Operation CHARM: Car repair manuals for everyone.

Repair Information






Repair Information

Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful. The usual basic safety precautions also, naturally 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 Repair Manual, are summarized here. They apply to this repair manual.

Transmission

Clean working conditions for the transmission, refer to => [ Clean Working Conditions ] Clean Working Conditions.

Clean the ATF pipes and ATF cooler after repairing the transmission.

Reusable components must be cleaned, checked and reconditioned if necessary before installation. Refer to => [ Input Shaft, Checking for Wear ] Final Drive, Differential (0AW Continuously Variable Transmission).

When installing the transmission, the following fluid levels should be checked and corrected if necessary:

ATF level

Gear oil in the front final drive

O-rings, Gaskets, Seals

O-rings, gaskets and seals must be replaced.

After removing gaskets, examine contact surface on housing/shaft for burrs resulting from removal or for other signs of damage.

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

To install, thinly coat gaskets along outer circumference and on sealing lip with ATF.

Coat O-rings with transmission fluid or Vaseline before inserting to prevent crushing rings during installation.

Always only use approved ATF or Vaseline. Other types of lubrication cause faults to occur in the transmission hydraulics.

When installing the 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).

Replace paper gaskets, thoroughly clean sealing surfaces and completely remove old seals.

Bolts and Nuts

Loosen the bolts opposite the tightening sequence.

Nuts and bolts which secure covers and housings should be loosened and tightened crosswise in stages if no tightening sequence is specified.

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

Always replace self-locking nuts and bolts.

Fasteners

Do not overstretch the circlips.






Always replace damaged or stretched circlips.

The circlips must fit completely inside the groove.

Replace the adapter sleeves. Installed position: Slit is longitudinal to direction of force.

Bearings

Coat bearing with ATF before inserting.

Only use Vaseline for the bearing and shim. Other types of lubrication lead to faults in the transmission hydraulics.

Adjusting Shims

Measure the adjusting shims at several locations with a micrometer. Different shim thicknesses make it possible to select the required thickness precisely; install two shims if necessary.

Check for burrs and damage. Only install perfect shims.