Repair Manual

REPAIR-MANUAL
5 HP - 19
ZF GETRIEBE GMBH SAARBRÜCKEN

Version 99/04/15
Subject to alterations
© Copyright 1998, all rights reserved. Published by

ZF Getriebe GmbH, Saarbrücken, Department MKTD
No part of this manual may be repoduced 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 information 1.1/1

1.1 Picture of the transmission 1.1/1
1.2 Power flow diagram 1.2/1
1.3 Specifications 1.3/1
1.3.1 Screw torque specifications 1.3/1
1.3.1.1 Pump 1.3/1
1.3.1.2 Cylinder DG 1.3/1
1.4 Making adjustments 1.4/1
1.4.0 Preparing the clearance measurement tool 1.4/1
1.4.1 Adjusting clearance of brake F (snap ring) 1.4/3
1.4.2 Adjusting clearance of brake D (snap ring) 1.4/5
1.4.3 Adjusting clearance of brake G (snap ring) 1.4/7
1.4.4 Adjusting clearance of brake E (snap ring) 1.4/9
1.4.5 Adjusting clearance of clutch A (snap ring) 1.4/11
1.4.6 Adjusting clearance of clutch B (snap ring) 1.4/13
1.4.7 Adjusting clearance of brake C (snap ring) 1.4/15
1.4.8 Output play (shim) 1.4.17
1.4.9 Input play (shim) 1.4.19
1.4.10 Adjusting the switch (detent spring) 1.4.21
1.5 Tightening torques 1.5/1
1.6 Transmission test (test bench/vehicle) 1.6/1
1.7 Special tools 1.7/1
2. Removing assemblies 2.1/1

2.1 Removing the converter, oil pan and automatic control unit 2.1/1
2.2 Removing the oil supply 2.2/1
2.3 Removing the input assembly 2.3/1
2.4 Removing the tower 2.4/1
2.5 Removing the output assembly 2.5/1
Disassembly
2.6 Output assembly 2.6/1
2.7 Tower 2.7/1
2.7.1 Planetary drive 2.7/1
2.7.2 Clutch F 2.7/4
2.7.3 Brake D/G 2.7/5
2.8 Input assembly 2.8/1
2.8.1 Clutch E 2.8/2
2.8.2 Clutch A 2.8/3
2.8.3 Clutch B 2.8/4
2.9 Oil supply with brake C 2.9/1
2.9.1 Brake C 2.9/1
2.9.2 Pump 2.9/2
99/04/15 5 HP 19 © ZF Getriebe GmbH Saarbrücken CD I

3. Assembly 3.1/1
3.1 Housing with selector mechanism and parking lock 3.1/1
3.2 Tower 3.2/1
3.2.1 Planetary drive 3.2/1
3.2.2 Clutch F 3.2/4
3.2.3 Brake DG with freewheel, 1st gear 3.2/6
3.3 Output assembly 3.3/1
3.4 Planetary drives I and II 3.4/1
3.5 Input assembly (with clutches A and B) 3.5/1
3.5.1 Clutch E (input) 3.5/1
3.5.2 Clutch A (input) 3.5/4
3.5.3 Clutch B (input) 3.5/7
3.6 Oil supply with brake C 3.6/1
3.7 Input assembly with oil supply 3.7/1
3.8 Automatic control unit, flow control valve, oil filter and oil pan 3.8/1
3.9 Position switch and converter 3.9/1
II CD 5 HP 19 © ZF Getriebe GmbH Saarbrücken 99/04/15

Preliminary information
This manual covers the procedure for repairing the complete transmission.
Repairs to this transmission must be carried out by persons trained by ZF Getriebe GmbH.
All disassembly and re-assembly work should be carried out in the order described.
The photographs apply to various versions and have therefore been kept general. They are not bin-
ding in every case.
Important changes that are specific to particular applications and need to be taken into account
when carrying out repair work are announced in Service Bulletins and training courses.
If this repair manual is given to a third party, it will not be covered by our alteration service.
The instructions and specifications given in the Service Bulletins must be followed when carrying
out repairs.
Depending on the damage that has occurred, it may be possible to limit repair work to this dama-
ge.
The following points should be noted:
• Seals, e.g. O-rings, shaft seals, gaskets and filters, should always be renewed.
• All O-rings, rectangular-section rings and other sealing rings should be smeared with
white petroleum jelly before being fitted.
• All bearings must be fitted in a lightly oiled condition.
• All lined clutch discs and steel discs on high-mileage transmissions ( > 80,000 km) must
be replaced.
• Following damage to clutches/brakes, the converter, oil tubes and oil cooler must be
thoroughly and adequately cleaned with a suitable cleaning agent.
Before carrying out repair work, make sure that:
• All special tools required are readily available.

The complete set of special tools is listed in Chapter 1.8.
• A suitable transmission test bench is available.
See Service Bulletins for the required test values.
99/04/15 5 HP 19 © ZF Getriebe GmbH Saarbrücken CD III

Please note:
In this manual, the automatic control unit is treated as a complete unit. It should not be disassem-
bled except by a specialist. It should be exchanged as a complete unit.
A separate manual is planned for the automatic control unit.
Important:
The transmission is filled with a long-life oil.
The oil does not have to be changed until it has been in use for 10 years.
The transmission must be delivered with the volume and type of oil specified in the relevant parts
list documentation (see ELCAT).
Otherwise, the transmission may fail.
Techn. After Sales Service Techn. Documentation After Sales Service School
Bach Reus Schultz
IV CD 5 HP 19 © ZF Getriebe GmbH Saarbrücken 99/04/15

1. General information
1.1 Picture of the transmission
99/04/15 5 HP 19 © ZF Getriebe GmbH Saarbrücken CD 1.1/1

1.2 Power flow diagram
1. Gear
2. Gear
3. Gear
4. Gear
5. Gear
Reverse Gear

1.3 Specifications
1.3.1 Screw torque specifications
1.3.1.1 Pump
10 3 According to specification 1056 700 300
screw the pump in the following order:
8 (see diagram)
15 11 5
1 13 1 ➮ 2 ➮ 3 ➮ ... ➮ 15
14
2 7
6
12
4
9 Attention!
Tighten screw 1 with 6 Nm, all others
with 10 Nm!
1.3.1.2 Cylinder DG
Screw in 3 machine screws 73.200 by

about 2 turns.
Initially, tighten the central screw at 30

Nm and the two outer ones at 15 Nm.
Now tighten the central screw at 63 Nm

and the two outer ones at 30 Nm.
Finally, tighten the two outer screws at

63 Nm.
98308

1.4 Making adjustments
1.4.0 Measuring the clutch pack
(procedure)
Place the two intermediate pieces

5p01 000 329 at the marked positions on
measuring fixture 5p01 000 330.
98009
Use knurled screw to turn adjusting de-

vice 5p01 001 458 to upper limit posi-
tion.
Attach force-measuring unit 5p01 000
329 to adjusting device 5p01 001 458.
98011
Fasten adjusting device with 4 knurled

screws to the measuring fixture using the
intermediate pieces.
Connect measuring plate 5p01 040 330
to force-measuring unit using fixing pin.
Use knurled screw to clamp the clutch

pack to be measured (with corrugated
steel clutch disc – if present – at the bot-
tom) in device at 200 N.
98012

