ZF 5HP19FL. Automatic Transmission Spare Parts Catalog

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1 ZF 5HP19FL Automatic Transmission Spare Parts Catalog

2 Warranty Information Warranty coverage for ZF passenger car transmission spare parts and kits covers the first 12 months after installation in the vehicle, or 24 months after purchase from ZF Industries, Inc. Warranty of the product is limited to replacement or repair, if found to be defective in ZF material or workmanship, and specifically does not cover removal, reinstallation, or any costs incidental to the repair of the vehicle, or any kind of consequential damages. All warranty and/or non-warranty returns must be approved. Disclaimer The specifications and information shown in this catalog have been compiled from accepted and reliable sources and is believed to be accurate at the time of publication. While ZF Industries, Inc. believes this information is correct, no guarantee or warranty is made as to the accuracy of the information and ZF Industries, Inc. cannot and does not accept or assume any responsibilities for errors, omissions, or consequential harm or damages. Replacement parts should not be used when they do not appear to fit. ZF Industries, Inc. disclaims all liability and responsibility for any harm resulting from any such modifications. Copyright Printed in USA Copyright 2003 ZF Industries, Inc. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of ZF Industries, Inc. Distributed By

3 Table of Contents 5HP19FL Transmission Overview (North American Applications) Make / Model / Model Year 02 5HP19FL Technical Information Torque, Gear Ratio & Weight 03 Transmission Oil Reference Guide 03 5HP19FL Lubrications 03 5HP19FL Technical Literature 03 5HP19FL General Transmission Oil Filling Procedure 04 5HP19FL General Differential Oil Filling Procedure 06 5HP19FL Spare Parts How To Use This Catalog 07 Gearbox Housing Group 08 Oil Sump Group 10 Oil Supply Group 11 Converter Group 13 Planetary Drive Groups 14 Front Axle Differential Group 16 Front Axle Output Group 18 Clutch Pack Groups 19 5HP19FL Valve Body Duct Plate Group 25 Valve Housing Groups 29 5HP19FL Selective Shims, Snap Rings & Kit Content 5HP19FL Selective Shims & Snap Rings 37 5HP19FL Kit Content 44 Miscellaneous Quotation / Order Form All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 1

4 5HP19FL Transmission Overview (North American Applications) Make / Model / Model Year Audi Make Model Style Model Year From Up to Code OE Part # ZF Part # Audi A4 Avant 1.8 Liter /96 07/99 DDT 01V Q /99 05/00 EFP 01V Q /00 10/00 EZS 01V G Audi A4 Avant 2.8 Liter /95 07/97 DCS 01V N /96 02/97 CJY 01V E /97 07/97 DRD 01V T /00 10/00 EZZ 01V P Audi A4 Sedan 1.8 Liter /96 07/99 DDT 01V Q /99 05/00 EFP 01V Q /00 10/00 EZS 01V G Audi A4 Sedan 2.8 Liter /95 07/97 DCS 01V N /96 02/97 CJY 01V E /97 07/99 DRD 01V T /00 10/00 EZZ 01V P Audi A6 Avant 2.8 Liter /97 07/98 DPS 01V P /99 04/01 EKC 01V E /00 04/01 EZZ 01V P Audi A6 Sedan 2.8 Liter /97 07/99 DPS 01V P /99 04/01 EKC 01V E /00 04/01 EZZ 01V P Audi A8 Sedan 3.7 Liter /97 12/98 CJZ 01V F Make / Model / Model Year VW Make Model Style Model Year From Up to Code OE Part # ZF Part # VW Passat Sedan 1.8 Liter /97 07/99 DDT 01V Q VW Passat Sedan 1.8 Liter /99 05/00 EFP 01V Q VW Passat Sedan 1.8 Liter /00 08/00 EZS 01V G VW Passat Sedan 2.8 Liter /97 08/00 DRD 01V T VW Passat Sedan 2.8 Liter /01 04/02 EZZ 01V P Note: This spare parts catalog includes only transmission specification numbers for North American applications. For all other 5HP19FL transmission specification numbers, please contact your preferred ZF passenger car transmission distributor for more information about available spare parts and kits. For North American 5HP19FL transmissions used in Porsche applications, please refer to the Porsche 5HP19FL / 5HP19HL / 5HP19HLA spare parts catalog. Type Plate: One type plate is located on the main housing of transmission; second type plate located on bottom of bell housing. Please refer to ZF transmission specification # when searching for spare parts and kits in this catalog (last three digits). Transmission Serial # ZF Transmission Specification # Vehicle Manufacturer Transmission # All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 2

