Repair Instructions
Repair Instructions
Transmission
• Thoroughly clean all connections and the surrounding area before disconnecting.
• When installing the transmission, make sure that the alignment sleeves between the engine and transmission are positioned correctly.
• Allocate bolts and other component using the. Refer to the electronic parts catalog ETKA.
• When installing mounting brackets, as well as other waxed components, the contacts surfaces must be cleaned. Contact surfaces must be free of grease and wax.
• After replacement of the manual transmission with a bevel box, check the oil level in the manual transmission. Refer to => [ Manual Transmission, Checking Gear Oil Level ] Manual Transmission, Checking Gear Oil Level and in the bevel box => [ Gear Oil in Bevel Box, Checking ] Gear Oil In Bevel Box, Checking.
• Capacities, refer to => [ Code Letters, Assembly Allocation, Ratios and Capacities ] Code Letters, Assembly Allocation, Ratios and Capacities, Specification, refer to the electronic parts catalog ETKA.
Shaft Seals, Sealing Rings, O-rings, Seals
• Always replace shaft sealing rings, O-rings, and seals.
• After removing gaskets and seals, always inspect the contact surfaces at housing or shaft for burrs resulting from removal, or for other signs of damage.
• Before installing the shaft seals, lightly oil the outer circumference and fill the space between the sealing lips - arrow - halfway with sealing grease (G 052 128 A1).
• The open side of the shaft seals point toward the fluid to be sealed in.
• When pressing in new shaft seal, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).
• To prevent crushing when installing, lightly lubricate O-rings before inserting.
• After replacement of seals, O-rings, and shaft sealing rings, check the oil level in the manual transmission. Refer to => [ Manual Transmission, Checking Gear Oil Level ] Manual Transmission, Checking Gear Oil Level or in the bevel box => [ Gear Oil in Bevel Box, Checking ] Gear Oil In Bevel Box, Checking.
Sealant
• Thoroughly clean housing joint surfaces before applying sealing compounds.
• Apply the sealing compound (AMV 188 200 03) evenly and not too thick.
• Do not allow sealing compound to enter ventilation openings.
Fasteners
• Do not stretch the circlips.
• Replace damaged or stretched circlips.
• Circlips must locate properly in the groove.
• Replace spring pins. Installed position: the slit - A - should be in line with the line of force - arrow -.
Bolts and Nuts
• Loosen bolts and nuts in reverse of tightening sequence.
• Tighten and loosen bolts or nuts for securing covers and housings without tightening sequence in diagonal sequence in stages.
• Replace self-locking bolts and nuts.
• The tightening specifications stated apply to non-oiled nuts and bolts.
• Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (for example tap). Otherwise there is a risk that the bolts will shear the next time they are removed.
• Ensure with screwed connections that the contact surfaces as well as the visible surfaces of nuts and bolts are waxed after assembly, if necessary.
Mount
• Install new tapered roller bearing as supplied and do not use additional oil.
• Install various bearings (removed tapered roller bearings) into transmission, lubricated with gear oil.
• Heat the inner rings of the tapered roller bearings to approximately 100 °C (212 °F) with the inductive heat unit (VAS 6414) before installing. Press on to the stop when installing so that there is no axial clearance.
• Do not interchange the outer or inner races of bearings of the same size.
• Tapered roller bearings installed on a shaft must be replaced as a set and use same make of bearings.
• Install needle bearings with lettered side (thicker metal) towards fitting tool.
Adjusting Shims
• Use a micrometer to measure the shims at several points. Tolerance variations make it possible to find the exact shim thickness required.
• Check for burrs and damage.
• Only install perfect shims.
Synchronizer Rings
• When reusing synchronizer rings, do not interchange them and always assign them to the same selector gear.
• Check for wear and replace if necessary.
• Check the grooves - arrow 1 - of synchronizer ring - A - and inner race for flat areas (grooves are worn).
• For coated synchronizer rings, coating must not be damaged.
• If an intermediate ring - B - is installed, check the intermediate ring on the outer contact surface - arrow 2 - and inner contact surface - arrow 3 - for grooves, scoring and blue coloring (from overheating).
• Check taper of drive gear for grooves and scoring.
• Coat with gear oil before installing.
Gears
• Clean prior to pressing on.
• For installation heat to approximately 100 °C (212 °F) with the inductive heat unit (VAS 6414) and during installation press on to the stop so that there is no axial clearance.
Selector Gears and Sliding Sleeves
• After installing, check 1st through 6th gear for minimal amount of axial clearance and for ease of movement.
• Damage to the synchronizer ring or gear wheel:
A Worn clutch spline camber on the synchronizer ring or gear wheel
• Compare: synchronizer ring or gear wheel not damaged:
B Worn clutch spline camber on the synchronizer ring or gear wheel
• Picture of damage on the locking collar:
C Worn longitudinal inner spline camber and the locking collar
• Comparison: locking collar not damaged:
D Undamaged longitudinal inner spline camber and the locking collar
Clutch Mechanism, Clutch
• If the clutch pedal does not return to the starting position (rest position) after the recoupling procedure, bleed the clutch system (further measures. Refer to => [ Information Regarding the Removal and Installation of the Clutch Master or Slave Cylinder ] Removal and Replacement).
• Do not tilt clutch pressure plate; loosen and tighten one after another in 90° increments.
• To reduce odor caused by a burnt clutch, thoroughly clean the transmission housing around the clutch as well as the engine on the transmission side.
• Only use compressed air to blow out the dual-mass flywheel.
• The clutch pressure plates are corrosion-protected and greased. With the exception of the friction surface on the clutch plate, do not clean the pressure plate. This will shorten the service life of the clutch considerably.
• The friction surfaces on the pressure plate and on the dual mass flywheel must be cleaned thoroughly (degreased).