Repair Instructions

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.

A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in the Repair Manual, are summarized here. They apply to this Repair Manual.

Special tools
A list of the special tools used in the Repair Manual are listed in folder. "Workshop equipment and tools" or "Special tools".

Transmission
^ When replacing rear final drive the oil level in rear final drive must be checked and, if necessary, corrected.

^ When assembling mounting brackets as well as waxed components clean contact surfaces. The contact surfaces must be free of wax and grease.

Gaskets, sealing rings
^ Replace O-rings.

^ Radial shaft oil seals.

Before installing:





Lightly oil outer circumference and pack space between sealing lips -arrow- half-full with sealing grease G 052 128 A1.

After installation:
Check gear oil in rear final drive; if necessary top off to lower edge of oil filler hole.

Locking elements
^ Replace circlips.

^ Do not over-stretch circlips.

^ Circlips must be properly seated in the base of the groove.





^ Replace spring pins.

Installation position: Slot longitudinal to line of force.

Nuts, bolts
^ Nuts and bolts which secure covers and housings should be loosened and tightened diagonally.

^ Parts which are particularly sensitive must not be tilted; loosen or tighten diagonally in stages.

^ Tightening torques stated apply to non-oiled nuts and bolts.

^ Replace self-locking bolts and nuts.

^ Make sure with all screw connections that contact surfaces as well as bolts and nuts are only waxed after assembly, if necessary.

Bearings
^ Attach needle bearing with the written side (greater plate thickness) to the installing tool.

^ Install new taper roller bearings in delivery condition and do not oil.

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

^ Heat inner races to approx. 100°C before installing.

^ Do not interchange outer or inner races of bearings of the same size. The bearings are paired.

Adjustment shims
^ Check thickness of shims by measuring at several points with a micrometer. Different tolerances make it possible to obtain exact shim thickness required.

^ Check for burrs and damage.

^ Install only adjustment shims which are in perfect condition.