General Repair Notes

Transmission 

• Observe rules of cleanliness for working on the transmission → Rules for cleanliness when working on transmission .
• Do not run engine with end cover removed or without ATF filling and do not tow vehicle.
• Only install clean parts: Remove packing from replacement parts immediately prior to installation and not before.
• After installing, the following fluid levels must be checked and topped off if necessary: ATF in planetary gear → ATF level, checking and topping off  and axle oil in front final drive → Gear oil level in front final drive, checking . Capacities and specifications → Capacities .

O-rings, seals, gaskets 

• Always replace O-rings, gaskets and seals.
• After removing gaskets, examine contact surface on housing/shaft for burr resulting from removal or for other signs of damage.
• Thoroughly clean housing joint surfaces before assembling.
• To install, thinly coat gaskets along outer circumference and on sealing lip with ATF.

• Lightly lubricate O-rings with ATF when installing to prevent the rings from being pinched when components are assembled.
• Only use ATF for automatic transmission components. Other types of lubrication cause faults to occur in the transmission hydraulics.
• Open sides of oil seals face fluid side.
• When pressing in new gaskets, make sure the sealing lip does not run on the same point as the sealing lip of the old seal (use insertion depth tolerances).

• After installing, the following fluid levels must be checked and topped off if necessary: ATF in planetary gear → ATF level, checking and topping off  or axle oil in front final drive → Gear oil level in front final drive, checking . Capacities and specifications → Capacities .

Bolts and nuts 

• Loosen bolts in reverse of tightening sequence.
• Nuts and bolts which secure covers and housings should be tightened in stages according to specified sequence and tightening method.
• Loosen and tighten bolts and nuts for securing covers and housings in a diagonal sequence and in stages, when no tightening sequence is specified.
• The tightening torques stated apply to unoiled bolts and nuts.

• Replace self-locking bolts and nuts.
• Clean threads of bolts that were applied with locking fluid using a wire brush. Then insert bolts with locking fluid AMV 185 101 A1  .
• Threaded holes into which self-locking bolts or bolts coated with locking fluid are installed, must be cleaned (e.g. tap). Otherwise there is a risk that the bolts will shear the next time they are removed.

Locking elements 

• Do not over-stretch circlips.
• Always replace circlips which have been damaged or over-tensioned.
• Circlips must be properly seated in the base of the groove.

Bearings 

• Install needle bearings with the lettering on the bearing (the side with thicker metal) facing towards the drift.
• Insert bearing with axle oil or ATF, depending on installation location.
• Do not interchange outer or inner races of bearings of the same size.
• Always replace taper roller bearings on one shaft together and use new bearings from a single manufacturer.

Adjustment shims 

• Use a micrometer to measure shims at several points. 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.

Guided Fault Finding 

Always perform Guided Fault Finding using Diagnostic Operation System VAS 5051 A before starting disassembly and assembly work.