Check the value on the force-measuring
unit.
98017
Then put measuring bar 5p01 060 330 on

the measuring plate, insert the measuring
base of the dial gauge into the groove of
the measuring plate on the top disc of the
pack and set the dial gauge to zero.
98018
Now measure down to the base plate

using the measuring bar.
Read off the measurement value ➮ MX
Note!
In each case, index X in MX stands for
the disc pack that was put in for the
clutches/brakes (A, B, C, D, E, F, G)
1.4/2 CD 5 HP 19 © ZF Getriebe GmbH Saarbrücken 99/04/15
1.4.1 Adjusting clearance of brake F
(snap ring)
Determine installation space EF for brake

F with measuring bar 5p01 000 330. To
do this, put measuring bar 5p01 000 330
onto the edge of the cylinder for brake F.
Put the measuring base on the highest
point of the disc supporting surface on
the piston and set the dial gauge to“0”.
Pull the measuring sensor upwards, guide
it into the snap-ring groove and press it
there against the groove’s upper edge.
Repeat measurement twice, turning by
120°.
98289
Average measurement values F1, F2, F3 ➮ WF
Determine thickness MF of the brake F

disc pack according to
Chapter 1.4.0: Measuring the disc pack.
➮ MF
Installation space EF is equal to WF plus

the thickness of the base F. ➮ EF
Test value PF is equal to installation

space EF minus MF
98290
The PF value must lie between 3.46 - 5.19 mm

Test specification 1060 700 062
Version B
Use test value PF to select snap ring SF.
Calculation:
E F = WF + F
PF = EF - MF
Clutch clearance LF should be 2.26 -

2.55 mm with 5 lined clutch discs.

Example (for 1.4.1):
F = 1.48 mm (Fußdicke)
F1 = 29.74 mm
F2 = 29.77 mm
F3 = 29.77 mm
WF = (29.74 + 29.77 + 29.77)/3

= 29.76 mm
MF = 27.2 mm
EF = 29.76 + 1.48
= 31.24 mm
PF = 31.24 - 27.2
= 4.04 mm
SF = 1.6 mm
LF = 4.04 - 1.6
➮ LF = 2.44 mm

1.4.2 Adjusting clearance of brake D
(snap ring)
Determine installation space ED for brake

D with measuring bar 5p01 000 330. To
onto the edge of the cylinder for brake D.
120°.
98294
Average measurement values D1, D2, D3 ➮ WD
Determine thickness MD of the brake D

➮ MD
Installation space ED is equal to WF plus

the thickness of the base F. ➮ ED
Test value PD is equal to installation

space ED minus MD.
98295
The PD value must lie between 4.65 - 6.45 mm

Test specification 1060 700 265 -
Version A
Use test value PD to select snap ring SD.
Calculation:
ED = WD + F
PD = ED - MD
Clutch clearance LD should be 2.29 -


F = 1.48 mm (base thickness)
D1 = 30.21 mm
D2 = 30.22 mm
D3 = 30.26 mm
WD = (30.21 + 30.22 + 30.26)/3

30.23 mm
MD = 26.34 mm
ED = 30.23 + 1.48
= 31.71 mm
PD = 31.71 - 26.34
= 5.37 mm
SD = 3.0 mm
LD = 5.37 - 3.0
➮ LD = 2.37 mm

1.4.3 Adjusting clearance of brake G
(snap ring)
Determine installation space EG for brake

G with measuring bar 5p01 000 330. To
onto the edge of the cylinder for brake G.
120°.
98296
Average measurement values G1, G2, G3 ➮ WG
Determine thickness ME of the brake E

➮ MG
Installation space EG is equal to WG

plus the thickness of the base F ➮ EG
Test value PG is equal to installation

space EG minus MG.
98297
The PE value must lie between 3.78 - 5.17 mm

Version A.
Use test value PG to select snap ring SG.
Calculation:
EG = WG + F
PG = EG - MG
Clutch clearance LG should be 1.79 -


G1 = 21.98 mm
G2 = 22 mm
G3 = 21.99 mm
WG = (21.98 + 22 + 21.99)/3
= 21.99 mm
MG = 19.23 mm
EG = 21.99 + 1.48
= 23.47 mm
PG = 23.47 - 19.23
= 4.24 mm
SG = 2.4 mm
LG = 4.24 - 2.4
➮ LG = 1.84 mm

1.4.4 Adjusting clearance of brake E
(snap ring)
Determine installation space EE for brake

E with measuring bar 5p01 000 330. To
onto the edge of the cylinder for brake E.
120°.
98335
Average measurement values E1, E2, E3 ➮ WE
Determine thickness ME of the brake E

➮ ME
Installation space EE is equal to WE plus

the thickness of the base F. ➮ EE
Test value PE is equal to installation

space EE minus ME.
98336
The PE value must lie between 3.04 - 4.46 mm

Version A
Use test value PE to select snap ring SE.
Calculation:
E E = WE + F
PE = EE - ME
Clutch clearance LE should be 1.78 -


E1 = 23.22 mm
E2 = 23.23 mm
E3 = 23.27 mm
WE = (23.22 + 23.23 + 23.27)/3

= 23.24 mm
ME = 21.64 mm
EE = 23.24 + 1.48
= 24.72 mm
PE = 24.72 - 21.64
= 3.08 mm
SE = 1.2 mm
LE = 3.08- 1.2
➮ LE = 1.88 mm

1.4.5 Adjusting clearance of clutch A
(snap ring)
Determine installation space EA for clutch

A with measuring bar 5p01 000 330. To
onto the edge of the cylinder for clutch
A. Put the measuring base on the highest
120°.
98342
Average measurement values A1, A2, A3 ➮ WA
Determine thickness MA of the clutch A

➮ MA
Installation space EA is equal to WA plus

the thickness of the base F. ➮ EA
Test value PA is equal to installation

space EA minus MA.
98343
Value PA should be between 3.09 - 4.58 mm

Version A
Use test value PA to select snap ring SA.
Calculation:
EA = WA + F
PA = EA - MA
Clutch clearance LA should be 2.06 -


A1 = 24.82 mm
A2 = 24.84 mm
A3 = 24.86 mm
WD = (24.82 + 24.84 + 24.86)/3

WA = 24.84 mm
MA = 22.43 mm
EA = 24.84 + 1.48
= 26.32 mm
PA = 26.32 - 22.43
= 3.91 mm
SA = 1.8 mm
LA = 3.91 - 1.8
➮ LA = 2.11 mm

1.4.6 Adjusting clearance of clutch B
(snap ring)
Determine installation space EB for clutch

B with measuring bar 5p01 000 330. To
onto the edge of the cylinder for clutch
B. Put the measuring base on the highest
120°.
98349
Average measurement values B1, B2, B3 ➮ WB
Determine thickness MB of the clutch B

➮ MB
Installation space EB is equal to WB plus

the thickness of the base F. ➮ EB
The test value PB is equal to installation

space EB minus MB.
98350
Value PB should be between 2.02 - 3.14 mm

Use test value PB to select snap ring SB.
Calculation:
E B = WB + F
PB = EB - MB
Clutch clearance LB should be 0.99 -


