General Repair Instructions

General repair instructions
The maximum possible care, cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also apply when performing vehicle repairs.
A number of generally valid instructions applicable for the various repair procedures -which were previously repeated a number of times at numerous places in the database -are summarized here.

Transmission
^ When installing ensure that the dowel sleeves between the engine and the transmission are correctly located.
^ When assembling mounting brackets as well as other waxed components the contacts surfaces must be cleaned. Contact surfaces must be free of grease and wax.
^ When changing a transmission fill it with gear oil to the lower edge of the filler hole.


Gaskets, sealing rings





^ Before installing oil seal, fill space between sealing lips with grease G 052 128 A1 -arrows-.
^ After installing, check oil level.
^ Thoroughly clean joint surfaces and apply sealant AMV 188 200 03.
^ Apply sealant uniformly but not too thick.
^ Replace"0-rings".

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





^ 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 nuts and bolts in stages in a diagonal sequence.
^ Tightening torques as specified are for unoiled bolts and nuts.
^ Replace self-locking bolts and nuts.
^ Make sure that on bolted connections the areas around the contact surfaces as well as the visible surfaces of nuts and bolts are rewaxed after assembly, if necessary.

Bearings
^ Install new tapered roller bearings as supplied and do not lubricate additionally.
^ Install needle bearings with lettered side (thicker metal) towards fitting tool.
^ Tapered roller bearings fitted to one shaft must be replaced as a set. Use the same make of bearings.
^ Heat inner races to approximately 100°C before installing.
^ Do not interchange outer or inner races of bearings of the same size. The bearings are matched in pairs.

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 perfect shims.

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

Selector gears
^ Before installing clean and heat on a hot plate to approximately 100°C.
^ Temperature can be checked with temperature tester V.A.G 1558.