ZF Transmission 5HP – 19 FL-A Repair Manual – PDF DOWNLOAD
FILE DETAILS:
ZF Transmission 5HP – 19 FL-A Repair Manual – PDF DOWNLOAD
Language : English
Pages : 246
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
ZF Transmission 5HP – 19 FL-A Repair Manual – PDF DOWNLOAD
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
TABLE OF CONTENTS:
ZF Transmission 5HP – 19 FL-A Repair Manual – PDF DOWNLOAD
Selection of language............................................................................................................................ 0 Repair manual.................................................................................................................................... 1 Contents..................................................................................................................................... 3 1. General............................................................................................................................... 9 1.1 Illustration of transmission..................................................................................................... 9 1.2 Power flow diagram............................................................................................................... 11 1.3 Specifications................................................................................................................... 13 1.3.1 Screw specifications....................................................................................................... 13 1.3.1.1 Differential cover................................................................................................... 13 1.3.1.2 Intermediate plate - pump-cylinder C................................................................................. 13 1.4 Making adjustments............................................................................................................... 15 1.4.0 Measuring the clutch packs (procedure)..................................................................................... 15 1.4.1 Clearances................................................................................................................. 17 1.4.1.1 Clearance, clutch F (snap ring)...................................................................................... 17 1.4.1.2 Adjusting Clearance of brake D (snap ring)........................................................................... 19 1.4.1.3 Adjusting Clearance of brake G (snap ring)........................................................................... 21 1.4.1.4 Adjusting Clearance of clutch E (snap ring).......................................................................... 23 1.4.1.5 Adjusting Clearance of clutch A (snap ring).......................................................................... 25 1.4.1.6 Adjusting Clearance of clutch B (snap ring).......................................................................... 27 1.4.1.7 Adjusting Clearance of brake C (snap ring)........................................................................... 29 1.4.2 Preload, differential...................................................................................................... 31 1.4.3 Bevel gear drive........................................................................................................... 35 1.4.3.1 Determining pinion position.......................................................................................... 35 1.4.3.2 Installed bearing height pinion shaft bearing....................................................................... 35 1.4.3.3 Determining backlash / crown wheel position......................................................................... 37 1.4.4 Detent spring switch....................................................................................................... 40 1.4.5 Output play (shim)......................................................................................................... 41 1.4.5.1 Output play (shim)................................................................................................... 41 1.4.5.2 Pinion projection................................................................................................... 42 1.4.6 Bearing adjustment , output gears.......................................................................................... 44 1.4.6.0 Preparation for bearing adjustment, shim washers.................................................................... 44 1.4.6.1 Projection, pinion bearing........................................................................................... 45 1.4.6.2 Projection, helical/intermediate gear bearing....................................................................... 46 1.4.6.3 Installation space, pinion.......................................................................................... 47 1.4.6.4 Installation space, intermediate gear................................................................................ 47 1.4.6.5 Installation space, helical gear.................................................................................... 48 1.4.6.6 Determining shim thickness – pinion, helical and intermediate gears................................................. 49 1.4.7 Play at input (washer).................................................................................................... 51 1.5 Tightening torques............................................................................................................... 53 1.6 Transmission test (test bench)................................................................................................... 55 1.7 Special tools.................................................................................................................... 57 1.8 Oilflow chart (position N according to DIN scheme)............................................................................... 85 2. Removal............................................................................................................................... 87 2.1 Removing converter, front axle output, valve body and position switch............................................................ 87 2.1.1 Removing converter......................................................................................................... 87 2.1.2 Removing front axle output................................................................................................. 88 2.1.3 Removing valve body........................................................................................................ 89 2.1.4 Removing the position switch............................................................................................... 91 2.2 Removing flange shaft, front-axle differential and parking lock.................................................................. 93 2.2.1 Removing flange shaft...................................................................................................... 93 2.2.2 Removing the differential ................................................................................................. 93 2.2.3 Removing the parking lock.................................................................................................. 94 2.3 Removing oil supply............................................................................................................. 95 2.4 Removing input with tower....................................................................................................... 97 2.4.1 Removing input............................................................................................................. 97 2.4.2 Removing the tower......................................................................................................... 98 2.5 Removing pinion shaft............................................................................................................101 2.6 Removing bearing sheels, bearings etc............................................................................................103 2.6.1 Transmisssion housing......................................................................................................103 2.6.2 Bearing race..............................................................................................................103 2.6.3 Front axle housing.........................................................................................................104 2.6.4 Differential cover.........................................................................................................104 2.6.5 Pinion shaft...............................................................................................................104 2.6.6 Intermediate and helical gears and pinion..................................................................................105 2.6.6.1 Intermediate gear....................................................................................................105 2.6.6.2 Helical gear.........................................................................................................105 2.6.6.3 Pinion...............................................................................................................106 2.6.7 Differential (visual check)................................................................................................106 2.6.8 Flange shaft...............................................................................................................107 2.7 Tower............................................................................................................................109 2.7.1 Planetary gears............................................................................................................109 2.7.2 Clutch F...................................................................................................................111 2.7.3 Brake D/G with 1st gear freewheel..........................................................................................112 2.8 Input............................................................................................................................115 2.8.1 Clutch E...................................................................................................................116 2.8.2 Clutch A...................................................................................................................117 2.8.3 Dismantling clutch B.......................................................................................................118 2.9 Oil supply with brake C..........................................................................................................119 2.9.1 Brake C....................................................................................................................119 2.9.2 Pump.......................................................................................................................120 3. Installation..........................................................................................................................123 3.1 Installing pinion shaft and differential.........................................................................................125 3.1.1 Adding parts to differential...............................................................................................125 