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 for individual repair procedures, that appear many times throughout the information, is summarized here. They apply to this service information.

Special Tools

Refer to Workshop Equipment and Special Tools for a complete list of special tools used in the service information.

Transmission 

• Clean the contact surfaces when installing brackets as well as parts that have been waxed. Contact surfaces must be free of wax and grease.
• Bolts and other components are a replacement part. Refer to the Parts Information.
• Check the transmission fluid level after installing the motor/transmission. Refer to TRANSMISSION FLUID LEVEL, CHECKING .

Seals and Gaskets 

Fig 1: Identifying Oil Seal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• Thoroughly clean the separating surfaces and then apply Sealant: AMV 188 200 03  .
• Fill the space between the sealing lips -arrow- on the radial shaft seal halfway with Sealing Grease:G 052 128 A1  .
• 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.

Circlips 

Fig 2: Identifying Circlip & Pliers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

• Replace the circlips.
• Do not stretch the circlips.
• The circlips must rest at the bottom of the groove.
• Replace the adapter sleeves. Installed position: slot is lengthwise to line 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 given apply to unoiled bolts and nuts.
• Replace self-locking bolts 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.