General Repair Instructions

GENERAL
Maximum possible care and cleanliness, as well as proper tools, are essential for satisfactory and successful transmission repairs. The generally applicable basic rules of safety naturally also apply when performing repair work.

A series of generally valid instructions that apply to individual repair operations-otherwise listed at several points in these Repair instructions.

AUTOMATIC TRANSMISSION
When the transmission is replaced, the ATF in the planetary gearbox and the gear oil in the final drive must be checked and topped up if necessary.

When installing the transmission, make sure that the dowel sleeves are correctly seated.

GASKETS, SEALS
Always replace O-rings.

RADIAL SHAFT SEALS
Before installing, pack the space between the sealing lips with multi-purpose grease. Do not oil the outer diameter of the seal.

After installing, check gear oil level or ATF level, correct if necessary.

LOCKING ELEMENTS
Do not over-stress circlips, replace if necessary.

Circlips must be properly seated, to the inside of the groove.

NUTS, BOLTS
When attaching covers and housings, loosen and tighten nuts and bolts evenly, alternating in a diagonal pattern.

Do not misalign particularly sensitive parts by tightening them unevenly, loosen and tighten evenly in stages.

Tightening torques specified in repair procedures are for non-oiled nuts and bolts.

Always install new self-locking nuts and bolts.

BEARINGS
Install needle bearings with the inscribed side (thicker metal) facing the drift.

Install all transmission bearings using gear oil. Oil the bearings particularly carefully for measuring the friction torque.

Heat inner races of tapered roller bearings to approx. 100°C (212°F) before installing.

Do not interchange inner and outer races for bearings of the same size.

When replacing tapered roller bearings, always replace all the bearings a the same shaft, and always use bearings from the same manufacturer.

SHIMS
Measure shims at several points with a micrometer to determine their thickness.

Different tolerances in shims of the same nominal thickness enable the required shim thickness to be precisely gauged.

Check for burrs or damage. Install only shims that are in proper condition.

ON BOARD DIAGNOSTIC (OBD)
Before performing repair work on the automatic transmission, precisely determine the cause of the malfunction.