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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
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2.6.6.3 Pinion Using puller 5x46 50
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99105 99106 99107 2.7 Tower 00/08/0
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99109 99110 98409 2.7.2 Clutch F 00
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99114 99115 99116 00/08/01 5 HP 19
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99118 99119 99120 2.8 Input 00/08/0
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- 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
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- 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
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- 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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- 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
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- Page 171 and 172: 3.8 Adding parts to flange shaft an
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- 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
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- 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
- Page 207 and 208: 99276 99277 98171 OBJECT Order-No.
- Page 209 and 210: 00057 00065 00066 OBJECT Order-No.
- Page 211 and 212: 00077 99281 99280 OBJECT Order-No.
- Page 213 and 214: 00081 00082 00083 OBJECT Order-No.
- Page 215 and 216: 98150 98155 99268 OBJECT Order-No.
- Page 217 and 218: 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