Repair Information

Repair Information

The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. 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 Shop Manual, are summarized here. They apply to this repair information.

Transmission

• Clean working conditions for the transmission. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

• Clean the ATF pipes and the ATF cooler after performing repairs on the transmission.

• Reusable components must be cleaned, checked and reconditioned if necessary before installation. Refer to => [ Diagnosis and Testing ] 01J,0AN Continuously Variable Transmission

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

• ATF level.

• Gear oil in front final drive.

• Capacities and specifications, refer to => Continuously
Variable Transmission 00 Specifications.

O-rings, Gaskets, Seals

• O-rings, gaskets and seals must be replaced.

• After removing gaskets, examine contact surface on housing/shaft for burr 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.

• 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 the 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.