General Repair Information

To perform a problem-free and successful repair, extreme caution and cleanliness, as well as properly functioning tools are an important requirement. The usual basic safety precautions apply when making vehicle repairs.

Some general repair information that applies to several procedures throughout this information is summarized. They apply to this repair information.

Transmission 

• Pay attention to the following when installing the motor/transmission.
• Clean the contact surfaces when installing brackets as well as parts that have been waxed. Contact surfaces must be free of grease and wax.
• For the correct bolts and other components, refer to the Parts Information.
• Check the transmission fluid level after installing the motor/transmission. Refer to TRANSMISSION FLUID LEVEL, CHECKING .

Seals, Sealing Rings 

Fig 1: Identifying Oil Seal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• Fill the space between the sealing lips halfway with Grease -arrow- before installing the radial shaft seal.
• Refer to the Parts Information for the grease allocation.
• The open side of the gaskets point toward the fluid to be sealed in.
• Lightly lubricate the O-rings before inserting to prevent the rings from being crushed during assembly.

Fasteners 

Fig 2: Identifying Circlip & Pliers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• Replace the circlips.
• Do not overstretch the circlips.
• The circlips must fit completely inside the groove.
• Replace the adapter sleeves. Installed position: Slit is longitudinal to direction of force.
  Fig 3: Identifying Spring Pins

  Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Bolts and Nuts 

• Always loosen or tighten bolts and nuts on covers and housings diagonally.
• The tightening specifications stated apply to non-oiled nuts and bolts.
• Replace self-locking screws and nuts after removing them.
• Make sure the contact surfaces and visible surfaces on the nuts and bolts are waxed after assembling.
• Use a thread cutter to clean all threaded holes containing self-locking bolts to remove any locking compound residue. Otherwise the bolts could shear the next time they are removed.
• Please make sure that the thread pitch is correct so that the proper thread cutter is used during cleaning, and the thread does not get damaged.