519FLA REPAIR MANUAL

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3. Installation 00003 35.184 /150 /120 35.010 /140 35.150 /110 /130 /120 /150 35.080 35.146 01.010/110 35.120 01.440 01.680 01.620 35.050 00/08/01 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken CD 35.280 35.300 35.190 01.410 35.040 35.020 35.030 (with new transmission housing only) Drive the following into transmission housing 10.010/110: breather 01.620 using drift 5x46 002 223, differential breather 01.680 using drift 5x46 001 468 and position switch pin 01.410 using drift 5x46 002 222. 3.1/1
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Versione00/08/01 CD REPAIR MANUAL 5
Page 3 and 4:
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 =
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Example (for 1.4.7): M1 = 0.88 mm M
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No. Designation Part List- Wrench s
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1.7 Special tools 98008 98034 00045
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00108 00053 97301 OBJECT Order-No.
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99250 99265 99274 OBJECT Order-No.
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99262 98002 99259 OBJECT Order-No.
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98395 91199 92223 OBJECT Order-No.
Page 67 and 68:
99264 00054 99256 OBJECT Order-No.
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99257 99253 00063 OBJECT Order-No.
Page 71 and 72: 98399 98400 98401 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 102 and 103: Use pliers 5x46 001 376 to remove t
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 125 and 126: 99134 00102 00004 00/08/01 5 HP 19
Page 127 and 128: 00006 00007 00008 00/08/01 5 HP 19
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
Page 150 and 151: Insert shaft 32.040/110 in ring gea
Page 152 and 153: Place needle roller thrust bearing
Page 155 and 156: 3.6 Input and installing 3.6.1 Clut
Page 157 and 158: 98338 00/08/01 5 HP 19 FL © ZF Get
Page 159 and 160: 99198 99199 99203 00/08/01 5 HP 19
Page 161 and 162: 98347 72.010 72.050 72.060 72.040 7
Page 163: 99207 99208 00/08/01 5 HP 19 FL ©
Page 166 and 167: 3.7.1 Oil supply Place washer 10.01
Page 168 and 169: 3.7.3 Brake C Pull a new O-ring sea
Page 170 and 171: 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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Page 212 and 213:
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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
Page 245 and 246:
99046 99047 99048 00/08/01 5 HP 19
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519FLA REPAIR MANUAL

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