5 5HP19FL Technical Information Torque, Gear Ratio & Weight 1 st 2 nd 3 rd 4 th 5 th Rev Input Torque Weight Oil Capacity Gear Gear Gear Gear Gear Gear (approximate) (approximate) 310 Nm kg (242 lbs.) ~9.4 liter (10 quart) Transmission Oil Reference Guide Make Oil Grade Type Plate (color) ZF Part # OE Part # Audi ESSO LT Green V N V F V E V Q V T V P V Q V E V G V P VW ESSO LT Green V Q V T V Q V G V P 5HP19FL Lubrications Amount ZF Part # Description 10 Liter Oil BURMAH SAF AG4 (Canister) All Use only in differential 20 Liter Oil ESSO LT (Canister) All Use only in transmission 205 Liter Oil ESSO LT (Drum) All Use only in transmission 5HP19FL Technical Literature Language ZF Part # Description English 5HP19FLFD 5HP19FL Functional Description All English 5HP19FLREP 5HP19FL Repair Manual All Eng/Ger HP19FL Wall Chart All English 5HPVBMAN 5-Speed Valve Body Manual All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 3

6 5HP19FL Technical Information (continued) 5HP19FL General Transmission Oil Filling Procedure Position vehicle horizontally on hoist and apply the handbrake. Connect tester to read off transmission oil temperature and engine speed. With the engine stopped, add ATF, only use lubricants as to specification (see Page 3), through the fill hole until oil emerges from fill hole. Install Fill Plug (Pos ). Start the engine (large consumers, such as A/C should be switched on). Shift through gears with engine running at idle speed. Select R and D and use step shift (manual-winter program) to shift through to 3 rd gear. Hold each gear for 3 seconds and engage the parking lock. Idle speed should be n eng = rpm (according to vehicle manufacturer s directive). Oil temperature should be between 86º 95ºF (30º 35ºC). NO YES Depending on value allow oil to cool down or warm up. Shift through gears with engine at idle speed. Select R and D and use step shift (manualwinter program) to shift through to 3 rd gear. Hold each gear for 3 seconds and engage the parking lock. Remove fill plug (Pos ) on housing. Continues on next page All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 4

7 5HP19FL Technical Information (continued) 5HP19FL General Transmission Oil Filling Procedure (continued) Continues from previous page Oil emerges at oil temperature below 95ºF (35ºC). NO YES Oil level in transmission is below minimum. Add ATF, only use lubricants as to specification (see Page 3), through the fill hole until oil emerges from fill hole. Wait until oil temperature reaches 104ºF ±18ºF (40ºC ±10ºC). Oil temperature must not exceed 122ºF (50ºC). Allow time for excess oil to drip then install Fill Plug (Pos ). Torque Fill Plug to 80Nm ±8Nm (see also Repair Manual). Fill Plug All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 5

8 5HP19FL Technical Information 5HP19FL General Differential Oil Filling Procedure Adding oil to 5HP19FL differential. Oil is added to the cold differential, approximately 68ºF (~20ºC), until it overflows. Allow time for excess oil to drip then install differential fill plug (Pos ). Torque fill plug to 35Nm ±3.5Nm (see also Repair Manual). Oil capacity is approximately 0.82 liter (~0.87 quart). Only use lubricants as to specification (see Page 3). Fill Plug All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 6

