519FLA REPAIR MANUAL

More documents

Recommendations

Info

Install vibration damper 36.230 on the transfer box housing using 4 screws 36.250. (Tightening torques: see Chapter 1.5) Press the journal of nut 36.190 into the output gear, using a suitable drift in the mandrel press. Important: Do not tilt the nut or this will cause problems with the expansion bolt. Push flange 36.260 into the output gear and secure with expansion bolt 36.270, but without tightening the bolt fully as yet. Important: The expansion bolt is tightened fully later. 6.2/4 CD 5 HP 19 FLA © ZF Getriebe GmbH Saarbrücken 99035 99036 99037 00/08/01
00005 99040 99042 00/08/01 5 HP 19 FLA © ZF Getriebe GmbH Saarbrücken CD 6.2.1.5 Intermediate and helical gear Using sleeve 5x46 002 219, press in roller bearings 37.130/120 and 37.130/130 on intermediate gear, using sleeve 5x46 002 218, press in roller bearings 37.150/120 and 37.150/130 on helical gear. 6.2.1.6 Front axle shaft Using sleeves 5x46 002 218 and 5x46 002 257 press on roller bearings 37.080/130 and 37.080/140 in the mandrel press. Using fixture 5x46 001 332 in the mandrel press, force shaft sealing ring 37.080/120 fully in. Important: For adjusting work, see Chapter 4.4 6.2.1.7 Adding remaining parts to intermediate housing Using fixture 5x46 002 282 in the mandrel press, force shaft sealing ring 37.240 in fully. Bushing 37.020, 2 cylindrical pins 37.310 and breather 90.480 must already be in the housing. The same conditions apply to the breather as for the one in the main transmission housing. The bushing must be pressed in to 10 ± 0.5 mm. 6.2/5
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
Page 48 and 49:
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
Page 57 and 58:
1.7 Special tools 98008 98034 00045
Page 59 and 60:
00108 00053 97301 OBJECT Order-No.
Page 61 and 62:
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.
Page 85:
1.8 Oilflow chart (position N accor
Page 88 and 89:
2.1.2 Removing front axle output Ta
Page 90 and 91:
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
Page 97 and 98:
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
Page 104 and 105:
2.6.3 Front axle housing Pull the b
Page 106 and 107:
2.6.6.3 Pinion Using puller 5x46 50
Page 109 and 110:
99105 99106 99107 2.7 Tower 00/08/0
Page 111 and 112:
99109 99110 98409 2.7.2 Clutch F 00
Page 113 and 114:
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
Page 119 and 120:
99124 99126 99127 00/08/01 5 HP 19
Page 121:
99131 98270 99133 00/08/01 5 HP 19
Page 124 and 125:
Adjustment overview Note: During tr
Page 126 and 127:
3.1.2 Front axle housing and front
Page 128 and 129:
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
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 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 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 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 244 and 245: 6.2.2 Adding parts to transmission
Page 246: Secure the transfer box housing to
show all

519FLA REPAIR MANUAL

Create successful ePaper yourself

Delete template?

Save as template?