General Repair Instructions

GENERAL REPAIR INSTRUCTIONS
Maximum possible care and cleanliness, as well as proper tools, are essential for satisfactory and successful transmission repairs. Also, the generally applicable basic rules of safety naturally apply when performing repair work.
A series of generally valid instructions that apply to individual repair operations-otherwise listed at several points are summarized here.

TRANSMISSION
^ When exchanging the automatic transmission, the levels of the ATF in the planetary gearbox and the gear oil in the final drive must be checked and corrected if necessary.
^ When installing the transmission, make sure that the dowel sleeves are correctly seated.

Rules Of Cleanliness For Working On Automatic Transmission
^ Thoroughly clean connecting points and the area around them before separating.
^ Place parts that have been removed on a clean surface and cover them. Use foil or paper. Do not use cloths with lint!
^ Carefully cover or close components that have been opened if repair will not be done immediately.
^ Install only clean parts. Only remove replacement parts from packaging when they are ready to be installed.
^ Always replace O-rings, sealing rings and gaskets.
^ After installation, check ATF level and top off if necessary.

O-RINGS, SEALS, GASKETS
^ Always replace O-rings, seals and gaskets.





^ Before installing radial shaft seals, lubricate the surface between the sealing lips and the outer circumference with grease.
^ After installing, check the gear oil and ATF levels, and correct if necessary.

CIRCLIPS AND RETAINERS
^ Do not over-stress circlips.
^ Replace if necessary.
^ Circlips must be properly seated in their grooves.

NUTS, BOLTS
^ Bolts and nuts attaching housings and covers or the valve body must be loosened and tightened in stages in accordance with the specified tightening sequence or method.
^ Loosen bolts and nuts in a sequence opposite to the tightening sequence.
^ Bolts and nuts attaching housings and covers must be loosened and tightened evenly in stages and in an alternating diagonal pattern if no tightening sequence is specified.
^ Tightening torques specified in repair procedures are for non-oiled nuts and bolts.
^ The threads of bolts which are coated with locking fluid must be cleaned with a wire brush and coated with AMV 185 100 Al before installation.
^ Always replace self-locking nuts.

BUSHINGS, BEARINGS
^ Install needle bearings with the inscribed side (thicker metal) facing the drift.
^ During installation, lubricate all transmission bearings using gear oil or VW ATF. Lubricate with special care for measuring turning torque.
^ Heat the inner races of taper roller bearings to approx. 100°C (212°F) before inserting.
^ Do not interchange the inner and outer races of the same size bearings.
^ Always replace taper roller bearings which are mounted on a shaft together as a set and use bearings from a single manufacturer.

SHIMS
^ Measure shims at several points with a micrometer. Different tolerances make it possible to obtain the exact shim thickness required.
^ Check for signs of burr and damage. Install only shims which are in perfect condition.

VALVE BODY
Replace the valve body if any of the selector elements are damaged.

ON BOARD DIAGNOSTIC (OBD)
Before carrying out repair work on the automatic transmission, precisely determine the cause of the malfunction. Refer to Transmission Control Systems.