9 How To Use This Catalog Table of Contents Each transmission group of this catalog is listed in the table of contents. This spare parts catalog includes only transmission specification numbers for North American applications. Technical Information All technical information is specific to the transmission models that are referenced in this catalog. Weight and oil capacity information are only approximate and may vary by actual transmission specification. For any technical inquiry, please contact your preferred ZF passenger car transmission distributor for assistance. For a list of technical literature available from ZF or for answers to frequently asked questions about ZF transmissions visit us at Spare Parts Each transmission is divided into groups (e.g. gearbox housing group). The position number (Pos #) is used to identify the location of each spare part in the transmission. A position number like is either a spare part or an assembly. A position number like /110 is a subcomponent of an assembly. Please contact your preferred ZF passenger car transmission distributor about availability of assemblies and subcomponents. The part number (ZF part #) is used to identify a specific spare part and is usually ten-digits (kits, lubricants, and technical literature have exceptions). Please use this part number, when ordering ZF spare parts. The description (Description) identifies the spare part. The quantity (Qty) is the amount of spare parts included in one transmission model for a certain position number. The quantity may vary depending on the transmission specification and certain spare parts may be used in multiple positions in the transmission. This catalog includes only spare parts for North American specifications of a ZF transmission application. The where used column ( ( )) shows the last three digits of the transmission specification that uses the listed spare part. If the column indicates All, then all North American transmission specification use this spare part. The notes column () gives more information about the spare part (e.g. included in a kit). Example: ( ) Gearbox Housing 1 087/ Gearbox Housing / Gearbox Housing 1 087/ Gearbox Housing Selective Shims, Snap Rings & Kit Content Each list for selective shims or snap rings is listed in this section of the catalog. Please measure the clearance according to the repair manual and select the required spare part from the table. The kit content section shows all available kits for the transmission models that are referenced in this catalog, including the content of each kit. All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 7

10 5HP19FL Spare Parts - Gearbox Housing Group Gearbox Housing 1 All (except 006) Gearbox Housing / Gearbox Housing 1 All (except 006) Gearbox Housing / O-Ring 2 All * Available in kit / Oil Tube 1 All Pin 1 All Pawl 1 All Leg Spring 1 All Connecting Bar 1 All Guiding Plate 1 All Torx Screw M8x30 3 All Locking Washer 1 All Speed Sensor 1 All Spacer Ring 1 All Torx Screw M6x27 1 All Detent Spring 1 All / Roller 1 All Torx Screw M6x13 2 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 8

11 5HP19FL Spare Parts - Gearbox Housing Group (continued) Selector Shaft 1 All / Selector Shaft 1 All / Gear Shift Lever 1 All / Clamping Sleeve 1 All Detent Disc 1 All Clamping Sleeve 1 All Shaft Seal 1 All * Available in kit Screw Plug M10x1 1 All * Available in kit Sealing Sleeve 5 All * Available in kit Sealing Sleeve 3 All * Available in kit Compression Spring 3 All Retaining Ring 3 All Selector Level 1 All Clamping Sleeve 1 All Position Switch 1 All (except 072/088) Position Switch 1 072/ Cylindrical Pin 1 All Cable Terminal 1 All Fixing Plate 1 All Torx Screw M6x15 2 All Counters. Screw M6x20 1 All Breather Tube 1 All Breather Cover 1 All Plug 2 All Breather 1 All Protecting Cap 1 072/ Plug 1 All (except 072/088) All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 9

12 5HP19FL Spare Parts Oil Sump Group Oil Sump 1 All Gasket 1 All Torx Screw M6x22 27 All Magnet 4 All Magnet 2 All Cap 1 All Screw Plug M6x1.5 1 All * Available in kit * Available in kit 5HP19FKFL * Available in kit * Available in kit 5HP19FKFL Screw Plug M30x1.5 1 All * Available in kit 5HP19FKFL O-Ring 1 All * Available in kit * Available in kit 5HP19FKFL All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 10

13 5HP19FL Spare Parts - Oil Supply Group Pump 1 All / Sleeve 1 All / Washer 1 All / Shaft Seal 1 All * Available in kit O-Ring 1 All * Available in kit Intermediate Sheet 1 All Intermediate Plate 1 All / Intermediate Plate 1 All / Counters. Screw M6x20 5 All Counters. Screw M6x40 8 All Counters. Screw M6x48 1 All Torx Screw M5x55 1 All Cylinder C 1 006/011/021/ Cylinder C 1 005/013/049/059/072/ O-Ring 1 All * Available in kit O-Ring 1 All * Available in kit Piston 1 All Torx Screw M5x14 3 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 11

