General Repair Instructions

General repair instructions
To ensure successful transmission repairs the greatest care and cleanliness and use of proper tools is essential. Obviously, the basic rules for safety are most important during any repair work.
A number of generally valid instructions applicable for the various transmission repair procedures are summarized here.

Transmission
^ When installing the transmission ensure that the dowel sleeves between the engine and transmission are correctly located.
^ When changing a transmission fill with gear oil to the lower edge of the filler hole.
^ Specifications.

Gaskets, sealing rings
^ Thoroughly clean joint surfaces and apply sealant AMV 188 001 02.
^ Apply sealant uniformly but not too thick.
^ Always replace "O-rings"
^ Radial shaft oil seals

Before installing: Lightly oil outer edge, fill space between sealing lips with grease.

Aider installation: Check transmission gear oil level; if necessary top-up to lower edge of oil filler hole, Specification.

Locking devices
^ Always replace circlips.
^ Do not overstretch circlips.
^ Circlips must locate properly in the groove.





^ Always replace spring pins
Installation position: Slot longitudinal to line of force.

Bolts and nuts
^ Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.
^ Especially delicate parts, such as clutch pressure plates, must not be distorted. Loosen and tighten bolts and nuts in stages in a diagonal sequence.
^ Tightening torques as specified are for unoiled bolts and nuts.
^ Always replace self-locking bolts and nuts.

Bearings
^ Install needle bearings with lettered side (thicker metal) towards installing tool.
^ Tapered roller bearings installed to one shaft must be replaced as a set. Use same make of bearings if possible
^ Heat inner races to approx. 100°C (212°F) before installing.
^ Do not interchange outer and inner races of bearings of the same size; bearings are paired.

Shims
^ Measure shims at several points with a micrometer. Tolerance variations make it possible to find the exact shim thickness required.
^ Check for burrs and damage.
^ Only install shims that are in perfect condition.

Synchronizer rings
^ Do not interchange. When reusing always install with the same gear.
^ Check for wear and replace if necessary.
^ Coat with gear oil before installing.

Gears
^ Before installing clean and heat on a hot plate to approx. 100°C (212°F).
^ Temperature can be checked with temperature tester VAG 1558 or equivalent.