Volvo Penta D4 gearbox service questions

scross

scross

Well-known member
Joined
Jan 30, 2015
Messages
2,098
Fluid Motion Model
C-28
Hull Identification Number
FMLC2831A717
Vessel Name
R-25 Classic - Sold
MMSI Number
367719470
Will be taking our 2017 C-28 for periodic service this spring. One of the service items will be the gearbox.
I believe VP uses the ZF 63A gearbox with the D4-260 engine. I also believe that Valvoline DEX/MERC ATF transmission fluid meets the specs for this gearbox. My third understanding is that the gearbox filter for the ZF 63A gearbox is ZF 3312-199-031 which includes a large and small O Ring.
Are my above assumptions correct?
How much of the Valvoline ATF fluid is needed for the service?
 
I just started this job today for my first time on our 2016 R29 with the D4-260. Our marine gear is the Volvo Penta HS63AE-C, which I believe is made by ZF for VP. The manual says the capacity is 4 litres, which is exactly how much I suctioned out after removing the filter. Apparently any good ATF-1 fluid is suitable.
The filter I got from the VP dealer/shop was a VP part # 3582069, which seems to cross reference with the ZF 331219903101 part. The large and small O-rings came with it and fit onto the cover plate.
Unfortunately, I had trouble with the fit, and found out the hole on one side of the filter is smaller than the one on the other side, so it doesn't fit on the seals and I couldn't get the cover back on. The VP shop is looking into this.
I sucked the oil out with a small Mighty Vac pump from below the filter chamber, because that's what the manual indicated. I had to switch to a small, flexible hose (about 3/8") to negotiate the bend in the passageway below the filter. I didn't try if the dipstick hole might give better access.
I'll post more once I find an answer to the filter issue.
 
The OEM filter # is ZFM-3312199031 it does and should have a small diameter opening and a larger diameter opening. The o-ring fit is snug. Install The o-ring to the cover. Do not drop the filter in the housing ! The filter needs to be installed with it fit to the cover. If you drop the filter into the housing and try to install the cover you have a 50/50 chance of a correct install. If you have an incorrect fit cover to filter you could damage the reverses gear. FIT THE FILTER TO THE COVER Then install the cover filter assembly into the housing and tighten. Volvo Penta filter part number is 3582069. This is a OEM filter for Volvo but an aftermarket filter for ZF. Both will work. When I change the oil I purchase 2 gallons of Valvoline ATF. It should be poured into the filter housing and level checked at the dip stick. Once the level is correct then install the filter. Start and run the engine. Shift Fwd/neutral/reverse. Shut down the engine and check level. Add if needed at the dipstick.
 
Thanks Brian!
 
The metal part of the lid that holds the small O-ring will not fit into the smaller hole in the filter. The hole in the filter is smaller than the metal rim. If I turn it over and put the small hole downward and test fit the filter, it doesn't seem to fit onto the seal at the bottom of the chamber. It rocks and wobbles. If I attach the filter (bigger hole) to the lid and try to install it, I can't press the lid assembly down far enough to engage the big O-ring.
The old filter has both holes the same size and it fits fine either way, but it has no markings on it. It was installed before I bought the boat.
So, if the holes are supposed to be different sizes, which way is up?
 
This is the information I received from Federal Marine Transmission in Countryside Illinois. This guy has been around forever and is old school. Do not buy aftermarket filters! The first sign that the filter is after market is both holes are the same size. The filter mesh is not fine enough and will let small debris pass through. OEM filter will only fit one way. The cover o-ring assembly will not fit the small OD hole. Always install the filter and cover as an assembly. Inspect the lower seal to confirm it is not damaged. Install filter/cover with socket head bolt loose. Use ATF as a lubricant on all o-rings.

I have installed the filters this way many times without incident. I did install it once on my C26 by dropping the filter in the housing. My next oil change I had a bad oil report from Blackstone. Large metal particulate visual in the oil.

Good luck with your filter installation issue.
 
