Repair Instructions

Repair instructions

WARNING!: Before working on the engine when it is running, move the selector lever into the "P" position and apply the parking brake.

The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also, naturally apply when performing vehicle repairs.

Special tools
A list of required special tools is shown at the beginning of most of the procedures covered in information.

Transmission
^ Observe rules for cleanliness when working on the transmission.
^ Never run the engine or tow the vehicle with the end cover removed or without sufficient ATF (automatic transmission fluid).
^ Install only clean parts do not remove replacement parts from their wrapping until you are ready to install them.
^ After installing a transmission, the following fluid levels must be checked and topped off if necessary.

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 housing joint surfaces before assembling.
^ Lightly lubricate the outside surface and sealing lip of oil seals with ATF before installing.
^ Lightly lubricate O-rings with ATF before inserting to prevent them being trapped and damaged when assembling.
^ Use only ATF in the parts of the transmission where ATF is the specified lubricant, other lubricants will cause malfunctions in the hydraulics.
^ The open side of the oil seals faces toward the side with a fluid filling.
^ When replacing oil seals, always vary the point at which the sealing lips make contact (use insertion depth tolerances).
^ After installing a transmission, the following fluid levels must be checked and topped off if necessary:

Nuts, bolts
^ Loosen the bolts in reverse sequence to the specified tightening sequence.
^ Nuts and bolts which secure covers and housings should be tightened in stages according to the specified sequence and tightening method.
^ Nuts and bolts which secure covers and housings should be loosened and tightened diagonally in stages if no tightening sequence is specified.
^ The tightening torques stated apply to non-oiled nuts and bolts.
^ Replace self-locking nuts and bolts.
^ The threads of bolts which are secured by a locking fluid should be cleaned with a wire brush. Then apply AMV 185 101 Al when inserting.
^ Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. with a tap). Otherwise there is a danger of bolts shearing when subsequently being removed.

Locking elements
^ Do not overstretch circlips.
^ Always replace circlips which have been damaged or over-tensioned.
^ Circlips must be properly seated in the base of the groove.

Bearings
^ Install needle bearings with the lettering on the bearing (the side with thicker metal) facing toward the drift or other tool used for installing.
^ Lubricate bearings with gear oil or ATF, depending on installation location.
^ Do not interchange the outer or inner races of bearings of the same size.
^ Always replace the tapered roller bearings on one shaft together and use new bearings from a single manufacturer.

Shims
^ Use a micrometer to measure the shims at several points. Different tolerances make it possible to obtain the exact shim thickness required.
^ Inspect for burrs and signs of damage. Install only shims which are in perfect condition.

Guided fault-finding
Before starting any repair work, always perform the guided fault-finding procedure using the VAS 5051.