General Repair Instructions

General 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, are summarized here.

Special tools
A list of special tools and workshop equipment required for repair procedures can be found at the start of each.

Transmission
- If the automatic transmission has been exchanged, the following fluid levels are to be checked:
- ATF in planetary transmission.
- Gear oil in front final drive.
- Fill levels and specifications.
- Engine must not run if oil pan or ATF has been removed. Do not tow vehicle.
- After removing transmission, prevent torque converter from falling out.
- Thoroughly clean connecting points and surrounding areas and then loosen bolts.
- Before installing transmission, check lifting aperture for torque converter.
- When installing ensure that the dowel sleeves between the engine and transmission are correctly located.
- Place removed parts on a clean surface. Cover parts to prevent soiling. Use plastic sheeting and paper. If necessary, use only lint-free cloth!
- Only install clean parts: Remove packing from replacement parts immediately prior to installation and not before.
- If repair work cannot be performed immediately, cover replacement parts from which packing has been removed.

Gaskets, sealing rings
- Always replace O-rings, oil seals and gaskets.
- Once oil seal/gasket has been removed, check contact surface on housing or shaft for burrs and damage. Rectify as necessary.
- Thoroughly clean housing connecting surfaces and apply sealant AMV 188 200 03.





- Before installing shaft-type oil seal, half fill space between sealing lips with grease G 052 128 A1 -arrows- and then install.
- Open side of oil seal faces oil.
- Before installing oil seals, moisten circumference of seal and sealing lip with ATF or gear oil depending on fitting location.
- Moisten O-rings with ATF to prevent damage occurring to the rings during assembly.
- Only use ATF for automatic transmission components. Other types of lubrication cause faults to occur in the transmission hydraulics.
- Check ATF level in planetary transmission or gear oil level in final drive following installation. Top up as necessary.
- ATF in planetary transmission.
- Gear oil in front final drive.
- Fill levels and specifications.

Locking devices
- Do not over stretch circlips. Replace as necessary.
- Circlips must locate properly in the groove.





- Replace spring pins
Installation position: Slot longitudinal to line of force.

Bolts and nuts
- Tighten and loosen bolts and nuts for securing covers and housings in a diagonal sequence.
- Do not cant particularly sensitive parts such as the valve body. Loosen and tighten nuts and bolts gradually and in diagonal sequence.
- Tightening torques as specified are for un-oiled bolts and nuts.
- Clean threads of bolts that were applied with locking fluid using a wire brush and apply AMV 185 100 A1 before replacing.
- Use thread tap to remove remains of locking fluid from all threaded holes in which self-locking bolts are to be screwed. Otherwise there is a risk that the bolts will shear the next time they are removed.
- Replace self-locking bolts and nuts.

Bearings
- Tapered roller bearings are allocated according to transmission date of manufacture and transmission code.
- Tapered roller bearings fitted to one shaft must be replaced as a set. Use same make of bearings.
- Install needle bearings with lettered side (thicker metal) toward fitting tool.
- Heat tapered roller bearing inner races to approx. 100°C before installing.
- Do not interchange outer or inner races of bearings of the same size. The bearings are matched in pairs.
- Depending on fitting location, apply gear oil or ATF to bearings before installing.

Shims
- Measure shims at several points with a micrometer. Tolerance variations make it possible to find the exact shim thickness required.
- Check for burrs and damage.
- Only install perfect shims.

Valve body
- The valve body should be replaced if scorched coupling elements are discovered.
- The valve body should be allocated according to the transmission code.

Guided fault finding, vehicle self diagnosis and measuring technology





- Before repair work is carried out on the automatic transmission, the fault cause should be determined as accurately as possible using vehicle diagnosis, testing and information system VAS 5051 in modes of operation "Guided fault finding", "Vehicle self-diagnosis" and "Test instruments".