General Repair Notes

General Repair Notes:, 012/01W, 5 SPD. M/T
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 carrying out vehicle repairs.

A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned at various points, are summarized under the term "components".

Components

Transmission
^ Transmissions are either made out of aluminum or magnesium.

Characteristics of magnesium transmissions





The inscription Mg Al 9 Zn 1 can be found in vicinity of arrows - 1 - and - 2 - on transmissions manufactured from magnesium.
Based on the transmission code, you can also determine whether the transmission housing is made out of magnesium.
^ Transmission housing, transmission cover and final drive cover must be constructed from the same material.
^ Bolts and other components which come into direct contact with the transmission have a surface coating which is adapted to transmission housings made out of aluminum or magnesium.
^ On transmissions made out of magnesium, the bolts for the following threaded connections must always be replaced: Transmission cover to transmission housing and final drive cover to transmission housing.
^ Contact corrosion occurs when incorrect components are used. Transmission will be damaged.
^ Allocate bolts and other components via the Electronic Parts Catalog (ETKA).
^ When installing transmission, make sure centering sleeves are correctly seated between engine and transmission.
^ When replacing manual transmission, gear oil must be filled up to lower edge of filler hole.
^ Filling quantity and specification.

Seals, sealing rings
^ Always clean joint surfaces and apply sealant AMV 188 001 02.
^ Sealant even - do not apply too thickly.
^ Replace O-rings.
^ Radial shaft seals. Before installing:





Lightly coat outside circumference, fill space between sealing lips - arrow - halfway with sealing grease G 052 128 A1.

After installing:
Check transmission oil level; if necessary, fill up to lower edge of filler hole, specification.

Circlips
^ Replace circlips.
^ Do not over-stretch circlips.
^ Circlips must be fully seated in groove.





^ Always replace roll pins, installed position: Slot is longitudinal to line of force.

Nuts, bolts
^ Loosen and tighten bolts or nuts for securing covers and housings in diagonal sequence.
^ Do not cant, and loosen and tighten especially sensitive parts - e.g. clutch pressure plates - in diagonal manner in stages.
^ The tightening torques stated apply to non-oiled nuts and bolts.
^ Always replace self-locking nuts and bolts.

Mount
^ Install new tapered roller bearing as supplied and do not use additional oil.
^ Install needle bearings with the lettering on the bearing (the side with thicker metal) facing the mandrel.
^ Always replace tapered roller bearings on one shaft together. If possible, use same manufacturer!
^ Heat inner races to approximately 100°C to install.
^ Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.

Shims
^ Measure shims at several points using a micrometer. Different tolerances make it possible to measure the required shim size exactly.
^ Check for burrs and signs of damage.
^ Only install perfect adjustment shims.

Synchronizer rings
^ Do not interchange. If re-using, allocate synchronizer rings to the same gear as before.
^ Check for signs of wear; replace if necessary.
^ Lubricate with transmission fluid before installing.

Gears
^ Before pressing on, clean and heat to approximately 100°C on a heater.
^ Temperature can be checked using Temperature Tester V.A.G 1558.

Sliding Gears
^ After assembling, check axial play of 1st to 5th sliding gears and check for free movement.

Clutch control
^ When removing transmission, remove clutch slave cylinder without disconnecting lines.
^ Do not operate clutch pedal after removing clutch slave cylinder with hydraulic line still connected. Otherwise, the piston will be pressed out of the clutch slave cylinder. Clutch slave cylinder will be destroyed when doing this.
^ Check the function of the clutch master and slave cylinders.
^ Bleeding of the clutch system should be performed with bleeding of the brake system
^ Do not cant clutch pressure plate; loosen and tighten in a diagonal sequence and in stages.
^ If the clutch has burnt out, thoroughly clean the bellhousing, flywheel and parts of the engine facing the transmission in order to reduce the smell of burnt linings.