Zf 5hp19

Posted on by



1) Use only ZF-LifeguardFluid5 or OEM approved transmission fluid. 2) If the transmission temperature rises above 50°C during the fluid level checking procedure the resulting oil level will be to low. ZF parts for automatic transmissions, ZF transmissions, ZF parts. Home; Contact Us; 4 Business; FAQ; Login / Register; My Cart: 0 item(s) / $0.00 Trans Fluid. 5 Speed; 6 Speed; 8 Speed; Oil change kits. Home 5 Speed Parts 5HP19. 26 item(s) - Page 1 of 2 Cylinder D/G 5HP18 - 5HP18A - 5HP19. Click for more information. Master rebuild box kit for the ZF-5HP19 5 speed automatic transmission. Transmission make: Audi, BMW, Porsche, and Volkswagen. Transmission model: ZF-5HP19, 01V, 5HP19FL, 5HP19FLA, 5HP19FLE. Year range: 1995-2008. This master overhaul transmission kit comes with the following rebuild parts: Full overhaul gasket set; Friction clutch plates. ZF 5HP19 HL (PORSCHE) Code: 1060 050 xxx 5 SPEED FWD (Full Electronic Control) SPRINGS & CIRCLIPS Cont 431B Circlip - 'B' Clutch Retaining (1.60mm) AR 5HP19.CIR11 431B Circlip - 'B' Clutch Retaining (1.40mm) AR 5HP19.CIR12 431B Circlip - 'B' Clutch Retaining (1.20mm) AR 5HP19.CIR13 431B Circlip - 'B' Clutch Retaining (1.00mm) AR 5HP19.CIR14.

Frequently asked questions
  • A) Transmissions fluid level checking.
    • 1) The transmission fluid temperature must be between 30°C and 35°C before checking can begin.Use test equipment to determine the trans temperature.
    2) The vehicle must be level with engine running at idle speed and air conditioning turned on.
    3) Step on the brakes firmly, apply parking brake fully and shift to D and R, briefly pausing in each position before shifting back to the Park position.
    4) With the engine running at idle speed and the selector in Park position, remove the filler plug. Monitor the transmission temperature, if a small stream of oil runs out at 40°C, the fluid level is correct.
    5) If no oil runs out when the filler plug is removed, the fluid level is too low and oil needs to be added until it overflows.
    6) With engine running, install the oil filler plug and tighten to proper torque.
  • B) Adding fluid after repairs.
    • 1) With the engine stopped and the transmission in Park position, remove the oil filler plug. Add transmission fluid until a small stream of oil runs out.
    2) Insert the filler plug and tighten by hand. Start the engine.
    3) With the engine running, remove the oil filler plug and add transmission fluid until a small stream of oil runs out. Insert the filler plug and tighten by hand.
    4) Follow the “Transmission fluid level checking” procedure described in section A) above.
  • C) Notes on fluid level and adding procedure.
    • 1) Use only ZF-LifeguardFluid5 or OEM approved transmission fluid.
    2) If the transmission temperature rises above 50°C during the fluid level checking procedure the resulting oil level will be to low. Let the transmission cool down and repeat the fluid level procedure.
    3) Have transmission fluid and a suitable oil pump available before starting the fluid level procedure. The transmission fluid temperature will rise quickly during the checking procedure.
  • D) Drain and filler plug location.

ZF 5HP19 FL/A Transmission Repair Manual PDF. 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.

Zf 5hp19 parts catalog5hp19

Zf 5hp19 Valve Body

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.

The following requirements should be met before the repair work is started:

Zf 5hp19 Transmission For Sale

  • The required special tools should be available.
    (The complete set of special tools is listed in Chapter 1.7)
  • A suitable transmission testing rig should be available.
    The required testing values can be found in the Service Bulletins…

CONTENTS

  • Preliminary information
  • 1. 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
        • 1.3.1.3 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
  • 3. 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

Zf 5hp19 Diagram

Language: English
Format: PDF
Pages: 246