519FLA REPAIR MANUAL

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99084 99085 99086 00/08/01 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken CD 2.5 Removing pinion shaft Turn the transmission through 180 degrees. Using a suitable hammer, drive the tightening rods of tool 5x46 001 400 through the marks on the shaft sealing ring. Mount the spindle plate on the tightening rods and secure in the second notch from the top. Turn the spindle to pull out the shaft sealing ring. Place wrench 5x46 001 422 on the nut. Place the counter-holder on the shaft. With a suitable lever and open-ended wrench, unscrew and remove the nut. (Wrench size = 41 mm) Note: If necessary turn the screw in a suitable threaded hole of the gearbox housing in order to create a support for the openend-wrench for the unscrew procedure. 2.5/1
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Versione00/08/01 CD REPAIR MANUAL 5
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Contents Page Preliminary informati
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3. Installation 3.1/1 Adjustments 3
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Note: This manual treats the valve
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1.2 Power flow diagram 1st GEAR Inp
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1.3.1.3Tightening yield strength cr
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Check the value on the force measur
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Example (for 1.4.1.1): F = 1.48 mm
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Example (for 1.4.1.2): F = 1.48 mm
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Example (for 1.4.1.3): F = 1.48 mm
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Example (for 1.4.1.4): F = 1.48 mm
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Example (for 1.4.1.5): F = 1.48 mm
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Example (for 1.4.1.6): F = 1.48 mm
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Example: (for 1.4.1.7) F = 1.48 mm
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Tighten the differential cover with
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Example: MD MU MO = 0.38 mm (preloa
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Place the differential-side inner b
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Screw the cover to the transmission
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1.4.4 Detent spring switch Using a
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1.4.5.2 Pinion projection Insert th
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1.4.6 Bearing adjustment, output ge
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1.4.6.2 Projection, helical/interme
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1.4.6.5 Installation space, helical
Page 50 and 51: Example: (for 1.4.6) Pinion: KRR =
Page 52 and 53: Example (for 1.4.7): M1 = 0.88 mm M
Page 54 and 55: No. Designation Part List- Wrench s
Page 57 and 58: 1.7 Special tools 98008 98034 00045
Page 59 and 60: 00108 00053 97301 OBJECT Order-No.
Page 85: 1.8 Oilflow chart (position N accor
Page 88 and 89: 2.1.2 Removing front axle output Ta
Page 90 and 91: Unscrew and remove the 17 large-hea
Page 92 and 93: Drive the clamping sleeve out of th
Page 94 and 95: Remove the 12 differential cover sc
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Page 105 and 106: 99096 99097 99098 00/08/01 5 HP 19
Page 107: 99102 99103 99104 2.6.8 Flange shaf
Page 110 and 111: Remove the angle washer, needle rol
Page 112 and 113: 2.7.3 Brake D/G with 1st gear freew
Page 114 and 115: Press out piston D by applying comp
Page 116 and 117: 2.8.1 Clutch E Insert the input sha
Page 118 and 119: 2.8.3 Dismantling clutch B Extract
Page 120 and 121: Pull O-ring seal off intermediate p
Page 123 and 124: 3. Installation 00003 35.184 /150 /
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Page 129 and 130: 99141 00023 00106 00/08/01 5 HP 19
Page 131: 99152 00/08/01 5 HP 19 FL © ZF Get
Page 134 and 135: Drive selector shaft sealing ring 0
Page 136 and 137: Press the pawl down and attach guid
Page 138 and 139: Install planet wheel carrier 42.010
Page 140 and 141: Install cup spring 77.010/160 press
Page 142 and 143: Press carrier (freewheel - inner ri
Page 144 and 145: Install two rectangular-section rin
Page 146 and 147: Using fixture 5x46 001 284, press t
Page 148 and 149: Insert thrust bearing 37.030 and sh
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Insert shaft 32.040/110 in ring gea
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Place needle roller thrust bearing
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3.6 Input and installing 3.6.1 Clut
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98338 00/08/01 5 HP 19 FL © ZF Get
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99198 99199 99203 00/08/01 5 HP 19
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98347 72.010 72.050 72.060 72.040 7
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99207 99208 00/08/01 5 HP 19 FL ©
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3.7.1 Oil supply Place washer 10.01
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3.7.3 Brake C Pull a new O-ring sea
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Attach assembly fixture 5x46 001 38
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Insert speedometer housing with bea
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3.9 Installing valve body, oil filt
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99233 99234 00041 00/08/01 5 HP 19
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99238 00/08/01 5 HP 19 FL © ZF Get
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00043 00044 Check the switch resist
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Versione00/08/01 CD REPAIR MANUAL (
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Contents Page Preliminary informati
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Preliminary information The 5HP19FL
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4. Allgemeines 4.1 Abbildung des Ge
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00/08/01 5 HP 19 FLA © ZF Getriebe
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Place the support plate on the inte
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4.4.3 Installation space - front ax
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4.4.6 Determining shim thicknesses
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1.5 Tightening torques No. Designat
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Remarks 4.7/2 Order-No. / Applicati
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Identical Remarks 4 HP 20 Identical
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Identical Remarks 3 HP 22 Q 4 HP 14
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Identical Remarks 4 HP 18 Q 4 HP 20
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Example: S PW = 0.2° M W = 1.75°
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Take out the 11 screws holding the
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99007 99090 00/08/01 5 HP 19 FLA ©
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99011 99012 00085 00/08/01 5 HP 19
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99016 99017 00/08/01 5 HP 19 FLA ©
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00088 99020 00/08/01 5 HP 19 FLA ©
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6. Installation 99024 6.1 Torsen II
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99029 99030 99028 00/08/01 5 HP 19
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6.2 Transmission housing and interm
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00093 99033 99034 00/08/01 5 HP 19
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00005 99040 99042 00/08/01 5 HP 19
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99046 99047 99048 00/08/01 5 HP 19
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519FLA REPAIR MANUAL

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