actuating lever) 1 0636 101 727 4423778 Shaft seal ring 1 0634 502 009 1068649 Cover 1 3306 308 002 388242

10 Dowel pin 1 0631 329 032 10455911 Actuating cam assembly 1 3306 199 008 40721112 Shift cover assembly 1 3306 108 002 40721015 Shift fork 1 3306 208 001 22356316 Shift rod 1 3307 301 012 28867317 Plug 1 0636 301 041 44237318 Sealing ring 1 3306 301 016 32657819 Dipstick 1 3306 201 006 34548020 Oil drain plug 1 3306 301 013 22856621 Hex screw 14 0636 010 376 21586922 Hex nut 15 0637 006 157 45578523 Plug 1 0630 361 101 32238224 Intermediate shaft 1 3306 303 006 46877225 Disc 2 3307 303 002 28870226 Intermediate gear 1 3306 303 001 25473027 Needle bearing 1 3306 303 007 21587828 Gasket 2 3306 301 014 25471529 Gasket cover plate (or LOCTITE 574) 1 3306 301 015 25471630 Shaft seal, input 1 0634 301 833 21587531 Seal ring 2 0634 300 146 40164732 Tapered roller bearing 2 0635 501 597 -34 Tapered roller bearing 1 0635 370 050 -36 Input shaft HBW 150 V - 1.8R «08» z = 27/22 1 3306 302 006 30408836 Input shaft ZF 15 MIV - 2.13R «001» z1/z3 = 24/22 1 3306 302 008 32581136 Input shaft ZF 15 MIV - 2.72R «003» z1/z3 = 18/22 1 3306 302 009 43919736 Input shaft ZF 15 MIV - 2.99R «002» z1/z3 = 19/22 1 3306 302 007 31395237 Shim 0.10 mm 2 3306 302 011 20647438 Shim 0.15 mm 2 3306 302 012 20647539 Shim 0.50 mm 2 3306 302 015 22854040 Shim 1.00 mm 2 3306 302 016 22853941 Hex head screw 1 3306 304 057 42028042 Spacer 1 3306 303 004 32625743 Thrust ring 2 3306 304 029 34478744 Gear HBW 150V - 1,8R «08» z = 42 1 3306 304 015 40722144 Gear ZF 15 MIV - 2.13R «001» z2 = 45 1 3306 304 014 40722044 Gear ZF 15 MIV - 2.72R «003» z2 = 43 1 3306 304 016 43919844 Gear ZF 15 MIV - 2.99R «002» z2 = 50 1 3306 304 013 40721945 Needle bearing 2 0635 300 148 20118746 Needle bearing 2 3306 304 021 25152447 Spacer 2 3306 304 025 25099248 Spring 4 3306 304 026 387391

* Up to letter «E» production date (see name plate description pag.46)

ItemNo

Part name Number per gearboxPart No Old p/n

ZF 15 MIV


58

49 Disc 2 3306 304 030 40713950 Ring half 4 3306 304 011 32683051 Internal clutch disc 8 3306 304 027 40723152 External clutch disc 8 3306 304 031 40723053 Shim 0.4 mm 2 3306 304 035 19571454 Shim 0.5 mm 2 3306 304 036 19571555 Shim 0.6 mm 2 3306 304 037 19571656 Shim 0.7 mm 2 3306 304 038 19571757 Disc carrier 2 3306 304 032 40723358 Ball 6 0635 460 015 10670059 Guide sleeve 1 3306 304 022 43960360 Change selector 1 3306 304 023 20681761 Pressure spring 3 3306 304 006 28740162 Stop pin 3 3306 304 033 18784063 Guide pin 3 3306 304 008 19527164 Torsion spring 3 3306 304 024 20679865 Gear z5= 43 1 3306 304 018 40723566 Intermediate shaft z6=29 1 3306 303 005 38841167 Cotter 2 3306 304 007 18784168 Tapered roller bearing 1 0635 370 053 -70 Shim 0.1 mm 2 0630 004 260 28083971 Shim 0.3 mm 1 0630 004 259 28084072 Shim 0.5 mm 1 0630 004 258 28084172 Nut (actuating lever) 1 0637 006 157 45578573 Ring 1 3306 304 054 34469074 Tapered roller bearing 2 0635 501 936 -76 Spacer ring 2 3306 304 009 32711578 Shim 1.3 mm 2 3306 304 042 34546978 Shim 1.4 mm 2 3306 304 043 34547078 Shim 1.5 mm 2 3306 304 044 34467378 Shim 1.6 mm 2 3306 304 045 34467478 Shim 1.7 mm 2 3306 304 046 34467578 Shim 1.8 mm 2 3306 304 047 34467678 Shim 1.9 mm 2 3306 304 048 34467778 Shim 2.0 mm 2 3306 304 049 34467878 Shim 2.1 mm 2 3306 304 050 34467978 Shim 2.2 mm 2 3306 304 051 34468078 Shim 2.3 mm 2 3306 304 052 34468178 Shim 2.4 mm 2 3306 304 053 34468280 Gear z = 33 1 3306 304 039 38841081 Key 1 0631 501 182 10533482 Output shaft 1 3306 304 041 34467083 Ring nut 1 3306 304 010 19541384 Ring 2 3306 304 040 34464485 0-Ring 1 0634 306 072 10559086 0-Ring 2 0634 303 690 29161887 Needle bearing 2 0635 303 056 26862088 Stud 4 0636 610 232 39633089 Plug 4 0636 301 039 33880590 Name Plate 1 3306 301 005 -91 Oil name plate 1 3304 301 016 387428

