General Repair Instructions

General repair instructions, 09L, 6 Spd. A/T AWD
The maximum possible care and cleanliness and proper tools are essential for satisfactory and successful transmission repairs. The usual basic safety precautions also naturally apply when performing vehicle repairs.

A number of generally applicable instructions for the various repair procedures - which were previously repeated at numerous places - are summarized here. They apply to the work described.

Transmission
^ Read the rules for cleanliness when working on the automatic transmission go to Rules for cleanliness.
^ Do not run engine or tow vehicle with oil pan removed or when there is no ATF in the transmission.
^ If the transmission has been removed from vehicle, secure torque converter to prevent it from falling out.
^ Thoroughly clean all joints and surrounding areas before disassembling.
^ Before installing transmission check position of torque converter.
^ When installing transmission make sure dowel sleeves are correctly seated.
^ Carefully cover or seal open components if repairs cannot be carried out immediately.
^ When installing a new automatic transmission, check the following fluid levels and top off if necessary: ATF in the planetary gearbox go to ATF level, checking and correcting, the gear oil in the front final drive go to Front final drive gear oil, the transfer gear oil go to Transfer gear oil. Capacities and specifications go to Capacities
^ When installing a new rear final drive, check the oil level in the rear final drive and top off if necessary. Capacities and specifications go to Rear Final Drive.

O-rings, oil seals, gaskets
^ Always install new O-rings, oil 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.





^ Before installing oil seals, fill the space between the sealing lips - arrow - half full with sealing grease G 052 128 A1
^ The open side of the oil seals faces toward the side with fluid filling.
^ Before installing, lightly lubricate outer circumference of seal and sealing lips with ATF or gear oil, depending on location.
^ Lightly lubricate O-rings with ATF before installation to prevent them from getting crushed during assembly.
^ Use only ATF in ATF area. Other lubricants will cause the transmission hydraulics to malfunction.
^ When installing a new oil seal, position the seal in the housing so that sealing lip does not contact the shaft in the same place as the old seal (make use of insertion depth tolerances).
^ Replace paper gaskets, clean all sealing surfaces thoroughly and remove previous gaskets completely.
^ After installing, check the relevant fluid levels and top off if necessary: ATF in planetary gearbox go to ATF level, checking and correcting, gear oil in front final drive go to Front final drive gear oil, transfer gear oil go to Transfer gear oil, gear oil in rear final drive go to Rear Final Drive.

Nuts, bolts
^ Loosen bolts in reverse sequence to the specified tightening sequence.
^ Nuts and bolts which secure covers and housings should be loosened and tightened in diagonal sequence and in stages if no tightening sequence is specified.
^ The tightening torques stated apply to non-oiled nuts and bolts.
^ Always replace self-locking bolts and nuts.
^ Clean threads of bolts which are secured by a locking compound with a wire brush. Then apply locking fluid AMV 185 101 A1 to bolts again before installing.
^ Threaded holes which take self-locking bolts or bolts coated with locking compound must be cleaned (using a tap or similar). Otherwise there is a danger of the bolts shearing when subsequently being removed.

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

Bearings
^ Lubricate bearings with gear oil or ATF, depending on location.

Mechatronics unit

CAUTION:
^ Before touching or removing the mechatronics unit, always discharge any static electricity by touching vehicle ground or other grounded object by hand.
^ Never touch the 16 contacts in connector - B - with your hands, as static discharge would damage the control module and mechatronics unit.

^ Replace the transmission if any of the shift elements are scorched.
^ Allocate mechatronics unit according to transmission code letters Parts catalog.





Guided fault finding, vehicle self-diagnosis and testing system
^ Before servicing the automatic transmission, the exact cause of the failure must be determined as precisely as possible via the vehicle diagnostic, testing and information system VAS 5051 A in the modes Guided Fault Finding, vehicle self-diagnosis and testing system.