14 5HP19FL Spare Parts - Oil Supply Group (continued) Cup Spring 1 All Stop-Ring 1 All Undulated Spring 1 All Steel Plate C 4 005/013 * Available in kit Steel Plate C 5 006/011/021/ * Available in kit Steel Plate C 3 049/059/072/088 * Available in kit Friction Plate C 4 005/013 * Available in kit Friction Plate C 5 006/011/021/ * Available in kit Friction Plate C 3 049/059/072/088 * Available in kit End Plate C 1 * Available in kit End Plate C 1 049/059/072/088 * Available in kit See Page 37 Clutch C Snap Ring 1 All Selective Snap Ring O-Ring 1 All * Available in kit Piston Ring 2 All * Available in kit Piston Ring 1 All * Available in kit Axial Needle Bearing 1 All See Page 37 Intermediate Plate Shim 1 All Selective Snap Ring Torx Screw M6x65 9 All Usit Ring 9 All * Available in kit All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 12

15 5HP19FL Spare Parts Converter Group Torque Converter J Torque Converter N /059/ Torque Converter F / Torque Converter A /049/ Torque Converter T All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 13

16 5HP19FL Spare Parts Planetary Drive Groups Bearing Set 1 All Shaft 1 005/011/013/021// 049/ Shaft 1 072/ Ring Gear / Shaft / Ring Gear Ring Gear 1 072/ / Snap Ring 1 005/011/013/021// 049/059/072/ /011/013/021// 049/ /011/013/021// 049/059/072/ Bearing Set 1 All Spider Clutch Bell 1 049/059/072/ Spider Clutch Bell Planet Carrier 1 /049/ Planet Carrier 1 072/ Sun Gear 1 072/ Sun Gear 1 049/ Sun Gear Axial Needle Bearing 1 All Sun Gear Shaft 1 All Bearing Set 1 All Intermediate Shaft 1 All Bearing Set 1 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 14

17 5HP19FL Spare Parts Planetary Drive Groups (continued) Planet Carrier 1 All Bearing Set 1 All Sun Gear 1 All Bearing Set 1 All Ring Gear 1 All / Ring Gear Carrier 1 All / Ring Gear 1 All / Snap Ring 1 All Bearing Set 1 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 15

18 5HP19FL Spare Parts Front Axle Differential Groups Bevel Gear Set Bevel Gear Set 1 006/059/ Bevel Gear Set Bevel Gear Set 1 011/ Bevel Gear Set 1 013/049/ / Tapered Roller Bearing 1 All / Tapered Roller Bearing 1 All Tapered Roller Bearing 1 All Nut 1 All See Page 37 Pinion Bearing Shim 1 All Selective Shim Retaining Ring 1 All Double Seal 1 All * Available in kit See Page 38 Diff. Bearing Shim 1 All Selective Shim See Page 39 Diff. Cover Shim 1 All Selective Shim O-Ring 1 All * Available in kit Cover 1 All / Differential Cover 1 All / Shaft Seal 1 All * Available in kit / Oil Baffle Plate 1 All / Magnet 1 All / Torx Screw M6x14 3 All Torx Screw M8x45 12 All Output Flange 1 013/049/ Output Flange 1 005/006/011/021// 059/088 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 16

19 5HP19FL Spare Parts Front Axle Differential Groups (continued) Bearing Ring 1 All Anti-Fatigue Bolt M8 1 All Flange Shaft 1 013/049/ Flange Shaft 1 005/006/011/021// 059/ / Speedo Cover 1 All / Shaft Seal 1 All * Available in kit / Ball Bearing 1 All / Flange Shaft 1 All / Magnetic Ring 1 All / Compression Spring 1 013/049/ / Tappet 1 013/049/ / Retaining Ring 1 All Speed Sensor 1 All / O-Ring 2 All * Available in kit Cap 1 All Sealing Ring 1 All * Available in kit Torx Screw M8x45 3 All Shaft Seal 1 All * Available in kit Parking Lock Wheel 1 All Compression Spring 1 All See Page 40 Idler Gear Shim 1 All Selective Shim See Page 41 Output Shaft Gear Shim 1 All Selective Shim See Page 40 Pinion Gear Shim 1 All Selective Shim Screw Plug M18x1.5 1 All * Available in kit All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 17

