5 Speed A/T 01L AWD

General repair instructions
Maximum possible care and cleanliness, as well as proper too Is, are essential for satisfactory and successful transmission repairs. Also, the generally applicable basic rules of safety naturally apply when performing repair work.

Special tools
A list of special tools used in this repair information appears at the beginning of certain service procedures.

Transmission
^ Do not run the engine or tow the vehicle if the oil pan is removed or if there is no ATF in the 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.
^ Capacities and specifications.
^ Before installing the transmission, check the installation dimension of the torque converter.
^ When installing the transmission, make sure that the dowel sleeves are correctly seated.
^ When the transmission is removed, secure the torque converter to prevent it from falling out of the transmission.
^ Thoroughly clean connection points and surrounding areas before disconnecting.
^ Place removed parts on a clean surface and cover them with foil or paper. Do NOT use cloths with lint!
^ Carefully cover or close open components if repairs are not to be carried out immediately.
^ Install only clean parts. Do not remove replacement parts from their wrapping until just before installing them.
^ Rules for cleanliness when working on the automatic transmission.

O-rings, seals, gaskets
^ Always replace sealing rings and gaskets.
^ After removing gaskets, always inspect the contact surface on the housing or shaft for burrs resulting from removal and for signs of damage.
^ Coat O-rings with a thin coat of ATF at outer circumference and at sealing lip before installing.
^ Coat sealing rings with ATF or Vaseline before inserting in order to avoid pinching of the rings during installation.
^ Never use other lubricants in surrounding area of the ATF. Otherwise danger of improper functioning of the hydraulic transmission control may occur.
^ The open side of each sealing ring faces the fluid to be sealed.
^ After installing, check the gear oil and ATF levels, and correct if necessary.

Circlips
^ 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.
^ If no tightening sequence is specified, bolts and nuts attaching housings and covers must be loosened and tightened in stages and in an alternating diagonal pattern.
^ Tightening torques specified in repair procedures are for non-lubricated 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.

Bearings
^ Install needle bearings with the inscribed side (thicker metal) facing the drift
^ Insert bearings into transmission using ATF. Oil with special care for friction torque measurements.
^ Do not interchange outer and inner rings with the same bearing diameter.
^ Always replace tapered roller bearings which are installed on one shaft as a set from a single manufacturer.

Adjustment shims
^ Measure adjustment shims in several locations with a micrometer. Different shim thicknesses make it possible to select the required thickness precisely.
^ Check for burrs or damage. Only install adjustment shims which are in perfect undamaged condition.