B1 = 14.11 mm
B2 = 14.14 mm
B3 = 14.17 mm
WB = (14.11 + 14.14 + 14.17)/3

= 14.14 mm
MB = 13.43 mm
EB = 14.14 + 1.48
= 15.62 mm
PB = 15.62 - 13.43
= 2.19 mm
SB = 1.2 mm
LB = 2.19 mm - 1.2 mm
➮ LB = 0.99 mm

1.4.7 Adjusting clearance of brake C
(snap ring)
Screw the cylinder to the oil supply using

2 M6 x 16 screws. (8 Nm)
Determine installation space EC for brake
C with measuring bar 5p01 000 330. To
onto the edge of the cylinder for brake C.
Repeat measurement twice, turning by 120°.
98361
Average measurement values C1, C2, C3 ➮ WC
Note:
Remove the screws afterwards.
Determine thickness MC of the brake C

➮ MC
Installation space EC is equal to WC plus

the thickness of the base F. ➮ EC
Test value PC is equal to installation

space EC minus MC.
98362
The PC value should be between 2.51 - 3.70 mm

Version A
Use test value PC to select snap ring SC.
Calculation:
EC = WC + F
PC = EC - MC
Clutch clearance LC should be 1.30 -


C1 = 21.35 mm
C2 = 21.37 mm
C3 = 21.39 mm
WC = (21.35 + 21.37 + 21.39)/3

= 21.37 mm
MC = 19.84 mm
EC = 21.37 + 1.48
= 22.85 mm
PC = 22.85 - 19.84
= 3.01 mm
SC = 1.6 mm
LC = 3.01 mm - 1.6 mm
➮ LC = 1.41 mm

1.4.8 Output play (shim)
With the measuring bar at a distance of

about 140 mm, insert an approximately
20-mm thick gauge block underneath. On
the gauge plate, set the dial gauge to “0”.
98316
Place output assembly on device

5x46 002 089.
Important !
To prevent distortion of measured values,
do not place on output flange. Move the
output flange in the output direction to a
98317
position where it is free from play.
Determine dimension A between the

machined surface of the extension and
the hub of the output flange.
98318

Using a depth gauge, determine dimensi-
on B between the machined surface of
the transmission housing and the machi-
ned surface of the parking lock wheel.
According to the parts list, play C should
be 0.15 to 0.35 mm.
The test dimension is 0.1 to 0.4 mm.
Test specification 1060 700 204.
98319
Thickness of washer S is now equal to B

minus A minus C.
Calculation:
S = B -A - C
Example: (for 1.4.8)
A = 2.818 mm
B = 4.8 mm
C = 0.15 to 0.35 mm
S = 4.8 - 2.818 - (0.15 to 0.35)

= 1.982 - (0.15 to 0.35)
= 1.632 to 1.832 mm
Chosen:
➮ S = 1.7 mm

1.4.9 Input play (shim)
Fasten the oil supply using at least 2

opposite machine screws.
(For tightening torque, see Chapter 1.5)
Clamp measuring device 5p01 002 379

to input shaft with a fixing screw at
about 2 mm above the stator shaft so that
there is no play. Set gauge to 0.
Requirement:
Axial needle roller bearing 10.390 and
thinnest shim 10.400 (SD= 1 mm) must
98369
be in place.
Determine axial play by pressing and

pulling on the handle (repeat measure-
ment).
Nominal axial play D = 0.05 - 0.35 mm

in accordance with Test specification
1056 700 203.
Take average of measured values M1, M2

➮M
Formula:
M = (M1+ M2)/2
S = M + SD - D
98370
If there is a deviation, insert a thicker

shim 10.400.
To do this, remove oil supply and input

assembly and insert the new shim instead
of the one used in the first measurement.
Then re-insert in accordance with

3.Fitting the input assembly with oil
supply.
Re-check axial play.

Example: (for 1.4.8)
M1 = 0.88 mm
M2 = 0.86 mm
SD = 1.00 mm
D = 0.05 to 0.35 mm
M = (0.88+ 0.86)/2 = 0.87 mm
S = 0.87 + 1.00 - (0.05 to 0.35)

= 1.87 - (0.05 to 0.35)
= 1.52 to 1.82 mm
Chosen:
➮ S = 1.7 mm

1.4.10 Adjusting the switch
(detent spring)
Move the detent disc to the N (neutral)

position with a suitable tool or by hand.
Place position gauge 5p01 002 321 on

the selector shaft, turn the position gauge
so that the locating pin in the transmis-
sion housing enters the cutout in the
position gauge and eliminate any play by
turning the knurled screw.
98279
Align the roller of the detent spring at

right angles to the detent disc and screw
the spring tight in this position using
auxiliary tool 5w04 000 583.
(See Chapter 1.5 for tightening torque)
Release the position gauge and move the

selector shaft through all the positions,
then back to N.
If installation has been performed cor-
rectly, the position gauge can easily be
placed on the selector shaft until it comes
into contact with the transmission hous-
98281
ing.

1.5 Tightening torques
No. Designation Part List- Wrench size Page Tightening

Item-No. No. torque [Nm]
1 Screw plug M10x1 01.650 Hexagonal socket 3.1/1 12 Nm

(transmission housing) SAF = 5 mm (±1.2 Nm)
2 Screw plug M18x1.5 01.010/340 Hexagonal socket 3.1/1 35 Nm

(transmission housing) SAF = 8 mm (±3.5 Nm)
3 Machine screw 01.010/150 TORX - TX 27 H 1.4/21 10 Nm + 30°

(detent spring) 3.1/1 (±0.3 Nm ±10°)
4 Screw plug 01.090 Hexagonal socket 3.1/2 20 Nm

(torsion spring) SAF = 6 mm (±2.0 Nm)
5 Machine screw 01.080 TORX - TX 27 3.1/3 10 Nm

(guide plate) (±1.0 Nm)

(tower) 3.2/7 (±1.5 Nm)
7 Slotted nut 14.040 Socket wrench 3.3/2 120 Nm

(output) 5X46 000 541 (±12.0 Nm)
8 Hexagon screw 14.110 3.3/3 23 Nm

(output) SAF = 13 mm (±2.3 Nm)
9 Countersunk screw 10.060/130 TORX - TX 27 1.3/1 10 Nm

(stator shaft/centering plate) 3.6/2 (±1.0 Nm)
10 Countersunk screw 10.100 TORX - TX 27 1.3/1 10 Nm

(intermediate plate/pump) 3.6/2 (±1.0 Nm)



(oil supply) 3.7/3 (±1.0 Nm)

(Hall-effect sensor) (±0.9 Nm)

(inductive transmitter) (±0.6 Nm)

No. Designation Part List- Wrench size Page Tightening
Item-No. No. torque [Nm]

(control unit) (±0.8 Nm)

(filter) (±0.6 Nm)

(oil pan) (±1.0 Nm)
19 Screw plug M16x1.5 03.010/130 Hexagonal socket 3.8/5 30 Nm

(oil pan) SAF = 8 mm (±3.0 Nm)

(cable clip) SAF = 10mm (±1.0 Nm)

(switch) SAF = 10 mm (±1.0 Nm)
22 Hexagon screw M10x55 3.9/3 20 Nm

(converter retaining bracket) SAF = 17 mm (±2.0 Nm)
23 Hexagon screw M10x16 3.9/3 20 Nm

(converter retaining bracket) SAF = 17 mm (±2.0 Nm)

