519FLA REPAIR MANUAL

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Preliminary information This manual covers the procedure for repairing the complete transmission. The repairing of this transmission is only allowed to persons with specific training from ZF Getriebe GmbH. The entire disassembly and assembly procedure is described in chronological order. The photographs were kept general in nature so that they can be used with various applications; they are not binding in every case. We use Service Bulletins and training courses to announce important information and application-specific changes that must be taken into consideration in maintenance work. If this repair manual is given to a third party, there will be no modification service. The Service Bulletins regulations and specifications must be followed when making repairs. Depending on the type of damage that has occured, the repair work can be limited to that which is necessary to repair the damage. In this case you must observe the following: • Seals (such as O-rings, shaft seals, gaskets, and filters) should always renewed. • All O-rings, rectangular-section rings, and other sealing rings must always be lubricated with petroleum jelly before installation. • All bearings must always be oiled lightly when installed. • For transmissions that have covered a large number of kilometers (> 80,000 km), all lined clutch discs and steel clutch discs should be replaced. • After clutches/ brakes have been damaged, the converter, oil tubes, and oil cooler, must be cleaned thoroughly with a suitable cleaning agent. • If brakes C or D has been damaged, or if a considerable distance has been covered (> 80,000 km), pistons C and D must be replaced. The following requirements should be met before the repair work is started: • The required special tools should be available. (The complete set of special tools is listed in Chapter 1.7) • A suitable transmission testing rig should be available. The required testing values can be found in the Service Bulletins. IV CD 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken 00/08/01
Note: This manual treats the valve body as a complete unit, which should not be disassembled without special knowledge; it should be exchanged as a complete unit. A separate repair manual is planned for the valve body. Important: The transmission is filled with long-life oil. The oil does not have to be changed until it has been in use for ten years. The transmission must only be delivered with the oil type and oil amount specified in the corresponding parts list documentation (see Part List). Technical Service Technical Documentation Training Center Bach Reus Schultz 00/08/01 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken CD V
Page 1 and 2: Versione00/08/01 CD REPAIR MANUAL 5
Page 3 and 4: Contents Page Preliminary informati
Page 5: 3. Installation 3.1/1 Adjustments 3
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 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 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
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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