General Repair Instructions

General repair instructions
To ensure successful transmission repairs, always work with particular care and maintain a high standard of cleanliness. It is also important to use the correct tools and to make sure they are in good condition. The basic rules for safety must also be observed during repair work.

Special tools
For a complete list of special tools used in this Repair information
Refer to Special Tools Supplier

Transmission
^ When installing, make sure that the dowel sleeves between the engine and transmission are correctly installed.
^ Thoroughly clean all connections and the surrounding area before disconnecting.
^ When replacing a transmission, fill with gear oil to the lower edge of the filler hole.

Notes: If gear oil is added with the transmission installed, check the oil level as follows:
^ Top off with gear oil to the lower edge of the filler hole and reinstall filler plug. Start engine, engage a gear and allow transmission to turn for about 2 minutes. Switch off engine and again top off gear oil to lower edge of filler hole.





O-rings, seals, gaskets
^ Always replace O - rings, seals and gaskets.
^ After removing gaskets and seals, always inspect the contact surface on the housing or shaft for burrs resulting from removal or for other signs of damage. Thoroughly clean joint surfaces and apply sealant AMV 188 200 03. Apply sealant uniformly but not too thickly.
^ Before installing seals, lightly oil outer circumference and fill space between sealing lips (arrow) with a small amount of grease.
^ The open sides of the seals face the oil side.
^ When replacing seals, always vary the point at which the sealing lips make contact (use insertion depth tolerances).
^ Lightly oil O-rings before installing. This prevents the rings from being pinched when inserting.
^ Check gear oil level after replacing gaskets and seals. If necessary, top off so that oil is level is at bottom edge of filler hole.





Locking devices
^ Do not over - stretch circlips.
^ Always replace circlips which have been damaged or over - stretched.
^ Replace roll pins. Position: slot - A - should be in line with the line of force (arrow).
^ Circlips must locate properly in the groove.

Bolts and nuts
^ Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.
^ Especially delicate parts, such as clutch pressure plates, must not be distorted. Loosen and tighten bolts and nuts in stages in a diagonal sequence.
^ Tightening torques as specified are for unoiled bolts and nuts.
^ Replace self - locking bolts and nuts.

Bearings
^ Install needle bearings with lettered side (thicker metal) toward installation tool.
^ Lubricate all transmission bearings with gear oil.
^ Always replace the tapered roller bearings on one shaft together as a set and use new bearings from the same manufacturer.
^ Heat inner races of tapered roller bearings to approximately 100°C (212°F) before installing. Press on up to stop when installing so there is no axial clearance.
^ Do not interchange outer or inner bearing races of the same size. The bearing races are matched in pairs.

Shims
^ Measure shims at several points with a micrometer. With the various tolerances it is possible to find the exact shim thickness required.
^ Check for burrs and damage.
^ Only install undamaged shims.

Synchronizer rings
^ Do not interchange. When reusing, always reinstall to the same gear.
^ Check for wear and replace if necessary.
^ Coat with gear oil before installing.

Gears
^ Observe installation position.
^ Before installing, clean and heat on a hot plate to approximately 100°C (212°F).
^ Temperature can be checked with VAG1558 temperature tester.

Sliding gears
^ After installing, check axial clearance of 1st through 5th speed sliding gears. The gears should have a small amount of axial clearance and should rotate freely.

Clutch mechanism
^ When removing transmission, remove clutch slave cylinder without disconnecting lines.
^ If the slave cylinder is removed with the hydraulic line attached, do not depress the clutch pedal. Otherwise the piston will be pressed out of the slave cylinder.
^ Make sure that the pressure plate is kept straight: loosen and tighten bolts in a diagonal sequence and in several gradual stages.
^ To reduce odor caused by a burnt clutch, thoroughly clean the bellhousing, flywheel and the parts of the engine facing the transmission.