1.6 Transmission test (test bench)
The following points must be checked:
Correct oil level
Proper oil level; observe the vehicle manufacturer’s specifications and ELCAT.
Oil level too low
This can result in:

- Engine over-reving or no power flow in curves or when starting from a stop
- Valve chatter due to air pockets in the oil
- General malfunctions
Among other things, burned clutches can be the result.
Oil level too high
Danger of loss due to splashing, formation of foam, strong temperature increases at high
road speeds. Loss of oil via breather; among other things, burned clutches and shifting prob-
lems can be the result.
Proper engine settings
Correct idle speed; follow specifications from vehicle manufacturer.
Power flow, forward and reverse
Correct adjustment of selector linkage or cable control; observe the vehicle manufacturer’s
specifications.
Cooler bypass respectively cooler connection on test bench
Do not overheat transmission, maximum +120° C

1.7 Special tools
OBJECT Order-No. / Application Remarks
1
5p01 000 329 Identical
- Force measuring unit
4 HP 20
5 HP 24
98008
2
- Measurement device for clutch
pack play 4 HP 20
5 HP 24
( measuring plate:
- short neck >20 mm
- long neck <20 mm
disc pack thickness)
98034
3
- Measurement device, bearing
play 4 HP 18 Q
4 HP 20
- Measurement device, clearance 5 HP 24
(top piece)
97301

Remarks Order-No. / Application OBJECT
4
5p01 002 327
- Adjustment tool, detent spring
98387
5
5p01 002 379
- Measurement device for axial
play
98388
6
5p04 000 208
- - Test plate for clutches A-G
98389

7
5w04 000 583 Identical
- Torque measuring unit
(Stahlwille 7380) 5 HP 24
98002
8
5x46 030 167 Identical
- Assembly bracket for pressing
down cup spring E 4 HP 14 Q
4 HP 18 Q
(equivalent to part 3 of device 4 HP 20
5x46 000 167) 4 HP 22
5 HP 18
5 HP 24
97305
9
- Sleeve for pump test
4 HP 18 Q
98135

10
5x46 000 422
- Drift for removing output flange
98391
11
Identical 5x46 000 541
- Slotted-nut wrench
5 HP 18
98392
12
Identical 5x46 000 545
- Lifting device for tower
5 HP 18
98393

13
5x46 000 576 identical
- Assembly bracket, taper, thrust
piece, brake C and G 5 HP 18
98394
14
- Counter support
5 HP 18
98395
15
- Assembly bracket, transmission,
complete 5 HP 18
98410

16
identical 5x46 000 685
- Drift for dowel pin in the selec-
5 HP 18 tor shaft
98396
17
- Press-in fixture for angular ball
5 HP 18 bearing, transmission extension
98397
18
- Drift, shaft seal for transmission
5 HP 18 extension
98398

19
- Work bench holder for assembly
bracket 5 HP 18
5 HP 24
5 HP 30
91199
20
- Counter support for output
flange 5 HP 24
5 HP 30
91188
21
- Locating pin for oil supply
(2 items) 5 HP 24
5 HP 30
92223

22
5x46 002 004
down cup spring A
98399
23
5x46 002 005
down cup spring B + F
98400
24
5x46 002 006
- Supporting fixture for tower
98401

25
5x46 002 007
- Centering device, brake C (with
centering pin and wedge)
98402
26
5x46 002 008
- Assembly drift for shaft seal,
pump
98403
27
5x46 002 009
- Removal device, oil supply
98404

28
5x46 002 010
- Assembly device, oil supply with
input assembly
98405
29
5x46 002 088
- Removal device, piston F
98406
30
5x46 002 089
- Assembly device, extension
98407

31
- Extracting handles for
converter (2 items) 3 HP 22
4 HP 22
5 HP 18
5 HP 24
5 HP 30
76046
32
5x95 000 038
- Drift, shaft seal, selector shaft
98408

2. Removing assemblies
2.1 Removing the converter, oil pan
and automatic control unit
Place complete transmission in assembly

bracket 5x46 000 620 with the oil pan at
the bottom and mount on assembly trol-
ley or work bench holder 5X46 000 763.
98201
Unscrew the oil inlet/drain plug and

drain off the oil.
(SAF hexagonal socket = 8 mm)
98202
Remove the converter retaining bracket

and remove the converter using two
extractor handles 5x56 000 090.
(SAF = 17 mm)
98203

Turn the transmission by 180°.
Unscrew the 22 screws used to fasten the
oil pan and remove it.
Remove the gasket from the transmission
housing.
Remove the magnets from the oil pan.
(Wrench size = Torx TX 27)
98204
Unscrew the 2 screws used to fasten the

oil filter and remove it.
98205
Remove retaining plate from the wiring

harness plug and insert the plug into the
transmission.
Unscrew the 2 screws of the inductive

transmitter (output speed) and remove the
transmitter.
98206

Unscrew the 14 screws with large heads
as shown on the left and place the auto-
matic control unit at an angle on the
transmission housing.
(Wrench size = Torx - TX 27)
98207
Unscrew the screw of the Hall-effect sensor

and pull the wiring harness leading to the
sensor out of the retaining groove.
Lift out the control unit.
(Wrench size = Torx - TX 27)
98208
To release the sleeve of the flow control

valve, press down and twist. Remove the
sleeve and spring.
Remove the 2 plastic tubes from the
transmission housing with a suitable tool.
Remove the piston of the flow control

valve with long-nosed pliers.
98209

Release position switch cable plug with
pliers and push out of retaining bracket.
Pull cable out of retaining clips. Move
selector shaft to N.
Remove position switch screws and
remove position switch
(SAF = 10 mm)
98210
Unscrew and remove the wiring harness

retaining bracket.
Remove 2 retaining clips.
(SAF = 10 mm)
98211
Drive the clamping sleeve out of the sel-

ector shaft and remove the selector shaft.
Remove the detent disc and connector
rod and release the rod from the disc.
Remove the shaft seal with a suitable
tool.
98212

Unscrew the 4 screws of the guide plate
and remove the guide plate.
98213
Unscrew the guide pin screw plug.

Remove the guide pin and take out the
pawl together with the torsion spring.
Please note:
The detent spring should normally be left
98214
in place.

2.2 Removing the oil supply

Remove the 9 screws holding the oil sup-
ply.
Clamp device 5x46 002 009 to stator
shaft.
Turn the spindle of the device so that it
points downwards and lift out the com-
plete oil supply unit.
Remove the axial adjustment washer and
needle cage.

98215

2.3 Removing the input assembly
Lift out the input shaft together with clut-

ches A, B and E, either by hand or using
device 5x46 002 010.
98217
Remove the 2 thrust washers and the

needle cage.
Lift out the intermediate shaft.
98218
Remove the angle washer, needle cage

and thrust washer.
Remove the sun shaft and the axial need-
le cage.
98220

Remove the sun wheel, planetary gear
set, angle washer, needle cage and thrust
washer.
98221
Remove the shaft with the ring gear,

thrust washer, needle cage, angle washer
and cup.
98222

2.4 Removing the tower
Remove the 3 machine screws and lift

out the tower.
Insert lifting device 5x46 000 545 into
the tower’s planet carrier and lock in the
centre by pressing down the clamping
device.
98223
Lift out the tower and insert into holding

device 5x46 002 006.
Remove the shim.
Please note:
98224
Shim may stick in the tower.

