519FLA REPAIR MANUAL

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Install planet wheel carrier 42.010. Place the complete unit on mounting fixture 5x46 002 006. Insert ring gear carrier 42.140/110 in ring gear 42.140/120 and retain with snap ring 42.140/130. Place thrust washer 42.180/110, needle roller thrust bearing 42.180/120 and angle washer 42.180/130 on the ring gear unit. Installed position (see picture) Place thrust washer 42.120/110, needle roller thrust bearing 42.120/120 and angle washer 42.120/130 on the planet wheel carrier and install the complete ring gear unit. Installed position (see picture) 3.3/2 CD 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken 99169 98285 99170 00/08/01
98287 00/08/01 /110 /130 /140 /120 /150 /160 77.010 /170 /180 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken 3.3.2 Clutch F /190 /200 /190 /200 /190 /210 Pull two new O-rings 77.010/130 and 77.010/140 on to piston 77.010/120 and press into cylinder F 77.010/110. Place pressure plate 77.010/150 on the piston. CD 3.3/3
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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 =
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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.
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99264 00054 99256 OBJECT Order-No.
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99257 99253 00063 OBJECT Order-No.
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98399 98400 98401 OBJECT Order-No.
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98405 98148 98406 OBJECT Order-No.
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99246 00059 00060 OBJECT Order-No.
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00065 00066 00067 OBJECT Order-No.
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00071 99249 00061 OBJECT Order-No.
Page 81 and 82:
97305 98155 99271 OBJECT Order-No.
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99270 00072 00062 OBJECT Order-No.
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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 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: 3.3 Tower, installing tower 3.3.1 P
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
Page 153: 99197 00/08/01 5 HP 19 FL © ZF Get
Page 156 and 157: Place cup spring 71.080 on piston E
Page 158 and 159: 3.6.2 Clutch A /110 /120 /190 /130
Page 160 and 161: Pull O-ring 71.160 on to ring 71.17
Page 162 and 163: Insert cup spring 72.110, press the
Page 165 and 166: 3.7 Oil supply and brake C and inst
Page 167 and 168: 99210 99211 99212 00/08/01 5 HP 19
Page 169 and 170: 99218 99219 99220 00/08/01 5 HP 19
Page 171 and 172: 3.8 Adding parts to flange shaft an
Page 173: 00037 99229 00038 00/08/01 5 HP 19
Page 176 and 177: Insert 5 sealing sleeves 01.270 int
Page 178 and 179: Attach oil filter 27.420 to the val
Page 180 and 181: 3.9.2 Installing position switch an
Page 182 and 183: Fasten converter retaining bracket
Page 184 and 185: subject to alterations © Copyright
Page 186 and 187: 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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