519FLA REPAIR MANUAL

Preliminary information
The 5HP19FLA repair manual is largely based on the 5HP19FL repair manual, and is identical as
far as the end of the automatic section
End of transmission housing including adjustment of bevel gear drive and input and output
endplay
For this reason, these sections of the repair manual are not repeated here and only a supplement is
provided for repairs to the four-wheel-drive section of the transmission, together with the corresponding
changes to the compoent transmission. It contains:
Supplement - changes compared with 5 HP 19 FL
Drive to front and rear wheels with Torsen II
Repairs to this section of the transmission must only be carried out by personnel that has received
training from ZF Getriebe GmbH.
All removal and assembly work is shown in chronological order. The supplement pages and the
differences compared with the 5 HP 19 FL shouldbe included in the 5 HP 19 FL repair manual at
the points were the output to the front axle is dealt with.
The photographs are general in nature so that they relate to various installations, and are therefore
not always applicable in all details.
Important amendments or modifications for specific applications that have to be taken into
account during repair work are issued in the form of Technical Bulletins or described during training
courses. There is no update service for this manual if it is passed on to third parties.
During all repair work the directives and information in the Technical Bulletins must be complied
with.
Depending on the fault or damage that has occurred, the repair can be restricted to the work
needed to eliminate it.
Please note:
• Seals such as O-rings, shaft sealing rings, gaskets and filters must never be re-used.
• All O-rings, rectangular-section rings and other sealing rings must be coated with
Vaseline before installing.
• All bearings should be lightly oiled before installing.
The following preconditions should be satisfied before repair work starts:
• The necessary special tools should be available.
The complete set of special tools is listed in Chapter 4.7.
• A suitable transmission test rig should be available.
Please refer to the Technical Bulletins for the relevant test values.
00/08/01 5 HP 19 FLA © ZF Getriebe GmbH Saarbrücken CD
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