Components
Components
Transmission
• When installing the transmission, make sure that the alignment sleeves between the engine and transmission are correctly positioned.
• Clean contact surfaces when repairing mounting brackets and waxed components. Contact surfaces must be completely free of oil and grease.
• Capacities --> [ Codes Letters, Allocation and Capacities ] Application and ID.
Gaskets and Seals
• Before installing, fill gap between sealing lips - arrow - of radial-shaft seals half way with sealing grease (G 052 128 A1).
• After installing, check gear oil level --> [ Transmission Oil, Checking and Filling ] Transmission Oil, Checking and Filling
• Thoroughly clean separation surfaces and apply sealant (AMV 188 200 03).
• Apply sealant uniformly, but not too thick.
Fasteners
• Replace circlip.
• Do not over-stretch circlips.
• Circlips must be properly seated in the base of the groove.
• Replace spring pins. Installation position: Slot is longitudinal to line of force.
Bolts and Nuts
• Loosen and tighten the cover and housing mounting bolts or nuts in a diagonal sequence.
• Especially delicate parts - e.g. clutch pressure plates - must not be distorted and must be loosened and tightened in stages in a diagonal sequence.
• The tightening torques stated apply to unoiled bolts and nuts.
• Replace self-locking bolts and nuts.
• For all hose connections, it must be checked that contact surfaces as well as bolts and nuts, if necessary, are to be waxed only after installation.
• All threaded bores in which self-locking bolts are threaded must be cleaned of remaining locking fluid using a tap. Otherwise there is danger that the bolts may shear when removed again.
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 towards the drift.
• Taper roller bearings fitted to one shaft must be replaced as a set. Use same make of bearings.
• To install, heat inner race to approximately 100 °C with Inductive Heat Unit (VAS 6414).
• Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.
Adjusting 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.
Synchronizer Rings
• Do not interchange. When reusing synchronizer rings, always install to the same gear.
• Check for wear and replace if necessary.
• Check groove - arrow 1 - of synchronizer ring - A - or of inner race on flat areas (grooves are worn).
• For coated synchronizer rings, coating must not be damaged.
• If an intermediate ring - B - is installed, check this intermediate ring on outer friction surface - arrow 2 - and inner friction surface - arrow 3 - grooves, scoring and blue coloring (from overheating).
• Check taper of drive gear for grooves and scoring.
• Coat synchronization with gear oil before installing.
Gears
• Before pressing on, clean and warm to 100 °C max. with Inductive Heat Unit (VAS 6414).
Selector Gears
• After assembly, check selector gears for minimum axial clearance and ease of movement.
Clutch
• Do not distort clutch pressure plate; loosen and tighten in a diagonal sequence and in gradual stages.
• To reduce odor caused by a burnt clutch, thoroughly clean the clutch bell housing and the flywheel running surface with a clean cloth.