General Repair Instructions

Accurate and successful transmission repairs require:
- Care and cleanliness
- Proper tools, in good working order
- Observation of basic safety rules

A number of valid general instructions for various repair procedures are summarized here. They apply to this repair information.

Transmission
- while installing transmission, be sure that the dowel pins for aligning the engine and transmission are properly located
- After replacing the transmission, top up with gear oil to the lower edge of the filler hole
- Refer to "Application, Ratios, Capacities". Application and ID

Gaskets, Seals
- Always replace 0-rings
- Always replace radial shaft seals
- Before installing radial shaft seals, pack space between sealing lips with grease, and apply light film of oil around outer diameter
- After installing radial shaft seals, check gear oil level. Top off if necessary, up to lower edge of filler hole.
- Thoroughly clean mating surfaces, then apply sealing compound AMV 18820003
- Apply sealant uniformly, not too thick

Circlips
- Always replace
- Do not over-stretch circlips
- Circlips must be fully seated in the groove





Spring Pins
- Always replace spring pins
- Installed position: slot is longitudinal to line of force (arrow)

Screw, Bolts And Nuts
- Loosen and tighten all cover and housing fasteners in a diagonal sequence
- Especially sensitive parts such as clutch pressure plates must not be distorted. Loosen and tighten fasteners evenly in stages, in a diagonal sequence
- Tightening torque specifications are valid only for un-oiled bolts and nuts
- Always replace self-locking bolts and nuts

Torx tools are required for disassembly and assembly of the transmission. The following tools are used:
- Torx J60: relay shaft bolts
- Torx T40 or T45: all other Torx bolts

Bearings
- Install needle bearings with lettering (side with thicker material) toward the installation tool
- Grease needle bearings for the input shaft in the crankshaft.
- Lubricate all bearings in transmission with gear oil before installing. Lubricate with particular care when measuring friction torque.
- Always replace tapered roller bearings on the same shaft as a set. Always use bearings from the same manufacturer if possible
- Heat inner races of taper roller bearings to approx. 100°C (212°F) before installing
- Do not interchange inner and outer bearing races with those from other bearings of the same size

Shims
- Measure shims at several points using a micrometer. Varying tolerances make it possible to select the precise shim thickness required
- Check for burrs and signs of damage
- Only install shims that are in perfect condition

Synchronizer Rings
- Do not interchange
- When re-using, install synchronizer rings with the same gear with which they were previously matched
- Check for signs of wear; replace if necessary
- Lubricate with gear oil before installing

Gears
- Before pressing on, clean and heat to approx. 100°C (212°F) on a hot plate