519FLA REPAIR MANUAL

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Remarks 1.7/18 Order-No. / Application OBJECT 5x46 002 156 Wedge, brake C 5x46 002 159 Core insert, roller bearing inner race, differential cover end 5x46 002 164 Output sleeve (sun wheel) CD 52 53 54 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken 99247 00055 00056 00/08/01
99246 00059 00060 OBJECT Order-No. / Application Remarks 55 56 57 5x46 002 165 Gearbox mounting bracket 5x46 002 166 2 converter pull-out handles 5x46 002 167 Differential locking fixture 00/08/01 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken CD 1.7/19
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
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Note: This manual treats the valve
Page 11:
1.2 Power flow diagram 1st GEAR Inp
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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
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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
Page 24 and 25: Example (for 1.4.1.4): 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 73: 98405 98148 98406 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
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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
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6. Installation 6.1/1 6.1 Torsen II
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Warning: The transmission, differen
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4.2 Power flow diagram 2nd GEAR 4th
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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 ©
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Example: (for 4.4) Front axle shaft
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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 ©
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Take off the thrust washer. Raise t
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Place the cover with the larger nee
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By turning the sun gear in either d
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6.2.1.1 Output gear Using sleeve 5x
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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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