519FLA REPAIR MANUAL

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Place cup spring 71.080 on piston E with the edge facing up. Pull a new O-ring seal 71.086 on to oil dam 71.084 and insert into piston E. Take the shaft out of the fixture. Press the oil dam down with assembly bracket 5x46 030 167 in the mandrel press and install non-ground circlip 71.090, using suitable pliers. Mount the shaft in the fixture again. Insert the complete disc set for clutch E, starting with spring disc 71.094. Follow this disc with steel disc 71.100 and lined disc 71.110 alternately. Install end disc 71.120 and secure it with snap ring 71.130. Important: Adjusting work: see Chapter 1.4.1.4 3.6/2 CD 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken 98333 98334 98337 00/08/01
98338 00/08/01 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken CD Take the shaft out of the fixture. Install two new rectangular-section rings 71.020 and 71.030 and a new O-ring 71.150 on the input shaft. 3.6/3
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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.
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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
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2.1.2 Removing front axle output Ta
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Unscrew and remove the 17 large-hea
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Drive the clamping sleeve out of th
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Remove the 12 differential cover sc
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99076 99077 99078 00/08/01 5 HP 19
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99082 99083 00/08/01 5 HP 19 FL ©
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Use pliers 5x46 001 376 to remove t
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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
Page 153: 99197 00/08/01 5 HP 19 FL © ZF Get
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
Page 188 and 189: Warning: The transmission, differen
Page 191: 4.2 Power flow diagram 2nd GEAR 4th
Page 195 and 196: 99038 99039 00094 00/08/01 5 HP 19
Page 197 and 198: 00098 00/08/01 5 HP 19 FLA © ZF Ge
Page 199 and 200: 00015 00016 00/08/01 5 HP 19 FLA ©
Page 201: Example: (for 4.4) Front axle shaft
Page 205 and 206: 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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