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REPAIR MANUAL 5 HP 19 FL/A ZF GETRIEBE GMBH SAARBRÜCKEN Versione00/08/01 CD subject to alterations 2000 all rights reserved and published by ZF Getriebe GmbH, Saarbrücken, Department MKTD No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose without the express written permission of ZF Getriebe GmbH,Saarbrücken Printed in Germany Contents Page Preliminary information II 1. General 1.1/1 1.1 Illustration of transmission 1.1/1 1.2 Power flow diagram 1.2/1 1.3 Specifications 1.3/1 1.3.1 Screw specifications 1.3/1 1.3.1.1 Differential cover 1.3/1 1.3.1.2 Intermediate plate pump cylinder C 1.3/1 1.3.1.3 Yield limit tightening, differential 1.3/1 1.4 Adjusting work 1.4/1 1.4.0 Measuring the disc sets procedure 1.4/1 1.4.1 Clearances snap ring 1.4/3 1.4.1.1 Clearance, clutch F snap ring 1.4/3 1.4.1.2 Clearance, brake D snap ring 1.4/5 1.4.1.3 Clearance, brake G snap ring 1.4/7 1.4.1.4 Clearance, clutch E snap ring 1.4/9 1.4.1.5 Clearance, clutch A snap ring 1.4/11 1.4.1.6 Clearance, clutch B snap ring 1.4/13 1.4.1.7 Clearance, brake C snap ring 1.4/15 1.4.2 Preload, differential 1.4/17 1.4.3 Bevel gear drive 1.4/21 1.4.3.1 Position of pinion 1.4/21 1.4.3.2 Backlash / crown wheel position 1.4/23 1.4.4 Switch detent spring 1.4/26 1.4.5 Endplay, output washer 1.4/27 1.4.5.1 Installation space, output 1.4/27 1.4.5.2 Pinion projection 1.4/28 1.4.6 Output gear bearing adjustment 1.4/30 1.4.6.0 Preparation for bearing adjustment shim washers 1.4/30 1.4.6.1 Projection, pinion bearing 1.4/31 1.4.6.2 Projection, helical/intermediate gear bearing 1.4/32 1.4.6.3 Installation space, pinion 1.4/33 1.4.6.4 Installation space, intermediate gear 1.4/33 1.4.6.5 Installation space, helical gear 1.4/34 1.4.6.6 Determining shim thickness, pinion, helical and intermediate gears 1.4/35