General Repair Instructions

General repair instructions
The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions naturally also apply when carrying out vehicle repairs.
A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points, are summarized here.


Transmission
When exchanging an automatic transmission the level of ATF in the planetary gearbox, gear oils in the front final drive and transfer gearbox must be checked.
^ When exchanging the rear final drive, fill with gear oil up to lower edge of filling hole.
^ When installing the transmission, make sure dowel sleeves between engine and transmission are correctly seated.


O-rings, Gaskets, Seals





^ Radial shaft seals: lubricate space between sealing lips with grease (arrow) before installing.
^ Always install new O-rings.
After installing, check fluid levels in affected areas and correct if necessary:
^ ATF level in planetary gearbox
^ Gear oil in front final drive
^ Gear oil in transfer gearbox
^ Gear oil in rear final drive
^ Capacities and specifications

Circlips
^ Do not overstretch circlips; replace if necessary.
^ Circlips must be properly seated in the grooves.

Nuts, bolts
^ Nuts and bolts for attaching covers and housings must be loosened and tightened diagonally.
^ Do not distort particularly sensitive parts, e.g. valve body. Loosen or tighten diagonally in stages.
^ Tightening torques stated apply to unoiled nuts and bolts.
^ Threads of bolts that have been secured with locking fluid must be cleaned with a wire brush. Coat bolts with AMV 185 100 A1 before installing.
^ Always replace self-locking nuts.

Bearings
^ Install needle bearings with the inscribed side (thicker sheet metal) facing the drift.
^ Heat the inner races of tapered roller bearings to approx. 100°C (212°F) before installing.
^ Do not interchange the inner and outer races of same size bearings.
^ When replacing tapered roller bearings which are mounted on a shaft together, always replace as a set and use bearings from a single manufacturer.
^ Lubricate bearings with gear oil or ATF, depending on location, before installing. Oil with special care when measuring friction torque.

Shims
^ Measure shims at several points with a micrometer. Different tolerances make it possible to obtain the exact shim thickness required.
^ Check for signs of burr and damage. Only install shims which are in perfect condition.

Valve body
For valve body application according to transmission code letters.

On Board Diagnostic (OBD)
Before carrying out repairs to the automatic transmission, determine the cause of the malfunction as precisely as possible with the aid of On Board Diagnostic (OBD).