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REPAIR MANUAL 5 HP 18 ZF GETRIEBE GMBH SAARBRÜCKEN Impressum Verantwortlich für den Inhalt Abteilung MKTD, ZFGetriebe GmbH, Saarbrücken Druck HAGERPAPPRINT GmbH, St. Ingbert Gedruckt in der BRD Published by ZF Getriebe GmbH, Saarbrücken, Department MKTD Printed in Germany by HAGERPAPPRINTGmbH, St. Ingbert. CONTENTS Page Preliminary information 1 1. General remarks 2 1.1 Drawing of transmission 2 1.2 Power flow schematic 3 1.3 Oil flow charts 4 1.4 Adjustment work 5/1 1.4.1 Release clearance at clutch F snap ring 5/1 1.4.2 Release clearance at brake G snap ring 5/2 1.4.3 Release clearance at brake D snap ring 5/3 1.4.4 Clearance at output side washer 5/4 1.4.5 Release clearance at clutch E snap ring 5/6 1.4.6 Release clearance at clutch A snap ring 5/7 1.4.7 Release clearance at brake C 1 snap ring 5/8 1.4.8 Transmission axiale clearance washer 5/9 1.4.9 Release clearance at brake C 2 two washers 5/11 1.5 Tightening torques 6 1.6 Troubleshooting faults,causes and remedies 7/1 1.7 Checking the transmission 8 1.8 Special tools 9 2. Dismantling 10 2.1 Dismantling according to assembly groups 10 2.2 Output side 16 2.3 Planetary gears,complete 18 2.3.1 Planetary gear set III 18 2.3.2 Clutch F 20 2.3.3 Brake DG with 1st gear freewheel 21 2.4 Input side 24 2.4.1 Clutch E 25 2.4.2 Clutch A 26 2.4.3 Clutch B and 3rd gear freewheel 27 2.4.4 Brake C 2 30 2.5 Oil supply unit with brake C 1 31 2.6 Housing with shift and parking pawl 32 3. Assembling according to assembly groups 35 3.1 Housing with shift and parking pawl 35 3.2 Planetary gear set,complete 39 3.2.1 Planetary gear set III 39 3.2.2 Clutch F 41 3.2.3 Brake DG with 1st gear freewheel 43 3.3 Output side 48 3.4 Planetary gear sets I and II 51 3.5 Input side 56 3.5.1 Clutch E 56 3.5.2 Clutch A 58 3.5.3 Clutch B and 3rd gear freewheel 61 3.5.4 Brake C 2 66 3.6 Oil supply unit with brake C 1 68 3.7 S