* Up to letter «E» production date (see name plate description pag.46)

ItemNo

Part name Number per gearboxPart No Old p/n

ZF 15 MIV


59

SEAL KITSZF M SPARE PARTS KITS

ZF 3M - ZF 5M KIT P/N 3303 199 001 ID/N 500426PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverO-Ring 1 0634 306 179 105524 Shift fork shaftSealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 4 3304 301 015 288739 CoverGasket 1 3306 301 015 254716 Shifting coverSealing ring 1 0634 301 830 280135 Input shaftSealing ring 1 0634 300 371 105153 Output shaft

ZF 10 M KIT P/N 3304 199 003 ID/N 500427PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverO-Ring 1 0634 306 011 105679 Intermediate shaftSealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 4 3304 301 015 288739 CoverGasket 1 3306 301 015 254716 Shifting coverSealing ring 1 0634 301 830 280135 Input shaftSealing ring 1 0634 300 371 105153 Output shaft

HBW 10 - ZF 12 M - ZF 15 M - ZF 15 MA KIT P/N 3306 199 001 ID/N 500428PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverO-Ring 1 0634 303 118 105530 Intermediate shaftSealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 4 3306 301 014 254715 CoverGasket 1 3306 301 015 254716 Shifting coverSealing ring 1 0634 301 833 215875 Input shaftSealing ring 1 0634 300 466 105159 Output shaft

ZF 15 MIV KIT P/N 3306 199 004 ID/N 500429PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverSealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 2 3306 301 014 254715 CoverGasket 1 3306 301 015 254716 Shifting coverSealing ring 1 0634 301 833 215875 Input shaftSealing ring 2 0634 300 146 401647 Output shaftO-Ring 1 0634 306 072 105590 Output shaftO-Ring 2 0634 303 690 291618 Output shaft

ZF 25 M - ZF 25 MA KIT P/N 3307 199 001 ID/N 500430 (EXCL. VERS. 22; 23)PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 106864 Shift coverSealing ring 2 3306 301 016 326578 Drain plug/oil dipstickGasket 4 3307 301 011 274251 CoverGasket 1 3306 301 015 254716 Shifting coverSealing ring 1 0634 301 832 284260 Input shaftSealing ring 1 0634 300 466 105159 Output shaft

ZF 30 M KIT P/N 3320 199 001PART NAME Q.TY P/N ID/N POSITIONSealing ring 1 0634 502 009 - Shift coverSealing ring 2 3306 301 016 - Drain plug/oil dipstickGasket 4 3307 301 011 - CoverSealing ring 1 0634 311 025 - Input shaftSealing ring 1 0634 311 026 - Output shaft


