519FLA REPAIR MANUAL

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Remarks 4.7/2 Order-No. / Application OBJECT 5p95 002 092 Spacing ring support, intermediate housing 5x46 001 327 Drift, vibration damper shaft sealing ring 5x46 001 332 Assembly fixture, front axle shaft sealing ring CD 5 HP 19 FLA © ZF Getriebe GmbH Saarbrücken 4 5 6 99279 99282 99278 00/08/01
99276 99277 98171 OBJECT Order-No. / Application Remarks 7 8 9 5x46 001 339 Mounting sleeve, front axle shaft sealing ring 5x46 001 535 Mounting sleeve, intermediate housing shaft sealing ring 5x46 001 955 Core insert, intermediate gear Identical 4 HP 20 5 HP 19 FL 00/08/01 5 HP 19 FLA © ZF Getriebe GmbH Saarbrücken CD 4.7/3
Page 1 and 2:
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
Page 18 and 19:
Example (for 1.4.1.1): F = 1.48 mm
Page 20 and 21:
Example (for 1.4.1.2): F = 1.48 mm
Page 22 and 23:
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
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
Page 50 and 51:
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
Page 59 and 60:
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
Page 92 and 93:
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
Page 115 and 116:
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
Page 121:
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
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
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98287 00/08/01 /110 /130 /140 /120
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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
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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 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: 4.7 Special tools 00053 99265 00073
Page 209 and 210: 00057 00065 00066 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 ©
Page 234 and 235: Take off the thrust washer. Raise t
Page 236 and 237: Place the cover with the larger nee
Page 238 and 239: By turning the sun gear in either d
Page 240 and 241: 6.2.1.1 Output gear Using sleeve 5x
Page 242 and 243: Install vibration damper 36.230 on
Page 244 and 245: 6.2.2 Adding parts to transmission
Page 246: Secure the transfer box housing to
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519FLA REPAIR MANUAL

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