2.5 Removing the output assembly.
Turn the transmission by 180° and undo

the 7 screws holding the transmission
extension.
(SAF = 13 mm)
98225
Remove the transmission extension.
98226
Remove all (screw) plugs from the trans-

mission housing.
Remove breather cover.
98227

Disassembly
2.6 Output assembly
Using a vice:
Insert output assembly into device 5X46

000 946. Remove O-ring from output.
Release slotted nut with a drift.
98228
Apply slotted-nut wrench 5x46 000 541

to slotted nut, unscrew and remove.
98229
Place output assembly on device

5x46 002 089.
Drive out output flange with drift
5x46 000 422 and plastic-faced hammer.
98230

Remove retaining ring with suitable
pliers.
Remove bearing inner race and lever out
the shaft seal.
98231
Push out the remaining components of

the double bearing with a suitable man-
drel in a press.
Important !
The bearing inner races are not inter-
98232
changeable.

2.7 Tower
Lift brake D/G and clutch F off the tower.
98233
2.7.1 Planetary drive

and thrust washer from the ring gear.
Take off the shaft with the ring gear.
98234
Separate the ring gear from the shaft by

removing the snap ring.
98235

and thrust washer from the planet carrier.
98236
Turn the planet carrier through 180° and

remove the snap ring from the shaft with
suitable pliers.
98237
Remove the parking lock wheel. Remove

the thrust washer, needle cage and angle
washer from the sun wheel.
98238

Remove the sun wheel.
Take the angle washer, needle cage and
angle washer off the planet spider. Take
the planet carrier out of the holding
device.
98239

2.7.2 Clutch F
Remove the snap ring from cylinder F

and take out the disc pack.
98240
Press the cup spring down with assembly

bracket 5x46 002 005 under a mandrel
press and remove the split stop ring.
Remove the cup spring and the pressure
plate.
98241
Insert device 5x46 002 088 in cylinder F.

Force the piston out with compressed air.
Pull the 2 O-rings off the piston.
98409

2.7.3 Brake D/G with freewheel, 1st
gear
Engage counter support 5X46 000 577 in

the holes of the freewheel carrier by
means of 3 cylindrical pins.
98242
Turn complete assembly by 180°.

Remove snap ring, brake G.
Remove the disc assembly.
Remove the 2 rectangular-section rings
from the carrier.
98243
Press the cup spring down with assembly

bracket 5x46 000 576 under a mandrel
press.
Remove the snap ring with suitable
pliers.
Remove the assembly bracket.
Lift off the thrust washer and the cup
spring.
98244

Force out piston G using compressed air
in the oil feed hole.
Pull the 2 O-rings off piston G.
98245
Lift cylinder D/G off the carrier and turn

it by 180°.
98246
Remove snap ring, brake D.

Remove the disc assembly and cup
spring.
98247

Force out piston D using compressed air
in feed hole.
Remove the 2 O-rings from the piston.
98248
Remove the 2 O-rings and the fixing

washer from the carrier.
Turn the carrier 180°.
Disengage the 3 cylindrical pins from the
counter support and remove it.
98249
Push the freewheel out of the carrier.
98250

2.8 Input assembly
Lift clutch B off A.

Remove the thrust bearing.
98251
Remove the snap ring from the input

shaft using suitable pliers.
98252
Push clutch E out of clutch A by slight

pressure on the input shaft.
Remove the 2 rectangular-section rings
and 1 O-ring from the input shaft.
Please note:
98253
Cylinder A meshes with the input shaft.
2.8.1 Clutch E
Insert the input shaft into the holding

device 5x46 002 006.
Remove the snap ring and the disc
assembly.
98254
Press down the cup spring with assembly

device 5x46 030 167 under a mandrel
press and remove the snap ring with a
suitable pair of pliers.
98255
Force out the piston, cup spring and oil

dam with compressed air in the oil feed
hole.
Remove the oil dam and cup spring from
the piston.
Pull 1 O-ring off the oil dam and 2 O-
rings off the piston.
98256

2.8.2 Clutch A
Remove the snap ring.

Remove the disc assembly.
98257
Push down the cup spring with assembly

device 5x46 002 004 under a mandrel
press, remove the split stop ring and cup
spring.
98258
Cover 2 holes with your fingers and

force the piston out with compressed air
through the 3rd hole.
Pull the 3 O-rings off piston A.
Push the ring and O-ring out of hub,
cylinder A.
Pull the O-ring off the ring.
98259

2.8.3 Disassembling clutch B.

Remove the disc pack.
98260
Push the cup spring down with assembly

bracket 5x46 002 005 and remove the
split stop ring.
Remove the cup spring.
98261
Cover one oil feed hole and force the

piston out with compressed air through
the other.
Pull the 2 O-rings off the piston.
98262

2.9 Oil supply with brake C
2.91 Brake C

Remove the disc pack.
98263
Push the cup spring down with assembly

bracket 5X46 000 576. Then remove the
split stop ring and the cup spring.
98264
Pull the external disc carrier together

with piston C off the oil supply.
Separate the piston from the external disc
carrier.
Pull the 2 O-rings off piston C.
98265

Pull 1 O-ring off the intermediate plate
and remove 3 rectangular-section rings
from the hub of the stator shaft.
98266
2.9.2 Pump
Remove 8 countersunk screws from the

outer pitch circle and 1 cheese-head
screw and the countersunk screw opposi-
te the latter from the inner pitch circle.
98267
Screw 2 long-shank screws into two

opposite holes in the outer pitch circle
and drive the pump out by tapping gently
on the screw heads.
98268

Remove the centering sleeve, intemediate
plate, pump wheel and pump ring gear.
98269
Lever out the shaft seal with a suitable

screwdriver and take off the disc.
Pull the O-ring off the pump casing.
98270
Important !
Only undo the 5 screws of the stator shaft
if the intermediate plate is damaged.
Push them out of the plate with a suitable
98271
drift.
3. Assembly
3.1 Housing with selector mechanism
and parking lock
01.010
01.620
01.650
/110
/340
/250 /160
/200
/320 01.090
/130
01.030
01.640 01.020 /150

01.040
01.050
01.060
/170
01.080
/180
Turn the transmission housing 01.010/110

so that the oil pan faces upwards.
Screw 11 screw plugs 01.650 and oil fil-
ler plug 01.010/340 into the transmission
housing 01.010/140.
Push 2 plugs 01.640 into transmission housing.
(For tightening torques see 1.5)
Please note:
In the most recent transmission housings,
there is only 1 screw plug 01.650.
If the transmission housing has been
changed, drive in new pins 01.010/250 (9.8
+ 1.2 mm) and 01.010/320 (5.5 - 0.5 mm),
and a new breather 01.620.
98272
Mounting specification 1060 700 347
Drive shaft seal 01.010/200 into the
transmission housing with drift 5x95 000
038.
Important!
Only if the detent spring is defective
Screw detent spring 01.010/130 on loosely
98273
with 2 screws 01.0101/150.
Latch connector rod 01.050 into detent

disc 01.010/170 and turn it.
Important!
If the transmission housing, detent disc
or selector shaft have been replaced or
the detent spring has been detached, the
detent spring must be readjusted.
Adjustment: Chapter 1.4.10

98274
Insert the detent disc and connector rod

into the transmission housing and push in
the selector shaft 01.010/160.
98275

Drive new slotted pin 01.010/180 into the
detent disc with driving pin 5x46 000
685.
Important !
In position “N”, the flat on the selector
98276
shaft must face away from the oil pan.
Insert pawl 01.030 and leg spring 01.040

into the transmission housing and fix
them by pressing in pin 01.020.
Then close the hole with screw plug
01.090.
(For tightening torques, see Chapter 1.5)
98277
Press down the pawl and fasten guide

plate 01.060 with 4 machine screws
01.080.
98278

3.2 Tower
3.2.1 Planetary drive III
42.120
/120
42.140
42.090
/110 42.100
/130
42.070
42.180 42.050
42.030
42.010
Insert thrust washer 42.070/110,

axial needle roller bearing 42.070/120
and angle washer 42.070/130 into parking
lock wheel 42.090.
98282

Mount sun wheel 42.050, and insert
angle washer 42.030/110 axial needle
roller bearing 42.030/120 and angle was-
her 42.030/130 over sun wheel hub.
98283
Mount planet carrier 42.010.