60

SEAL + CLUTCH PACK KITS

HBW 10 - ZF 12 M - ZF 15 M - ZF 15 MA KIT P/N 3306 199 007 ID/N 500438PART NAME Q.TY P/N ID/N POSITION

Sealing ring 1 0634 502 009 106864 Shift cover

O-Ring 1 0634 303 118 105530 Intermediate shaft

Sealing ring 2 3306 301 016 326578 Drain plug/oil dipstick

Gasket 4 3306 301 014 254715 Cover

Gasket 1 3306 301 015 254716 Shifting cover

Sealing ring 1 0634 301 833 215875 Input shaft

Sealing ring 1 0634 300 466 105159 Output shaft

Thrust washer 2 3306 304 029 344787 Bearing/gear

Inner clutch disc 8 3306 304 027 407231 Clutch pack

Outer clutch disc 8 3306 304 031 407230 Clutch pack

Shim 0.4 mm 2 3306 304 035 195714 Clutch pack


Spring 3 3306 304 024 206798 Disc carrier

ZF 10 M KIT P/N 3304 199 004 ID/N 500437PART NAME Q.TY P/N ID/N POSITION


O-Ring 1 0634 306 011 105679 Intermediate shaft


Gasket 4 3304 301 015 288739 Cover





Inner clutch disc 8 3304 304 040 - Clutch pack





ZF 3 M - ZF 5 M KIT P/N 3303 199 002 ID/N 500436PART NAME Q.TY P/N ID/N POSITION


O-Ring 1 0634 306 179 105524 Shift fork shaft


Gasket 4 3304 301 015 288739 Cover











61

ZF 15 MIV KIT P/N 3306 199 005 ID/N 500439PART NAME Q.TY P/N ID/N POSITION



Gasket 2 3306 301 014 254715 Cover




O-Ring 1 0634 306 072 105590 Output shaft

O-Ring 2 0634 303 690 291618 Output shaft


Inner clutch disc 8 3306 304 027 407231 Clutch pack





SEAL + CLUTCH PACK KITS

ZF 25 M - ZF 25 MA KIT P/N 3307 199 002 ID/N 500440 (EXCL. VERS. 22; 23)PART NAME Q.TY P/N ID/N POSITION



Gasket 4 3307 301 011 274251 Cover










ZF 30 M KIT P/N 3320 199 003PART NAME Q.TY P/N ID/N POSITION

Sealing ring 1 0634 502 009 - Shift cover

Sealing ring 2 3306 301 016 - Drain plug/oil dipstick

Gasket 4 3307 301 011 - Cover

Sealing ring 1 0634 311 025 - Input shaft

Sealing ring 1 0634 311 026 - Output shaft

Thrust washer 2 3307 304 020 - Bearing/gear


Outer clutch disc 10 3307 304 005 - Clutch pack

Shim 0.4 mm 2 3306 304 035 - Clutch pack

Shim 0.5 mm 2 3306 304 036 - Clutch pack

Spring 3 3306 304 024 - Disc carrier


62

BEARING KITS (ALL VERSIONS)

ZF 25 M - ZF 25 MA KIT 501224 P/N 3307 199 003PART NUMBER DESCRIPTION LOCATION Q.TY0635 370 042 Tapered roller bearing Input shaft 20635 370 051 Tapered roller bearing Output shaft 20635 300 148 Needle cage Reverse gear 23306 304 021 Needle bearing inner race Reverse gear 23307 303 004 Cage Intermediate shaft 10635 303 056 Needle bearing Shift cover 23307 302 006 Shim 0.10 mm Input + Output shaft 4

ZF 10 M KIT 501221 P/N 3304 199 005PART NUMBER DESCRIPTION LOCATION Q.TY0635 501 943 Tapered roller bearing Input + Output shaft 40635 300 530 Cage Intermediate shaft 13304 304 037 Needle cage Reverse gear 23304 304 022 Needle bearing inner race Reverse gear 23304 302 011 Shim 0.10 mm Input + Output shaft 4

ZF 3 M - ZF 5 M KIT 501220 P/N 3303 199 003PART NUMBER DESCRIPTION LOCATION Q.TY0635 501 943 Tapered roller bearing Input + Output shaft 40635 300 526 Cage Intermediate shaft 10635 300 411 Needle cage Reverse gear 23303 304 012 Needle bearing inner race Reverse gear 23304 302 011 Shim 0.10 mm Input + Output shaft 4

HBW 10 - ZF 12 M - ZF 15 M KIT 501222 P/N 3306 199 003PART NUMBER DESCRIPTION LOCATION Q.TY0635 501 597 Tapered roller bearing Input + Output shaft 40635 300 148 Needle cage Reverse gear 23306 304 021 Needle bearing inner race Reverse gear 23306 303 007 Cage Intermediate shaft 10635 303 056 Needle bearing Shift cover 23306 302 011 Shim 0.10 mm Input + Output shaft 4

ZF 15 MIV KIT 501223 P/N 3306 199 006PART NUMBER DESCRIPTION LOCATION Q.TY0635 501 597 Tapered roller bearing Input shaft 20635 370 050 Tapered roller bearing Clutch shaft 10635 370 053 Tapered roller bearing Clutch shaft 13306 303 007 Cage Intermediate shaft 10635 501 936 Tapered roller bearing Output shaft 20635 300 148 Needle cage Reverse gear 23306 304 021 Needle bearing inner race Reverse gear 20635 303 056 Needle bearing Shift cover 10630 004 260 Shim 0.10 mm Clutch shaft 23306 302 011 Shim 0.10 mm Input + Output shaft 4

ZF 30 M P/N 3307 199 002PART NUMBER DESCRIPTION LOCATION Q.TY0635 370 042 Tapered roller bearing Input shaft 20635 370 051 Tapered roller bearing Output shaft 20635 300 148 Needle cage Reverse gear 43306 304 021 Needle bearing inner race Reverse gear 40635 300 114 Cage Intermediate shaft 20635 303 056 Needle bearing Shift cover 23307 302 006 Shim 0.10 mm Input + Output shaft 4


63

10. Drawings (Explosion view)


64

68a

68b

68c68

d


65


66

ZF-HURTH MARINE

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SERVICE MANUAL AND SPARE PARTS LIST