Components

Components

Transmission

• When installing manual transmission, make sure centering sleeves are correctly seated between engine and transmission.

• Clean contact surfaces when repairing mounting brackets and waxed components. Contact surfaces must be completely free of oil and grease.

• Allocate bolts and other components via the.

Seals, Sealing Rings

• Always replace O-rings, gaskets and seals.

• After removing gaskets and seals, always inspect the contact surfaces at housing or shaft for burrs and damage and repair them.

• Before installing, fill gap between sealing lips of radial-shaft seals half way with sealing grease (G 052 128 A1) - arrow -.





• After installation, check gear oil and fill up => [ Gear Oil, Checking and Filling ] Service and Repair.

• Lubricate O-rings with gear oil before installing, this prevents rings from being damaged when inserting.

• Always clean joint surfaces and apply sealant (AMV 188 200 03).

• Apply sealant evenly, do not apply too thick.

Circlips

• Replace circlips.

• Do not over stretch circlips.

• Circlips must be fully seated in groove.

• Replace roll pins. Installation position: Slot is longitudinal to line of force.





Bolts, Nuts

• Loosen and tighten bolts or nuts for securing covers and housings in diagonal sequence.

• Delicate parts, must not be distorted, such as clutch pressure plates. Loosen and tighten nuts and bolts in stages in a diagonal sequence.

• Tightening specifications stated apply to non-lubricated nuts and bolts.

• Always replace self-locking nuts and bolts.

• For all hose connections, check contact surfaces as well as bolts and nuts, if necessary, are to be waxed only after installation.

• All threaded bores in which self-locking bolts are threaded must be cleaned of remaining locking fluid using a tap. Otherwise there is danger that the bolts may shear when removed again.

Bearings

• Install new tapered roller bearing as supplied and do not oil.

• Install needle bearings with lettering on bearing (the side with thicker metal) facing drift.

• Replace tapered roller bearings on one shaft together and use new bearings from same manufacturer.

• Heat inner races to a maximum of 100° C to install.

• Do not interchange inner and outer bearing races with those from other bearings of same size, bearings are paired.

Shims

• Measure shims at several points using a micrometer. Different tolerances make it possible to measure the required shim size exactly.

• Check for burrs and signs of damage.

• Only install perfect shims.

Synchronizer Rings

• Do not interchange. If reusing, install synchronizer rings to same gear as before.

• Check for signs of wear; replace if necessary.

• Check grooves - arrow 1 - of synchronizer ring - A - or inner race for flattened areas (grooves are worn).





• Coating must not be damaged with coated synchronizer rings.

• If an intermediate ring - B - is installed, check it on outer friction surface - arrow 2 - and inner friction surface - arrow 3 - for scoring, signs of wear and blue discoloration (due to overheating).

• Check cone of gear wheel for scoring and signs of wear.

• Lubricate synchronizer ring with gear oil before installing.

Gear Wheels

• Before pressing on, clean and heat to a maximum of 100° C on a heater.

• Temperature can be checked using temperature tester (V.A.G 1558), ignition tester ( V.A.G 1767) or diesel tester (V.A.G 1743 ).