519FLA REPAIR MANUAL

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00/08/01 5 HP 19 FLA © ZF Getriebe GmbH Saarbrücken CD 4.3 Specifications 4.3.1 Screw connection specifications 4.3.1.1 Transfer box housing Tighten the screws initially in the following order. 7 ➮ 12 Then finally tighten the screws in numerical order (see diagram) 1 ➮ 2 ➮ 3 ➮ ... ➮ 17 Important: The numbers indicate the actual order of final tightening. (Simplification of specification 1060 700 133) (Tightening torques: see Chapter 4.5) When adjusting the output gear bearings, omit the screws with the numbers 4, 5, 6. 4.3/1
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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.
Page 71 and 72:
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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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
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3.2 Installing shift and parking lo
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99161 00027 99164 00/08/01 5 HP 19
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3.3 Tower, installing tower 3.3.1 P
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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 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 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
Page 229: 99016 99017 00/08/01 5 HP 19 FLA ©
Page 233 and 234: 00088 99020 00/08/01 5 HP 19 FLA ©
Page 235 and 236: 6. Installation 99024 6.1 Torsen II
Page 237 and 238: 99029 99030 99028 00/08/01 5 HP 19
Page 239 and 240: 6.2 Transmission housing and interm
Page 241 and 242: 00093 99033 99034 00/08/01 5 HP 19
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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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