20 5HP19FL Spare Parts Front Axle Output Groups Gasket 1 All * Available in kit Bush 1 All Axial Needle Bearing 1 All See Page 41 Output Shim 1 All Selective Shim Front Axial Housing 1 All (except 006) Front Axial Housing Pinion Pinion 1 All (except 006) / Tapered Roller Bearing 1 All / Tapered Roller Bearing 1 All Idler Gear Idler Gear 1 All (except 006) / Tapered Roller Bearing 1 All / Tapered Roller Bearing 1 All 011/013/021/049/059/ Helical Gear 1 072/ Helical Gear Helical Gear 1 005/ / Tapered Roller Bearing 1 All / Tapered Roller Bearing 1 All Torx Screw M8x45 14 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 18

21 5HP19FL Spare Parts Clutch Pack Groups Cylinder A 1 005/006/011/021/ Cylinder A Cylinder A 1 059/ Cylinder A 1 049/ / Cylinder A 1 005/006/011/021/ Cylinder A Cylinder A 1 059/ Cylinder A 1 049/ / O-Ring 1 All * Available in kit / O-Ring 1 All * Available in kit / Cup Spring 1 All / Stop Plate 1 All / Piston 1 All / Spring Clutch Disc 1 049/059/072/ Spring Clutch Disc / Steel Plate A 4 013/049/ Steel Plate A 5 005/006/011/021// 059/088 * Available in kit * Available in kit * Available in kit * Available in kit / Friction Plate A * Available in kit Friction Plate A 5 005/006/011/021/ * Available in kit Friction Plate A 4 049/072 * Available in kit Friction Plate A 5 059/088 * Available in kit / End Plate A 1 All * Available in kit * Available in kit /230 See Page 42 Clutch A Snap Ring 1 All Selective Snap Ring O-Ring 1 All * Available in kit All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 19

22 5HP19FL Spare Parts Clutch Pack Groups (continued) Input Shaft 1 All Piston Ring 1 All * Available in kit Sealing Ring 1 All * Available in kit Piston 1 013/049/ Piston 1 005/006/011/021// 059/ O-Ring 1 All * Available in kit O-Ring 1 All * Available in kit Cup Spring 1 All Oil Dam 1 All O-Ring 1 All * Available in kit Retaining Ring 1 All Spring Clutch Disc 1 All Steel Plate E 4 013/049/ Steel Plate E 5 005/006/011/021// 059/088 * Available in kit * Available in kit * Available in kit * Available in kit Friction Plate E * Available in kit Friction Plate E 5 005/006/011/021/ * Available in kit Friction Plate E 4 049/072 * Available in kit Friction Plate E 5 059/088 * Available in kit End Plate E 1 All * Available in kit * Available in kit See Page 42 Clutch E Snap Ring 1 All Selective Snap Ring O-Ring 1 All * Available in kit O-Ring 1 All * Available in kit Ring 1 All Retaining Ring 1 All Axial Needle Bearing 1 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 20

23 5HP19FL Spare Parts Clutch Pack Groups (continued) Cylinder B 1 All Piston 1 All O-Ring 1 All * Available in kit O-Ring 1 All * Available in kit Undulated Spring Undulated Spring 1 049/059/072/ Steel Plate B 2 All Friction Plate B 2 * Available in kit * Available in kit * Available in kit Friction Plate B 2 049/059/072/088 * Available in kit End Plate B 1 All * Available in kit * Available in kit See Page 42 Clutch B Snap Ring 1 All Selective Snap Ring Cup Spring 1 All Stop-Ring 1 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 21

24 5HP19FL Spare Parts Clutch Pack Groups (continued) Cylinder D Cylinder D 1 005/006/011/021/ Cylinder D 1 049/ Cylinder D 1 059/ / Cylinder D 1 005/006/011/021/ Cylinder D 1 013/049/ Cylinder D 1 059/ / Piston 1 All / O-Ring 1 All * Available in kit / O-Ring 1 All * Available in kit / Cup Spring 1 All / Undulated Spring Spring Clutch Disc 1 049/059/072/ / Steel Plate D Steel Plate D 6 059/ / Friction Plate D 5 /049/072 * Available in kit * Available in kit * Available in kit * Available in kit * Available in kit Friction Plate D 5 049/072 * Available in kit Friction Plate D 6 059/088 * Available in kit / End Plate D 1 All * Available in kit * Available in kit /200 See Page 43 Clutch D Snap Ring 1 All Selective Snap Ring / Fitting Key 2 All Piston 1 All O-Ring 1 All * Available in kit O-Ring 1 All * Available in kit All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 22

