Procedures

General Repair Information

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 carrying out vehicle repairs.

A number of generally applicable instructions for individual repair procedures, which are otherwise mentioned at various points in this repair information, are summarized under => [ Components ]. They apply to this repair information.

Components

Transmission

• Make sure that the alignment sleeves between the engine and transmission are positioned correctly when installing the transmission.

• Clean the contact surfaces when installing the brackets as well as any waxed components. Contact surfaces must be free of grease and wax.

• For the correct bolts and other components, refer to the Parts Catalog.

• Fill the gear oil when repairing the manual transmission.






Gaskets and Seals

• Fill the space between the sealing lips halfway with sealing grease for seal (G 052 128 A1) - arrow - before installing the radial shaft seal.





• The open side of the seal points toward the fluid to be sealed in.

• After installing, check the fluid level. Refer to => [ Transmission Fluid, Checking and Filling ] Service and Repair.

• Lightly lubricate O-rings before installing to prevent them from being crushed when inserting.

• Thoroughly clean the separation surfaces and apply sealing paste (AMV 188 200 03).

• Apply the sealant paste evenly and not too thick.

Sealant

• Always thoroughly clean the separating surfaces on the housing before applying the sealant.

• Apply the sealing paste (AMV 188 200 03) evenly and not too thick.

• Do not allow any sealant paste to get into the ventilation holes.

Clips

• Replace the circlips.

• Do not overstretch the circlips.

• The circlips must fit completely inside the groove.

• Replace the roll pin. Installed position: The slit is longitudinal to the direction of force.





Bolts and Nuts

• Always loosen or tighten bolts and nuts for covers and housings diagonally.

• Especially delicate parts, such as clutch pressure plates, must not be distorted. Loosen and tighten the bolts and nuts in stages and in a diagonal sequence.

• The tightening specification stated apply to non-lubricated nuts and bolts.

• Always replace self-locking nuts and bolts.

• Make sure the contact surfaces and visible surfaces on the nuts and bolts are waxed after assembling.

• Use a thread tap to clean all threaded holes containing self-locking bolts to remove any locking compound residue. Otherwise the bolts could shear the next time they are removed.

Bearings

• Install the new tapered roller bearings. It is not necessary to lubricate them.

• Install needle bearings with the lettered side (thicker metal) facing the installation tool.

• Replace all the tapered roller bearings that are on the same shaft. Use tapered roller bearings from the same manufacturer.

• To install, heat the bearing inner races to approximately 100 degrees C (212 degrees F) with the inductive heat unit (VAS 6414).

• Do not interchange the inner and outer bearing races with those from other bearings of the same size, bearings are paired.

Adjusting Shims

• Measure the adjusting shims at several locations using 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 them. When reusing synchronizer rings, always install them to the same gear.

• Check for wear and replace if necessary.

• Check the grooves - arrow 1 - on the synchronizer ring - A - and the inner race for flat areas (grooves are worn).





• The coating on the synchronizer rings must not be damaged.

• If an intermediate ring - B - is installed, check the intermediate ring on the outer contact surface - arrow 2 - and inner contact surface - arrow 3 - for grooves, scoring and blue coloring (from overheating).

• Check the taper on the drive gear for grooves and scoring.

• Coat the synchronizer ring with transmission fluid and then install.

Gears

• Before pressing on, clean and warm them to 100 degrees C (212 degrees F) Max. with the inductive heat unit (VAS 6414).

Selector Gears

• After assembling, check the selector gears for minimum axial clearance and ease of movement.

Clutch

• Do not tilt the clutch pressure plate. Loosen and tighten it diagonally and in small steps.

• To reduce odor caused by a burnt clutch, thoroughly clean the clutch housing and the flywheel running surface with a clean cloth.