General Repair Instructions

General repair instructions, 02M, 5 and 6 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 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 - 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 O-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 un-oiled 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 VAG 1558.