Components

Components

Transmission

• Observe the rules of cleanliness for working on the transmission. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

• Do not run the engine with the end cover removed or without Automatic Transmission Fluid (ATF), and do not tow vehicle.

• Only install clean parts: Remove packing from replacement parts immediately prior to installation and not before.

• After installing, the following fluid levels must be checked and topped off if necessary:

• ATF in the planetary gear, refer to => [ ATF Level Checking ] ATF Level Checking.

• Gear oil in the front final drive, refer to => [ Front Final Drive, Gear Oil Level Checking ] [1][2]Final Drive, Differential (01J Transmission).

• For capacities and specifications, refer to => [ Capacities ] Specifications.

O-rings, seals and gaskets

• Always replace O-rings, seals and gaskets.

• After removing the gaskets, examine the contact surface on the housing/shaft for burrs resulting from removal or for other signs of damage.

• Thoroughly clean the housing joint surfaces before assembling.

• To install, lightly coat the gaskets along the outer circumference and on sealing lip with ATF.

• Lightly lubricate O-rings with ATF when installing to prevent the rings from being pinched when components are assembled.

• Only use ATF for automatic transmission components. Other types of lubrication cause faults to occur in the transmission hydraulics.

• Open sides of oil seals face fluid side.

• When pressing in new gaskets, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).

• After installing, the following fluid levels must be checked and topped off if necessary:

• ATF in the planetary gear, refer to => [ ATF Level Checking ] ATF Level Checking.

• Gear oil in the front final drive, refer to => [ Front Final Drive, Gear Oil Level Checking ] [1][2]Final Drive, Differential (01J Transmission).

• For capacities and specifications, refer to => [ Capacities ] Specifications.

Bolts and nuts

• Loosen bolts in the reverse order of the tightening sequence.

• Nuts and bolts which secure covers and housings should be tightened in stages according to the specified sequence and tightening method.

• Loosen and tighten bolts and nuts for securing covers and housings in a diagonal sequence and in stages, when no tightening sequence is specified.

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

• Replace self locking bolts and nuts.

• Clean the threads of bolts that were applied with locking compound using a wire brush. Then insert bolts with locking compound (AMV 185 101 A1).

• Threaded holes into which self locking bolts or bolts coated with locking compound were installed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.

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.

Bearings

• Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift.

• Insert bearing with axle oil or ATF, depending on installation location.

• Do not interchange outer or inner races of bearings of the same size.

• Always replace taper roller bearings on one shaft together and use new bearings from a single manufacturer.

Adjustment shims

• Use a micrometer to measure shims at several points. 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.

Guided Fault Finding

Always perform Guided Fault Finding using vehicle diagnostic testing and information system (VAS 5051A) before starting disassembly and assembly work.