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    ZF 5hp24e Repair Manual

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    ZF 5hp24e Repair Manual

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    tamara
    233 views10 pages
    ZF

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    Zf 5hp24e Repair Manual

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    Copyright:

    © All Rights Reserved
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    Download as pdf or txt
    233 views10 pages

    ZF 5hp24e Repair Manual

    Uploaded by

    tamara
    ZF

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 10

    Zf 5hp24e Repair Manual

    Full download: http://manualplace.com/download/zf-5hp24e-repair-manual/

    REPAIR MANUAL

    5 HP - 24

    ZF GETRIEBE GMBH SAARBRÜCKEN


    Status 98/08/01

    This is the cut pages sample. Download all 130 page(s) at: ManualPlace.com
    subject to alterations

    © Copyright 1998 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
    Table of Contents
    Page
    Preliminary information II

    1. General information 1.1/1


    1.1 Picture of the transmission 1.1/1
    1.2 Diagram of power flow 1.2/1
    1.3 (Previously used for the oil supply diagrams, not currently used)
    1.4 Making adjustments 1.4/1
    1.4.0 Measuring the disc sets (procedure) 1.4/1
    1.4.1 Adjusting clearance of brake F (snap ring) 1.4/2
    1.4.2 Adjusting clearance of brake D (snap ring) 1.4/4
    1.4.3 Adjusting clearance of brake E (snap ring) 1.4/6
    1.4.4 Adjusting clearance of clutch C (snap ring) 1.4/8
    1.4.5 Adjusting clearance of clutch A (snap ring) 1.4/10
    1.4.6 Adjusting clearance of clutch B (snap ring) 1.4/12
    1.4.7 Output play (shim) 1.4.14
    1.4.8 Input play (shim) 1.4.15
    1.4.9 Adjusting switch (detent spring) 1.4.16
    1.5 Tightening torques 1.5/1
    1.6 Transmission test (test bench/vehicle) 1.6/1
    1.7 Special tools 1.7/1
    1.8 Function tests 1.8/1
    1.8.1 Position switch 1.8/1

    2. Disassembly 2.1/1
    2.1 Disassembly of the transmission as of the assembly group 2.1/1
    2.2 Brake F with freewheel, 1st gear 2.2/1
    2.3 Output 2.3/1
    2.4 Tower I 2.4/1
    2.4.1 Brake D, E and clutch C 2.4/1
    2.4.2 Planetary drive (III, II and I) 2.4/6
    2.5 Tower II 2.5/1
    2.6 Oil supply 2.6/1
    2.7 Transmission with flow control valve and breather 2.7/1
    2.8 Transmission with selector mechanism and parking lock 2.8/1

    3. Assembly 3.1/1
    3.1 Transmission with selector mechanism and parking lock 3.1/1
    3.2 Brake F with freewheel, 1st gear 3.2/1
    3.3 Tower I 3.3/1
    3.3.1 Planetary drive (III, II and I) 3.3/1
    3.3.2 Brake (E and D) 3.3/4
    3.3.3 Assembly, clutch C 3.3/9
    3.4 Output 3.4/1
    3.5 Tower II (input with clutches A and B) 3.5/1
    3.5.1 Clutch A (input) 3.5/1
    3.5.2 Clutch B (input) 3.5/3
    3.6 Oil supply 3.6/1
    3.7 Control unit, oil pan and converter 3.7/1
    (Complete control unit, see parts list, technical cover sheet, position Y02)
    5 HP 24 © ZF Getriebe GmbH Saarbrücken, 98/08/01 I
    Preliminary information

    This manual covers the procedure for repairing the complete transmission.

    The repairing of this transmission is only allowed to persons with an 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 Bulletines and training 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 Bulletines 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.

    Here, you must observe the following:

    • Seals (such as O-rings, shaft seals, gaskets and filters) must always be renewed.
    • All O-rings, rectangular-section rings, and other sealing rings must always be lubricated
    with white petroleum jelly before installation.
    • All bearings must always be in a slightly oiled condition when installed.
    • For transmissions that have been used for a large number of kilometers
    (> 80,000 km), all lined clutch discs and steel discs must be replaced.
    • After clutches/ brakes have been damaged, the converter, oil tubes, and oil
    cooler, must be cleaned thoroughly.
    • If brake F has been damaged, or if a considerable distance has been covered
    (> 150,000 km), piston F must be replaced.

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

    • 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 Bulletines.

    II 5 HP 24 © ZF Getriebe GmbH Saarbrücken, 98/08/01


    Note:

    This manual treats the automatic control unit as a complete unit, which should not be disassem-
    bled without special knowledge; it should be exchanged as a complete unit.

    A separate repair manual is planned for the automatic control unit.

    Important:

    The transmission is filled with life-time oil.

    The oil does not have to be changed until it has been in use for ten years.

    The transmission may only be delivered with the oil type and oil amount specified in the corre-
    sponding parts list documentation (see ELCAT), otherwise there is danger of gearbox failure.

    Techn. After Sales Service Techn. Documentation After Sales Service School

    Bach Reus Schultz

    5 HP 24 © ZF Getriebe GmbH Saarbrücken, 98/08/01 III


    1. General information
    1.1 Picture of the transmission

    5 HP 24 © ZF Getriebe GmbH Saarbrücken, 98/08/01 1.1/1


    1.2 Power flow diagram

    Gang = Gear ratio

    5 HP 24 © ZF Getriebe GmbH Saarbrücken, 98/08/01 1.2/1


    Zf 5hp24e Repair Manual
    Full download: http://manualplace.com/download/zf-5hp24e-repair-manual/

    This is the cut pages sample. Download all 130 page(s) at: ManualPlace.com

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