Place the unit on supporting fixture
5x46 002 006 and secure with snap ring
42.100.
Turn the unit by 180°.
Important !
Make sure that the axial bearings remain
98284
centered.
Insert the ring gear carrier 42.140/110

into the ring gear 42.140/120 and secure
with snap ring 42.140/130.
Place thrust washer 42.180/110, axial

needle roller bearing 42.180/120 and
angle washer 42.180/130 on the ring gear
unit.
98285

Place thrust washer 42.120/110, axial
angle washer 42.120/130 on planet carrier
and mount the complete ring gear unit.
98286

3.2.2 Clutch F
/210
/190
/200
/190
77.010
/200
/190
/180
/170
/160
/150
/120
/140
/130
/110
Press 2 new O-rings 77.010/130 and

77.010/140 onto piston 77.010/120 and
press this into cylinder F 77.010/110.
Place pressure plate 77.010/150 on
piston.
98287

Insert cup spring 77.010/160, press down
with assembly bracket 5x46 002 005 on a
mandrel press and mount the split stop
ring 77.010/170.
98288
Insert the complete disc assembly, star-

ting with the spring disc 77.010/180.
Then insert alternate steel discs
77.010/190 and lined discs 77.010/200.
Secure upper steel disc with snap ring
77.010/210.
Important. !
98291
For adjustment see Chapter 1.4.1
Place clutch F on the planetary drive, tur-

ning it backwards and forwards as you do
so until the teeth on the lined discs and
the ring gear mesh fully.
Check by looking through the cutouts in

the cylinder. The final disc must not have
been pushed upwards by the lining discs.
The gap at the top must be larger than
that at the bottom.
98292

3.2.3 Brake DG with freewheel, 1st
gear
73.090
/110
73.140
73.140
/120
73.100
/140 /130
/140
/140
/120 73.200
/110 73.070
73.060
/150 73.050
73.010
/160
73.060
/170
73.050
/180
73.040
/170
73.120
73.080
/180 73.110
/190
73.030
73.020
/200
73.024
73.022
First determine the release clearance of

the brakes DG.
For that mount 2 O-rings 73.010/130, /140
on piston D 73.010/120.
Mount 2 O-rings 73.022, 73.024 on
piston G 73.020. Mount both pistons in
cylinder DG 73.010/110.
Important !
For adjustment see Chapter 1.4.2, 1.4.3
To avoid distortion of the measurements,
the pistons must be fully in contact. If
necessary, press them home with a suitable
98293
drift.
Hold the freewheel 73.100/120 firmly
and press the carrier (internal sprag race)
73.100/110 into it, turning the carrier
clockwise as you do so.
98298
Place the complete unit on the counter

support 5x46 000 577 and engage the 3
cylindrical pins of the support in the free-
wheel by turning.
Pull on 2 O-rings 73.100/140.
98299
Insert cup spring 73.010/150 and fixing

washer 73.090 into cylinder DG.
98300

Place cylinder DG on a suitable surface
and press the complete carrier into the
cylinder until it meets the stop.
Turn the unit by 180°.
Caution !
Take care that the assembly does not fall
98301
apart!
Insert cup spring 73.030 on side G of the

cylinder DG.
Mount thrust washer 73.110.
98302
Place snap ring 73.120 on the taper of

assembly device 5x46 000 576 and press
it down slightly with a pressure piece.
Place taper on the hub, place the pressure
piece over it and insert the bracket of the
assembly device into the cylinder.
Press down the complete unit on a
mandrel press.
Important !
The teeth on the thrust washer must mesh
with the teeth on the carrier.
98303

Mount 2 rectangular-section rings 73.140
on the carrier.
Insert disc pack G, starting with spring
disc 73.040, followed alternately by steel
discs 73.050 and lined discs 73.060.
Insert final disc 73.070 and secure with
snap ring 73.080.
98304
Turn the complete unit and remove the

counter support.
Insert disc assembly D, starting with
spring disc 73.010/160, followed alter-
nately by steel discs 73.010/170 and
lined discs 73.010/180.
Insert end disc 73.010/190 and secure
98305
Place brake DG with 1st gear freewheel

on clutch F and move backwards and for-
wards until the teeth on the lined discs
mesh fully with the interior disc carrier.
Insert lifting device 5x46 000 545 into
the planet carrier of the complete plane-
tary drive (tower). Press down the lever
in the centre.
Please note:
This is not possible if brake DG has been
mounted incorrectly on F.
98306

Turn the transmission housing by 90°.
Insert the tower into the transmission
housing, making sure that the 3 holes are
aligned with one another.
Important !
The transmission housing must remain in
98307
this position.
Fasten the tower securely with 3 machine

screws 73.200.
Important !
Screw tightening instructions see
Chapter 1.3.1
98308
The lifting device must remain attached.

3.3 Output assembly
14.030
14.010
/140
/110
/120
/130
14.040
14.110
14.100 14.050
Place extension 14.010/110 on the sup-

porting surface of the press-in device
5x46 000 760.
Place ball bearing 14.010/120 on the
press-in pin of the tool. Press it into the
extension on the mandrel press and
secure with snap ring 14.010/130.
Important !
The two inner races of the bearings must
not be mixed up or turned relative to one
another. The cutouts at the edges must
98310
face one another.
Turn the extension around and mount
shaft seal 14.010/140 under the mandrel
press using press-in pin 5x46 000 761.
Pull on O-ring 14.100.
98311
Mount the extension on holding device

5x46 002 089. Insert output flange
14.030 into the double bearing and press
it in on the mandrel press using a suitable
mandrel.
98312
Work with a vice:
Place the output flange on holding device

5x46 000 946.
Screw slotted nut 14.040 onto the output
flange and tighten with wrench 5x46 000
541.
Secure the slotted nut and secure at two
points on the circumference.
98313

Place disc 14.050 on the parking lock
wheel in the transmission housing.
Please note:
98315
For adjustment, see Chapter 1.4.8
Place output assembly on and fasten with

7 hexagon screws 14.110.
98320

3.4 Planetary drives I and II
32.060
32.080
32.090
32.120 32.074
32.140
32.160 32.020
/130
32.180
32.040
32.200 /110
/120
Turn the transmission by 180 ° and pull

out lifting device 5x46 000 545 using the
central handle.
Place spider clutch bell 32.074 on the
freewheel.
98321

