ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog .
ZF 5HP19FLA Automatic Transmission - Spare Parts CatalogTable of Contents5HP19FLA Transmission Overview (North American Applications)Make / Model / Model Year5HP19FLA Technical InformationTorque, Gear Ratio & WeightTransmission Oil Reference Guide5HP19FLA Lubrications5HP19FLA Technical Literature5HP19FLA General Transmission Oil Filling Procedure5HP19FLA General Differential Oil Filling Procedure5HP19FLA General Transfer Case Oil Filling Procedure5HP19FLA Spare PartsHow To Use This CatalogGearbox Housing GroupOil Sump GroupOil Supply GroupConverter GroupPlanetary Drive GroupsFront Axle Differential GroupRear Axle Output GroupFront Axle Output GroupInternal Differential Lock GroupClutch Pack Groups5HP19FLA Valve BodyDuct Plate GroupValve Housing Groups5HP19FLA Selective Shims, Snap Rings & Kit Content5HP19FLA Selective Shims & Snap Rings5HP19FLA Kit ContentMiscellaneousQuotation / Order FormNotesAll Rights ReservedFor Reference 5758 2003 ZF Industries, Inc. - Page 1
ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog5HP19FLA Transmission Overview (North American Applications)Make / Model / Model Year – AudiMake ModelStyleAudi A4Quattro 1.8 LiterAudiA4Quattro 2.8 LiterAudiA4Quattro 3.0 LiterAudiAudiS4A6Quattro 2.7 LiterQuattro 2.7 LiterAudiA6Quattro 2.8 LiterAudiAudiAudiA6Quattro 3.0 LiterAllroad QuattroAllroad Quattro 2.7 LiterModel Year1998 – 200220002000 – 20012002 – 20032002 – 20031996 – 19971998 – 19991999 – 20002000 - 20012002 – 20032002 – 20031999 – 20021998 – 20002000 – 20011998 – 1999199920002000 – 20012002 – 20032002 – 20032000 – 2003From – Up to08/97 – 12/9808/99 – 05/0005/00 – 10/0009/01 – 06/0207/02 –10/95 – 04/9708/97 – 12/9808/99 – 05/0006/00 – 08/0109/01 – 06/0207/02 –08/99 – 05/0005/99 – 05/0006/00 – 05/0108/97 – 07/9802/99 – 07/9908/99 – 05/0006/00 – 05/0106/01 –09/02 –05/00 – QDPTEKXEKDFASFEJFXLEYKOE Part #01V 300 043H01V 300 044G01V 300 049F01V 300 045Q01V 300 052Q01V 300 041G01V 300 043A01V 300 046H01V 300 049M01V 300 045T01V 300 052T01V 300 046T01V 300 046T01V 300 049K01V 300 042Q01V 300 046K01V 300 046H01V 300 049M01V 300 050K01V 300 052N01V 300 050AZF Part #1060 040 0181060 040 0301060 040 0541060 040 0731060 040 1011060 040 0021060 040 0121060 040 0351060 040 0651060 040 0871060 040 1031060 040 0441060 040 0441060 040 0631060 040 0131060 040 0361060 040 0351060 040 0651060 040 0751060 040 0931060 040 053From – Up to06/98 – 04/9908/99 – 05/0003/01 – 04/0212/01 – 04/02CodeDRNEKDFASGAKOE Part #01V 300 043A01V 300 046H01V 300 049M01V 300 052PZF Part #1060 040 0121060 040 0351060 040 0651060 040 100Make / Model / Model Year – VWMake ModelStyleModel YearVWPassat Sedan 2.8L (4-Motion) 1999 – 200120002001 – 2003VWPassat Sedan 4.0L (4-Motion) 2002 – 2003Note: This spare parts catalog includes only transmission specification numbers for North Americanapplications. For all other 5HP19FLA transmission specification numbers, please contact your preferredZF passenger car transmission distributor for more information about available spare parts and kits.Type Plate: One type plate is located on the main housing of transmission; second type platelocated on bottom of bell housing. Please refer to ZF transmission specification # whensearching for spare parts and kits in this catalog (last three digits).Transmission Serial #ZF Transmission Specification #Vehicle Manufacturer Transmission #All Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 2
ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog5HP19FLA Technical InformationTorque, Gear Ratio & WeightInput Torque420 ear0.80RevGear4.10WeightOil Capacity(approximate)(approximate) 142 kg (312 lbs.) 9.5 liter (10.1 quart)Transmission Oil Reference GuideMakeAudiOil GradeESSO LT 71141Type Plate (color)GreenVWESSO LT 71141GreenZF Part #1060 040 0021060 040 0121060 040 0131060 040 0181060 040 0301060 040 0351060 040 0361060 040 0441060 040 0531060 040 0541060 040 0631060 040 0651060 040 0731060 040 0751060 040 0871060 040 0931060 040 1011060 040 1031060 040 0121060 040 0351060 040 0651060 040 100OE Part #01V 300 041G01V 300 043A01V 300 042Q01V 300 043H01V 300 044G01V 300 046H01V 300 046K01V 300 046T01V 300 050A01V 300 049F01V 300 049K01V 300 049M01V 300 045Q01V 300 050K01V 300 045T01V 300 052N01V 300 052Q01V 300 052T01V 300 043A01V 300 046H01V 300 049M01V 300 052P5HP19FLA LubricationsAmount10 Liter20 Liter205 Liter10 Liter0.050 LiterZF Part #Where usedDescription(1060 040 )0671 090 162 Oil BURMAH SAF AG4 (Canister)All0671 090 1660671 090 169S671 600 020V671 600 020AllOil ESSO LT 71141 (Canister)Oil ESSO LT 71141 (Drum)Oil STURACO FM 1992Oil STURACO FM 1992NotesUse only in differential andtransfer caseUse only in transmissionAllUse only in transmissionAllUse only in transfer caseAllUse only in transfer case5HP19FLA Technical LiteratureLanguageZF Part HP19FLREP1060 764 0025HPVBMAN5HP19FLA Functional Description5HP19FLA Repair Manual5HP19FLA Wall Chart5-Speed Valve Body ManualAll Rights ReservedFor Reference OnlyWhere used(1060 040 )NotesAllAllAllAll 2003 ZF Industries, Inc. - Page 3
ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog5HP19FLA Technical Information5HP19FLA General Transmission Oil Filling ProcedurePosition 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. 03.130).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 3rd gear.Hold each gear for 3 seconds and engage the parking lock.Idle speed should be neng 650 950 rpm (according to vehicle manufacturer’s directive).Oil temperature should be between 86º 95ºF (30º 35ºC).NOYESDepending on value allow oil to cool down orwarm up.Shift through gears with engine at idle speed.Select R and D and use step shift (manualwinter program) to shift through to 3rd gear.Hold each gear for 3 seconds and engagethe parking lock.Remove fill plug (Pos. 03.130) on housing.Continues on next pageAll Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 4
ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog5HP19FLA Technical Information5HP19FLA General Transmission Oil Filling Procedure (continued)Continues from previous pageOil emerges at oil temperature below 95ºF (35ºC).NOYESOil level in transmission is below minimum.Add ATF, only use lubricants as tospecification (see Page 3), through the fillhole 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. 03.130). Torque Fill Plug to 80Nm 8.0Nm (see also Repair Manual).Fill PlugAll Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 5
ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog5HP19FLA Technical Information5HP19FLA General Differential Oil Filling ProcedureAdding oil to 5HP19FLA 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. 35.370).Torque fill plug to 35Nm 83.5Nm (see also Repair Manual).Oil capacity is approximately 0.82 liter ( 0.87 quart). Only use lubricants as to specification(see Page 3).Fill PlugAll Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 6
ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog5HP19FLA Technical Information5HP19FLA General Transfer Case Oil Filling ProcedureAdding oil to 5HP19FLA transfer case (Parallel Axis Torsen – PAT) with separate oil content.Oil is added to the cold differential, approximately 68ºF ( 20ºC), until it overflows.Allow time for excess oil to drip then install transfer case fill plug (Pos. 36.350).Torque fill plug to 35Nm 3.5Nm (see also Repair Manual).Oil capacity is approximately 0.80 liter ( 0.85 quart). Only use lubricants as to specification(see Page 3).Note: The addition of 0.034 liter ( 0.036 quart) Sturaco FM 1992 (see Page 3) is only necessary after atransfer case repair or renewal (exchange) of the Torsen differential.After installation in the transfer case, it is added in a vertical position and in a direct axial direction to theTorsen differential.Fill PlugAll Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 7
