519FLA REPAIR MANUAL

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subject to alterations © Copyright 2000 all rights reserved and published by ZF Getriebe GmbH, Saarbrücken, Department MKTD No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose without the express written permission of ZF Getriebe GmbH, Saarbrücken Printed in Germany
Contents Page Preliminary information IX 4. General 4.1/1 4.1 Illustration of transmission 4.1/1 4.2 Power flow diagram 4.2/1 4.3 Specifications 4.3/1 4.3.1 Screw specifications 4.3/1 4.3.1.1 Transfer box housing 4.3/1 4.4 Adjusting work 4.4/1 4.4.0 Preparations for bearing adjustment (shim washers) 4.4/1 4.4.1 Bearing projection, front axle shaft 4.4/2 4.4.2 Bearing projection, helical/intermediate gear 4.4/3 4.4.3 Installation space, front axle shaft 4.4/4 4.4.4 Installation space, intermediate gear 4.4/4 4.4.5 Installation space, helical gear 4.4/5 4.4.6 Determining thickness of shim washers for front axle shaft, helical and intermediate gears 4.4/6 4.5 Tightening torques 4.5/1 4.7 Special tools 4.7/1 4.8 Functional checks 4.8/1 4.8.1 Checking backlash in Torsen II (angle) 4.8/1 5. Removal 5.1/1 5.1 Rear-axle output with Torsen II 5.1/1 5.2 Front-axle output 5.2/1 5.3 Removal work on transmission housing 5.3/1 Dismantling 5.4/1 5.4 Helical and intermediate gears and front axle shaft 5.4/1 5.4.1 Helical gear 5.4/1 5.4.2 Intermediate gear 5.4/1 5.4.3 Front axle shaft 5.4/1 5.5 Housing sections 5.5/1 5.5.1 Intermediate housing 5.5/1 5.5.2 Vibration damper 5.5/1 5.5.3 Dismantling transfer box housing 5.5/1 5.5.4 Removing both needle roller sleeves 5.5/3 5.6 Rear axle shaft and output gear 5.6/1 5.6.1 Rear axle shaft 5.6/1 5.6.2 Output gear 5.6/1 5.7 Dismantling Torsen II 5.7/1 00/08/01 5 HP 19 FLA © ZF Getriebe GmbH Saarbrücken CD VII
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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
Page 7:
Note: This manual treats the valve
Page 11:
1.2 Power flow diagram 1st GEAR Inp
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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
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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
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
Page 42 and 43:
1.4.5.2 Pinion projection Insert th
Page 44 and 45:
1.4.6 Bearing adjustment, output ge
Page 46 and 47:
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
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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.
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.
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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
Page 99:
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
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
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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
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Adjustment overview Note: During tr
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3.1.2 Front axle housing and front
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3.1.4 Installing pinion shaft in tr
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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 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 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 217 and 218: 00090 00089 00/08/01 5 HP 19 FLA ©
Page 219 and 220: 99243 99244 99003 00/08/01 5 HP 19
Page 221: 99005 99006 00/08/01 5 HP 19 FLA ©
Page 225: 99008 99009 99010 00/08/01 5 HP 19
Page 228 and 229: Using drift 5x46 002 277, force the
Page 231: 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
Page 246:
Secure the transfer box housing to
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