General Repair Information

Carefulness, cleanliness and the correct tools are required for transmission repairs to be successful. 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 this repair service information, are summarized here.

Special Tools

A complete list of special tools and shop equipment used in this repair service information can be found at the beginning of each repair procedure. Also a complete list of the special tools used in each repair group, can be found at the end of each repair group under "Special Tools".

With small fasteners with a minimal tightening specification, uncertainties often exist. For these fasteners torque wrench V.A.G 1783 can be used.

Fig 1: Identifying Torque Wrench V.A.G 1783

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Transmission

Do not run the engine and do not tow the vehicle if the transmission pan is removed or if there is no transmission fluid inside the transmission.
Always clean the connection points and the area around them first, and then loosen them.
When installing the transmission, make sure the centering sleeves are correctly installed between the engine and transmission.
Place removed parts on a clean surface and cover them so that they do not get dirty. Use foil, paper or a lint free cloth.
Only install clean components: Remove the replacement parts from their packaging just prior to installing them.
Carefully cover or seal unpacked components, if repairs cannot be performed immediately.
With the transmission removed, secure the torque converter so that it cannot fall out.

Guided Fault Finding, On Board Diagnostic (OBD) and Test Instruments

Fig 2: Identifying Identifying Vehicle Diagnosis, Testing And Information System VAS 5051B

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Before beginning any repair work on the automatic transmission, determine the cause of the damage using "Guided Fault Finding".

Perform Guided Fault Finding using, for example, the vehicle diagnostic tester VAS 5051 B.

O-rings Seals and Gaskets

Fig 3: Identifying Oil Seals Sealing Lips

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Replace O-rings, seals and gaskets unless otherwise specified.
After removing O-rings and seals, always inspect the contact surfaces at the housing or shaft for burrs resulting from removal, or for other signs of damage.
Before installing the O-rings or seals, lightly oil the outer circumference and fill the space between the sealing lips -arrow- halfway with sealing grease for sealG 052 128 A1.
The open side of the seals point toward the fluid to be sealed in.
Use Automatic Transmission Fluid (ATF) only. Other lubricants cause malfunctions.
After replacing the seals, O-rings and gaskets, check the transmission fluid level and fill if necessary. Refer to AUTOMATIC TRANSMISSION FLUID LEVEL, CHECKING .

Bolts and Nuts

Fig 4: Identifying Nut And Bolt

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Loosen or tighten bolts and nuts for the covers or housings diagonally.
The tightening specification stated apply to non-lubricated nuts and bolts.
Use a wire brush to clean the threads of bolts that were installed with liquid locking fluid. Install the bolts using the liquid locking fluidAMV 185 101 A1.
Clean the threaded holes for the self-locking bolts or for the bolts coated with locking fluid. Otherwise there is a risk that the bolts will shear the next time they are removed.
Always replace self-locking nuts and bolts.