25 5HP19FL Spare Parts Clutch Pack Groups (continued) Cup Spring 1 All Undulated Spring 1 049/059/072/ Spring Clutch Disc Steel Plate G 3 013/049/ Steel Plate G 4 005/006/011/021// 059/088 * Available in kit * Available in kit * Available in kit * Available in kit Friction Plate G 3 049/072 * Available in kit Friction Plate G 4 059/088 * Available in kit Friction Plate G * Available in kit Friction Plate G 4 005/006/011/021/ * Available in kit * Available in kit * Available in kit End Plate G 1 All See Page 43 Clutch G Snap Ring 1 All Selective Snap Ring Fixing Washer 1 All Carrier Carrier 1 049/059/072/ / Carrier 1 All / Free Wheel Free Wheel 1 049/059/072/ / O-Ring 2 All * Available in kit Thrust Washer 1 All Snap Ring 1 All Piston Ring 1 All * Available in kit Piston Ring 1 All * Available in kit Snap Ring 1 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 23

26 5HP19FL Spare Parts Clutch Pack Groups (continued) Cylinder F 1 005/006/011/021/ Cylinder F Cylinder F 1 049/ Cylinder F 1 059/ /006/011/021// 059/ Cylinder F 1 013/049/ / Cylinder F / Piston 1 All / O-Ring 1 All * Available in kit / O-Ring 1 All * Available in kit / Pressure Plate 1 All / Cup Spring 1 All / Stop-Ring 1 All / Undulated Spring 1 049/059/072/ Spring Clutch Disc / Steel Plate F 5 013/049/ Steel Plate F 6 005/006/011/021// 059/088 * Available in kit * Available in kit * Available in kit * Available in kit / Friction Plate F * Available in kit Friction Plate F 5 005/006/011/021/ * Available in kit Friction Plate F 4 049/072 * Available in kit Friction Plate F 5 059/088 * Available in kit /210 See Page 43 Clutch F Snap Ring 1 All Selective Snap Ring All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 24

27 5HP19FL Valve Body Duct Plate Group Duct Plate Duct Plate 1 049/059/072/ Speed Sensor (Hall Effect) 1 049/059/072/ Speed Sensor Torx Screw M6x /059/072/ Torx Screw M5x Spacer Ring Screen 1 All Valve 1 All Valve Ball Ball 3 049/059/072/ Valve Orifice D= Valve Orifice D= /059/072/ Valve Orifice D= /059/072/ Valve Orifice D=1.7 1 All Valve Orifice D= /059/072/ Valve Orifice D=1.2 1 All Valve Orifice D= /059/072/ Valve Orifice D= Valve Orifice D= Valve Orifice D= /059/072/ Valve Orifice D=2.5 1 All Valve Orifice D=1.0 1 All Valve Orifice (solid) Valve Orifice D= Valve Orifice D= Valve Orifice D= /059/072/ Valve Orifice D= Valve Orifice D= /059/072/088 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 25

