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

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.