05 390DA Transmission Failed

[almostenuff]

My Starboard Trans had been acting up in reverse. Whenever it was up to temp,it wouldn't always provide reverse thrust unless I increased rpms. Last night, I just got up on plane with engine sync on when the boat settled back down like I had chopped power. I pulled the throttle back and then I advanced both throttles. The port worked normally, but the starboard just increased rpms with no thrust. No gear pressure registered, but gear temp was high at 170-port was 130. I had just checked fluids the day before. And the tranny fluid only has 25 hours since it was changed in Feb

I do not have a sea ray dealer nearby and I'm not sure my marina mechanic has ZF transmission experience. I could use some advice...

 

[Kreole Kid]

Enuff, did you verify that the transmission is in fact engaging when you shift forward or back? I mean, you are gonna need two people for this. Lift your hatch and have someone put it in forward and reverse, while you are watching the cable move at the point where it connects to the transmission linkage. It might be as simple as that:thumbsup:

 

[almostenuff]

Thanks, but no cables. Today I started the engine and put it into gear and the boat had forward thrust and gearbox pressure, but nothing in reverse. Then, after a few more tries, nothing either direction. Fluid level looked okay, but smelled "different" than the port. Not burnt, just stronger. Anyone else?

 

[Kreole Kid]

Do you have the digital throttles and shift?


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[alnav]

Can you post the exact model of your ZF transmission? I have the repair manual for the ZF63/80/85 if you have one of those models.

 

[almostenuff]

Hi and thanks. It's a ZFE 80-1V. The E designates electronic shift. Maybe there's a troubleshooting chapter? Personally, I thinks it's in the pump or control block. Maybe a blocked passage (wishful thinking). The hotter temperature tells me that I need to pull the cooler and clean it

 

[alnav]

The manual I have does not purport to cover the electronic shift or the V version but I suspect the basics are the same. You are welcome to a copy, PM me with an email and I will send it. I took a look at the ZF site for your version and got reminded how god-awful the download utility is. I coudn't even find the manual I downloaded some time ago.
There is a troubleshooting chapter and a blockage is one of the main potential faults for the transmission not working. I would examine the filter, that's the last stop for fluid before the diverter valve. If you haven't taken that out before, there should be an allen fitting; loosening that will let you take the cover off the fitting and remove it.

 

[almostenuff]

Thanks, but I found a manual that covers it. Unfortunately, the tranny is toast. ZF techs talked me through checking the oil filter and it looked and smelled horrible, plus the metal flakes, although sparkly, made me sick. New tranny and damper $6250 shipped, labor remains to be seen.

Pay very close attention to the oil analysis when you buy a boat and don't listen when the broker says that it's not uncommon for there to be "stuff" in the tranny fluids. Everything I saved in negotiations just disappeared.

 

[Rayman4545]

i just posted earlier today. Last week noticed that when running my 2000 54 SeaRay Sundancer at dockside, the port gear would not go into reverse and was even slow to go into forward gear. Checked the transmission fluid levels which were OK. Checked my engine manuals and was reassured when it stated that the cables were the problem 90% of the time.(slipping, corroded, etc.). Manuel recommended replacing cables for both transmissions every 5 years. Unfortunately, my mechanic has very little or no experience with this type of problem. Am a little nervous to call the major boat transmission companies since I don't want to get screwed if it is a simple repair.