519FLA REPAIR MANUAL

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3.9 Installing valve body, oil filter and oil pan, position switch, converter 3.9.1 Installing valve body, oil filter and oil pan 03.010 03.070 03.080 03.120 01.270 03.130 01.280 01.300 01.310 27.410 27.420 03.100 03.020 03.040 /020 27.440 00/08/01 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken CD 27.340/116 01.130 01.120 01.140 27.340 27.400 27.390 27.360 27.350 3.9/1
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Versione00/08/01 CD REPAIR MANUAL 5
Page 3 and 4:
Contents Page Preliminary informati
Page 5 and 6:
3. Installation 3.1/1 Adjustments 3
Page 7:
Note: This manual treats the valve
Page 11:
1.2 Power flow diagram 1st GEAR Inp
Page 14 and 15:
1.3.1.3Tightening yield strength cr
Page 16 and 17:
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
Page 24 and 25:
Example (for 1.4.1.4): F = 1.48 mm
Page 26 and 27:
Example (for 1.4.1.5): F = 1.48 mm
Page 28 and 29:
Example (for 1.4.1.6): F = 1.48 mm
Page 30 and 31:
Example: (for 1.4.1.7) F = 1.48 mm
Page 32 and 33:
Tighten the differential cover with
Page 34 and 35:
Example: MD MU MO = 0.38 mm (preloa
Page 36 and 37:
Place the differential-side inner b
Page 38 and 39:
Screw the cover to the transmission
Page 40 and 41:
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
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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.
Page 63 and 64:
99262 98002 99259 OBJECT Order-No.
Page 65 and 66:
98395 91199 92223 OBJECT Order-No.
Page 67 and 68:
99264 00054 99256 OBJECT Order-No.
Page 69 and 70:
99257 99253 00063 OBJECT Order-No.
Page 71 and 72:
98399 98400 98401 OBJECT Order-No.
Page 73 and 74:
98405 98148 98406 OBJECT Order-No.
Page 75 and 76:
99246 00059 00060 OBJECT Order-No.
Page 77 and 78:
00065 00066 00067 OBJECT Order-No.
Page 79 and 80:
00071 99249 00061 OBJECT Order-No.
Page 81 and 82:
97305 98155 99271 OBJECT Order-No.
Page 83 and 84:
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
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Unscrew and remove the 17 large-hea
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Drive the clamping sleeve out of th
Page 94 and 95:
Remove the 12 differential cover sc
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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
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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
Page 111 and 112:
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
Page 117 and 118:
99121 99122 99123 2.8.2 Clutch A Ex
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99124 99126 99127 00/08/01 5 HP 19
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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 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 177 and 178: 99233 99234 00041 00/08/01 5 HP 19
Page 179 and 180: 99238 00/08/01 5 HP 19 FL © ZF Get
Page 181 and 182: 00043 00044 Check the switch resist
Page 183 and 184: Versione00/08/01 CD REPAIR MANUAL (
Page 185 and 186: Contents Page Preliminary informati
Page 187 and 188: Preliminary information The 5HP19FL
Page 189: 4. Allgemeines 4.1 Abbildung des Ge
Page 193: 00/08/01 5 HP 19 FLA © ZF Getriebe
Page 196 and 197: Place the support plate on the inte
Page 198 and 199: 4.4.3 Installation space - front ax
Page 200 and 201: 4.4.6 Determining shim thicknesses
Page 203: 1.5 Tightening torques No. Designat
Page 206 and 207: Remarks 4.7/2 Order-No. / Applicati
Page 208 and 209: Identical Remarks 4 HP 20 Identical
Page 214 and 215: Identical Remarks 3 HP 22 Q 4 HP 14
Page 216 and 217: Identical Remarks 4 HP 18 Q 4 HP 20
Page 218 and 219: Example: S PW = 0.2° M W = 1.75°
Page 220 and 221: Take out the 11 screws holding the
Page 223: 99007 99090 00/08/01 5 HP 19 FLA ©
Page 227 and 228:
99011 99012 00085 00/08/01 5 HP 19
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99016 99017 00/08/01 5 HP 19 FLA ©
Page 233 and 234:
00088 99020 00/08/01 5 HP 19 FLA ©
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6. Installation 99024 6.1 Torsen II
Page 237 and 238:
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
Page 243 and 244:
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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