519FLA REPAIR MANUAL

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Identical Remarks 4 HP 18 FL Identical 5 HP 18 5 HP 19 Identical 5 HP 18 5 HP 19 1.7/8 Order-No. / Application OBJECT 5x46 000 530 Dismantling sleeve for double pinion-shaft bearing 5x46 000 545 Tower lifting fixture 5x46 000 576 Assembly bracket, taper,, thrust block brake C and DG CD 22 23 24 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken 99255 99245 98394 00/08/01
98395 91199 92223 OBJECT Order-No. / Application Remarks 25 26 27 5x46 000 577 - Rotation prevention device 5x46 000 763 -Workbench holder 5x46 001 007 - Locating pin for oil supply (2) Identical 5 HP 18 5 HP 19 Identical 4 HP 20 5 HP 18 5 HP 19 5 HP 24 5 HP 30 Identical 5 HP 19 5 HP 24 5 HP 30 00/08/01 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken CD 1.7/9
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 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 63: 99262 98002 99259 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
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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
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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
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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
Page 165 and 166:
3.7 Oil supply and brake C and inst
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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 209 and 210:
00057 00065 00066 OBJECT Order-No.
Page 211 and 212:
00077 99281 99280 OBJECT Order-No.
Page 213 and 214:
00081 00082 00083 OBJECT Order-No.
Page 215 and 216:
98150 98155 99268 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
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99005 99006 00/08/01 5 HP 19 FLA ©
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99008 99009 99010 00/08/01 5 HP 19
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Using drift 5x46 002 277, force the
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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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