28 5HP19FL Valve Body Duct Plate Group (continued) Valve Orifice (solid) 1 049/059/072/ Valve Orifice D=1.0 1 All Rubber Part 1 All * Available in kit Piston 1 All * Available in kit Valve Orifice D=1.0 1 All Valve Orifice D= /059/072/ Rubber Part 1 All * Available in kit Piston 1 All * Available in kit Valve Orifice D=1.0 1 All Rubber Part 1 All * Available in kit Piston 1 All * Available in kit Valve Orifice D=1.0 1 All Gasket Intermediate Sheet 1 * Available in kit Gasket 1 049/059/072/088 * Available in kit Intermediate Sheet 1 049/059/072/ Torx Screw M5x60 4 All Torx Screw M5x60 7 All Torx Screw M5x40 10 All Fixing Plate 1 All Cylindrical Pin 1 All Torx Screw M6x44 5 All Wiring Harness 1 049/059/072/ Wiring Harness / O-Ring 2 All * Available in kit Cable Terminal 1 All Clip 1 All Retaining Clamp 1 All Torx Screw M6x / Torx Screw M6x /013/021/ Torx Screw M6x / Torx Screw M6x59 16 All (except 005/011) Filter 1 All * Available in kit 5HP19FKFL / Sealing Ring 1 All Torx Screw M5x / Torx Screw M5x12 2 All (except 005/011) Valve 1 049/059/072/ Valve 1 049/059/072/ Protecting Cap 1 All * Available in kit * Available in kit 5HP19FKFL All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 26

29 5HP19FL Valve Body Duct Plate Group (continued) Exploded view of Duct Plate Group for following applications: All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 27

30 5HP19FL Valve Body Duct Plate Group (continued) Exploded view of Duct Plate Group for following applications: /059/072/088 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 28

31 5HP19FL Valve Body Valve Housing Groups Valve Housing Valve Housing 1 049/059/072/ Selector Shift Valve 1 All Piston 1 All Spring Cup 1 All Compression Spring 1 049/059/072/ Compression Spring Piston 1 All Stop Plate 1 All Piston Piston 1 049/059/072/ Compression Spring 1 049/059/072/ Compression Spring Valve Valve Spool 1 All Compression Spring Compression Spring 1 049/059/072/ Plug Support Plate Piston 1 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 29

32 5HP19FL Valve Body Valve Housing Groups (continued) Spring Cup Piston Damper Piston 1 049/059/072/ Compression Spring Compression Spring 1 049/059/072/ Stop Plate Piston Piston 1 049/059/072/ Compression Spring Compression Spring 1 049/059/072/ Valve Spool 1 All Compression Spring Compression Spring 1 049/059/072/088 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 30

33 5HP19FL Valve Body Valve Housing Groups (continued) Support Plate 1 All Piston Piston 1 049/059/072/ Compression Spring Compression Spring 1 049/059/072/ Valve Spool 1 All Compression Spring Compression Spring 1 049/059/072/ Sealing Cap 1 049/059/072/ Support Plate 1 All Cover Cover 1 049/059/072/ Torx Screw M5x Torx Screw M5x /059/072/088 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 31

34 5HP19FL Valve Body Valve Housing Groups (continued) Valve Housing 1 049/059/072/ Valve Housing Valve Spool 1 All Compression Spring 1 049/059/072/ Compression Spring Support Plate 1 All Gear Shift Slide 1 All Compression Spring Compression Spring 1 049/059/072/ Plug 1 All Support Plate 1 All Piston 1 All Compression Spring Compression Spring 1 049/059/072/ Support Plate 1 All Valve Spool 1 All Compression Spring Compression Spring 1 049/059/072/ Support Plate 1 All Piston 1 All Spring Cup 1 All Compression Spring Compression Spring 1 049/059/072/088 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 32

35 5HP19FL Valve Body Valve Housing Groups (continued) Piston 1 All O-Ring 1 All * Available in kit Plug 1 All Locking Wire 1 All Stop Plate 1 All Piston Piston 1 049/059/072/ Stop Plate 1 049/059/072/ Spring Cup Compression Spring 1 049/059/072/ Compression Spring Compression Spring Piston Damper Piston 1 049/059/072/ O-Ring 1 All * Available in kit Plug 1 All Locking Wire 1 All Stop Plate Piston Piston 1 049/059/072/088 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 33

36 5HP19FL Valve Body Valve Housing Groups (continued) Compression Spring Compression Spring 1 049/059/072/ Piston 1 049/059/072/ Plug 1 All Support Plate 1 All Valve Spool 1 All Compression Spring 1 049/059/072/ Compression Spring Support Plate 1 All Piston 1 All Compression Spring Compression Spring 1 049/059/072/ Support Plate 1 All Solenoid Valve 3 049/059/072/088 * Available in kit Solenoid Valve Pressure Regulator 3 * Available in kit * Available in kit Pressure Regulator 3 049/059/072/088 * Available in kit / O-Ring 3 049/059/072/ / O-Ring Fixing Plate 2 All Torx Screw M5x12 4 All * Available in kit * Available in kit * Available in kit * Available in kit All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 34

