Procedures

General Repair Information

To ensure perfect and successful transmission repairs, the greatest care and cleanliness as well as the use of good and proper tools is essential. The usual basic safety precautions also apply when carrying out vehicle repairs.

A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in the Workshop Manual, are summarized here. It applies to this repair manual.

Transmission

• When installing the transfer case, ensure that the dowel sleeves between the transmission and transfer case are correctly positioned.

• Clean contact surfaces when repairing mounting brackets and waxed components. Contact surfaces must be completely free of oil and grease.

• Allocate bolts and other components.

• When exchanging a transfer case, the gear oil must be filled up to lower edge of filler hole. Refer to => [ Checking Gear Oil Level in Transfer Case ] Service and Repair.

• Capacities and specifications of transfer case. Refer to => [ Transfer Case 0AQ Identification ] Transfer Case 0AQ Identification.

• When exchanging a front final drive, the gear oil must be filled up to lower edge of filler hole. Refer to => [ Axle Oil Level in Front Final Drive, Checking ] Axle Oil Level In Front Final Drive, Checking.

• Capacities and specifications of front final drive. Refer to => [ Code, Transmission Allocation, Ratios and Capacities ] Code, Transmission Allocation, Ratios and Capacities.

• When exchanging a rear final drive, the gear oil must be filled up to lower edge of filler hole. Refer to => [ Rear Final Drive Axle Oil Level, Checking ] Rear Final Drive Axle Oil Level, Checking.

• Capacities and specifications of rear final drive. Refer to => [ Rear Final Drive 0AB Identification ] Rear Final Drive 0AB Identification.

Sealant

• Thoroughly clean housing joint surfaces before applying the sealant.

• Apply sealant (AMV 174 004 01) evenly and not too thick.

O-rings, Shaft seals, Sealing Rings and Seals

• Replace damaged O-rings.

• The open side of the shaft seals point toward the fluid to be sealed in.

• When pressing in new shaft seals, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).

• Lightly lubricate O-rings before installing to prevent them from being crushed when inserting.

Shaft seals

Before installing:

Lightly lubricate outer edge and fill space between sealing lips - arrow - halfway with grease (G 052 128 A1).





After installation:

• Check gear oil level in transfer case. Refer to => [ Checking Gear Oil Level in Transfer Case ] Service and Repair.

• Check gear oil level in front final drive. Refer to => [ Axle Oil Level in Front Final Drive, Checking ] Axle Oil Level In Front Final Drive, Checking.

• Check gear oil level in rear final drive. Refer to => [ Rear Final Drive Axle Oil Level, Checking ] Rear Final Drive Axle Oil Level, Checking.

Fasteners

• Do not over-stretch circlips.

• Always replace damaged or over-stretched circlips.

• Circlips must locate properly in the groove.

Bolts and Nuts

• Loosen and tighten the cover and housing mounting bolts or nuts in a diagonal sequence.

• The tightening specifications stated apply to non-oiled nuts and bolts.

• Replace self-locking bolts and nuts.

• For all hose connections, it must be checked that contact surfaces as well as bolts and nuts, if necessary, are to be waxed only after installation.

• 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 installed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed. Pay attention to the thread pitch when cleaning with a thread cutter.

Bearing

• Install needle bearings with lettered side (thicker metal) towards fitting tool.