General Repair Instructions

General repair instructions, 0A3, 6-Speed All Wheel Drive M/T
Proper tools and the maximum possible care and cleanliness are essential for satisfactory transmission repairs. The usual basic safety precautions also naturally apply when carrying out repair work.

A number of generally applicable instructions for the various repair procedures are summarized under the designation "Components".

Special tools
For a complete list of special tools used in these Repair procedures.

Components

Transmission
^ Select the correct bolts and other components according to transmission code letters.
^ When installing a new transmission, check the oil level and fill up with oil if necessary Transmission gear oil, checking level.
^ Capacities and specifications go to Code letters, assignment of mechanical units, transmission ratios, capacities
^ When installing a new rear final drive, check the oil level in the rear final drive and top off if necessary.
^ Thoroughly clean all joints and surrounding areas before dismantling.
^ When installing transmission ensure dowel sleeves are correctly seated.

Sealants
^ Thoroughly clean joint surfaces on transmission housing etc. before applying sealing paste.
^ Apply sealing paste AMV18800102 evenly and not too thick.
^ Breather holes must remain free of sealing paste.

O-rings, oil seals, gaskets
^ Always install new O-rings, oil 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 oil seals, lightly oil the outer circumference of the seal and fill the space between the sealing lips - arrow - about half full with grease G052128A1.
^ The open side of the oil seals faces toward the side with fluid filling.
^ When installing a new oil seal, position the seal in the housing so that sealing lip does not contact the shaft in the same place as the old seal (make use of insertion depth tolerances).
^ Lightly oil O-rings before installing to prevent them being trapped and damaged when assembling.
^ After replacing seals and gaskets, check and, if necessary, top off oil level in transmission.

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





^ Replace spring pins. Position: the slit - A - should be in line with the line of force - arrow -.

Nuts, bolts
^ Loosen the nuts and bolts in reverse sequence to the specified tightening sequence.
^ Nuts and bolts which secure covers and housings should be loosened and tightened in diagonal sequence and in stages if no tightening sequence is specified.
^ Loosen and tighten particularly sensitive parts in diagonal sequence and in stages, taking care to keep them straight.
^ The tightening torques stated apply to non-oiled nuts and bolts.
^ Always replace self-locking bolts and nuts.
^ Clean the threads of bolts which are secured by a locking compound with a wire brush. Then apply locking fluid AMV185101A1 to bolt threads before installing.
^ Threaded holes which take self-locking bolts or bolts coated with locking fluid must be cleaned (using a tap or similar). Otherwise there is a danger of the bolts shearing when subsequently being removed.

Shims
^ Use a micrometer to measure the shims at several points. Tolerance variations make it possible to obtain the exact shim thickness required.
^ Check for burrs and damage.
^ Do not install shims which are damaged or not in perfect condition.

Bearings
^ Install needle bearings so the lettering (side with thicker metal) faces towards the installing tool.
^ Grease needle bearing for transmission input shaft in rear of flywheel.
^ Lubricate all bearings in transmission housing with gear oil before installing.

Clutch mechanism
^ When removing transmission, remove clutch slave cylinder without disconnecting lines.
^ Do not depress the clutch pedal after removing the clutch slave cylinder if the hydraulic line is still connected. Otherwise the piston will be pressed out of the clutch slave cylinder. As a result the clutch slave cylinder will be destroyed.
^ If the clutch pedal does not return to its initial position after releasing it, you must bleed the clutch system.
^ The clutch system should be bled at the same intervals as the brake system.
^ Note assembly instructions for SAC pressure plate.
^ On vehicles with SAC pressure plate an adjuster ring has to be reset when only the clutch plate is replaced.
^ If the clutch has burnt out, thoroughly clean the bell housing, flywheel and parts of the engine facing the transmission in order to prevent odors.