Clutch Plates for BW 196 / ZF 1960 Transmission

[Mike57]

I have a 2002 65 Hatteras Convertible with ZF transmissions. It is likely that I need new Clutch plates and ZF is indicating they don't carry them any longer. The Clutch plates are listed as:
3081-202-027 for the friction plates and 3081-302-079 for the steel plates. I have a cross reference to a company in Brazil that makes equivalents to these and have been waiting for a response from them.

Does anyone have leads on where I might source these parts.

 

[Captain Ralph]

Contact Travis with serial number

https://adrpowersystems.com/locations/central-florida

 

[Bob Bradley]

It's good to have you around, Ralph.

 

[Scarlett]

I am not sure about this but might be worth checking. Kansaki in Japan make ZF nock off transmissions for Yanmar engines. Not sure if they are close enough copies to be able to use parts on both.

 

[Mike57]

Thank you Captain Ralph. ADR has the parts in stock. Superseded parts numbers for the friction discs and are available as a 16 disc kit. Not inexpensive but certainly available. I have not yet dug into the transmission so I will share the symptoms and see if any of you have suggestions.

The port side is slow to respond going into forward and the Clutch pressure is lower than the starboard side at idle. It does not slip after getting into gear but the clutch pressure is lower than expected until the rpm is raised. Over 700 rpm everything matches. It is fine going into reverse and makes 300 psi at 550 rpm. As a trouble shooting approach, I have swapped the entire control heads from port to starboard and will be trial running tomorrow.

Does anyone have recommendations for a shop if I have to go into the clutches? The local authorized ZF dealer indicates they do not have the tools to remove the Gears to get at the clutches or the seals on the clutch piston. I am in San Diego, CA.

 

[Captain Ralph]

Did you ask ADR if they have an affiliate on the Left Coast?

 

[Captain Ralph]

It's good to have you around, Ralph.

Thank you brother, I do try to help.

These kids at ADR have supported all of my ZF & TD issues for years.
Great shop.

 

[Mike57]

Thanks for the guidance to ADR. They were very helpful and I gathered all of the parts necessary to replace clutch plates. The harder part came with regard to the tooling required to get to the clutches. ZF will only sell them to Authorized Service Centers and I understand the price approaches $10K, not including those required for a deeper dive. I figured out the source for some of the tooling for the press fit gears and it turned out to be SKF. Their prices were equally astounding.
I managed to source a combination of used and new tools internationally for under $1500 and removed the press fit gear. It turned out that a portion of the rubber piston seal was trapped between the piston and the gear. My opinion is it had been trapped since new 1800 hours ago (An Assembly Error). My clutch plates looked great and measured within .0005 of the new ones I received from ADR. My Oil Analysis showed no signs of clutch material so I went back together with the original plates. Here are a few pictures of the pinched ring and the tools in use to get to it apart, and back together. Installed parts cost me less than $200, Tools closer to $2K. It runs really well with great clutch pressures and quick smooth shift responses

 

[Captain Ralph]

Outstanding good news.
Thx for the update.