Components
Components
Transmission
• Allocate bolts and other components according to the transmission code using the electronic parts catalog ETKA.
• Always clean the connection locations and the area around them before loosening.
• When replacing or repairing a manual transmission, check the fluid level and fill if necessary.
• Use the transmission code to determine capacities and specifications.
Sealant
• Thoroughly clean the housing joint surfaces before applying the sealing compound.
• Apply sealing compound (AMV 188 001 02) evenly and not too thick.
• Do not allow any sealing compound to get into the ventilation holes.
O-rings, Shaft Seals, Seals
• O-rings, shaft seals and seals must be replaced.
• 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.
• Thoroughly clean housing joint surfaces before assembling.
• Before installing the shaft seals, lightly oil the outer circumference and fill the space between the sealing lips - arrow - halfway with grease (G 052 128 A1).
• The open side of the shaft seals point toward the fluid to be sealed in.
• Press in new shaft seal, so that the sealing lip does not run on the same point as the sealing lip of the old shaft seal (use insertion depth tolerances).
• Lightly lubricate O-rings before installing to prevent them from being crushed when inserting.
• After replacing the seals and the sealing rings, check the transmission fluid level and fill if necessary.
Fasteners
• Do not overstretch the circlips.
• Installed position for some of the locking rings: The ring is narrower on top and this shape matches its installed location. This makes it easier for the pliers to grab the circlip when removing and installing it.
• Always replace damaged or stretched circlips.
• The circlips must fit completely inside the groove.
• Replace the adapter sleeves. Installed position: Slit - A - should be in line with the line of force - arrow -.
Bolts and Nuts
• Loosen the bolts and nuts opposite the tightening sequence.
• Nuts and bolts which secure covers and housings should be loosened and tightened diagonally and in steps if no tightening sequence is specified.
• Parts which are particularly sensitive to distortion must be kept straight when removing and installing; loosen or tighten diagonally in stages.
• The tightening specifications stated apply to non-oiled nuts and bolts.
• Always replace self-locking nuts and bolts.
• Use a wire brush to clean the threads of bolts that were screwed in with locking compound. Next, use locking compound (AMV 185 101 A1) to install the bolts.
• Clean the threaded holes for the self-locking bolts or for the bolts coated with locking fluid. Otherwise there is a risk that the bolts will shear the next time they are removed.
Adjusting Shims
• Measure the adjusting shims at several locations with a micrometer. Tolerance variations make it possible to find the exact shim thickness required.
• Check for burrs and damage.
• Only install perfect shims that have never been damaged.
Bearings
• Set needle bearings, ball sleeves and roller sleeves with the inscribed side (greater thickness) facing toward drift.
• Insert all the bearings in transmission with gear oil.
• Heat inner races of 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 there is no axial clearance.
• Warm inner race for needle and roller bearings to 130 °C (266 °F) max.
• Do not interchange outer and inner bearing races with those from other bearing of the same size. The bearings are paired.
• Replace all the tapered roller bearings that are on the same shaft. Use tapered roller bearings from the same manufacturer.
Gears, Synchronizer Hubs, Selector Gear Inner Races
• To install, heat gear wheel inner race to approximately 100 °C (212 °F) with the (VAS 6414).
• Heat the synchronizer hub to approximately 100 °C (212 °F) with the (VAS 6414) before installing. Press on as far as the stop when installing so there is no axial play.
• Heat the gears to approximately 150 °C (302 °F) with the (VAS 6414) before installing. Press on to the stop when installing, so there is no axial clearance.
• Pay attention to the installed location.
Selector Gears
• After assembly, check selector gears of 1st through 6th gear for axial play of 0.15 to 0.50 mm or more of movement.
Input Shaft
• If the surface of the input shaft is visibly damaged near the needle bearing in the dual mass flywheel - arrow -, then replace both the input shaft and the needle bearing. Refer to => [ Dual Mass Flywheel Needle Bearing ] Dual Mass Flywheel Needle Bearing.
• Replace the driveshaft. Refer to => [ Transmission ] Transmission.
• Check the input shaft near the bearing in the drive plate - arrow - for scoring. Replace the needle bearing in the drive plate if necessary.
Synchronizer Rings
• Do not interchange them. When reusing synchronizer rings, always install to the same gear wheel.
• Check for wear and replace if necessary.
• Install coated with transmission fluid.
• Check coated friction surfaces - arrows 2 - from intermediate ring - B - for damage (flat areas, disintegrating areas or carbon layer).
• Check the inner friction surface - arrow 1 - of the synchronizer ring - A - and the outer friction surface - arrow 4 - of the inner race - C - for grooves and scoring.
• On inner races - C - with coated friction surfaces - Arrow 3 -, check coating for damage (disintegrating carbon layer).
Damage on the Selector Gears and Locking Collars
• Damage to the synchronizer ring or gear wheel:
A Worn clutch spline camber on the synchronizer ring or gear wheel
• For comparison: synchronizer ring or gear wheel not damaged:
B Undamaged 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
• For comparison: locking collar undamaged
D Undamaged longitudinal inner spline camber and the locking collar
• Synchronizer rings coated with carbon must be replaced together with the locking collar. The gear wheels must be replaced as well depending on the amount of wear.