Repair Instructions

Repair instructions, 09G, 6 Speed A/T
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.
A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in these procedure, are summarized here.

Special tools
A listing of special tools required precedes most procedures.

Transmission
^ Do not run engine or tow vehicle with oil pan removed or when there is no ATF in the transmission.
^ When replacing the automatic transmission the ATF must be checked and topped off, if necessary.
^ If the transmission is removed from the vehicle, secure the torque converter to prevent it from dropping out.
^ Thoroughly clean all unions and the adjacent areas before disconnecting.
^ Check the installation depth of the torque converter before installing the transmission.
^ Before installing, ensure that the dowel sleeves are correctly located.
^ Place removed parts on a clean surface and cover. Use sheeting and paper and cover with lint-free cloths.
^ Carefully cover or seal open components if repairs cannot be performed immediately.
^ Only install clean components: do not remove replacement parts from their wrapping until they are ready to be installed.

O-rings, seals, gaskets
^ Always replace O-rings, sealing rings 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.
^ Always replace paper seals. Completely remove old seal and clean sealing surfaces thoroughly.
^ Lightly lubricate the outer circumference and sealing lip of sealing rings with ATF before installing.
^ Lightly lubricate O-rings with ATF before inserting to prevent them being trapped and damaged when assembling.
^ Do not use any other lubricants in or on components that are lubricated with ATF. Otherwise, problems may occur with the hydraulic actuation of the transmission.
^ The open side of the sealing rings faces toward the side with fluid filling.
^ After installing, check ATF level and correct as necessary.

Locking elements
^ Do not over-stretch circlips; replace if necessary.
^ Circlips must be properly seated in the base of their groove.

Nuts, bolts
^ Loosen the bolts in reverse sequence to the specified tightening sequence.
^ Nuts and bolts which secure covers and housings should be loosened and tightened crosswise in stages if no tightening sequence is specified.
^ Replace self-locking nuts.
^ The threads of bolts which are secured by a locking compound should be cleaned with a wire brush. Then apply AMV 185 101 A1 when inserting.
^ The tightening torques stated apply to non-oiled nuts and bolts.

Guided fault finding, vehicle self-diagnosis and testing system





^ Before performing repairs to the automatic transmission, determine the cause of the malfunction as precisely as possible using the vehicle diagnostic, testing and information system VAS 5051 in "Guided fault finding", "Vehicle self-diagnosis" and "Testing system" modes.