Thanks Brian for that good information.
With more research I find that the ZF part number ZFM-3312199031 does cross reference to the Volvo Penta number 3582069 on the box I got. However, on the filter itself in the box I found a number 3312301037, with no manufacturer name. When I google this number it comes up as a third party chinese filter on Amazon, Aliexpress, Ebay etc.;made by JEENDA and other no-name knock-offs. They are supposed to be a match, but some reviews complained of the same fit issues.
So, did Volvo Penta have supply chain issues and sourced the chinese copies to put in their boxes? The VP dealer is looking into it.
It looks like the bottom seal in the filter chamber has a raised lip where it fits around the steel tube. The larger filter hole fits over the lip and seats nicely on the flat part of the seal. If I install the filter small hole down, it barely slides over the steel tube and rests on the raised lip, so it wobbles and won't seat on the seal. Maybe the small hole is just a millimeter or 2 smaller than it should be?
I will go back to the boat with my calipers and have a closer look and try again.
 
Ron,
Minutes ago I ordered a filter on Amazon. It says “Brand: ZF - ZF OEM Marine Oil Filter, Part# 3312199031” and was $62.08 shipped.
Amazon also sells the JEENDA brand you referenced at about 1/4 the price of the ZF filter. JEENDA says it is compatible with the ZF 63A gear box but your experience tells me maybe not.
I also noted that Marine Parts Source sells the ZF branded filter for just a little more than Amazon.
 
The key word here is aftermarket! I showed the Volvo filter to the owner of Federal marine and he said I don’t know who manufactured that but when he pulled the filter out of the sealed ZF box he said I know this is a OEM part and that is all I would use. I did purchase Volvo filters in the past until talking with him. Since then I only use ZF filters out of a ZF box. I have Hurth/ZF gears in my Mainship pushed by 4LHA STP Yanmar. I Purchase my parts from Toad. They offer aftermarket and OEM parts. I am a firm believer in OEM. It is a shame that the cost of Volvo parts and Volvo engines that Volvo would source parts out to a manufacturer that makes out of spec parts. From the sound of it that may be the case.
 
For those of you using the original ZF gear filters, do you see a part number on the filter itself; or do you just trust the number on the package?
I have had the Volvo Penta dealer/shop bring in more filters, and again the VP box has Chinese part numbers on the filters inside.
I had them bring in a supposed OEM original ZF filter from their other branch, which is listed on the ZF website as an official ZF parts depot. Again, it had the Chinese part number on the filter, even though the box looked and was marked as ZF original.
What gives?
Either the factory is putting Chinese filters in the boxes; or a supply middle-man is sourcing supply from the internet instead of from the factory. Both illegal, I would think?
Or is ZF now partnered with JEENDA, AIPICO, or other Chinese factories to make their parts?
The mystery continues...
 
Update: I had another go at installing the new Chinese-numbered filter. With much fiddling and pressing I did get it installed; BUT the lid is sticking up above the case by about 1/8", or half the lid thickness.
Looking again at the video posted above, the lid there does end up being slightly raised, about 1/16". This looks more like mine did with the old filter. If I reinstall the old filter, I can get the lid almost flush with the case. So I know I didn't mess up the seals. I even tried the new filter with the old O-rings. It still sits up 1/8".
If I install the lid without the filter, it sits flush with the case, so I know it's not a fit issue with the lid.
I hate to say "good enough", but is it OK with the lid sticking up 1/8"? Am I just being too fussy?
 
Ron,
Just had the same experience as you did. Despite paying over $60 for the “ZF OEM 3312199031” part I got was a JEENDA 3312301037 labeled filter in a ZF logo box. Returned it immediately.
Noted that the center holes on the filter were both the same size which I believe is a sign of the knock off part.
.
 
scross":3n3plkf2 said:
Ron,
Just had the same experience as you did. Despite paying over $60 for the “ZF OEM 3312199031” part I got was a JEENDA 3312301037 labeled filter in a ZF logo box. Returned it immediately.
Noted that the center holes on the filter were both the same size which I believe is a sign of the knock off part.
.
Click to expand...
That really sucks. It's the reason I support the local shops and buy less online now, but even that doesn't work anymore. What's next, cheap whisky in my brand name scotch bottle? Tofu in my T-bone steak? CocaCola bottles with no-name cola syrup in them? Airplane tickets that don't actually reserve you a seat on a plane? Oh, ya, that's already a thing. 🙁
What is this world coming to? Sigh.
 
Ron,
Yeah. This was a Marysville, WA dealer selling online through Amazon. Will try Toad that Brian used.
 
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