General Repair Instructions

General repair instructions
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.

Special tools
For a complete list of special tools
go to Special Tools Catalog

Transmission
^ When installing a new transmission, the oil level must be checked and oil added if necessary .
^ Capacities and specifications
^ When exchanging the rear final drive the oil level in rear final drive must be checked and, if necessary, corrected.
^ Thoroughly clean all unions and the adjacent areas before disconnecting.
^ When installing transmission, ensure that the dowel sleeves are installed correctly.

O-rings, seals, gaskets
^ Always replace O-rings, seals and gaskets.
^ After removing gaskets and seals, always inspect the contact surface on the housing or shaft for burrs resulting from removal or for other signs of damage.
^ Thoroughly clean housing joint surfaces before assembling.





^ Before installing radial shaft seals, lightly oil outer circumference and pack space between sealing lips -arrow- half-full with sealing grease G 052 128 Al.
^ The open side of the seals faces toward the side with fluid filling.
^ When replacing seals, always vary the point at which the sealing lips make contact (use insertion depth tolerances).
^ Lightly oil O-rings before installing to prevent them being trapped and damaged when assembling.
^ After replacing seals and gaskets check oil level in transmission.

Sealants
^ Thoroughly clean housing joint surfaces before applying sealing paste.
^ Apply sealing paste AMV 188 001 02 evenly and not too thick.
^ Breather holes must remain free of sealing paste.

Locking elements
^ Do not over-stretch circlips.
^ Always replace circlips which have been damaged or over-tensioned.
^ Circlips must be properly seated in the base of the groove.





^ Replace spring pins. Installation position: Slot -A- longitudinal to line of force -arrow-.

Nuts, bolts
^ Slacken the nuts and bolts in reverse sequence to the specified tightening sequence.
^ Nuts and bolts which secure covers and housings should be slackened and tightened diagonally.
^ Parts which are particularly sensitive (e.g. clutch pressure plates) must be kept straight and slackened and tightened diagonally in stages.
^ The tightening torques stated apply to non-oiled nuts and bolts.
^ Replace self-locking bolts and nuts.
^ The threads of bolts which are secured by a locking fluid should be cleaned with a wire brush. Then apply AMV 185 101 Al when inserting.
^ Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (e.g. with a tap). Otherwise there is a danger of bolts shearing when subsequently being removed.

Mount
^ Attach the needle bearing with the written side (greater plate thickness) to the installing tool.
^ Grease needle bearing for transmission rear input shaft in flywheel.
^ Lubricate all bearings in transmission housing with gear oil before installing.
^ Heat inner races of taper roller bearings to approximately 100°C before installing. Press in onto stop when installing so there is no axial play.
^ Do not interchange inner or outer races of bearings of the same size.
^ Always replace the taper roller bearings on one shaft together and use new bearings from a single manufacturer.
^ The taper roller bearings for the output shaft and the differential in the transmission are low friction bearings. Do not additionally oil new taper roller bearings when measuring friction torque. The bearings are pre-treated at the factory with a special type of oil for this purpose.

Adjustment shims
^ Use a micrometer to measure the shims at several points. Different tolerances make it possible to obtain exact shim thickness required.
^ Check for burrs and damage.
^ Only install perfect, undamaged shims.

Gears, synchros, inner races for sliding gears
^ Heat gears and synchros to approximately 100°C before installing. Press in onto stop when installing so there is no axial play.
^ Heat inner races for sliding gears to approximately 100°C when installing.
^ Temperature can be checked with temperature tester V.A.G 1558.
^ Note installation position.

Sliding gears
^ After installing, check 1st to 6th sliding gears and reverse sliding gear for axial play of 0.15 to 0.35 mm and check that they rotate freely.

Synchronizer rings
^ Do not interchange synchronizer rings. When reusing always reinstall to the same gear.
^ Check for wear; replace if necessary.
^ Coat with gear oil when installing

Clutch mechanism
^ When removing transmission, remove clutch slave cylinder without disconnecting pipes.
^ Do not depress the clutch pedal after removing the slave cylinder if the hydraulic pipe is still connected. Otherwise the piston will be pressed out of the slave cylinder.
^ Do not tilt clutch pressure plate, loosen and tighten diagonally in small steps.
^ If the clutch has burnt out, thoroughly clean the bell housing, flywheel and parts of the engine facing the transmission in order to reduce the smell.