Insert shaft 32.040/110 into ring gear
32.040/120 and secure with snap ring
32.040/130.
98322
Insert angle washer 32.020/110, axial

thrust washer 32.020/130.
98323
Insert the output shaft and ring gear into

the transmission housing.
98324

Insert thrust washer 32.060/110, axial
needle roller cage 32.060/120 and angle
washer 32.060/130.
98325
Insert planet carrier 32.080 into the trans-

mission housing.
98326
Insert sun wheel with cup 32.090 into the

planet carrier.
98327

Insert axial needle roller bearing 32.120
into the cup.
98328
Insert sun wheel shaft 32.140 and check

operation.
If assembly has been carried out correct-
ly, the cup should turn in the opposite
direction to the sun wheel shaft.
98329
Slide angle washer 32.160/110, axial

needle cage 32.160/120 and thrust
washer 32.160/130 over the end of the
intermediate shaft 32.180 and insert the
intermediate shaft.
98330

Insert thrust washer 32.200/110 , axial
needle cage 32.200/120 and thrust
washer 32.200/130 over the journal of the
intermediate shaft.
98331

3.5 Input assemby
3.5.1 Clutch E
71.050 71.060
71.070
71.130
71.120
71.010
71.110
71.100
71.030 71.094
71.020
71.150
71.086 71.090
71.084
71.080
Pull new O-rings 71.060 and 71.070 onto

piston E 71.050.
Push piston E into cylinder E on input
shaft 71.010.
98332

Place cup spring 71.080 with the edge of
the cup facing upwards onto piston E.
Pull a new O-ring 71.086 onto oil dam
71.084 and insert into piston E.
98333
Push the oil dam down with assembly

bracket 5x46 030 167 on a mandrel press
and fit retaining ring 71.090 with suitable
pliers.
98334
Insert complete disc assembly of clutch

E, starting with spring disc 71.094.
Then mount alternately steel discs 71.100
and lined discs 71.110.
Mount final disc 71.120 and secure with
snap ring 71.130.
Please note:
98337

Mount 2 new rectangular-section rings
71.020 and 71.030 and new O-ring
71.150 on the input shaft.
98338

3.5.2 Clutch A
70.010 /170
/140
/160
/180
/130
/120
/110 71.160
71.170
71.180
/230
/220
/210
/200
/190
Pull new O-rings 70.010/120,

70.010/130, 70.010/160 onto piston A
70.010/180.
98339

Push piston A into cylinder A 70.010/110
and insert cup spring 70.010/140 with the
convex side upward.
98340
Press cup spring down with assembly

device 5x46 002 004 and secure with
split fixing washer 70.010/170.
98341
Insert complete disc pack of clutch A.

Start with spring disc 70.010/190, follo-
wed alternately by outer discs 70.010/200
and lined discs 70.010/210.
Add final disc 70.010/220 and secure
Please note:
98344

Pull O-ring 71.160 onto ring 71.170,
insert into hub of cylinder A and push in
until it stops.
98345
Engage clutch A in splines via the input

shaft and push in as far as the stop.
Next push on ring with O-ring as far as
the stop.
Fix clutch A on input shaft by means of
ground retaining ring 71.180.
98346

3.5.3 Clutch B
72.100 71.200
72.090
72.080
72.070
72.064
72.140
72.110
72.040
72.060
72.010 72.050
Pull 2 new O-rings 72.050, 72.060 onto

piston B 72.040 and push into cylinder B
70.010.
98347

Insert cup spring 72.110, push down the
cup spring with assembly device
5x46 002 005 and secure with split stop
ring 72.140.
98348
Insert clutch pack B.

Start with spring disc 72.064, insert alter-
nately steel discs 72.070 and lined discs
72.080.
Place final disc 72.090 on top and secure
with snap ring 72.100.
Please note:
98351
Place axial bearing 71.200 on cylinder A.

Align lined discs of clutch B and insert
over cylinder A, turning at the same time.
98352

3.6 Oil supply with brake C
10.160
10.060
/110 10.120 10.380
10.370 10.340
10.310
10.360
/130
10.300
10.100
10.290
10.040
10.270
10.030
10.010 10.250
/120 10.240
10.210
10.500
10.200
/150 10.190
/160
10.180
Insert disc 10.010/150 into the pump

casing and mount shaft seal 10.010/160
using assembly sleeve 10.010/160.
98353

Re-assemble pump 10.010 in such a way
that the marks on the pump impeller and
the pump ring gear are at the top.
98354
Insert centering sleeve 10.010/120 into

pump casing and position intermediate
plate 10.040.
Then pull new O-ring 10.030 onto pump
casing.
98355
Screw 2 centering pins 5x46 001 007 into

intermediate plate 10.060/110.
Heat the intermediate plate to about 70 -
80° C at the seat for the stator shaft and
insert stator shaft into the plate using the
centering pins. Remove the centering
pins.
Screw the stator shaft loosely to the inter-
mediate plate with 5 countersunk screws
10.060/130.
98356

Twist 2 centering pins (M6) into the
pump, place the intermediate plate over
them and push in.
Remove the centering pins.
Loosely screw in 8 countersunk screws
10.100, 1 countersunk screw 10.120 and
1 machine screw 10.160.
Important !
Screw tightening instructions see
98357
Chapter 1.3.1
Pull new O-ring 10.360 onto oil supply

and 3 new rectangular-section rings
10.370, 10.380 onto the hub of the stator
shaft.
Check that the pump runs easily with
plug gauge 5x46 000 306.
98358
Place cylinder C 10.180 on oil supply

and align.
Pull 2 new O-rings 10.190, 10.200 onto
piston 10.210.
Press piston into cylinder C.
98359

Place cup spring 10.240 onto piston C,
press down with assembly bracket l 5x46
000 576 under a mandrel press and secu-
re with split stop ring 10.250.
98360
Insert complete disc assembly of brake

C.
Starting with spring disc 10.270, alterna-
tely insert steel discs 10.290 and lined
discs 10.300, ending with a thick outer
disc 10.310.
Then secure with snap ring 10.340.
Please note:
98363

3.7 Input assembly with oil supply
10.400
10.390
10.440
Place shim 10.400 on cylinder B.

Stick angle washer/axial needle cage on
stator shaft hub with a little white petro-
leum jelly.
Important !
For necessary adjustments, we suggest
the thinnest shim from the O.T.K.
Then insert correct shim as determined

98364
during adjustment.
Align lined discs, brake C, with tool
5x46 002 007 and wedge with plastic
wedge 5x46 002 007.
Place oil supply over input shaft until
lined discs are completely inside disc
carrier C.
Important!
98365
Remove plastic wedge again.
Clamp assembly device 5x46 002 010

onto the input shaft, flush with the stator
shaft.
98366
Now insert the complete unit in the trans-

mission housing, turning it as you do so,
until lined discs of clutch A and E are
completely inserted, and press into end
position with firm pressure on the device.
At the same time, centre the oil supply
over the transmission with centering pin
5x46 002 007 in such a way that the bore
of the oil-supply flow control valve is in
alignment with the hole in the trans-
mission housing.
Please note:
The driving splines of the cup must enga-
ge fully in cylinder B. To ensure this,
98367
turn both the cup and the input shaft.
Fasten the oil supply with 9 screws
10.440 and new Usit-rings.
Turn the transmission so that the oil pan
is at the top.
Please note:
98368

