519FLA REPAIR MANUAL

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Use pliers 5x46 001 376 to remove the snap ring from the transmission housing. Using fixture 5x46 001 209, remove the pinion shaft from the transmission housing. Screw the threaded bracket of the fixture into the thread on the pinion shaft (if necessary hold the pinion shaft with one hand at the pinion). Insert the pin of the bell on the fixture into a tapped hole in the housing. To pull out the pinion shaft, turn the nut above the bell and hold the nut on the spindle. Remove the countersunk screw for locating the pinion shaft bearing from the transmission housing. (Wrench size – 36 mm) (Torx TX-27) 2.5/2 CD 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken 99087 99088 99089 00/08/01
99090 99091 99092 00/08/01 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken CD Dismantling 2.6 Removing bearing sheels, bearings etc. 2.6.1 Transmisssion housing Remove front-axle output bearing shells with tool 5x46 022 002 (Kukko 22-2) combined with 5x46 021 008 (Kukko 21- 8) or 5x46 021 007 (Kukko 21-7). Take off the shim washers. Important: Insert plastic tabs between the support bracket and the sealing face, or else the sealing face will be damaged beyond repair. Allocate the bearing shells and shim washers to the correct bearings. Do not exchange them, or noise problems will occur ➮ transmission failure. Remove the differential bearing shell from the transmission housing; this can normally be done by hand, but if necessary use tool 5x46 022 002 combined with 5x46 021 007. Remove the shim washer. Note: The breather does not have to be removed unless it is damaged or malfunctioning. 2.6.2 Bearing race Heat the bearing shell with a hot-air blower to remove it from the bearing race. To do this, place the bearing race on assembly bracket 5x46 000 576, take off the shim washer and allocate it to the correct bearing with the bearing shell. 2.6/1
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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
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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
Page 97 and 98: 99076 99077 99078 00/08/01 5 HP 19
Page 99: 99082 99083 00/08/01 5 HP 19 FL ©
Page 104 and 105: 2.6.3 Front axle housing Pull the b
Page 106 and 107: 2.6.6.3 Pinion Using puller 5x46 50
Page 109 and 110: 99105 99106 99107 2.7 Tower 00/08/0
Page 111 and 112: 99109 99110 98409 2.7.2 Clutch F 00
Page 113 and 114: 99114 99115 99116 00/08/01 5 HP 19
Page 115 and 116: 99118 99119 99120 2.8 Input 00/08/0
Page 117 and 118: 99121 99122 99123 2.8.2 Clutch A Ex
Page 119 and 120: 99124 99126 99127 00/08/01 5 HP 19
Page 121: 99131 98270 99133 00/08/01 5 HP 19
Page 124 and 125: Adjustment overview Note: During tr
Page 126 and 127: 3.1.2 Front axle housing and front
Page 128 and 129: 3.1.4 Installing pinion shaft in tr
Page 130 and 131: Attach magnet 35.150/140 to oil dam
Page 133 and 134: 3.2 Installing shift and parking lo
Page 135 and 136: 99161 00027 99164 00/08/01 5 HP 19
Page 137 and 138: 3.3 Tower, installing tower 3.3.1 P
Page 139 and 140: 98287 00/08/01 /110 /130 /140 /120
Page 141 and 142: 99172 /200 /190 /110 /180 /170 73.1
Page 143 and 144: 99173 99174 99176 00/08/01 5 HP 19
Page 145 and 146: 00031 99180 99181 00/08/01 5 HP 19
Page 147 and 148: 3.4 Installing front axle output 99
Page 149 and 150: 3.5 Planetary gear sets I and II 99
Page 151 and 152: 99191 99192 99193 Insert thrust was
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99197 00/08/01 5 HP 19 FL © ZF Get
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Place cup spring 71.080 on piston E
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3.6.2 Clutch A /110 /120 /190 /130
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Pull O-ring 71.160 on to ring 71.17
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Insert cup spring 72.110, press the
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3.7 Oil supply and brake C and inst
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99210 99211 99212 00/08/01 5 HP 19
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99218 99219 99220 00/08/01 5 HP 19
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3.8 Adding parts to flange shaft an
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00037 99229 00038 00/08/01 5 HP 19
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Insert 5 sealing sleeves 01.270 int
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Attach oil filter 27.420 to the val
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3.9.2 Installing position switch an
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Fasten converter retaining bracket
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subject to alterations © Copyright
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6. Installation 6.1/1 6.1 Torsen II
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Warning: The transmission, differen
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4.2 Power flow diagram 2nd GEAR 4th
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99038 99039 00094 00/08/01 5 HP 19
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00098 00/08/01 5 HP 19 FLA © ZF Ge
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00015 00016 00/08/01 5 HP 19 FLA ©
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Example: (for 4.4) Front axle shaft
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4.7 Special tools 00053 99265 00073
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99276 99277 98171 OBJECT Order-No.
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00057 00065 00066 OBJECT Order-No.
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00077 99281 99280 OBJECT Order-No.
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00081 00082 00083 OBJECT Order-No.
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98150 98155 99268 OBJECT Order-No.
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00090 00089 00/08/01 5 HP 19 FLA ©
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99243 99244 99003 00/08/01 5 HP 19
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99005 99006 00/08/01 5 HP 19 FLA ©
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99008 99009 99010 00/08/01 5 HP 19
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Using drift 5x46 002 277, force the
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99018 99019 00/08/01 5 HP 19 FLA ©
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Take off the thrust washer. Raise t
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Place the cover with the larger nee
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By turning the sun gear in either d
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6.2.1.1 Output gear Using sleeve 5x
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Install vibration damper 36.230 on
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6.2.2 Adding parts to transmission
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Secure the transfer box housing to
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519FLA REPAIR MANUAL

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