519FLA REPAIR MANUAL

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Take out the sun gear and the planetary gear set and the angle washer, needle roller cage and thrust washer. Remove the shaft with the ring gear, thrust washer, needle roller cage, angle washer and pot. 2.4.2 Removing the tower Release snap ring from transmission housing. Place lifter 5x46 000 545 in the planet wheel carrier of the tower and press the tensioner down in the centre to lock it into position. 2.4/2 CD 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken 99079 99080 99081 00/08/01
99082 99083 00/08/01 5 HP 19 FL © ZF Getriebe GmbH Saarbrücken CD Lift out the tower and insert it into mounting fixture 5x46 002 006. Remove angle washer, needle thrust bearing cage and angled washer. Note: The angle washer may adhere to the planet wheel carrier and be difficult to remove. 2.4/3
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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
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 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: 99076 99077 99078 00/08/01 5 HP 19
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
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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
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00098 00/08/01 5 HP 19 FLA © ZF Ge
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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
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99276 99277 98171 OBJECT Order-No.
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00057 00065 00066 OBJECT Order-No.
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00077 99281 99280 OBJECT Order-No.
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00081 00082 00083 OBJECT Order-No.
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98150 98155 99268 OBJECT Order-No.
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00090 00089 00/08/01 5 HP 19 FLA ©
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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
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6.2.2 Adding parts to transmission
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Secure the transfer box housing to
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519FLA REPAIR MANUAL

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