3.8 Automatic control unit, flow
control valve, oil filter and oil pan
27.040
27.060
27.020
10.540
27.360
10.550
10.500
27.030
10.540
27.350
10.510
10.540
10.550
10.540
27.410
10.520 27.390
27.340/116
/020
27.420
27.440
03.010/120
03.020
03.010
03.050
03.010/130
03.044

Check that all the clutches and brakes
work using test plate 5p04 000 208 and
compressed air.
Remove the test plate after testing.
Important!
Screw the test-plate screws to the trans-
98371
mission housing at 8 Nm.
Insert piston 10.500 into bore of flow

control valve.
Then fit new tube 10.550 with 2 new O-
rings 10.540 into this bore. Press spring
10.510 with sleeve 10.520 into tube and
twist until it locks.
Press in new tube 10.550 with 2 new O-
rings 10.540 into the adjacent bore.
Please note:
On more recent transmissions (Transm.
No. >7735), clip retaining clips for the
cable 27.350 and 27.360 of the Hall-
effect sensor to corresponding webs on
98372
the control unit.
Place the complete control unit on at an

angle.
Fasten Hall-effect sensor 27.020 using
screw 27.030 and clip connecting cable
to housing web.
98373

Pull 2 new O-rings 27.340/116 onto
wiring harness plug 27.340.
Insert plug in hole, engage guide pin in
slot and fix with tab washer 27.390.
Lay the cable for the Hall-effect sensor as

close as possible to the wall of the hou-
sing to prevent it from being trapped.
Please note:
On more recent transmissions (Transm.
No. > 7735), the cable of the Hall-effect
sensor is pressed into the cable clips (see
98374
Service Bulletin).
Select “N”.
Align control unit and press on by hand.
Important!
Detent disc pin must be inserted correctly
into the slot in the manual valve and the
guide pin must be inserted correctly in
98375
the transmission housing.
Insert inductive transmitter 27.040 in the

hole provided and fasten it with 2 screws
27.060.
98376

Fix the automatic control unit with 14
screws 27.410.
98377
Place oil filter 27.420 on control unit

with new sealing ring 27.420/020 and
fasten with 2 screws 27.440.
98378
Insert 8 magnets 03.010/120 into reces-

ses in the oil pan 03.010 - all around the
oil filter intake opening.
Place a new, lightly oiled paper gasket
03.020 on the sealing face of the trans-
mission housing. Working diagonally,
fasten the oil pan with 22 screws 03.044.
Please note:
For BMW, make sure that the stick-on label
98379
03.050 has been applied to the oil pan.
Screw new oil drain plug 03.010/130 into
the oil pan.
98380

3.9 Position switch and converter
01.630
27.340/118
22.020 01.420
01.424 01.400
01.550
/120
01.570
01.560
Attach cable clips 01.420, 01.424 to

webs.
Screw holder 01.550 to transmission hou-
sing using screw 01.560.
Move selector shaft to the “N” position.
98381

Slide the position switch along the selec-
tor shaft until the locating pin of the
transmission housing enters the hole in
the switch.
Make sure that the cable runs behind the
position switch.
Clip cable into the cable clips, insert the
plug into the holder and lock.
Fasten position switch with 2 screws
01.570.
98382
Screw 2 handles 5x56 000 090 into the

converter and carefully insert the conver-
ter 22.020.
98383
Turn the transmission by 90° and turn the

converter carefully backward and forward
until the pump drive journals have enga-
ged.
Remove the handles.
98384

Screw the converter retaining bracket
5T95 000 099 to the converter and the
transmission housing with 2 screws.
Important!
The converter fastening screw must not
be too long - recommended length 16
mm. Otherwise the converter will be
98385
damaged and will not operate correctly.
Check the switch with a multimeter

(Ohm setting), referring to the table.
Insert breather cover 01.630 into the

breather.
Then fit all the transport plugs/caps:
- 1 transport plug for selector shaft
- 1 screw plug 27.340/118 on EGS

wiring harness
98386

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REPAIR-MANUAL

ZF GETRIEBE GMBH SAARBRÜCKEN

© Copyright 1998, all rights reserved. Published by

No part of this manual may be repoduced or transmitted in any form

1. General information 1.1/1

2. Removing assemblies 2.1/1

99/04/15 5 HP 19 © ZF Getriebe GmbH Saarbrücken CD I

II CD 5 HP 19 © ZF Getriebe GmbH Saarbrücken 99/04/15

The following points should be noted:

Before carrying out repair work, make sure that:

• All special tools required are readily available.

99/04/15 5 HP 19 © ZF Getriebe GmbH Saarbrücken CD III

A separate manual is planned for the automatic control unit.

The transmission is filled with a long-life oil.

Bach Reus Schultz

IV CD 5 HP 19 © ZF Getriebe GmbH Saarbrücken 99/04/15

99/04/15 5 HP 19 © ZF Getriebe GmbH Saarbrücken CD 1.1/1

99/04/15 5 HP 19 © ZF Getriebe GmbH Saarbrücken CD 1.2/1

Screw in 3 machine screws 73.200 by

Initially, tighten the central screw at 30

Now tighten the central screw at 63 Nm

Finally, tighten the two outer screws at

99/04/15 5 HP 19 © ZF Getriebe GmbH Saarbrücken CD 1.3/1

Place the two intermediate pieces

Use knurled screw to turn adjusting de-

Fasten adjusting device with 4 knurled

Use knurled screw to clamp the clutch

99/04/15 5 HP 19 © ZF Getriebe GmbH Saarbrücken CD 1.4/1

Then put measuring bar 5p01 060 330 on

Now measure down to the base plate

Read off the measurement value ➮ MX

Determine installation space EF for brake

Determine thickness MF of the brake F

Installation space EF is equal to WF plus

Test value PF is equal to installation

The PF value must lie between 3.46 - 5.19 mm

Use test value PF to select snap ring SF.

Clutch clearance LF should be 2.26 -

99/04/15 5 HP 19 © ZF Getriebe GmbH Saarbrücken CD 1.4/3

WF = (29.74 + 29.77 + 29.77)/3

1.4/4 CD 5 HP 19 © ZF Getriebe GmbH Saarbrücken 99/04/15

Determine installation space ED for brake

Determine thickness MD of the brake D

Installation space ED is equal to WF plus

Test value PD is equal to installation

The PD value must lie between 4.65 - 6.45 mm

Use test value PD to select snap ring SD.

Clutch clearance LD should be 2.29 -

99/04/15 5 HP 19 © ZF Getriebe GmbH Saarbrücken CD 1.4/5

F = 1.48 mm (base thickness)

WD = (30.21 + 30.22 + 30.26)/3

1.4/6 CD 5 HP 19 © ZF Getriebe GmbH Saarbrücken 99/04/15

Determine installation space EG for brake

Determine thickness ME of the brake E

Installation space EG is equal to WG

Test value PG is equal to installation

The PE value must lie between 3.78 - 5.17 mm

Use test value PG to select snap ring SG.

Clutch clearance LG should be 1.79 -

99/04/15 5 HP 19 © ZF Getriebe GmbH Saarbrücken CD 1.4/7