General Repair Instructions

5 Speed Manual 02J

General repair instructions
To ensure perfect and successful transmission repairs, the greatest care and cleanliness as well as the use of good and proper tools is essential. Obviously, the basic rules for safety are also applicable during repair work.
A number of generally valid instructions applicable for the various repair procedures -which were previously repeated a number of times at numerous places -are summarized here.

Transmission
- When installing ensure that the dowel sleeves between the engine and the transmission are correctly located.
- When changing a transmission fill with gear oil to the lower edge of the filler hole.
- Refer to Specifications.

Note:
- If the oil level is topped up with the transmission installed, check the oil level as follows:
- Fill with oil to the lower edge of the filler hole and reinstall the filler plug. Start the engine, engage a gear and allow the transmission to turn for approx. 2 minutes. Switch off the engine and again top-up with oil to the lower edge of the filer hole.

Gaskets, sealing rings
- Thoroughly clean joint surfaces and apply sealant AMV 188 200 03.
- Apply sealant uniformly but not too thick
- Replace O-rings.
- Radial shaft oil seals

Before installing:





Lightly oil outer circumference, fill space between sealing lips (arrow) with grease G 052 128 A1.
After installation:
Check transmission oil; if necessary top-up to lower edge of oil filler hole.

Locking devices
- Replace circlips
- Do not overstretch circlips
- 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.
- Especially delicate parts, such as clutch pressure plates, must not be distorted. Loosen and tighten bolts and nuts in stages in a diagonal sequence.
- Tightening torques as specified are for unoiled bolts and nuts.
- Replace self-locking bolts and nuts.

Bearings
- Install needle bearings with lettered side (thicker metal) towards fitting tool.
- Lubricate all transmission bearings with gear oil.
- Tapered roller bearings installed to one shaft must be replaced as a set. Use same make of bearings if possible!
- 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 matched in pairs.

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.

Synchronizer rings
- Do not interchange. When reusing always install with the same gear.
- Check for wear and replace if necessary.
- Coat with gear oil before installing.

Selector gears
- Before installing clean and heat on a hot plate to approx. 100°C.
- Temperature can be checked with temperature tester V.A.G 1558.