General Repair Instructions

5 Speed Manual 02J

General Repair Instructions

The greatest care and cleanliness and the use of good and proper tools is essential for successful transmission repairs. Obviously, all basic rules for safety are also applicable during repair work.

Transmission

- When installing the transmission ensure that the dowel sleeves between the engine and transmission are correctly located.
- When replacing a transmission fill with gear oil to the lower edge of the filler hole.
- Capacities and specifications

Note:

- If the oil level is topped up with the transmission installed, check the oil level as follows:
- Fill with oil to lower edge of filler hole and re-install filler plug.
- Start engine, engage a gear and allow transmission to turn for approx. 2 minutes.
- Switch off engine and again top-up oil to lower edge of filler hole.

Gaskets, seals

- Thoroughly clean joint surfaces and apply sealant, Part No. AMV 188 200 03.
- Apply sealant uniformly but not too thick.
- Always replace O-rings,
- Always replace radial shaft oil seals.

Before installing:






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

After installation:
Check transmission oil; if necessary top-up to lower edge of oil filler hole.

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 tighter bolts and nuts in stages in a diagonal sequence.
- Tightening torques as specified are for un-oiled bolts and nuts.
- Always replace self-locking bolts and nuts.

Bearings

- Install needle bearings with lettered side (thicker metal) toward installation tool.
- Lubricate all transmission bearings with gear oil.
- Tapered roller bearings installed on 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 shims for burrs and darnage.
- Only install perfect shims.

Synchronizer rings

- Do not interchange. When reusing always install on the same gear.
- Check for wear and replace it 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.