General Repair Instructions

General repair instructions
To ensure perfect transmission repairs, the greatest care and cleanliness as well as the use of good and proper tools is essential. Obviously, the basis rules for safety are also applicable during repair work.

A number of generally valid instructions applicable for the various repair procedures.

Transmission
^ When installing make sure 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.

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

Gaskets, sealing rings
^ Thoroughly clean joint surfaces and apply sealant AMV 188 200 03.
^ Apply sealant uniformly but not too thick.
^ Replace "O-rings".
^ Radial shaft oil seals.





Before installing:
- Lightly oil outer edge, fill space between sealing lips -arrow- with grease G 052 128 A1.

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

Locking devices
^ Replace circlips.
^ Do not overstretch circlips.
^ Circlips must be install 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.
^ Delicate parts, must not be distorted, such as clutch pressure plates. 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 with threaded connections that the areas of the contact surfaces as well as the visible surfaces of nuts and bolts are rewaxed after assembly.

Bearings
^ Install new tapered roller bearings as supplied and do not lubricate.
^ Install needle bearings with lettered side (thicker metal) toward installing tool.
^ Tapered roller bearings installed to one shaft must be replaced as a set. Use same make of bearings.
^ Heat inner races to approximately 100°C before installing.

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 install to the same gear.
^ Check for wear and replace if necessary.
^ Coat with gear oil before installing.

Gear wheels
^ Before installing clean and heat on a hot plate to approximately 100°C.
^ Temperature can be checked with temperature tester VAG 1558.