Repair Information
Repair Information
The maximum possible care, cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also apply when carrying out vehicle repairs.
Some general repair information that applies to several procedures throughout this service information is summarized here. It applies to this repair information.
Oil, environmental and disposal regulations
• Handle ATF, axle oil and other oils carefully.
• Dispose of drained oil properly.
• Follow the legal environmental and disposal regulations.
• Follow the information provided on oil packaging.
Transmission
• Observe cleanliness rules when working on automatic transmissions. Refer to => [ Cleanliness Working Conditions ] Cleanliness Working Conditions.
• Do not run the engine or tow the vehicle with the oil pan removed or if there is no ATF in the transmission.
• Secure torque converter on removed transmission to keep it from falling out.
• Check installation dimension of torque converter before installing transmission. Refer to => [ Torque Converter, Installing ] Torque Converter, Installing.
• When installing transmission, ensure alignment bushings are fitted correctly.
• When replacing the automatic transmission, check the following fluid levels and fill if necessary: ATF in planetary gearing. Refer to => [ ATF Level In Planetary Gearing, Checking and Correcting ] ATF Level In Planetary Gearing, Checking and Correcting, gear oil in front final drive => [ ATF Level In Planetary Gearing, Checking and Correcting ] ATF Level In Planetary Gearing, Checking and Correcting, and gear oil in transfer case => [ Gear Oil Level in Transfer Case, Checking and Correcting ] Gear Oil Level in Transfer Case, Checking and Correcting. Capacities and specifications => [ Capacities ] 01V, 01VA Transmission.
• When replacing the rear final drive, check the oil level fill if necessary.
O-rings, shaft seals, seals
• O-rings, shaft seals and seals must be replaced.
• After removing seals, check the sealing surfaces on the housing or shaft for burrs resulting from removal or damage.
• Thoroughly clean housing joint surfaces before assembling.
• Before installing, lubricate shaft seal outer circumference and sealing lips with ATF or gear oil, depending on installation location.
• Coat O-rings with ATF before inserting to prevent crushing rings during installation.
• Never use any other lubricants in the same areas as the ATF. Otherwise, there is a risk that the hydraulic transmission controls could malfunction.
• Before installing the shaft seal, fill space between sealing lips - arrow - halfway with Grease (G 052 128 A1).
• The open side of the shaft seals point toward the fluid to be sealed in.
• Press in new shaft seal, so that the sealing lip does not run on the same point as the sealing lip of the old shaft seal (use insertion depth tolerances).
• After installing, checking gear oil level or ATF level and correct if necessary.
Fasteners
• Do not strain circlips (replace if necessary).
• Circlips must locate properly in the groove.
Bolts and Nuts
• Loosen bolts in reverse of 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.
• Clean threads of bolts that were applied with locking fluid using a wire brush. Then insert bolts with Locking Fluid (AMV 185 101 A1).
• Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. with a thread tap). Otherwise there is a risk that the bolts will shear the next time they are removed.
• The tightening specifications stated apply to non-oiled nuts and bolts.
Mount
• Install needle bearings with lettered side (thicker metal) towards fitting tool.
• Insert bearing in transmission with ATF. Lubricate especially carefully for friction torque measurement.
• 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.
Adjusting Shims
• Measure shims at several points using a micrometer. Different shim thicknesses make it possible to select the required thickness precisely.
• Check for burrs and damage. Only install perfect shims.
Valve Body
• Replace the transmission if any of the shift elements are scorched.
• Allocate the valve body to the transmission code.
Guided fault finding, vehicle diagnosis and test instruments
• Before performing repairs on the transmission, the cause of the malfunction must be determined as accurately as possible in the operating modes " Guided Fault Finding", "Vehicle On-Board Diagnosis" and " Test Instruments".