5 Speed A/T 01V

General repair instructions

Maximum possible care and cleanliness, as well as proper tools, are essential for satisfactory and successful transmission repairs. Also, the generally applicable basic rules of safety naturally apply when performing repair work.
A series of generally valid instructions that apply to individual repair operations-otherwise listed at several points-are summarized here. They apply to this Transmission.

Transmission
^ The engine may not be run with the oil pan removed or without ATE in planetary gear set, and the vehicle may not be towed.
^ When exchanging the automatic transmission, ATF in planetary gear set and differential as well as gear oil in final drive must be checked or topped up.
^ When exchanging the automatic transmission, the levels of the ATF in the planetary gearbox and the gear oil in the final drive must be checked and corrected if necessary.
^ Check torque converter installation specification before installing the transmission.
^ When installing the transmission, make sure that the dowel sleeves are correctly seated.
^ Secure torque converter against falling out when transmission is removed.
^ Thoroughly clean connecting points and the area around them before separating.
^ Place parts that have been removed on a clean surface and cover them. Use foil or paper. Do not use cloths with lint!
^ Carefully cover or close components that have been opened if repair will not be done immediately.
^ Install only clean parts. Only remove replacement parts from packaging when they are ready to be installed.
^ Rules for cleanliness when working on the automatic transmission.

O-rings, seals, gaskets
^ Always replace O-rings, seals and gaskets.
^ After removing O-rings, check contact surface on housing or shaft for removal dependent burrs or damage.
^ Coat O-rings with ATF at outside circumference and at sealing lip for installation.
^ Coat O-rings with ATF or Vaseline when installing, to prevent pinching of the rings during installation.
^ Do not use any other lubricants in ATF area. Otherwise malfunctions of the hydraulic transmission control may occur.
^ The open side of the oil seals faces the fluid to be sealed in.
^ Check and if necessary top up transmission oil or ATF fluid after installing.

Circlips and retainers
^ Do not over-stress circlips.
^ Replace if necessary.
^ Circlips must be properly seated in their grooves.

Nuts, bolts
^ Bolts and nuts attaching housings and covers or the valve body must be loosened and tightened in stages in accordance with the specified tightening sequence or method.
^ Loosen bolts and nuts in a sequence opposite to the tightening sequence.
^ Bolts and nuts attaching housings and covers must be loosened and tightened evenly in stages and in an alternating diagonal pattern if no tightening sequence is specified.
^ Tightening torques specified in repair procedures are for non-oiled nuts and bolts.
^ The threads of bolts which are coated with locking fluid must be cleaned with a wire brush and coated with AMV 185 100 A1 before installation.
^ Always replace self-locking nuts.

Bushings, bearings
^ Install needle bearings with the inscribed side (thicker metal) facing the drift.
^ Insert gears in transmission with ATF. Lubricate with special care for measuring friction torque.
^ Do not interchange the inner and outer races of the same size bearings.
^ Always replace taper roller bearings which are mounted on a shaft together as a set and use bearings from a single manufacturer.

Shims
^ Measure shims at several points with a micrometer. Different tolerances make it possible to obtain the exact shim thickness required.
^ Check for signs of burr and damage. Install only shims which are in perfect condition.

On Board Diagnostic (OBD)
Before carrying out repair work on the automatic transmission, precisely determine the cause of the malfunction