• Zf Gearbox Manual

Hi there, I have 99 prostar 205, LTR 330 with a ZF Hurth 450D transmission that seems to give me some issues. If I'm using it straight from the ramp, idling up to temp and then general usage it works perfectly all day.

Stop start etc The issue starts if we decide to go to the other side of the lake or back. Travelling at around 30-35mph for about 20 minutes. Once we stop, then try to ski the transmission can do 2 things. it will go into gear and need more revs as it seems to slip. really hard to move the throttle controller (locks up) especially in forward If you leave it for 10-15minutes its seems to go back to normal.

Zf Gearbox Manual

Its starting to be a big issue, especially when the wife is trying to drive onto the trailer. I have changed the fluid twice to get out the old fluid that was in it when I purchased it.

Using the correct fluid Dex 3 etc. I have thought it could be over heating. Any thoughts on what the issue could be?

Hi gents, I did see that video a few months ago. I pulled the throttle controller apart and regreased the internals, changes the brass pivots to the cables.

Tested the cables and all that is perfect. I did also think it could be the lever not fully engaging, but why doesn't it during the whole day? The first time it slipped I did change over the fluid again as I though some of the old fluid might still be in there. The next day it was fine again. I thought great I'm back on the water.

Then it happened again. It's fine until I drive it for that 20min+ at 30-35mph.

The original reason I changed the fluid was it was little brown when doing my initial maintaince check. I just got the boat and replaced all the hoses, leads, plugs, cleaned the throttle body, new K&N pod filter, oil, filter, etc. The transmission cooler was full of an old impeller. I then checked the cooling system and that had some impeller in it as well. Even though it had the cooling system on it I changed over the thermostat.

As I really didn't know the service history I went over the whole boat. The engine runs perfect and doesn't go over temp. It runs really good apart from this transmission issue.

Every time it has happened (3 times) I have changed over the fluid, so the next day its fine. The only thing I haven't checked. When it does play up, leave it and try it again once it all cools down (the next day) Its at the end of our season over here, so I'm trying to find out if it needs to come out when I bring it home.

Ive left it at the lake for any testing. Thanks for your help gents.

I really appreciate it. Hi gents, I did see that video a few months ago. I pulled the throttle controller apart and regreased the internals, changes the brass pivots to the cables. Tested the cables and all that is perfect.

I did also think it could be the lever not fully engaging, but why doesn't it during the whole day? The first time it slipped I did change over the fluid again as I though some of the old fluid might still be in there. The next day it was fine again. I thought great I'm back on the water.

Then it happened again. It's fine until I drive it for that 20min+ at 30-35mph. The original reason I changed the fluid was it was little brown when doing my initial maintaince check. I just got the boat and replaced all the hoses, leads, plugs, cleaned the throttle body, new K&N pod filter, oil, filter, etc. The transmission cooler was full of an old impeller.

I then checked the cooling system and that had some impeller in it as well. Even though it had the cooling system on it I changed over the thermostat. As I really didn't know the service history I went over the whole boat. The engine runs perfect and doesn't go over temp. It runs really good apart from this transmission issue.

Every time it has happened (3 times) I have changed over the fluid, so the next day its fine. The only thing I haven't checked.

When it does play up, leave it and try it again once it all cools down (the next day) Its at the end of our season over here, so I'm trying to find out if it needs to come out when I bring it home. Ive left it at the lake for any testing. Thanks for your help gents. I really appreciate it.

After the initial change of the brown colored fluid what was the color of the fluid on subsequent changes? Also does your boat have a trans temp warning light and is it functional? Some ProStars have to warning lights, one for engine temp and one for trans temp. Wr450f 2016 service manual. They should both illuminate when the key is in the on position with the engine off.

Hi gents, thank you for your input everybody. mgs96ps, I think i'll take the cooler lines off the trans and see if its clear.

Ill will also try a pressure test on the lines to see if the cooler is leaking. I don't recall seeing any water in the fluid. I left the old fluid for a few days and checked to see if anything had separated (water mixed in the fluid). I also did look inside with a inspection camera I'll also look into a new safety today switch as well. Not easy to get in Aus, I'll look at bakesonline.