3.1.2 Front axle housing and front axle gears....................................................................................126 3.1.3 Pinion shaft...............................................................................................................126 3.1.4 Installing pinion shaft in trans - mission housing.........................................................................128 3.1.5 Installing differential in trans - mission housing.........................................................................128 3.1.6 Installing pinion-shaft sealing ring, parking lock gearwhee and bearing race...............................................130 3.2 Installing shift and parking lock mechanism......................................................................................134 3.3 Tower, installing tower..........................................................................................................137 3.3.1 Planetary gear set III....................................................................................................137 3.3.2 Clutch F...................................................................................................................139 3.3.3 Brake DG with 1st gear freewheel...........................................................................................141 3.3.4 Installing the tower.......................................................................................................145 3.4 Installing front axle output.....................................................................................................147 3.5 Planetary gear sets I and II.....................................................................................................149 3.6 Input and installing.............................................................................................................155 3.6.1 Clutch E...................................................................................................................155 3.6.2 Clutch A ..................................................................................................................158 3.6.3 Clutch B ..................................................................................................................161 3.6.4 Installing the input.......................................................................................................163 3.7 Oil supply and brake C and installing............................................................................................165 3.7.1 Oil supply.................................................................................................................166 3.7.2 Checking drag torque of pump (oiled).......................................................................................167 3.7.3 Brake C ...................................................................................................................168 3.7.4 Installing oil supply and brake C.........................................................................................169 3.8 Adding parts to flange shaft and installing......................................................................................171 3.9 Installing valve body, oil filter and oil pan, position switch, converter........................................................175 3.9.1 Installing valve body, oil filter and oil pan..............................................................................175 3.9.2 Installing position switch and converter...................................................................................180 3.9.2.1 Installing and checking position switch..............................................................................180 3.9.2.2 Installing the converter.............................................................................................181 3.9.3 Installing breather cover and protective transit caps......................................................................182 Repair manual 5 HP 19 FLA (Supplement).......................................................................................................183 Contents.....................................................................................................................................185 4.General................................................................................................................................189 4.1 Illustration of the transmission.................................................................................................189 4.2 Power flow diagram...............................................................................................................191 4.3 Specifications...................................................................................................................193 4.3.1 Screw connection specifications............................................................................................193 4.3.1.1 Zwischengehäuse......................................................................................................193 4.3.1.1 Transfer box housing.....................................................................................................193 4.4 Output shaft bearing adjustment..................................................................................................195 4.4.0 Preparations for bearing adjustment (shim washers).........................................................................195 4.4.1 Front axle shaft bearing projection.......................................................................................196 4.4.2 Projection at helical/intermediate gear bearings...........................................................................197 4.4.3 Installation space - front axle shaft......................................................................................198 4.4.4 Installation space, intermediate gear......................................................................................198 4.4.5 Installation space, helical gear..........................................................................................199 4.4.6 Determining shim thicknesses for front axle shaft and helical and intermediate gears.......................................200 4.5 Tightening torques...............................................................................................................203 4.7 Special tools....................................................................................................................205 4.8 Functional check.................................................................................................................217 4.8.1 Checking backlash, Torsen II (angle).......................................................................................217 5. Removal...............................................................................................................................219 5.1 Rear axle output with Torsen II..................................................................................................219 5.2 Front axle output................................................................................................................221 5.3 Removing parts from transmission housing.........................................................................................223 5.4 Dismantling Helical / intermediate gears and front axle shaft....................................................................225 5.4.1 Helical gear...............................................................................................................225 5.4.2 Intermediate gear..........................................................................................................225 5.4.3 Front axle shaft...........................................................................................................225 5.5 Housing sections.................................................................................................................227 5.5.1 Intermediate housing.......................................................................................................227 5.5.2 Vibration damper...........................................................................................................227 5.5.3 Transfer box housing.......................................................................................................227 5.5.4 Removing both needle roller sleeves........................................................................................229 5.6 Rear axle shaft and output gear..................................................................................................231 5.6.1 Rear axle shaft............................................................................................................231 5.6.2 Output gear................................................................................................................231 5.7 Dismantling Torsen II unit.......................................................................................................233 6. Installation..........................................................................................................................235 6.1 Torsen II .......................................................................................................................235 6.2 Transmission housing and intermediate housing....................................................................................239 6.2.1 Adding certain parts to intermediate housing measuring projections at helical and intermediate gears and front axle sha....239 6.2.1.1 Output gear..........................................................................................................240 6.2.1.2 Rear axle shaft.....................................................................................................240 6.2.1.3 Vibration damper.....................................................................................................240 6.2.1.4 Transfer box housing.................................................................................................241 6.2.1.5 Intermediate and helical gear........................................................................................243 6.2.1.6 Front axle shaft.....................................................................................................243 6.2.1.7 Adding remaining parts to intermediate housing.......................................................................243 6.2.2 Adding parts to transmission housing.......................................................................................244 6.2.2.1 Inserting helical and intermediate gears and front axle shaft.......................................................244 6.2.2.2 Installing intermediate housing on transmission housing.............................................................245 6.2.2.3 Installing Torsen II................................................................................................245 6.2.2.4 Installing transfer box housing on intermediate housing.............................................................245 6.2.2.5 Inserting oil drain and filler plugs................................................................................246
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V