519FLA REPAIR MANUAL

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Place the cover with the larger needle roller sleeve on the workbench with the outside facing down. Place a narrow thrust washer around the cover bore. Place the front sun gear on the thrust washer and guide it into the bore in the cover. Place a broad thrust washer on the sun gear. Place the three pairs of planet gears on the running marks in the cover as indicated by their markings and engage them with the sun gear. When looking clockwise, the first planet gear of each pair has the tooth gap at the top. Mesh the planet gears together and with the front sun gear. Important: Looking outwards from the longitudinal axis of the Torsen II unit and towards the pairs of planet gears, their teeth taper towards the top in a manner similar to the appearance of a fir tree. Place the housing over the planet gears in accordings with the markings and position the front sun gear on the cover. Note: To check whether the cover and housing are accurately located, insert screws from the top through the housing into the cover. (They must screw in easily by hand.) 6.1/2 CD 5 HP 19 FLA © ZF Getriebe GmbH Saarbrücken 99025 99026 99027 00/08/01
99029 99030 99028 00/08/01 5 HP 19 FLA © ZF Getriebe GmbH Saarbrücken CD Move the housing up evenly until it is in contact with the cover, and press it in with light blows of a plastic-faced hammer. Take out the screws. Turn the planet gear several times. Insert a wide thrust washer into the housing. Install the rear sun gear. Note: This is rather difficult the first time and calls for skilled manipulation with the fingers. Is then easier. Looking clockwise, pull the 2 front planet gears (those with the tooth gap at the top) upwards out of the housing by about 40 mm. Engage the sun gear teeth in the planet gear tooth gaps. Tilt the sun gear upwards, away from the third pair of planet gears. Pull the third planet gear (with the tooth gap at the top) out of the housing. Tilt the sun gear back so that the sun gear teeth mesh with the teeth gaps in the planet gears. Guide the sun gear with planet gears slowly downwards. 6.1/3
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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.
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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
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99172 /200 /190 /110 /180 /170 73.1
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99173 99174 99176 00/08/01 5 HP 19
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00031 99180 99181 00/08/01 5 HP 19
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3.4 Installing front axle output 99
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3.5 Planetary gear sets I and II 99
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99191 99192 99193 Insert thrust was
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99197 00/08/01 5 HP 19 FL © ZF Get
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Place cup spring 71.080 on piston E
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3.6.2 Clutch A /110 /120 /190 /130
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Pull O-ring 71.160 on to ring 71.17
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Insert cup spring 72.110, press the
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3.7 Oil supply and brake C and inst
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99210 99211 99212 00/08/01 5 HP 19
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99218 99219 99220 00/08/01 5 HP 19
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3.8 Adding parts to flange shaft an
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00037 99229 00038 00/08/01 5 HP 19
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Insert 5 sealing sleeves 01.270 int
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Attach oil filter 27.420 to the val
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3.9.2 Installing position switch an
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Fasten converter retaining bracket
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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 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 ©
Page 234 and 235: Take off the thrust washer. Raise t
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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