Thanks for the upload of the repair manual. Bouyhead, after each change the fluid wasn't as red as it was when i put it in. My initial thought was it could still be some of the old fluid in there. The second replacement was cleaner.

I haven't changed it since the last trip so I might check the lines etc then give it a trial. I don't have a temp gauge for the trans on the dash. But I have been looking at a temp sender for testing purposes. Small price to pay for the short term. OK latest update, I have the boat back home and I'm back on the transmission issue I have been having still with no resolution.

The process of elimination is the following. I have checked that the fluid is getting pumped back into the trans by taking off the return line. When it started to pump fluid I did notice at the start it was a little brown, then went red.

I thought there might be a block in the elbows into the trans. I thought I would check the filter first. I cant get the filter off as the bolts will not move.

I'm guessing they are rusted / seized. The shifter spool does seem a little rough to move back and forth. Maybe the seal is stuffed. It does seem like the spool heats up and expands and that's why it locks up.

I know the seal wouldn't cause that but maybe the filter is blocked and its not letting enough fluid through. So I'll have to take the trans out. I'm going to get it looked at to see if the service people can find the issue.

I don't have much too loose except a few hundred dollars. In Australia some people are selling the new ZF45c from $3000-$4000.

Close to double what you pay in the US. US price $1200 for trans and $500 freight ($2400 aus) plus import taxes etc. We get ripped off over here. Anyway enough complaining as that's not going to fix it. Drop the trans and send it off, pull the motor to replace the leaking oil pan.

Just one question for you, Just a double check.you have done this probably 100 times already Checking the transmission fluid: bit brown, maybe a bit low 1. Boat is sitting in the water engine running 2. Immediately after engine shut down, unscrewing the transmission fluid stick, setting fluid stick on top of the transmission fluid inlet to check transmission fluid level (hence not threading back into inlet to check fluid level & immediately after engine shut down, two person check, to shut engine off, other to check fluid level) Doing the two person immediately after shut down, gives a more accurate reading, before the fluid has a chance to drain back/out of the trans cooler lines and into the transmission. Maybe this was just a helpful tip when you have taken the old trans out & new in. Yes, fill the transmission to fluid capacity and in addition. Fill each trans lines and oil cooler with DEX 3, as while holding them vertical, one end capped to fill the lines, then turn them up side down and drain the trans lines and cooler into a clean container.then add what is in the container to the transmission specified fluid capacity.

This is what your trying to check with an immediate engine shut down, trans fluid still up in the lines & oil cooler, before it has a chance to drain back. One might get a sense the transmission is full, engine is shut down, boat is in the water, pull the fluid stick out, fluid stick is sitting on the threaded filler hole, not threaded in, all looks good, but maybe the fluid had drained from the lines causing a false full. So, maybe if you hadn't done a two person transmission fluid level check, could give it a shot, & maybe just a bit low on fluid.My best guess.if not helping you, maybe someone else someday. From the Top of the World. Also, Maybe for the conditions, water type, or what ever reason, low on fluid or not.you could bump up to a larger oil cooler. Hi all, Bought a new transmission, new damper plate, new trans lines and a new cooler.

Needed new exhaust hoses as the old ones I had to cut off. New oil pan and drain line as the old one was rusted out. Replaced all the set screws, washers and rubbers for the engine / trans mounts. Replaced the mallory brass drive gear for the oil pump / cam. All new hoses throughout. New spark plugs and impeller. Cleaned up the electrics and re-taped the cables.

Next project is to lift the plenum, clean it up, also get the injectors cleaned and tested. Add a water/fuel separator and change over the fuel pump filter.

Can get crap fuel where we ski. Also making a seat adjuster from a car. So it can be raised to see where your going at certain speeds. Im 6'3' and its hard for me to see sometimes. But perfect when skiing. Looking forward to getting back on the water. Another month and we will have the weather to do it in Australia.