General Repair Instructions
General repair instructions, 01V, 5 SPD. A/T (AWD)
The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also, naturally apply when performing vehicle repairs.
A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points, are summarized here.
Special tools
A list of special tools and workshop equipment required for repair procedures can be found at the start of each "Special Tools" catalog.
The catalog is also available on CD-ROM and can be ordered the usual way via Bertelsmann.
Transmission
^ If the automatic transmission has been replaced, the following fluid levels are to be checked:
^ ATF in planetary gear.
^ Gear oil in front final drive.
^ Gear oil in center differential.
^ Capacities and specifications.
^ If rear final drive is replaced, fill it with gear oil to lower edge of filling hole.
^ Capacities and specifications.
^ Do not run engine or tow vehicle with oil pan removed or when there is no ATF in the transmission.
^ If the transmission is removed from the vehicle, secure the torque converter to prevent it from falling out.
^ Thoroughly clean connecting points and surrounding areas and then loosen bolts.
^ Check installation dimension of torque converter before installing transmission.
^ When installing ensure that the alignment sleeves between the engine and transmission are correctly located.
^ Place removed parts on a clean surface. Cover parts to prevent soiling. Use sheeting or paper. Do not use fluffy cloths!
^ Only install clean parts: Remove packing from replacement parts immediately prior to installation and not before.
^ Carefully cover or plug unpacked components if repairs cannot be performed immediately.
^ 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.
Valve body
^ Replace the transmission if any of the shift elements are scorched.
^ Valve body must be allocated to transmission code letters original parts distributor.
Gaskets, sealing rings
^ Always replace O-rings, seals and gaskets.
^ Once a seal or gasket has been removed, check contact surface on housing or shaft for burrs and damage. Repair as necessary.
^ Thoroughly clean housing connecting surfaces and apply sealant AMV18820003.
^ Before installing shaft-type oil seal, fill the space between sealing lips half way with grease G052128A1 - arrow - and then install.
^ Open side of oil seal faces oil.
^ Before installing oil seals, moisten circumference of seal and sealing lip with ATF or gear oil depending on fitting location.
^ Moisten O-rings with ATF to prevent damage occurring to the rings during assembly.
^ Only use ATF for automatic transmission components. Other types of lubrication cause faults to occur in the transmission hydraulics.
^ Check ATF level in planetary gear or gear oil level in final drive following installation. Top off as necessary.
^ ATF in planetary gear, checking and topping off.
^ Gear oil in front final drive.
^ Gear oil in center differential.
^ Gear oil in rear final drive
^ Capacities and specifications.
Locking elements
^ Replace circlip.
^ Do not over-stretch circlip, replace if necessary.
^ Circlips must be properly seated in the base of the groove.
^ Replace spring pins. Installation position: Slit longitudinal to direction of force - arrows -
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.
^ The tightening torques stated apply to unoiled bolts and nuts.
^ Clean threads of bolts that were applied with locking fluid using a wire brush. Apply locking fluid AMV185100A1 before reinstalling.
^ Use thread tap to remove remains of locking fluid from all threaded holes in which self-locking bolts are to be screwed. Otherwise there is a risk that the bolts will shear the next time they are removed.
^ Replace self-locking bolts and nuts.
^ Ensure with screwed connections that the contact surfaces as well as the visible surfaces of nuts and bolts are rewaxed after assembly, if necessary.
Bearings
^ Tapered roller bearings are allocated to the date of transmission manufacture and code letters in original parts distributor.
^ Always replace tapered roller bearings on one shaft together and use new bearings from the same manufacturer.
^ Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift.
^ Heat inner races/tapered roller bearings to approximately 100°C before inserting.
^ Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.
^ Insert bearing with axle oil or ATF, depending on installation location.
Adjustment shims
^ Measure shims at several points using a micrometer. Varying tolerances make it possible to measure the required shim thickness exactly.
^ Inspect for burrs and signs of damage.
^ Install only shims that are in perfect condition.
Guided Fault Finding, On Board Diagnostic (OBD) and Test Instruments
^ Before repair work is performed on the automatic transmission, the fault cause should be determined as accurately as possible using diagnostic operation system VAS5051 A in modes of operation "Guided Fault Finding", "Vehicle Self-Diagnosis" and "Test Instruments".
Gear wheels
Before pressing on, clean and heat to a maximum of 100°C on a heater.
Temperature can be check using temperature tester V.A.G1558, ignition tester V.A.G1767 or diesel tester V.A.G1743.