09EA Transmission
Repair Information
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 in the shop manual, are summarized here. They apply to this repair information.
Guided fault finding, vehicle diagnosis and test instruments
• Try to determine the exact cause of the fault using the vehicle diagnosis tester.
Guided fault finding, adaptation values and adaptation drive
• Perform a transmission adaptation after certain maintenance measures: The is connected, select and perform J217 - adaptation values, checking/adaptation drive (Repair Group 38), in guided functions. Refer to => [ Transmission Adaptation, MY 2006 ] 09EA Transmission.
Oil, Environmental and Disposal Regulations
CAUTION!
Risk of transmission damage.
• All filling equipment must be clean.
• Do not mix different fluids.
• Only approved ATF fluids available as a replacement part may be used.
• Other oils can cause malfunctions or transmission failure.
• Handle ATF, transmission fluid and other oils carefully.
• Dispose of drained ATF properly.
• Follow the legal environmental and disposal regulations.
• Follow the information provided on oil packaging.
Selector Mechanism Emergency Release
If the battery has been disconnected or is discharged and the vehicle must be towed or pushed, it will be necessary to push the shift mechanism emergency release to shift the selector lever from P to N. Refer to => [ Selector Mechanism Emergency Release from P ] Selector Mechanism Emergency Release from P.
Transmission
• Automatic transmission clean working conditions, refer to => [ Clean Working Conditions ] Clean Working Conditions.
• Do not let the engine run or tow the vehicle when the oil pan is removed or when there is no ATF in the engine.
• With left flange shaft removed, secure the torque converter so that it cannot fall out.
• When installing torque converter, check installation dimension => [ Installation Dimension: ] Torque Converter.
• When installing transmission, make sure that the alignment bushings are installed correctly.
• When installing the transmission, the following fluid levels should be checked and corrected if necessary? ATF in planetary gear, gear oil in front final drive, and gear oil in transfer case.
O-rings, Shaft Seals, Sealing Rings and Seals
• Always replace O-rings, shaft seals, sealing rings and seals after removal.
• After removing gaskets, examine contact surface on housing/shaft for burr resulting from removal or for other signs of damage.
• The open side of the shaft seals point toward the fluid to be sealed in.
• Before installing, lightly lubricate shaft seal outer circumference and sealing lips with ATF or gear oil, depending on installation location.
• Coat O-rings with ATF before inserting to prevent crushing rings during installation.
• Always only use approved ATF. Other types of lubrication cause faults to occur in the transmission hydraulics.
• Press in new shaft seal, so that the sealing lip does not run on the same point as the sealing lip of the old shaft seal (use insertion depth tolerances).
• Replace paper gaskets, thoroughly clean sealing surfaces and completely remove old seals.
• Check the following fluid levels and fill if necessary: ATF level in the planetary gear, gear oil level in the front final drive and gear oil level in the transfer case.
Bolts and Nuts
• Loosen the bolts opposite the tightening sequence.
• Nuts and bolts which secure covers and housings should be tightened in steps according to the specified tightening sequence and method.
• Nuts and bolts which secure covers and housings should be loosened and tightened crosswise in stages if no tightening sequence is specified.
• Always replace the self-locking nuts and bolts.
• Clean threads of bolts that were applied with locking fluid using a wire brush. Use locking fluid when installing the bolts.
• Threaded holes into which self-locking bolts or bolts coated with locking fluid are screwed, must be cleaned (for example tap). Otherwise there is a risk that the bolts will shear the next time they are removed.
• The tightening specifications stated apply to non-oiled nuts and bolts.
Fasteners
• Do not overstretch the circlips.
• Always replace damaged or stretched circlips.
• The circlips must fit completely inside the groove.
• Replace the adapter sleeves. Installed position: Slit is longitudinal to direction of force.
Bearings
• Install needle bearings with lettered side (thicker metal) racing the fitting tool.
• Lubricate the bearings with gear oil or with ATF, depending on the installation location.
• Do not interchange the outer or inner races for the same size bearings.
• Always replace the tapered roller bearings on one shaft together and use new bearings from a single manufacturer.
Adjusting Shims
• Measure the adjusting shims at several locations with a micrometer. Tolerance variations make it possible to find the exact shim thickness required.
• Check for burrs and damage. Only install perfect shims.
Mechatronic
CAUTION!
There is a risk of destroying the transmission control module (Mechatronic) with static discharge.
• Always discharge static electricity before working with connectors or the Mechatronic. Do this by touching a grounded object, for example vehicle ground, the vehicle or the hoist.
• Do not touch contacts in transmission connector with hands.
• Allocate the Mechatronic according to the transmission code letters.