Transmission and Drivetrain: Service and Repair

Components

O-rings, Gaskets and Seals
^ Always replace O-rings, gaskets and seals.
^ Always clean separation surfaces.

Before Installing





^ Before installing the radial shaft seals, lightly oil the outer circumference and fill the space between the sealing lips -arrow- halfway with sealing grease G 052 128 A1.
^ Before installing the flange shaft/driveshaft radial shaft seals, lightly lubricate the outer circumference and the space between the sealing lips with high performance Haldex clutch oil.
^ The open side of the gaskets points toward the fluid to be sealed in.

After Installation
^ Check the oil level in the Haldex clutch.

Circlips
^ Do not over stretch circlips.
^ Always replace damaged or overstretched circlips.
^ Circlips must be properly seated in the base of the groove.





^ Replace spring pins. Installation position: Slit -A- should in line with the line of force -arrow-.

Bolts and Nuts
^ Replace self-locking bolts and nuts.
^ Loosen and tighten bolts and nuts for securing covers and housing parts in diagonal sequence.
^ Clean screws installed with locking compound with a wire brush. Replace with locking compound AMV 185 101 A1.
^ Remove locking compound residue in threaded holes with a thread tap. Otherwise, screws may shear off during next removal.
^ Delicate parts must not be cross-threaded. Loosen and tighten in stages in a diagonal sequence.
^ The tightening specification stated apply to non lubricated nuts and bolts.
^ Only wax all the contact surfaces on the threaded connection bolts and nuts after installing.

Mount
^ Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift.
^ Lubricate all gearbox bearings with gear oil.
^ Taper roller bearings fitted to one shaft must be replaced as a set. Use same make of bearings.
^ Heat inner races to approximately 100°C before installing.
^ Do not interchange inner and outer bearing races with those from other bearings of the same size, bearings are paired.

Adjusting Shims
^ Measure shims at several points using a micrometer. Varying tolerances make it possible to measure the required shim thickness exactly.
^ Inspect for burrs and signs of damage.
^ Install only shims that are in perfect condition.