ZF 5HP19FLA Automatic Transmission - Spare Parts CatalogHow To Use This CatalogTable of ContentsEach transmission group of this catalog is listed in the table of contents. This spare parts catalog includesonly transmission specification numbers for North American applications.Technical InformationAll technical information is specific to the transmission models that are referenced in this catalog. Weightand oil capacity information are only approximate and may vary by actual transmission specification. Forany technical inquiry, please contact your preferred ZF passenger car transmission distributor forassistance. For a list of technical literature available from ZF or for answers to frequently asked questionsabout ZF transmissions visit us at www.zf-group.com.Spare PartsEach transmission is divided into groups (e.g. gearbox housing group). The position number (Pos #) isused to identify the location of each spare part in the transmission. A position number like 01.010 is eithera spare part or an assembly. A position number like 01.010/110 is a subcomponent of an assembly.Please contact your preferred ZF passenger car transmission distributor about availability of assembliesand 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 ZFspare 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 positionnumber. The quantity may vary depending on the transmission specification and certain spare parts maybe 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 (Where used (10 000 )) shows the last three digits of the transmissionspecification that uses the listed spare part. If the column indicates “All”, then all North Americantransmission specification use this spare part.The notes column (Notes) gives more information about the spare part (e.g. included in a kit).Example:Pos #01.010ZF Part #1056 201 0841056 201 08701.010/110 1056 301 1741056 301 175DescriptionQtyGearbox HousingGearbox HousingGearbox HousingGearbox Housing1111Where used(1056 000 )087/088081Notes087/088081Selective Shims, Snap Rings & Kit ContentEach list for selective shims or snap rings is listed in this section of the catalog. Please measure theclearance 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 thiscatalog, including the content of each kit.All Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 8
ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog5HP19FLA Spare Parts - Gearbox Housing GroupPos #01.010ZF Part #DescriptionQty1060 201 066 Gearbox Housing11060 201 0761060 201 0781060 201 0821060 201 098Gearbox HousingGearbox HousingGearbox HousingGearbox Housing111101.010/110 1060 301 100 Gearbox Housing11060 301 1111060 301 1121060 301 1201060 301 13001.010/130 0734 313 06001.010/140 1056 301 14001.0201060 301 01701.0301060 324 00601.0401060 324 00401.0501060 201 00501.0601060 324 00701.0800736 617 07401.1000630 504 00301.1200501 314 43201.1301056 301 09401.1400736 101 13101.1801060 206 02301.180/120 1060 306 00701.2000736 101 2401111211111131111112Gearbox HousingGearbox HousingGearbox HousingGearbox HousingO-RingOil TubePinPawlLeg SpringConnecting BarGuiding PlateTorx Screw M8x30Locking WasherSpeed SensorSpacer RingTorx Screw M6x27Detent SpringRollerTorx Screw M6x13Where used(1060 040 s* Available in kit 1060 298 031AllAllAllAllAllAllAllAllAllAllAllAllAllAllNote: Parts marked with * are only available in kits.All Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 9
ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog5HP19FLA Spare Parts - Gearbox Housing Group (continued)Pos #ZF Part 2001.3301060 206 0211056 306 0431060 206 0170501 320 3961060 206 0150501 320 3960734 319 6240501 318 5720734 317 2680734 317 2270732 041 7460630 532 8001056 206 0380501 320 39601.4000501 209 896 Position Switch10501 317 994 Position Switch1Where usedQtySelector ShaftSelector ShaftGear Shift LeverClamping SleeveDetent DiscClamping SleeveShaft SealScrew Plug M10x1Sealing SleeveSealing SleeveCompression SpringRetaining RingSelector LeverClamping Sleeve11111111533311Notes(1060 040 )AllAllAllAllAllAllAll* Available in kit 1060 298 031All* Available in kit 1060 298 031All* Available in kit 1060 298 031All* Available in kit 1060 298 054/063/065/073/075/087/093/100/101/103Note: Parts marked with * are only available in kits.All Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 10
ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog5HP19FLA Spare Parts - Gearbox Housing Group (continued)Pos 1.64001.680ZF Part #DescriptionWhere usedQty01.6840631 306 1840501 318 9010501 315 0330501 318 8990736 101 2330736 401 0650501 318 9000501 314 8090501 315 4550501 212 9141060 290 0260501 319 031Cylindrical PinCable TerminalTerminalFixing PlateTorx Screw M6x15Counters. Screw M6x20Breather TubeBreather CoverPlugBreatherBreatherCable Terminal11112111211101.7000501 318 771 Protecting Cap10637 900 038 Plug1Notes(1060 040 )AllAll073/087/101/103AllAllAllAllAllAllAll (except : Parts marked with * are only available in kits.All Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 11
ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog5HP19FLA Spare Parts – Oil Sump GroupPos #ZF Part #DescriptionWhere usedQty(1060 040 )03.0101060 203 002 Oil Sump1All03.0201056 303 031 Gasket1All03.04403.07003.08003.1000736 101 3181043 301 0361043 301 0361060 303 002Torx Screw M6x22MagnetMagnetCap27421All03.1200636 308 026 Screw Plug M6x1.51All03.1300636 302 102 Screw Plug M30x1.50734 313 176 O-Ring11AllNotes* Available in kit 1060 298 031* Available in kit 5HP19FKFLAllAllAllAll* Available in kit 1060 298 031* Available in kit 5HP19FKFL* Available in kit 5HP19FKFL* Available in kit 1060 298 031* Available in kit 5HP19FKFLNote: Parts marked with * are only available in kits.All Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 12
ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog5HP19FLA Spare Parts - Oil Supply GroupPos #ZF Part 0.0601060 210 0241043 319 0581056 310 0750734 310 3160734 313 1781060 310 0911060 210 0321060 210 03510.060/110 1060 210 0301060 210 03410.060/130 0736 401 06110.1000736 401 06210.1200736 401 06310.1600736 101 iptionWhere usedQtyPumpSleeveWasherShaft SealO-RingIntermediate SheetIntermediate PlateIntermediate PlateIntermediate PlateIntermediate PlateCounters. Screw M6x20Counters. Screw M6x40Counters. Screw M6x48Torx Screw M5x55111111111158111060 310 105 Cylinder C11060 310 106 Cylinder C10734 313 0060734 313 1171056 310 0810736 101 1970501 315 9291056 310 061111311O-RingO-RingPistonTorx Screw M5x14Cup SpringStop-RingNotes(1060 040 )AllAllAllAll* Available in kit 1060 298 031All* Available in kit 1060 298 031AllAll (except 093/100)093/100093/100All (except 7/093/100/103002/018/030/035/054/065/073/101All* Available in kit 1060 298 031All* Available in kit 1060 298 031AllAllAllAllNote: Parts marked with * are only available in kits.All Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 13
ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog5HP19FLA Spare Parts - Oil Supply Group (continued)Pos 0.39010.40010.440ZF Part #DescriptionWhere usedQty0501 316 284 Undulated Spring1060 310 004 Steel Plate C141060 310 004 Steel Plate C51060 310 027 Steel Plate C31019 273 019 Friction Plate C1019 273 019 Friction Plate C1060 210 037 Friction Plate C4531060 210 037 Friction Plate C51060 310 005 End Plate C11060 310 027 End Plate C1See Page 460734 313 1620750 113 0150734 401 2130750 115 437See Page 460736 101 1650750 112 07611211199Clutch C Snap RingO-RingPiston RingPiston RingAxial Needle BearingIntermediate Plate ShimTorx Screw M6x65Usit RingNotes(1060 040 030/035/054/065/073/101All* Available in kit 1060 298 026Selective Snap RingAll* Available in kit 1060 298 031All* Available in kit 1060 298 031All* Available in kit 1060 298 031* Available in kit 1060 298 026* Available in kit 1060 298 025* Available in kit 1060 298 024* Available in kit 1060 298 024* Available in kit 1060 298 022* Available in kit 1060 298 022* Available in kit 1060 298 026* Available in kit 1060 298 025AllAllSelective ShimAllAll* Available in kit 1060 298 031Note: Parts marked with * are only available in kits.All Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 14
ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog5HP19FLA Spare Parts – Converter GroupPos #22.020ZF Part #4168 025 0464168 025 0634168 025 0694168 025 0854168 025 1274168 025 1864168 025 189DescriptionQtyTorque Converter N28Torque Converter F31Torque Converter A33Torque Converter F35Torque Converter T45Torque Converter Q56Torque Converter P561111111Where used(1060 040 075/087/103002100093NotesNote: Parts marked with * are only available in kits.All Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 15
ZF 5HP19FLA Automatic Transmission - Spare Parts Catalog5HP19FLA Spare Parts – Planetary Drive GroupsPos #ZF Part #Description32.0201056 232 105 Bearing Set132.0401056 232 089 Shaft1060 232 026 Shaft1060 232 048 Ring Gear11132.040/110 1056 232 085 Shaft132.040/120 1056 332 037 Ring Gear1060 332 028 Ring Gear1132.040/130 0730 513 330 Snap Ring132.0601056 232 104 Bearing Set132.0741050 317 060 Spider Clutch Bell11056 232 079 Spider Clutch Bell11050 232 052 Planet Carrier11060 232 0321060 232 0411060 232 0421060 232 0500735 368 0431060 202 0011056 232 1011056 232 0711056 232 .200Where usedQtyPlanet CarrierSun GearSun GearSun GearAxial Needle BearingSun Gear ShaftBearing SetIntermediate ShaftBearing SetNotes(1060 040 6/087/103054/065/073002/012/013/0
Audi A4 Quattro 3.0 Liter 2002 – 2003 09/01 – 06/02 FEQ 01V 300 045T 1060 040 087 2002 – 2003 07/02 – GBJ 01V 300 052T 1060 040 103 Audi S4 Quattro 2.7 Liter 1999 – 2002 08/99 – 05/00 EMP 01V 300 046T 1060 040 044 Audi A6 Quattro 2.7 Liter 1998 – 2000 05/99 – 05/00 EMP 01V 300 046T 1060 040 044
ZF 6HP19X / 6HP21X Automatic Transmission – Spare Parts Catalog Type Plate Information The type plate is located on the main housing of the transmission. Please refer to the ZF transmission specification # when searching for spare parts and kits in this catalog. Transmission Serial # ZF Transmission Specification # Vehicle Manufacturer .
applications. For all other 5HP24 transmission specification numbers, please contact your preferred ZF passenger car transmission distributor for more in formation about available spare parts and kits. Type Plate: Located on the main housing of transmission. Please refer to ZF transmission
ZF 5HP30 Automatic Transmission - Spare Parts Catalog 5HP30 Spare Parts - Gearbox Housing Group Pos # ZF Part # Description Qty Where used (1055 000 _) Notes 01.010 1055 201 070 Gearbox Housing 1 010/017/027/029/032/ 040 1055 201 072 Gearbox Housing 1 026/028/031 1055 201 073 Gearbox Housing 1 011/030
ZF 6HP19 / 6HP21 Automatic Transmission – Spare Parts Catalog Type Plate Information The type plate is located on the main housing of the transmission. Please refer to the ZF transmission specification # when searching for spare parts and kits in this catalog. Transmission Serial #
ZF 5HP24 Automatic Transmission - Spare Parts Catalog 5HP24 Transmission Overview (North American Applications) Make / Model / Model Year – BMW (A5S 440Z) Make Model Style Model Year From – Up to Code OE Part # ZF Part # BMW 540i E39 Sedan (M60)
ZF 5HP30 Automatic Transmission - Spare Parts Catalog 5HP30 Transmission Overview (North American Applications) Make / Model / Model Year – BMW (A5S 560Z) Make Model Style Model Year From – Up to Code OE Part # ZF Part # BMW 540i E34 Sedan
ZF 5HP24 Automatic Transmission - Spare Parts Catalog 5HP24 Transmission Overview (North American Applications) Make / Model / Model Year – BMW (A5S 440Z) Make Model Style Model Year From – Up to Code OE Part # ZF Part # BMW 540i E39 Sedan (M60)
Abrasive Jet machining can be employed for machining super alloys and refractory from materials. This process is based on surface erosion process. The process parameters that control metal removal rate are air quality and pressure, Abrasive grain size, nozzle material, nozzle diameter, stand of distance between nozzle tip and work surface. INTRODUCTION: Abrasives are costly but the abrasive .