37 5HP19FL Valve Body Valve Housing Groups (continued) Valve Housing 1 005/006/ Valve Housing 1 011/021/ Valve Housing 1 049/059/072/ Compression Spring Compression Spring 1 049/059/072/ Piston 1 049/059/072/ Piston Compression Spring 1 049/059/072/ Compression Spring Piston 1 011/021/ Piston 1 005/006/ Piston 1 049/059/072/ Piston Piston 1 049/059/072/ Piston 1 All Stop Plate 1 All Compression Spring 1 All Piston 1 All Compression Spring 1 049/059/072/ Compression Spring Cover 1 049/059/072/ Cover Torx Screw M5x18 5 All All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 35

38 5HP19FL Valve Body Valve Housing Groups (continued) Valve Housing Valve Housing 1 005/011/013/021/ Valve Housing 1 049/059/072/ Compression Spring 1 All Piston 1 All (except 006) Piston Compression Spring 1 All Piston 1 049/059/072/ Piston Plug Plug 1 049/059/072/ Support Plate 1 All Valve Orifice D=1.2 1 All Stop Plate 1 All Valve Spool 1 All Compression Spring 1 049/059/072/ Compression Spring Support Plate 1 All Pressure Regulator 1 * Available in kit Pressure Regulator 1 049/059/072/088 * Available in kit / O-Ring 1 049/059/072/088 * Available in kit / O-Ring Fixing Plate 1 All Torx Screw M5x12 1 All * Available in kit * Available in kit All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 36

39 5HP19FL Selective Shims & Snap Rings 5HP19FL Selective Snap Ring Pos # Select. Parts Description Qty Clutch C Snap Ring 1 All Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A=2.80 5HP19FL Selective Shim Pos # Select. Parts Description Qty Intermediate Plate Shim 1 All Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A=3.60 5HP19FL Selective Shim Pos # Select. Parts Description Qty Pinion Bearing Shim 1 All Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A=1.42 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 37

40 5HP19FL Selective Shims & Snap Rings (continued) 5HP19FL Selective Shim (continued) Pos # Select. Parts Description Qty Pinion Bearing Shim 1 All Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A=1.87 5HP19FL Selective Shim Pos # Select. Parts Description Qty Diff. Bearing Shim 1 All Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A=1.37 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 38

41 5HP19FL Selective Shims & Snap Rings (continued) 5HP19FL Selective Shim (continued) Pos # Select. Parts Description Qty Diff. Bearing Shim 1 All Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A=1.92 5HP19FL Selective Shim Pos # Select. Parts Description Qty ( ) Diff. Cover Shim 1 All Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A=1.57 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 39

42 5HP19FL Selective Shims & Snap Rings (continued) 5HP19FL Selective Shim (continued) Pos # Select. Parts Description Qty ( ) Diff. Cover Shim 1 All Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A=1.90 5HP19FL Selective Shim Pos # Select. Parts Description Qty ( ) Idler Gear Shim 1 All Pinion Gear Shim Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A=2.00 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 40

43 5HP19FL Selective Shims & Snap Rings (continued) 5HP19FL Selective Shim Pos # Select. Parts Description Qty ( ) Output Shaft Gear Shim 1 All Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A=1.90 5HP19FL Selective Shim Pos # Select. Parts Description Qty ( ) Output Shim 1 All Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A= Shim A=8.60 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 41

44 5HP19FL Selective Shims & Snap Rings (continued) 5HP19FL Selective Snap Ring Pos # Select. Parts Description Qty ( ) /230 Clutch A Snap Ring 1 All Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A=2.80 5HP19FL Selective Snap Ring Pos # Select. Parts Description Qty ( ) Clutch E Snap Ring 1 All Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A=2.80 5HP19FL Selective Snap Ring Pos # Select. Parts Description Qty ( ) Clutch B Snap Ring 1 All Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A= Snap Ring A=2.20 All Rights Reserved For Reference Only 2003 ZF Industries, Inc. - Page 42

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