Components

Components, 02X, 6-Speed Four-Wheel Drive M/T

Transmission
^ Select correct bolts and other components according to transmission code letters.
^ When installing a new transmission, check oil level and fill up with oil if necessary.
^ Capacities and specifications go to Code letters, allocation, transmission ratios, capacities
^ When installing a new rear final drive unit, check oil level in rear final drive and top off if necessary.
^ Thoroughly clean all joints and surrounding areas before Disassembling.
^ When installing transmission make sure dowel sleeves are correctly seated.

Sealants
^ Thoroughly clean joint surfaces on transmission housing etc. before applying sealing paste.
^ Apply sealing paste AMV18800102 evenly and not too thick.
^ Breather holes must remain free of sealing paste.

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.
^ Thoroughly clean housing joint surfaces before assembling.





^ Before installing oil seals, lightly oil the outer circumference of the seal and fill the space between the sealing lips - arrow - about half full with grease G052128A1.
^ The open side of the oil seals faces toward the side with fluid filling.
^ 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).
^ Lightly oil O-rings before installing to prevent them from being trapped and damaged when assembling.
^ After replacing seals and gaskets, check and, if necessary, top off oil level in transmission.

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





^ Replace spring pins. Position: the slit - A - should be in line with the line of force - arrow -.

Nuts, bolts
^ Loosen nuts and 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.
^ Loosen and tighten particularly sensitive parts in diagonal sequence and in stages, taking care to keep them straight.
^ The tightening torques stated apply to non-oiled nuts and bolts.
^ Always replace self-locking bolts and nuts.
^ Clean the threads of bolts which are secured by a locking compound with a wire brush. Then lubricate bolts with locking compound AMV185101A1 again before installing.
^ Threaded holes which take self-locking bolts or bolts coated with locking compound must be cleaned (using a thread tap or similar). Otherwise there is a danger of the bolts shearing when subsequently being removed.

Shims
^ Use a micrometer to measure the shims at several points. Tolerance variations make it possible to obtain the exact shim thickness required.
^ Check for burrs and damage.
^ Only install perfect, undamaged shims.

Bearings
^ Install new tapered roller bearings as supplied; do not lubricate with oil.
^ Lubricate all bearings (except tapered roller bearings) with gear oil before installing in transmission.
^ Heat inner races of tapered roller bearings to approx. 100° C before installing. Press in onto stop when installing so there is no axial clearance.
^ Do not interchange the outer or inner races of bearings of the same size (the bearings are paired).
^ If required, replace tapered roller bearings on one shaft together and use new bearings from a single manufacturer.
^ Install needle bearings so the lettering (side with thicker metal) faces toward the installing tool.
^ Lubricate needle bearing for transmission input shaft in rear of flywheel.

Synchronizer rings
^ Do not interchange synchronizer rings. When reusing, always install to the same gear.
^ Check for wear; replace if necessary.
^ Lubricate with gear oil before installing.

Gear wheels and synchronizing hubs
^ Before installing, clean and heat on a hot-plate to 130° C (maximum).
^ Press in onto stop when installing so there is no axial clearance.
^ The temperature can be measured with temperature tester V.A.G. 1558, ignition tester V.A.G 1767 or diesel tester V.A.G 1743.
^ Note installation position.

Selector gears
^ After installing, check 1st to 6th speed selector gears for minimal axial play and freedom of movement.

Clutch actuation
^ When removing transmission, remove slave cylinder without disconnecting hydraulic lines.
^ Do not depress the clutch pedal after removing the slave cylinder if the hydraulic line is still connected. Otherwise the piston will be pressed out of the slave cylinder. As a result the slave cylinder will be destroyed.
^ If the clutch pedal does not return to its initial position after releasing it, you must bleed the clutch system.
^ The clutch system should be bled at the same intervals as the brake system.
^ Make sure that the pressure plate is kept straight: loosen and tighten bolts in a diagonal sequence and in several gradual stages (does not apply to SAC pressure plates).
^ Note assembly instructions for SAC pressure plate.
^ On vehicles with SAC pressure plate an adjuster ring has to be reset when only the clutch plate is replaced.
^ If the clutch has burned out, thoroughly clean the bell housing, flywheel and parts of the engine facing the transmission in order to prevent odors.