5HP19FL-A Transmission Repair Manual



5HP19FL-A Transmission Repair Manual PDF

5HP19FL-A Transmission Repair Manual (Version 99/04/01).  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.

CONTENTS

  • General
  • 1.1 Illustration of transmission
  • 1.2 Power flow diagram
  • 1.3 Specifications
  • 1.3.1 Screw specifications
  • 1.3.1.1 Differential cover
  • 1.3.1.2 Intermediate plate-pump-cylinder C
  • Yield limit tightening, differential
  • 1.4 Adjusting work
  • 1.4.0 Measuring the disc sets (procedure)
  • 1.4.1 Clearances (snap ring)
  • 1.4.1.1 Clearance, clutch F (snap ring)
  • 1.4.1.2 Clearance, brake D (snap ring)
  • 1.4.1.3 Clearance, brake G (snap ring)
  • 1.4.1.4 Clearance, clutch E (snap ring)
  • 1.4.1.5 Clearance, clutch A (snap ring)
  • 1.4.1.6 Clearance, clutch B (snap ring)
  • 1.4.1.7 Clearance, brake C (snap ring)
  • 1.4.2 Preload, differential
  • 1.4.3 Bevel gear drive
  • 1.4.3.1 Position of pinion
  • 1.4.3.2 Backlash / crown wheel position
  • 1.4.4 Switch detent spring
  • 1.4.5 Endplay, output (washer)
  • 1.4.5.1 Installation space, output
  • 1.4.5.2 Pinion projection
  • 1.4.6 Output gear bearing adjustment
  • 1.4.6.0 Preparation for bearing adjustment (shim washers)
  • 1.4.6.1 Projection, pinion bearing
  • 1.4.6.2 Projection, helical/intermediate gear bearing
  • 1.4.6.3 Installation space, pinion
  • 1.4.6.4 Installation space, intermediate gear
  • 1.4.6.5 Installation space, helical gear
  • 1.4.6.6 Determining shim thickness, pinion, helical and intermediate gears
  • 1.4.7 Play at input (washer)
  • 1.5 Tightening torques
  • 1.6 Checking transmission (on test rig/in vehicle)
  • 1.7 Special tools
  • 1.8 Oil flow chart (Position N according to DIN)
  • Removal
  • 2.1 Removing converter, front axle output, valve body and position switch
  • 2.1.1 Removing converter
  • 2.1.2 Removing front axle output
  • 2.1.3 Removing valve body
  • 2.1.4 Removing position switch
  • 2.2 Removing flange shaft, front-axle differential and parking lock
  • 2.2.1 Removing flange shaft
  • 2.2.2 Removing differential
  • 2.2.3 Removing parking lock
  • 2.3 Removing oil supply
  • 2.4 Removing input with tower
  • 2.4.1 Removing input
  • 2.4.2 Dismantling tower
  • 2.5 Removing pinion shaft
  • Dismantling
  • 2.6 Removing bearing shells, bearings etc.
  • 2.6.1 Transmission housing
  • 2.6.2 Bearing race
  • 2.6.3 Front axle housing
  • 2.6.4 Differential cover
  • 2.6.5 Pinion shaft
  • 2.6.6 Intermediate and helical gears and pinion
  • 2.6.6.1 Intermediate gear
  • 2.6.6.2 Helical gear
  • 2.6.6.3 Pinion
  • 2.6.7 Differential (visual check)
  • 2.6.8 Flange shaft
  • 2.7 Tower
  • 2.7.1 Planetary gears
  • 2.7.2 Clutch F
  • 2.7.3 Brake D/G with 1st gear freewheel
  • 2.8 Input
  • 2.8.1 Clutch E
  • 2.8.2 Clutch A
  • 2.8.3 Clutch B
  • 2.9 Oil supply with brake C
  • 2.9.1 Brake C
  • 2.9.2 Pump
  • Installation
  • Adjustments
  • 3.1 Installing pinion shaft and differential
  • 3.1.1 Differential
  • 3.1.2 Pinion shaft
  • 3.1.3 Installing pinion shaft in transmission housing
  • 3.1.4 Installing differential in transmission housing
  • 3.1.5 Installing pinion-shaft sealing ring, parking lock gear and bearing race
  • 3.2 Installing shift and parking lock mechanism
  • 3.3 Adding parts to tower and installing
  • 3.3.1 Planetary gear set III
  • 3.3.2 Clutch F
  • 3.3.3 Brake DG with 1st gear freewheel
  • 3.3.4 Installing tower
  • 3.4 Adding parts to front-axle output and installing
  • 3.5 Installing planetary gear sets I and II
  • 3.6 Input and installing
  • 3.6.1 Clutch E
  • 3.6.2 Clutch A
  • 3.6.3 Clutch B
  • 3.6.4 Installing input
  • 3.7 Brake C oil supply and installing
  • 3.7.1 Oil supply
  • 3.7.2 Checking drag torque of pump (oiled)
  • 3.7.3 Brake C
  • 3.7.4 Installing oil supply and brake C
  • 3.8 Flange shaft and installing
  • 3.9 Installing valve body, oil filter and oil pan, position switch and converter
  • 3.9.1 Installing valve body, oil filter and oil pan
  • 3.9.2 Installing position switch and converter
  • 3.9.2.1 Installing and checking position switch
  • 3.9.2.2 Installing converter
  • 3.9.3 Installing breather cover and protective transit caps

Language: English
Format: PDF
Pages: 246
Size: 27.2 Mb
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