General Notes on Repair

General notes on repair
To repair the transmission perfectly and successfully the greatest care and levels of cleanliness must be used. The tools must also be in perfect condition. When performing a repair the general safety rules must be kept in mind.

Special tools
A summary of the special tools used in the repair manual can be found in the library section of VESIS.

Transmission
^ When an automatic transmission is replaced the following fluid levels must be checked:
^ ATF in planetary gearbox and final drive.
^ Do not run the engine or tow a vehicle with the transmission oil pan removed or when there is no ATF in transmission.
^ Secure torque converter to prevent it falling out when the transmission is removed.
^ Clean joints and connecting points thoroughly before loosening.
^ When installing the transmission ensure that the dowel sleeves between the engine and the transmission are seated correctly.
^ Place parts that have been removed on a clean surface and cover so that they are not soiled. Use foil and paper. Do not use fluffy cloths!
^ Only install clean components: Only unpack replacement parts immediately prior to installation.
^ Carefully cover opened components or seal them if the repair cannot be performed immediately.
^ Replace the transmission if any of the selector elements are scorched or burned.
^ A basic (default) setting must be performed each time the transmission is reinstalled.

Gaskets, seals
^ Always replace O-rings, seals and gaskets.
^ After removing seals/gaskets etc. always check the contact surfaces on housings or shafts for burrs and damage and correct before reinstalling.
^ The open side of an oil seal faces toward the oil.
^ Before installing an oil seal moisten the outer surfaces and the sealing lip sparingly with ATF.
^ Moisten O-rings with ATF to prevent damage to the O-ring when installing.
^ Only use ATF in the areas of the ATF. Other lubricants will cause the hydraulic elements to malfunction.
^ After installing, check ATF level in planetary gearbox/final drive and correct levels as necessary.

Nuts, bolts/screws
^ Loosen and tighten the nuts, bolts/screws for securing the covers and housings in a diagonal sequence.
^ Do not cant particularly sensitive parts, e.g. valve body, and loosen and tighten in stages using diagonal sequence.
^ The torque settings indicated refer to the nonlubricated screws and bolts.
^ Threads of bolts/screws that are secured by locking fluid are to be cleaned with a wire brush. Then insert bolts/screws with AMV 185 100 A1.
^ All threaded holes where locking fluid is employed must be cleaned with a thread tap to remove remnants of locking fluid. Otherwise there is a danger that a bolt/screw will shear when reinstalling.
^ Always replace self-locking nuts and bolts/screws.

Valve body
^ The valve body is allocated according to the transmission code parts catalog.

Guided fault finding, vehicle self-diagnosis and measuring technology





^ Before servicing the automatic transmission, determine the cause of the malfunction as precisely as possible with the Vehicle Diagnosis, Test and Information System VAS 5051 and with the aid of "Guided fault finding", "Vehicle self-diagnosis" and "Measuring technology".