General Instructions

Transmission
- To ensure satisfactory and successful gearbox repairs, the maximum possible care and cleanliness, and the use of the proper tools is essential. The basic rules for safety are also important when performing repair work.
- When fitting the gearbox to the engine, ensure that the dowel sleeves are correctly located.
- Loosen and tighten all cover and housing bolts in a diagonal sequence.
- Be sure to always replace self-locking nuts and bolts.
- When a new gearbox has been installed, it must be filled with oil.
- If the gearbox is to be filled with oil after it has been installed in the vehicle, check the oil level as follows:
Fill with oil up to lower edge of filler plug hole and refit plug.
Start the engine, engage a gear and allow gearbox to turn over for approx. 2 minutes.
Switch off the engine and top off the gearbox oil to the lower edge of filler plug hole again.

Gaskets and Seals
- Thoroughly clean mating surfaces, then apply sealing compound AMV 18820003.
- Apply sealant uniformly, not too thick.
- Always replace 0-rings.
- Before installing radial shaft seals:
Pack space between sealing lips with grease, and apply a light film of oil around the outer diameter.
- After installing radial shaft seals:
Check gear oil level. Top off if necessary, up to lower edge of filler hole;

Circlips
- Always replace.
- Do not over-stretch circlips.
- Circlips must be fully seated in the groove Spring pins.





Spring pins
- Always replace spring pins.
- Installed position:
slot is longitudinal to line of force.

Bolts and nuts
- Loosen and tighten all cover and housing fasteners in a diagonal sequence.
- Especially sensitive parts such as clutch pressure plates must not be distorted. Loosen and tighten fasteners evenly in stages, in a diagonal sequence.
- Tightening torque specifications are valid only for unoiled bolts and nuts.
- Always replace self-locking bolts and nuts Bearings.

Bearings
- Install needle bearings with lettering (side with thicker material) toward the installation tool.
- Lubricate all bearings in transmission with gear oil before installing. Lubricate with particular care when measuring turning torque.
- Always replace tapered roller bearings on the same shaft as a set. Always use bearings from the same manufacturer if possible.
- Heat inner races of taper roller bearings to approx. 100° (212°F) before fitting.
- Do not exchange inner and outer races of same-size bearings.

Shims
- Measure shims at several points using a micrometer. Variations in tolerance make it possible to select the precise shim thickness required.
- Check for burrs and damage.
- Only install shims in perfect condition Synchronizer rings.
- Do not interchange.
- When re-using, install synchronizer rings with the same gear.
- Check for wear and replace if necessary.
- Coat with gear oil before installing Gears.

Gears
- Before pressing on, clean and heat on a hot plate to approx. 100° (212°F).
- Check temperature with VAG 1558 temperature tester (or the equivalent).