Repair Instructions

Considerable care and cleanliness as well as the proper tools are essential prerequisites for performing proper and successful transmission repairs. The general basic rules of safety also apply to repair work.
A number of generally applicable notes for individual repair procedures - which are otherwise listed several times at many points in the service procedures - have been combined here.

Transmission
- Do not run the engine and do not tow the car if the oil pan is removed or does not contain ATF
- If the automatic transmission is replaced, check the ATF in the planetary gear and the gear oil in the final drive and top up, if necessary.
- Capacities and specifications; refer to Specifications.
- Before installing the transmission, check the installed dimension of the torque converter.
- When installing the transmission, ensure that the dowel sleeves are correctly located.
- When the transmission is removed, protect the torque converter from dropping out.
- Thoroughly clean connection points and the surrounding area before disconnecting.
- Place removed parts on a clean surface and cover. Use sheeting and paper. Do not use fluffy cloths!
- Carefully cover or seal open parts if repairs are not performed immediately.
- Install only clean parts; do not remove replacement parts from their wrapping until just before installing.
- Pay attention to the rules for cleanliness when performing work on the automatic transmission.

O-rings, seals, gaskets
- Always replace O-rings, seals and gaskets.
- After removing gaskets, examine the contact surface on the housing or shaft for burrs or signs of damage related to disassembly.
- Apply a thin coat of petroleum jelly to O-rings before inserting in order to avoid the rings being squeezed when being installed.
- Apply a thin coat of petroleum jelly to the outer circumference and to the sealing lip of sealing rings for installing.
- Always use only a small quantity of petroleum jelly. Other greases cause operational problems to the hydraulic transmission control.
- The open side of the seals faces toward the sealing fluid.
- After installing, check level of gear oil or ATF and adjust to correct level, if necessary.

Circlips
- Do not over-tension circlips; always replace.
- Circlips must be properly positioned in the base of the groove.

Nuts and bolts
- Tighten nuts and bolts for attaching covers and housings or the valve body in stages in accordance with the specified tightening order and method.
- Loosen the bolts in the opposite order of tightening.
- Tighten and loosen nuts and bolts for attaching covers and housings diagonally in stages if no specific tightening order is stated.
- The tightening torques stated apply to nuts and bolts which have not been oiled.
- Clean the threads of bolts to be installed with locking fluid with a wire brush. Then install bolts with AMV 185 100 Al.
- Replace self-locking nuts.

Bearings
- Install needle bearings with the inscribed side (thicker metal) facing the insertion drift.
- Install bearings with gear oil or ATF depending on the installed location.

Shims
- Measure shims at several points with a micrometer. Different tolerances are available which make it possible to precisely gauge the required thickness of shim.
- Check shim for burrs or damage.
- Install only shims which are in good condition.

On Board Diagnostic (OBD)
- Before performing repair work on the automatic transmission, determine the cause of the malfunction as accurately as possible by means of, On Board Diagnostic (OBD), refer to Powertrain Management; Computers and Control Systems.

WARNING!
When a second technician is required to read test equipment during a road test, move the front passenger seat to the rear most position, place the test equipment on the floor between the front passenger's feet. Objects between front seat occupants and the airbag can increase the risk of injury in an accident.