ZF 5HP19FL Automatic Transmission - Spare Parts Catalog .

ZF 5HP19FL Automatic Transmission - Spare Parts CatalogTable of Contents5HP19FL Transmission Overview (North American Applications)Make / Model / Model Year5HP19FL Technical InformationTorque, Gear Ratio & WeightTransmission Oil Reference Guide5HP19FL Lubrications5HP19FL Technical Literature5HP19FL General Transmission Oil Filling Procedure5HP19FL General Differential Oil Filling Procedure5HP19FL Spare PartsHow To Use This CatalogGearbox Housing GroupOil Sump GroupOil Supply GroupConverter GroupPlanetary Drive GroupsFront Axle Differential GroupFront Axle Output GroupClutch Pack Groups5HP19FL Valve BodyDuct Plate GroupValve Housing Groups5HP19FL Selective Shims, Snap Rings & Kit Content5HP19FL Selective Shims & Snap Rings5HP19FL Kit ContentMiscellaneousQuotation / Order FormNotesAll Rights ReservedFor Reference Only02030303030406070810111314161819252937444849 2003 ZF Industries, Inc. - Page 1

ZF 5HP19FL Automatic Transmission - Spare Parts Catalog5HP19FL Transmission Overview (North American Applications)Make / Model / Model Year – AudiMake ModelStyleAudi A4Avant 1.8 LiterAudiA4Avant 2.8 LiterAudiA4Sedan 1.8 LiterAudiA4Sedan 2.8 LiterAudiA6Avant 2.8 LiterAudiA6Sedan 2.8 LiterAudiA8Sedan 3.7 LiterModel Year1997 – 199920002000 – 20021996 – 19971996 – 199719972000 – 20021996 – 199920002000 – 20021996 – 19981996 – 19981996 – 19992000 – 200219982000 – 20012000 – 20011998 – 19992000 – 20012000 – 20011997 – 1999From – Up to07/96 – 07/9908/99 – 05/0005/00 – 10/0007/95 – 07/9710/96 – 02/9703/97 – 07/9705/00 – 10/0007/96 – 07/9908/99 – 05/0005/00 – 10/0007/95 – 07/9710/96 – 02/9703/97 – 07/9905/00 – 10/0008/97 – 07/9808/99 – 04/0106/00 – 04/0108/97 – 07/9908/99 – 04/0106/00 – 04/0108/97 – ZDPSEKCEZZDPSEKCEZZCJZOE Part #01V 300 041Q01V 300 043Q01V 300 048G01V 300 041N01V 300 041E01V 300 042T01V 300 048P01V 300 041Q01V 300 043Q01V 300 048G01V 300 041N01V 300 041E01V 300 042T01V 300 048P01V 300 042P01V 300 046E01V 300 048P01V 300 042P01V 300 046E01V 300 048P01V 300 041FZF Part #1060 030 0131060 030 0491060 030 0721060 030 0051060 030 0111060 030 0211060 030 0881060 030 0131060 030 0491060 030 0721060 030 0051060 030 0111060 030 0211060 030 0881060 030 0271060 030 0591060 030 0881060 030 0271060 030 0591060 030 0881060 030 006From – Up to07/97 – 07/9908/99 – 05/0005/00 – 08/0010/97 – 08/0003/01 – 04/02CodeDDTEFPEZSDRDEZZOE Part #01V 300 041Q01V 300 043Q01V 300 048G01V 300 042T01V 300 048PZF Part #1060 030 0131060 030 0491060 030 0721060 030 0211060 030 088Make / Model / Model Year – tStyleSedan 1.8 LiterSedan 1.8 LiterSedan 1.8 LiterSedan 2.8 LiterSedan 2.8 LiterModel Year1998 – 19991999 – 200020001998 – 20001991 – 2003Note: This spare parts catalog includes only transmission specification numbers for North Americanapplications. For all other 5HP19FL transmission specification numbers, please contact your preferred ZFpassenger 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 Porsche5HP19FL / 5HP19HL / 5HP19HLA spare parts catalog.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 5HP19FL Automatic Transmission - Spare Parts Catalog5HP19FL Technical InformationTorque, Gear Ratio & WeightInput Torque310 ear0.74RevGear4.10WeightOil Capacity(approximate)(approximate)110 kg (242 lbs.) 9.4 liter (10 quart)Transmission Oil Reference GuideMakeAudiOil GradeESSO LT 71141Type Plate (color)GreenVWESSO LT 71141GreenZF Part #1060 030 0051060 030 0061060 030 0111060 030 0131060 030 0211060 030 0271060 030 0491060 030 0591060 030 0721060 030 0881060 030 0131060 030 0211060 030 0491060 030 0721060 030 088OE Part #01V 300 041N01V 300 041F01V 300 041E01V 300 041Q01V 300 042T01V 300 042P01V 300 043Q01V 300 046E01V 300 048G01V 300 048P01V 300 041Q01V 300 042T01V 300 043Q01V 300 048G01V 300 048P5HP19FL LubricationsAmount10 Liter20 Liter205 LiterZF Part #Where usedDescription0671 090 162 Oil BURMAH SAF AG4 (Canister)0671 090 166 Oil ESSO LT 71141 (Canister)0671 090 169 Oil ESSO LT 71141 (Drum)(1060 030 )NotesAllUse only in differentialAllAllUse only in transmissionUse only in transmission5HP19FL Technical LiteratureLanguageZF Part HP19FLREP1060 764 0025HPVBMAN5HP19FL Functional Description5HP19FL Repair Manual5HP19FL Wall Chart5-Speed Valve Body ManualAll Rights ReservedFor Reference OnlyWhere used(1060 030 )NotesAllAllAllAll 2003 ZF Industries, Inc. - Page 3

ZF 5HP19FL Automatic Transmission - Spare Parts Catalog5HP19FL Technical Information (continued)5HP19FL 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 5HP19FL Automatic Transmission - Spare Parts Catalog5HP19FL Technical Information (continued)5HP19FL 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 8Nm (see also Repair Manual).Fill PlugAll Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 5

ZF 5HP19FL Automatic Transmission - Spare Parts Catalog5HP19FL Technical Information5HP19FL General Differential Oil Filling ProcedureAdding 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. 35.370).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 PlugAll Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 6

ZF 5HP19FL 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 7

ZF 5HP19FL Automatic Transmission - Spare Parts Catalog5HP19FL Spare Parts - Gearbox Housing GroupPos 18001.180/12001.200ZF Part #1060 201 0661060 201 0671060 301 1001060 301 1010734 313 0601056 301 1401060 301 0171060 324 0061060 324 0041060 201 0051060 324 0070736 617 0740630 504 0030501 314 4321056 301 0940736 101 1311060 206 0231060 306 0070736 101 240DescriptionQtyGearbox HousingGearbox HousingGearbox HousingGearbox HousingO-RingOil TubePinPawlLeg SpringConnecting BarGuiding PlateTorx Screw M8x30Locking WasherSpeed SensorSpacer RingTorx Screw M6x27Detent SpringRollerTorx Screw M6x131111211111131111112Where used(1060 030 )All (except 006)006NotesAll (except 006)006All* Available in kit 1060 298 032AllAllAllAllAllAllAllAllAllAllAllAllAllAllNote: Parts marked with * are only available in kits.All Rights ReservedFor Reference Only 2003 ZF Industries, Inc. - Page 8